Compositional Effects on the Performance of High-Permeability Emulsified Asphalt for Prime Coat Applications

High-permeability emulsified asphalt has emerged as a promising prime coat for enhancing interlayer bonding in semi-rigid pavement structures. However, its widespread adoption remains limited by insufficient permeability and inconsistent mechanical properties. This study systematically investigated the effects of emulsifier ionic type (cationic or anionic), kerosene dosage (0–20%), and diluted asphalt content (corresponding to oil-water ratios of 5:5 and 4:6) on the comprehensive performance of high-permeability emulsified asphalt. Fundamental physical tests (sieve residue, evaporation residue, penetration, softening point, ductility), permeability evaluation, rotational viscosity measurements, and adhesion performance tests were conducted. Grey relational analysis (GRA) was employed to quantify the influence of each factor and their interactions on key performance metrics. The results reveal that anionic emulsifiers significantly improved low-temperature ductility and permeability. A low kerosene dosage (<10%) enhanced permeability and viscosity but compromised thermal stability at higher levels. Reducing the diluted asphalt content partially offset these adverse effects. GRA identified kerosene dosage as the dominant factor influencing permeability, softening point, and adhesion performance while emulsifier ionic type primarily affected ductility, and oil-water ratio strongly governed emulsification quality and viscosity. These findings provide quantitative insights for optimizing the composition of high-permeability emulsified asphalt and serve as a theoretical foundation for its engineering application in durable prime coats.