IRC:SP_1QO-201 J.

DevendraKumar
SOME.LBO

USE OF
COLD MIX TECHNOLOGY
IN CONSTRUCTION
AND
MAINTENANCE OF ROADS
USING BITUMEN EMULSION

Publis hed by:

INDIAN ROADS CONGRESS

Kama Koti Mary,
seee-e. RK Puram,
New Delhi-l1 0 022

January, 2014 Devendra Kumar

SOME.LBG

Prce . t 9()C}-

{Plus Packlng &. Postage

IRC:$P:1QO-2014

First Published January. 20 14

(AN Rights Reserved. No part of this publicatiOn shall be reprodured.

translated or transmined in any form or by any means without the
permission of the Indian Roads Congress)

Printed by India Offset Press, Delhi-110064

,1000 Copies
 IRC:SP.'OO-201':'

Contents

Page No

Pe rsonnel 01the Highways Speciscatoos and Standards Committee

, Introduction t

2 Chemistry of Bitumen EmulslOtl. Productioo and Handling 4

3 Specilication and Tes~ 13

4 Specification and Testing of Aggregates 19

5 Spray Applications 22

6 Surface Treatments 27

7 Cold MIxes 4'

Half Warm Mixes 49

Uaintenance Mixtures Using Bitumen Emulsion 50

0'" ~ :ydIng Using Bltumeo Emutsioo 53

....._ . for Bituminous Road Construction Using Emulsions 59

67
71
 IRC:SP:1QO-201 ..1

PERSONNEL OF THE HIGHWAYS SPECIFICATIONS

AND STANDARDS COMMITTEE
(As o n 19"' July, 2013)

Ka ndasatny, C Orredor General (RDI & S pi. Secv 10 Govl of lrOil ,

Mnstry of Road Transport & Iligtl", ays. Transport
''''''''"'''''' Shavan. New Delhi

Add!. Oircctor Ger-al. Uonostry 01 Road Trat'JSD(lrI &

I lighWays. Transport Bhavan. New Deh

TheChiefElgii (R l S .R&T. Monostry 01 Road

Transport & H;ghways Transport Bh<rr.In. New DeIti

Mom....

Chief E ngo - . (Rele:!.) UORTH. New Dei hi

N1vtsot. l & T. Murnbao

Head. f PC DiYn. CRRl ( Retd ,~ f aridabad

Chef Er'lgfter. PWO (Hlghwa ys~ AizwaI (U1zoramj

a .... ,-ay. Or S Doredl:o". CenlrnI Road Research Inslilule. New Delli

D' OG(RDI & AS fRetd ). MORTH . New Delhi

Chef E,giloee. {ReId l. Haryana PWD. Sonopal

s Chief Eng",eer (Reid.). MORTH. New Delhi

t s s Professor & Coordinator, ceoee of Transpoltalion

Engg .. Oeptt. of O vil Engg . liT Roor1<ee , ROOfl<ee

Dr L.R Chief ExeculM! , loR. Kadlyali & As socj ales. New DeIhl

...,.
-
Ch ief Eng;neer. (Reld l. MORTH. New Delli

Chief Engineer, DTIOC l id . New Dellli

Engi.-.eer-in-Chief, Haryana PWO. Chandigarh

Ex- Scentlst. CRR!, New Delhi

Engineer<n-Ch;el. Haryana Slate AgrJQJlture MarKeting

Ba-ard Pancll kul.~ (Haryana)

Inlercontinenta l Con sulta nts and Technocrats Pvt, l id "

New Delhi.

Addl , Directo r Gene'al, (Reid. ), MORTH. New Deihl

Chief Enginee' (Planning), MORTH . New Delhi

:. < Direc10f (Tech.). Natioo al Rura l Road Development Agency,

(Min 01 Rural Development ). New Delhi
IRC:S P:1QO.20 14

2J. Prad han, B.C. cruel Eog "loeer. Nalior\al Highways. Bhub>oneshwar

Prasad . O N ChIef EogiONf, (NH). RCO, Patna

"es
ae _., "".
Rao. PJ ConsuIlng E"gi< . HNo. 399. Sedor-19. Faridabad

E'9' "",r--in-Cl'loef (R&B) Admn . Road &. 8uIdIng De(ln ,

.""",,,'"
Reprcsenlal ive of BRO (Sh,; a.a ceu Opt. 00 . HQ DGB R, New oees.ttc 010
"
". Sa rka r, 0<, PK Professor, Deplt. of Transport PlannIng .
Sd'IOOl of Pla......-.g &. Atc:hrtecture, New Delhi

as Sharma, ......... KumIor CEO OI9l '"'eys), GMR Higt'Ways Uniled. 8anQaIore

ac Sharma. M.P. Member (TechnCal), National Hoghways Au\hoIiIy of

Ind ia. New Delhi

OG(RD ) &. AS (Reid). MaRTH, New Delhi

" Sharma , S.C

Sinha. A.V DG( RO) &. 55 (Reid.) MORTH New Delhi

32

33 g.,gh. B N
.... """
-'Ie,,1bei fPro,ec:ts). National H:gt>ways Autnolity of Indoa.

