Influence of Additives on the Curing Kinetics and Delay Time Sensitivity of Mono-Component Polyurethane Mixtures

Polyurethane (PU) mixtures are a promising high-strength, rapid-curing alternative to conventional asphalt, but their widespread application is hindered by slow curing rates and sensitivity to ambient moisture. To address these limitations, this study systematically evaluated the efficacy of three additives—lignin-based fiber, Glauber’s salt, and green vitriol—in regulating the curing behavior and performance of PU mixtures. Marshall stability, volumetric properties, and moisture resistance were measured under both outdoor and controlled laboratory curing conditions. Lignin fiber uniformly accelerates early-stage curing by enhancing moisture distribution via capillary action. Glauber’s salt releases crystalline water, drastically boosting early-age strength (by 162.4% after 2 days) but at the cost of an increased air void content (up to 8.1%) and reduced long-term water stability (residual stability <80%). Green vitriol acts through Fe2+ catalysis and crystalline water release, with its effectiveness being highly temperature- and delay-time-dependent. Combining fiber with Glauber’s salt yields the highest early strength but the shortest construction window (<1 h) and the most severe volumetric deterioration beyond the optimal delay time. All mixtures achieved high ultimate strength after sufficient curing (7 days), but the improvement varied significantly with additive type—ranging from 52.2% (fiber alone) to 162.4% (Glauber’s salt alone). Moreover, even under ideal curing, incomplete –NCO conversion persisted, indicating intrinsic cross-linking limitations. The residual stability of all mixtures fell below the 80% specification for conventional asphalt, suggesting that this metric alone is insufficient for assessing the moisture resistance of high-strength PU mixtures. This study demonstrates that while additives significantly enhance early-age performance, their application requires carefully optimized dosage, delay time, and temperature control to balance early strength gains with long-term volumetric integrity and durability. The findings provide revised evaluation metrics and practical guidelines for implementing PU mixtures in rapid pavement construction and repair.