Preparation and Rheological Properties of Waterborne Epoxy Resin Emulsified Asphalt

To address the lack of systematic quantitative studies on waterborne epoxy resin (WER)-modified emulsified asphalt regarding its rheological optimization and engineering applicability, this study fills the gap by preparing WER-modified emulsified asphalt via a two-step process. New findings reveal that 20% WER content significantly enhances elastic components, creep-recovery, fatigue life, and fracture energy. The main objective is to establish a theoretical basis for high-performance pavement materials. Modified emulsified asphalt specimens with different waterborne epoxy resin contents were prepared using a two-step method of "emulsification followed by compounding". The stability of the emulsions was quantitatively evaluated by zeta potential, storage stability, particle size distribution, and demulsification time. Their rheological parameters, multi-stress creep-recovery characteristics, fatigue life, and low-temperature crack resistance were systematically tested across the full temperature range using a dynamic shear rheometer and a bending beam rheometer. In addition, the bonding performance, strength development behavior, and water resistance durability were comprehensively assessed through pull-out tests, Marshall stability and splitting strength tests, as well as freeze-thaw cycle tests. These properties were compared with those of unmodified emulsified asphalt (UEA-0) and SBR-modified emulsified asphalt (SBR-EA). With an increase in waterborne epoxy resin content, the elastic component of the modified asphalt improved significantly, and the phase angle continuously decreased. The specimen with 20% waterborne epoxy resin content (WER-EA-20) exhibited the best performance: its phase angle was lower than those of the other groups under high-, medium-, and low-temperature conditions. After seven creep-recovery cycles, its creep-recovery rate remained at 33%, substantially higher than the 8% observed for the unmodified specimen. The fatigue life reached 15,000 cycles under a shear stress of 2.1 MPa. At -10 °C, the fracture strength was 0.92 MPa, and the fracture energy reached 21.4 J. Furthermore, the pull-out strength of WER-EA-20 was 0.86 MPa, with the failure mode identified as asphalt cohesive failure. After 37 days of curing, the Marshall stability reached 22.5 kN, and the splitting strength was 1.36 MPa. After 40 freeze-thaw cycles, the freeze-thaw splitting strength ratio (TSR) of WER-EA-20 remained above 75%, representing an improvement of more than 110% compared to the unmodified UEA-0 (TSR ≈ 35.5%), which highlights the significant enhancement in water resistance imparted by the waterborne epoxy resin. Compared to SBR-EA, WER-EA-20 has a higher softening point, a lower suitable mixing temperature, and better anti-aging properties. Waterborne epoxy resin can effectively improve the viscoelastic properties and overall road performance of emulsified asphalt, and the modification effect increases with increasing dosage.