"as Singh, Nlrma l J;j

Vasava . S.B.
OG (RO) & SS (ReId. ), MORTH . New D<llhi

Ctuef Engi.--r & Add l, Secretary (Paochayal)

Roads & 8UIlding Dept , ~

ae Yadav. Dr V.K. AddI , 0Qa0r Gener3I . OG8R, New Delhi

Corresponding Members

t. B hattachafya, C.C OG(RO) & AS (Retd.) MaRTH , New Delhi

, Cas. Or. Ann>esh Assoc:iafe Professor. lIT. Kanpur

3. Justo . Dr C .E.G 334. 1 4~ MaorI. 25 Cross. BanashankaOi 2nd Stage.

R

Bangalor&-560 070.
, Momin, S.S. (Pa sl President. IRe ) 604 A. Isran; Tower. Mumbai

s Pandey. Prof, B 8 . Advrsor. liT Kharagpur. Kharagpur

Kanda samy, C. Dlredo.- G<Jnerai (Road Developmeo1) & SpeeiaI

Sec relary, MORTH and P resKJent. IRe. New DelhI

2. Prasad , Vlslmu Shlm kar Secre tary General. IndIan Roads Congress , New Delfli

"
 IRC: SP:1()()..201':

LIST OF ABBREVIATIONS

IRe Indian Roads Congress

AASHTD American Assoication of State Highway and "rransoortabon Officials

. ,5 Bureau of Indian Standards

CUBM Cold Mixed Bituminous Macadam

CMSDBC Cold Mixed Semi Dense Bi!uminous Concrete

AsTM American Society for Testing of Matelials

WMM Wet Mill Macadam

WBM Water Bound Macadam

e RM Crusher Run Macadam

55 Slow setting
Ms Medium Setting

Rs Rapid Setllng
 IRC SP 100.201.&

USE OF COLD MIX TEC HNOLO GY IN CONSTRUCTION A ND

MAINTENANCE OF ROADS USING BITUMEN EMULSIO N

1 INTRODUCTION
The Road Ma intenance and As set Management (H-6 ) Committee con stitu ted a sub-g roup
lJOda the cha irmanship of Or PK. Jain wit h other members as Shri K. Sitaramanjaneyulu .
Dr. N , K . S. Pundhir. Shri M. N . Nagabhushana. Shri AbhiShek Mitta!, Dr. M.C. Ja in eoo
Dr. I.K. Patenya , for formulation of "Use of Col d Mix Technolog y in Construction and
Main tenance of Roads Using Bitumen Emu lsion ". Th e draft document prepared by lhe
sub-group wa s discussed by the Committee in series of meetings. The H-6 Committee
approved the draft document in its meeting held on 4"' May, 20 13 fo r placing before High ways
Specifica tions & Standards Committee (HSS) Com mittee. The HSS Committee approv ed
the draft document in its meeting he ld on 19" July. 2013 fO( placi ng it before the Council.
The Cou ncil in its meeting he ld at New Delhi on 11 " and 12"' August. 20 13 approv ed the draft
document on 'Use of Col d Mix Technology in Construction and Maintena nce of Roads Using
Bitumen Emulsion" and authorised IRC to publish the sa me.

The Compo sition of H-6 Committee is as given below:

S.C . S harma - - Con venor
Dr. S.S. Jain ---- Co-convenor
K. Sitaram anianeyulu ---- Member Secretary

Members
D.P. Gupta RK Singh
Dinesh Kumar R P. Singh
Or. Ashok Kuma r S. Pyng rope
Or. G .V.S. Raju S.S. Nahar
Or. IK Pateri ya The Chief Engineer (H ), Qua lity
Or. L.R Kadiyall A ssurance and Research. Chennai
Dr. M.C , Jain The Chief Engi neer (NH ). HP PWD
Dr. PK Jain The Chief Engineer (NH), Rajasthan
M .C .8om PWD (RK Gupta)
Manoj Ku ma r The Chief Eng ineer (NH ), Maharashtra
NirmalJit Singh PWD (P.S. Mandpe)
R .K. Pandey The Chief General Manager. NHAI
(SM J.S. Chanda)

Corresponding Member

Dr. A. vee rareaavan Dr. Dharamveer Singh

Or. K . Sud hakar Reddy Prof. Prithvi S ingh Kand hal

1
IRC:SP: 100-201 4

Co-opt "'ember
M. N. Naqabhusban a

Ex-Officio "'embers

C . Kandasa my Director General (Road De velopment) &

Special secretary, Mo RT& H and
President. IRC
VIShnu Shankar Prasad Secretary General, IRC

