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KUP-60-S: Effective Road Maintenance with emulsified Bitumen


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KUP-60-S (60% Solid Bitumen)¬†is a high-performance bitumen product designed for wearing course stabilisation, particularly on roads. Here’s what makes KUP-60-S a valuable tool for road maintenance:

  • Emulsified for Easy Use: Unlike traditional hot asphalt, KUP-60-S is an emulsion, allowing for a cold application process. Simply mix it with water on-site for convenient use.
  • Effective Stabilisation: KUP-60-S strengthens and protects existing road surfaces, extending their lifespan and reducing the need for frequent repairs. This translates to significant cost savings in the long run.
  • Site-Specific Solutions: KUP-60-S adapts to various road conditions and drainage systems. Performance is influenced by factors like the existing road base stability and drainage design. We recommend consulting with a qualified professional to determine the optimal application strategy for your specific needs.
  • KUP-60-S (B): Affordable Spray-on Option: We also offer KUP-60-S (B) with a 45% bitumen content (BC range). This option provides a more cost-effective solution for projects focusing solely on spray-on applications.

Benefits of KUP-60-S:

  • Reduced Maintenance Costs: Extends road life, minimizing costly repairs and road closures.
  • Improved Safety: Enhanced road stability translates to safer driving conditions.
  • Cold Application: Eliminates the need for hot asphalt equipment, simplifying the process and reducing energy consumption.
  • Faster Application (KUP-60 (B)): The “spiked application” technique with KUP-60-S (B) offers a time-saving approach for efficient road maintenance.

Spiked Application for KUP-60-S (B):

This unique method minimizes grading needs while maximizing product effectiveness:

  1. Grading: Shape the road surface to the desired profile and pay particular attention to good drainage to avoid sitting roadside water during the rainy season.
  2. Misting: After your initial first week application of 10%, apply a light spray of diluted KUP-60-S (B) (2.5% or 5% mix) twice daily gradually reducing to once daily and then skipping days, continuously monitoring the road condition and reducing or increasing accordingly. The objective is to create a 30 mm seal on the road
  3. Seal Formation: Witness the rapid formation of a bitumen seal as subsequent sprays are applied.
  4. Regular Application: Continue spraying after water evaporation to create a strong, durable surface.
  5. Minimize Grading: Extensive grading after application can disrupt the newly formed seal. KUP-60-S performs best with minimal post-application grading.
  6. Ongoing Maintenance: The process begins with a 30mm seal application. This acts as the foundation. After a week, you can start spraying the product directly onto the sealed surface, twice a day for the first month (or potentially just the first two weeks). This spraying builds upon the initial 30mm seal.

Weatherproofing and Leaching:

This product is designed to withstand rainy seasons. While some leaching might occur with other products, special binders in our formula (KUP-XIL products) minimize leaching during rain.

In the unlikely scenario that you encounter minor wear during heavy rain, this can be easily addressed after the season. It’s important to note that once the initial seal is fully cured and dry, it should not leach at all, even during rain.

Refer to the pictures above for the before and after for project results.


Afgri Bloedrivier New Access Road, Dundee, KZN, SA (high rainfall) 

Wearing Course Stabilized with KUP-60 Bitumen plus KUP-XIL.

Very good durability with minimal maintenance done for 24 months.


Some Frequently Asked Questions and Answers


  1. Can one store solution in plastic JoJo water tanks 10m3?
    10m³ Chemical Storage tanks will be 100% fine, but for future and potential increased volumes we should look at possible self-bunded steel tanks with 30kL capacity.
    Water tanks can work, but those are never guaranteed should something burst. The manufacturers of tanks always say anything with sg (specific gravity) other than water is not their problem.
  2. Can it be pumped out and into the bowser with just a normal water pump?

Yes, it can be pumped with normal pumps.


  1. How often does in need agitating in storage?      

For storage tanks you can agitate every day or two. For a couple of minutes only. No need for intense agitation, just need everything to become mixed together again


  1. Can agitation be done just before preloading into the bowser?

Yes, and one can also use the same pump for agitation. Then it boils down to your pipe work only.


  1. Can excavators be on the road
    Excavators and track equipment will always cause damage, mostly when these turn on the tracks. The continued spraying and maintenance will reseal if there are damaged areas.
    Suggestion: Before the rainy season the excavators are minimized so that the seal can be properly achieved for protection of underfoot parts during rains


  1. Can the road be used while doing spike application and when?
    Yes, roads can be used.
    The spike application plus spray on does not require traffic stops. You use your truck tires for compaction of the scarified area as well.
    Only disruptive part is a grader and water bowser also in the road, working for that period of scarifying and spraying


  1. Is there not a waiting period to dry.?
    Can the bitumen component stick to the truck tires?
    This applies to the bitumen spike (KUP-60-S). The initial solution should not exceed 10% with neat bitumen as this tends to cause extreme tackiness as spray on spike application


  1. How to treat areas with 20-30cm very fine dust using KUP SS penetrating liquid

To ensure a strong foundation, begin by applying a light spray of the KUP-SS product to the dust. Repeat this pre-wetting process with KUP-SS a couple of times, until the dust achieves a dense consistency. With the dust firmly compacted, proceed with applying the KUP-XIL-B sealant to create a secure final layer

Click the link for more information on the KUP-SS product.




  1. Can these products be used for warehouse flooring?

Application: Warehouse flooring stabilization

Target thickness: 150mm (typical for warehouse floors)

Desired property: Water resistance (achieved by the KUP-XIL variant)


  1. Tariff numbers and Import

The KUP-XIL B product as sent from SA has 2 x tariff numbers (HS codes).

2839.19 and 2714.90.10

 SADC exemption to duties, but these components are duties free in any case


  1. Payments and Banking

Truck Stop only accepts $ or £ payments for export


Please do not hesitate to reach out to us for any other questions.


KUP-60-S, KUP-60-S (45%)



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