Flexible (Brtuminous) pavements constitute over 90 percent of the total road flelW()rX including
airfield pavements in India Hot mixed bituminous materials and mixes are generally used for
the construction of base course, binder course and wearing course of a fle xible pavement.
The paving bitumen (V G-10, VG-20. VG-JO and VG-40; as per IS:73), is used as a binder.
II is either solid or se mi solid at ambient tempe rature and co nverted into fluid stale by either
heating or by addition of pet roleu m solvent or by emulsify ing bitumen in water. High amou nt
of energy is consumed for heating of aggregates and bitumen for construction of roa ds
using trad ition al hot mix tech nology. The followin g are some of the disadvan tages of hot mix
technolog ies :
... High leve l of noise and air pollution
... Emission of green house gases
... Compromise with the dlKablhty of bitll1en due to aging during heating
... High energy consumption
... Unsafe lor ma inlenance crew
Another form of bituminous binder is the rotbad< bitumen, wh ich is brought into fluid state by
adding petroleum solven t suc h as naphtha or kerosene oil. In the field , solvent evaporates
as the curing of cut-back bitumen take s place. This tech nolog y has limited applications due
to its inherent disadvantages and rt is not environm ent friendly. The third type o f bitu minous
binder, which is rapidly growin g is the cat ionic bitumen emulsion. It avaita tse in fluid state
at ambient temperature and it is prepared by microsco pic dis persion of solid or semisoiid
bitu me n in water usi rlQ cotlordal null and chemical emulsifiers.

Emulsion was developed for the first time in the 1900s and its use in pavement applications
started in the 19205. The early use of bitumen em ulsion w as restricted to only spra y
applications and as dust pamauves. Over the years, with de velopment of new types. grades.
seecacetcos. and avai lability of imfJl'lfe<l construction eq uipments and practices. emulsion
based cold mix technology offered a wide range of sokrtions for conslJUction and maintenance
o f roads ,

In India, bitu men emulsion fou nd its use only in the 19705 , The entire wor1d used 12 milli on
tonnes of emulsion du ring mid sev enties. India con sumed only 20.000 tonnes til l 1996, out
of the total bitumen co nsum ption of abo ut 2 million tones. However. there has now been
a steady rise in the use of bitumen emu lsion recently and significa nt growth in dem and
of emulsion has been observe d after 2005. At the present time. practically all the road

2
 IRC :SP; 1ClO-20 1A

construction and maintenance requirements can be me t with the use of bitumen emulsion as
!:WIder by way of wa nn and cold mix tech nologies. JudiCious selection and appropriate use
of these tech nolog ies can yield sig nificant eco nomies, environmental benefits and energy
security as far as con struction and main tenan ce of roads are concerned.

l ately, bitumen emulsion has also been used in half wann mixes. micro surfacing and in
CXlId recycling : more especially in lu ll depth reclamation wor1<.s. Resu lts obtained from field
tnals conducted by CRRI and oi l companies on cold mixes and bitumen emulsion based
applications underdrfferent traffic and dimatic conditions have been found to be encouraging .
Several factors that have lead to the increasi ng use of bitumen emulsion in mad con struction
~ and maintenance are listed below:
, , The energy scafClty and crisis.
, Bitumen emcrsons do not require petroleum soIYentlo make it liquid.
, Bitumen emulsions can generally be used without acIditiooal heating .
, Concerns abo ut reducing atmospheric pollution .
, The abil ity of certain types ot bitumen emulsions to coa t dam p agg reg ate
surface. wh ich eventually reduces the fuel requi rements for heating and
drying aggregates.
, Availab ility of a variety of emulsion types wh ich have led to development of
new fOllTlulalions and improved laboratory procedures in order to sa tisfy the
design and coos truetioo requirements .
, The ability to use cold bituminous material s at remote sites .
, The applicability of emulsions for use in peevennve maintenance so as to
increase the servce lile of existing distressed pavements.
, Success stories of the use of wann and cold mi x technologies in construction
and maintenance of rura l roads .
, Hea lth of construction workers
The uses of emulsion in construction and maintenance applications covered in these
guidelines are given be low;

Surface Treatmenllncluding Maintenance Including Periodic T....t....nts Other ApphcatlOns

PreV&ntiYe and Corrective
1I;IIm-nance Cold MlIles Warm II,...

--''''"""",..,.. - ,...." - ~- -,n

_e-

---,.. - --
e-
Derose Mixes

"""-
Po!hole Repaif

Microsurtac:irog
-- Boluminous M rad3<n
-
Grad< Seil! 'll
Soil Stal.*l:iIbOIl

-- Cape Seal
Chip Seal
--- Pr&m" Carpet
M,x Seal Surfacing
sem-nense
BItuminous Concrete
cncice/seiecton of Cold M,. Treatments lor differen t Clim atefTra ffic conditions (warrants ) 15
given in Annell4.

3
IRC :SP:100-2014

Bitumen em ulsion based mixes include:

a) Co ld Mixes (CM)
These mixes are normaRy prod uced with unheated aggregates and bitumen emulsion.

bl Half Wann Aspha lt Mixes (HWA MJ

These mixes are produced by mixing bitumen em ulsion. or foamed bitumen with wa rm
ag gregates ( 1QO1O"C), laid and compacted at a temperature be tween 80-9O"C.

cl Wann Asphollt Mi xes (WAM )

These guidelines apply to the bitumen emulsion based cold mixes, which are suitable for
low to moderate traffic and are not recommended for he'l vily trafficked roads and areas
where atmospheric tempera ture is high . However. bitumen emu lsion based patchi ng mixes
for repairing pothole s are recommended lor all tra ffIC and climatiC conditions. For selection
of cold mix treatments lor diffetent traffic and climatic conditions. reference l1\3y be made to
An nflx I.

2 CHEMISTRY O F BITUMEN EMULSION. PRODUCTION AND HANDLING

2.1 Introductio n
Emulsion is a colloidal system . which finds vital place in our da~y lives. Milk, Mayonnaise,
Paints, lotions, Cre am and Rubberlatex are some ol the well known examples. An emulsion is
a two phase system in which one constituent is dispersed into anolher. In each case, addition
of certain chemica ls with mechanical processing is requ ired. It should be we ll understood
that an emulsion system is very complex and many variables may come inlo play, when
analyzing a particular type or emul sion system.

This chaptet covers the bas ics of emulsion 's chemistry pertaining to its composition, stability,
and performance

2.2 Composition of Bitumen Emulsion

Bitumen emulsion is a two-phase system consisting of bitumen , water and one or more
additives wh ich assist in its formation. stabi lization and in modifying its properties. The bitumen
is dispersed throughout the water phase in the Ioml ct oseete globules, typically O.1 to 50 urn
in diameter, wh ich are held in suspension by eeceo-statc charge sta bilized by an emulsifier.
Depending on the composition of raw materials . which go into bitumen emulsion , these may
include bitumen, Woller, emulsifier, acid or cau stic , polymers , salts, SOlvents, add itives, and
emulsion stabilizers .

2.2.1 Bitumen

It is a viscou s material ceoveo from refining of etude petroleum. The composition of bitumen
has a significant effect on process of emulsification. its physical properties and subsequent
performance .

4
 IRC :SP; 1()().2Q1 ':

2.2.2 Water
Water and hydrocarbons are not soluble in each other. Depellding on its source. water may
contain varying amount of dissolved salts sudl as calcium Of maglleSium cart:>onate (Iou nd
in "hard' water). Of suspended particles of rust (iron o xide) Of silt (very fine day particles).
rtereroee. quality of water has significant effects on the stability and performance of enotseo.
Water containing ca lcium amounting 10 more tha n 75 ppm is considered to be ' hard water"
wtIile water oon tarning ca lcium le ss tha n 75 ppm is considered to be "soft water". II is desirable
to use only "so ft water' for making emulsiOn o f bitumen.
2.2.3 EmvlSifier

Emu lsifier is a ch em ical additive tha i is ad ded 10 water prior 10 the production of an emulsion.
Its functi on is to stabilize emulsion during its prod uction, storage and transportati on. The
amount and type of emulsifier is also critical for determining the performance of em ulsion,
whe n it is applied in the fiel d. A ca re in selection of emulsifier is th us absolutely necessary.

2.2.4 Acid or caustic

Acid or Al kali is added in co mb ination o f the emu lsifier and water to "activate" the emu lsifier.

2.2.5 Polymers

Polymers and rubber late x ma y be added 10 emu lsion to impro ve physical properties of
resid ue. Polymers ca n improve resistance toward s wear and lear of the pavement. These
may be ad ded to the bitumen prior to emulSIficatiOn in a solid form. Polymers and rubbers
can also be added to the emulsifter soluliOn in the form ot tate x (sm all poIymef particles
suspended in waler phase ). which can be in cstooc ()( anionic form (similar to bitumen
emulsion). The choice of polymer or jatex type [l.e., natural ()( SBR latex, or solid SBS) would
depend on the physical properties desired.

2.2.6 ~ts

Solvents such as the diesel. hea vy ()( Iighl gas Oil, kerosene . naphtha. etc are added to
bilu men emulsions to red uce the viscosity of binder. This is oft en done to allow proper mixing
of aggregate w ith emu lsion and to keep it wor1uIbie. The highly volatile solvents. sucn as
naphtha alld light gas oil. are used in the case , where rapid cu nng Of early return 10 full
strength (due to relative ly quick evapora tion ) is required. Medium cu re a.ltback systems use
kerosene. while slow cure systems typically use dies el and heavy gas oil.

2.2.7 Additives

Additives may also be used to enhance the performance o f bitumen in emulsion. Additives
ble nded with bit umen prior to the emulsifi cation ca n provide improved properties of em ulsion
such as the un iform parucre size , storag e stability, cu ring , and adhesion to agg regate, all of
which resu lt in higher strength and re sistan ce to w ater damage.

5
 IRC :$P:100- 20 14

2.2.8 StilbillLer8

Stabilizers are used. in case, where very high stability of emlisiorl is required (such as
demanding mixing grade applications ) or where improved quality and hig~ storage stability
of emulSiOn are needed. Stabilizers are often not Yel)I effective as emulsmers by themselves.
but are used in conjuncbon with emulSifiers to enhance their performance,

2.2,9 Structure of bitumen emulsion

Bitumen emulsions consist of very fine spherical dropl ets of bitumen suspended in water.
Bitumen emulSion pa rticles are small enough that they experience Brownian mo vement. One
gram of bitumen emu lsio n (a volume roughly equal to a sugar cc be ) call contai n over one
bill ioo bitumen droplets. These one billioo droplets of bit ume n in emulsio n have a tota l surface
area of approximately 1 square meter. The typical structure of ca tion ic bitumen emulsion is
shown in Fig. 2.1 .

,- - - Y -

Fig. 2. ' Struel\Ire 01 Calionic BitI.rnen EIflllb;on

2.3 Production of Bitumen Em uls ion

Most of the bitumen emulsions are manufactured by continuous process using a colloid
m~l, whictl consists of a high-speed rotor revolving at 1000 to 6000 revo/ubonslminute in
a stat or. Hot bitumen and emulsifier solutions are fed separately but simultaneously into
the colloid mi ll. The temperature of two componen ts is critical to the emulsification process.
The viscosity of bitumen entering int o conoid mill should not exceed 0.2 Pa-s (2 Pcee j. If a
harder grade bitumen or modified bitumen is used. the emul Sificatioo process become s more
difficult. Higher tem perature is needed to allow bit umen to be pumped into an d dispe rse in
the colloidal mill ; dispersion of bitumen requires more power input to the mi ll. wh ich further
increases the production tempe rature. Pressurized mills are used fo r bit umen having high
visco sity at norm al emulsification temperat ure and to allow higher output wit h no rmal bitumen.
Emu lsions with te mperature up to 130"C are produced under high pressure and em ulsion
outpu t must be cool ed do wn to below l 000C tesore being discharged into sto rage tanks . A
hatch process can also be used for produ ct ion of emulsion wherein the type 01mi xer used

... ~-
 IRC:SP :1OQ-201 4

is chosen to suit the con sistency of end product. It ma y either be a high-speed propeAer Jor
low viscosity emulsion or a slow z -oece mixer for paste-uke industrial emulsion. SChematic
diagrams of COI"1tinuous and ba lch type emulsion manufacturing facihtles are shoYm in
Figs. 2.2 and 2.3. Bitumen emulsion can be prepared us il"ig a on-site mobile plant or olf-site
stationa ry ptant The mobile plan t may save cost of transportatiOn of water.

,,- ~ -,

~f'
,~ -
,~-

"-
~ B-. '... ' f ...... .A

[I
~

M '~

COllOID _ .
HEA TEA

Figs. 2.2 & 2.3 Schematic Diagrams : Emulsion Production

2.4 Classi fication of B itume n Em u lSion s

Bilumen emulsions are cla ssified into four ca tegories: anionic, cationic. clay and non-ionic.
Cationic and anionic emulsions are widely used for construction and maintenance of roads.
The term anionic and cationic emulsions refer to the electrical charge s surrounding bitumen
particles in emulsion. Emulsions are further classified on the basis of how quickly the bitumen
droplets wil l coalesce. The terms RS . U S. SS and OS are rela tive terms only and ha ve been
used to simplify the classificatiOn. These terms expand 10 mea n Rapid-Setting (RS ). Medium-
Seltlng (MS). Slow-Setting (5 5) and OUick-Sett lng (OS).

IS 8887 prescnbes specificatiOn for cahon e bitu men emu lsion. ASTM and AA SHTO have
also developed standards and specifications for various grades of bitumen emulsions.
The varlous gradi ngs of emulsions, as mentiOned in IS. ASTM and AASHTO. are shown in
Table 2.1.

T" bIe 2.1 Classification o f Bitumen Emu ls ion as per Different Sta ndards

Asphalt Emulsion Cationic: B,~n Emubion CatiO,"C: A$phall Emulsion

(ASTM D9n.AA5HTO 111140) (15-8887) (ASTM D 2397: AASHTO 101I208)
RS-' RS-' CR5-'
RS-2 RS-2 CR5-2
HFRS2
MS-'
MS_2 "' CMS2
MS_2h CMS2h

7 oevendfli Kumar
SQME.L8G
IRC: SP: 1OG-20 14

HFM5-1
HFMS-2
HFMS-2tl
HFMS-2S
SS ~ , C5S-1
S5 -111 C5 5-1h
c s-tn cc s-tn
Note : 1) The numbers and letters relate to voscoslty of \he emulSIOO and hardl'le$$ of base
bitl.meo , The Iel1er "C' oeocies to ca eooc . The addrtlOn of 'h' means that harder base
bitumeo has been used.
2) Ooly ca!lonic emulsions are used in lnd<a
Rapid Sett ing grade of bitumen emulsion (RS~ 1), Specified in Indian Standard , is specially
recommended for la ck coat applica tion, while Rapid Setting grade of emulsion RS-2 is
recommended for su rfac e dressing WOI'k. A Medium Setting grade of emulsion (MS) is used
lor mixes with high coarse aggreg ates (minimum of 80 percenl) all of which are reta ined
on 2 .36 mm IS Sieve and practlCaRy none of which pass through 180 microo IS Sieve see.
MS grade is also used for su rface dressing and Penetration Macadam. Slow Setting gra de
(SS-1) is used m.- other applications suet as fog seal, crack seal and pnme coat. wh ile Slow
Settinq grad e SS~2 is u sed for plant mix es with graded and fin e aggreg ates, a substantial
quantity o f which should pass 2,3 6 mm IS Sie ve size, and a po rtion of whi ch shou ld pas s 75
micron IS Sieve see

The emulsion for rnicro-surfadng is required to meellRCIlSSA specifications. A requirement

of 3 percent of solid o f rubber/polymer by weight of bitumen in the emutsion is always needed
for complian ce . The addition o f rubber addrtive enhance the high temperature performance
of bitumen and permits application of micro-su rfacing in filling of ruts. Adding one le tter (P,
S or l ) to the end of the grade (e. g . CR S - 2P ) normally de signates the mooned emulsion.
Specifica tions of ca tio nic emulsion (A STM 0 2397, AASHTO M 208) permit so lvent in some
grades but res trict the amount. Some use r agencies specify an addltiClOal ca tionic sand-
mixing grade clesigned as CMS - 2S , wh ich contains more solvent than oth er catooc grade,
while IS:8887 does not permit addition of soIvenVwater_

2,5 Variables A ffe<:ting Quality of Bitumen Emulsi on

The re are many factors wh ich affect the production, storage, u se, and performance of a
bitumen emulsion that it would be difficult to single out any one variable as being the mo st
significa nt one. Nevertheless, certain variables having significant effect on quality and
performance of em ulsions include the following:
Chemical orocenes o f bit umen
Consisten cy and quant ity of bitumen
Particle size of bitumen in the emulsion
Quality and dose of emulsifier

..
 IRC:S P: 100-20 14

Man ufacturing conditio ns such as temperature. pressure. and shear rate

Ionic charge on the emulsion partiCleS
Sequence of additlOfl of the ing redients
Equipment used in manufacturing of emulsion
Properties of chem ical modifiers Of polymers
Qua lity of water particularly the hardnes s
The se factors can be varied to sui t the available aggreg ates or construction specifications. It
is always advisable to oonsu lt the emulsion supplier with respect 10 a particular aggregate. as
there are few rules. which appl y under all oonditions. while so me rules are ma terial (ag gregate
and emulsioo ) specific.

2.6 Properties of B itumen Emuls ions

The importan t prope rties of bitume n emu lsions are given below:

Stability
Viscosity
Breaking and cu ring

Adhesion
2.6.1 StatHIdy of emulsion

Emul sion having low bitumen co ntent and low viscosity is prone to lo wer stability, The density
of bitumen a t am bient temperature is slightly greater tha n aqueous pha se of emulsion and
eventually bitumen particles in such emulsion tend to settle down resulting in a rich layer of
tower bit ume n content. The velocity of dispersed phase particles in the downward movem ent
ca n be estimated by using Stolle's law.
1X, 1(PI - p;)

where.

9 = gravitational force: r = radius of particle; 1', =specific gravity of bitumen; I'l =specific
gravity o f aqueous phase and '1 = vi scosity of aqueo us phase.

Therefore . the settlement can be red uced by eq ualizing the density o f dispersed phase and
clrspersion medium and it ca n be achieved by add ing buffer sa lts like calcium chloricle in
aqueous phase.

2.6.2 Viscosdy of emulsion

The visco sity of emulsion at conditions duri ng spra ying is of prime imp ortance . The viscosity
of emulsion ca n be measured using orifice type vrsccrneters such as Standard TarViscomete r
Of Saybolt Furo! Viscometer.

9
IRC :SP:100-2014

The viscosity of emulsion can 00 enhanced by the fo llowing methods.

8 y increasing the concentration of dispersed pha se (bitlJTlen)
8y increasing the viscosity of co ntinuous phase
8y reducing the range of parti cle size distr ibution.
The converse changes wiM. sim ilarly, decrease the viscosity of emulsion. However, emulsiOn
viscosity is almost independent of the viscosity of disperse d phase (bitum en).

2.6.3 EVeakJng and curing

2.6.3. 1 Breaking

If the bitumen em ulsiOn is to perform its ulti mate function as a binder. the water must separa te
out from the bitumen phase and evaporate. This separation of water from bitumen is called
"b reakmq". For su rfa ce treatments and seals, emulsion s ar e formulated to brea k chemically
upon contact WIth a foreign substa nce such as aggregate and pavement surface. When
using anion ic and cationic rapid-setting and medium setting emulsions, the break ing of the
bitumen emulsion droplets on the aggregate develops thro ugh elec troc hemica l factors. For
slow-setting emulsions, the mechanism is through water evaporation. For dense mees. more
time is needed to allow for mixing and placement. Therefore. emulsions used for den se
mixe s are formula ted for de layed breaking. A rapid-set emulsion will have a short breaking
lime (withi n one to five minutes after bei ng applied), whereas a medium- or slow-set emulsion
may take longer time.

2.6.32 Curing

Curi ng involves the developlnent of co hesion. The end result is a continuous co hesive film
that hold s the aggregate in place wi th a strong adhesive bond . For this to happen, the water
must completely evaporate , and the bitumen particles have to coalesce ancl bond to the
aggregate. The water is removed by evecoretoo. by pressure (rolling). and by adsorption
onto the aggregate surface. Water evaporation ca n be fairly ra pid und er favourable weath er
conditions, but high humidity, low tempera tures . or rain soon after applica tion ca n defer
needed cu ring . When medium seltng and slow selting grades of emulsion ar e used for
paving mixes, the use o f slightly damp aggregate facilitates the mixi ng and coating process.
The development of streng th in the slow sening types depends mainly on evaporation and
absorption. Mixing grade emulsion usually contains some petroletJm solvent to aid in the
mixing and coating process. During curi ng process, so me o f solvent ev aporates.

2.6.3.3 Factors affecting breaking and curing

The factors affecting the brea king and curing properties of cold mi xes are given below:
Water absorption - A rough texture as well as porous aggrega te oeceeses
the breaking ancl setting time by absorbing water
Aggregate moisture content - T he wet aggreg ate facilitates easy coaling
but i1tends to slow the curing process due to increased time needed for the
eveooraton of water.

10
 IRC:SP :1OQ-2014

Weather ccocncos - Tempera ture. humidity. and wind velocity have a

bea ring on water ev aporation and emu/sifiel' migration_ The bre<lking occurs
more QUickly at warmer temperatures but !hat is fI()( always lhe case . Hot
weathe r can also cause skin formation on chip seals . Chemical formulations
are a vailable for faster breaking.
Mechanical fac tors - Rol ler pressure and , to a limited ex tent. slow moving
traffic. forces the water 10 e vaporate from the cold mix and helps to a ttain mix
cooesoe. cu re and stabil ity.
Surface are a - Greater agg rega te su rface are a. particularly e xcessive fines,
acce lerates the breaking of emulsions and that is why sand equivalent test is
important.
Surface chemistsy - Qu antum of aggregate surface charge. in combination
with the ,"tensity of emulsifier charge. can anect setting rate. partiCularly for
cationic emulsions. Ca lcium and magnesium ions on the aggregate surface
can react w ith certain anion ic emulsifiers and thereby can accelerate setting
process.
Emulsion and aggregate temperature - Breaking is retarded when
temperatures of emulsil::m and aggregate are low.
Type and amount of emu lsifier - The surfactant used in the manufacture of
em ulsion determines the breaking characteristic of fine mixes.
The supp lier of emulsion is the best source of information in order to con trol the above listed
parameters.

2.6.4 AdheSion properties

The Qualityofbood between bitumen and aggregate or existing surface depends on a number
0( racers. as lis ted below:

type and amount o f emulsifier

bitumen grade
pH of the emulsifier solution
particle size distribution of the emulsion
aggregale properties

2.7 Precaution s for St oring and Handling

The fol lowi ng aspects need due consideration during the storing and handling of bitume n
emulsions:
SIOfe preferably between 1O"C and 5O"C.
Should not be heated above 85"C. a s at elevated temperatures water
evaporate and thereby, changing the cha racteristics of emulsion , may lead
10breaking .

11
lRC:S P:100-20 14

Do not allow freezing. Freezing below 4C may cause breaking of emulsion

leading to se pa ration bitu men from water,
Do not allow temperature of surface 10 exceed 85OC . Since it w ill cau se pre -
mature bf"eakJng of the emulsiOn.
Do not use jet of air 10 ag itate emulsion, as this ma y cause emulsiOn to
break.
When heClbng bitumen emulsion , ag itate It gently to eliminate or red uce skin
form ation.
Protect pumps, valves, and lines from freezing in wi nter. Drain pumps and
service ac cording to the manufact ure's reco mmendations.
Blow out line and leave drain plu gs open when they are not in service
Use pumps with peoper oearances for halldlill9 emulsion, Tighlly fitted pumps
ca n bind and seeec
Warm th e pump 10 about 65"C to facilitate start-up.
When d ~uting bitumen emulsion. check the qwlity and compa tibility 01waler
with the emulsion by testing a small quantity in a test nee.
If possible. use warm and so ft w ater for dilution. Alway s add water slowl y to
the emu lsion (not the emulsion to the w ater)
Avoid rep eated pumping and reca lculating. as the visco sity may drop and air
may become entrained . ca using the emulsion to be unstable.
Pla ce inlet pipe s and return lines at the bo ttom of tanks 10 prevent foaming .
Pump from the ecnorn of tank to mi nimize con taminatiOn from skinning
Remember that emulsions with the sa me grade designation can be very
different chemically and also in performance.
Agitate emulsions genlly that have been suojected to prolonged storage.
This may be do ne by rec irculation
Avoid brea thing fume s, vapors, an d mist
Obtain a co py of supplier's materia l safety data sheet (MSDSl Read MSDS
ca refully and follow it
Do not mix different classes. types , and grades of emulsions in tanks and
dis tribut0r5 .
Do not dilute rapid -sening grades of bitumen emulsion with water. Medium
and slow se tting gra des ma y how ever be diluted , but always add soft water
slowl y to the bitu men emu lsion .
Do notload bitum en emulsion into storage tan ks, tan k cars, tank transpo rts,
or distributors co ntainin g remains of incomp atible ma teners.

12
 IRC:SP:1QO-2014

3 SPECIFICATION AND TE STING

3.1 Specification

Emulsions as per IS 8887are classified into live types such as R5-1 , RS-2 MS. S5-1 and
55-2 depending upon their setting cnerecie-eece and use. The recommended uses and
specifications for different types o f bitumen emutsoos are given in Tables 3.1 to 3.3 .

Table 3.1 Recommended uses lor Diffe rent Types 01 EmUls ion

".. RlICOmmendeod USK

RS 1 A QUick setting emlAsion used lor lad. coat
RS-2 A quid< sening emulsion used for w rface lrealmenl, surface dressing, Penetration Macadam,
Peoelraboo Grouting
.S A medium sen'ng emulsion used lor plant or road mixes with COOl"'" aggregate for premix
~ ...
SS-l
SS-2
A slow setting emulsion used lor priming
A slow senill9 emulsion used for plant mIxes wrth graded fine aggregale in SDBC, MSS,
DBM arid BC. This emulsion;s ersc used lor slurry seallreatmenl arid lack coal
,.
Modilied Modified emulsion is used for m;crosurfaci

Table 3.2 Specifi cations of Cationic B itumen Emu lsio n

,~
",-,!lH <II' Bitumen Emulsion e.- 01 Emulsion (Soller G ' -I
., .....
'n'
'J
ii)
-, ....on s.,. __
ResocJue

~ by
600 mo;nln

Furd
IS _ I'"
RS !
co
"'0
". '"
551

'"
'00
'"
1$:_1

1$.3117

."""
iii)
Voscool 81$ , Seconds
e zsc
,d_al_
0Mg0'
1&1"'-
~

eo-too ,......

~ ~
.
...soc
",.""

~
...",
~

15: _1

" .... ""'" - -

_".1"0".
-,. ac 15:8887
' J Slorage ~ 'llo, """,, , 2'
"
' K
" " 15:8881

0' Coaeng~--~
ill Co8lo'9- <Iry ilggrwg.:rtes Goo>l
15:_7

b) CoalIng alief spaying ""'1...-

,.
,.

" ....
c) Coe\Ing, _ *'Ne;pI""
~-
""""'9-' .
a 1$8881
w)
...-
~ 10 ~%

';;;1

.,
Moscitlolity WIth wal er (<:oagutaloon)

Tesl e on R _:
ill J-IModu" b~ llVa pora lion. % , min,
b) Penelration. Z5"C! 100 gml 5 sec .
c) Ouctility nt 2T"C. ern.. min.
~

-~~
so
81). 150
so
~
Coegulatoon

"
81).150
00
-- ~

es
so.r so
00
Immiscible

eo
60-1 20
00
15.8687

15 :8687
15 :1203
15 :1200
d) SolubI lity In Tric/1lorocl hylcne , %, sa se sa se se 15 :1216
~.

13
IRC:SP:10G-2014

Table 3.3 Properti es o f Modified Bitu me n Em u ls io n for Microsurtacing (IRC :S P-8 1)

S.No. Proper1i", R"quir"m",nt Ml'tl>od of Test

""
Residue on 500 micron IS si"'ve (% ma ss). maximum 0.05 IS:8887
VIscosity by Say bolt Furcl Viscometer. at 25"C. seconds 20 -100 IS:8887

"') Coagulation of emulsion at low tempe rature

Stor<l98 stability after 24 II (168 h), %, ma ximum
Nil
2 (4)
18 :8887
18:8887
') Particle charge, H' 18 :8887
6) Tests on ResKlue:
0) Residue by evaporation , % minimum 60 18 8887
6) Penetration. 25"C / 100 gm / 5 sec, 40 - 100 18 ,1203
0) Ductility at 27"C, em. minimum so 18 :1208
6) Softentng Point. "C. minimum sr 18 1205
,) Elastic Recovery . %. minimum so 18: 15462
Solubility In Trichloroethy lene , %, mlntmUm sr
"
18:1216
In case erastc recovery rs tested for Torsional ElasticRecovery. the rnmerarm value shall be 20% ,

3.2 Testing
The testing of emulsion is esse ntial before its packaging, storage and release for transportation
to ensure the quality of product against the applicab le requirements. Tests such as Penetration,
Ductility and Solubility in Trichloroethylene are also applicable on residue of bitumen emulsion
as it has to perform the functio n of binder after break ing and evaporation of water. These
spec ifications describe the importance and significance of various test method s applicable
to bitumen emulsion to ensure the qualily and application for intended use. Proper sampling
should be ensured as detailed in IS:8887-2004 before testing the bitumen emulsion.

3.2.1 Residue on 600 micron IS sieve

An emulsion is characterized by the uniform distribution with respect to size of particles of
bitumen droplets in aqueous phase. This dispersion should not conta in foreign particles of
any type whatsoever, which are likely to clog the nozz les and fi lters of spraying equipments.
Therefore. sieve test is considered as an Important test to ascerta in the quality of bitume n
emulsion. In this test previously weighed 4 liters representative sample is filtered throug h
600 micron sieve at specified temperature (25 or 500<:) afte r rinsing the sieve with distilled
water except in case of invert ed emul sion ($ S-l grade). After filtering the emulsion. sieve
is repeatedly washed with distilled water until washings are clear and then dried in oven at
105 5C for 2 hou rs and the residue over sieve is determined by weighing. The complete
details of the test method experiment have been provided in Annexure-B of IS:8887. The
weight of retained residue on sieve should not be more than 0.05 percent by mass, as per
the requirements indicated in IS:8887.

3.2.2 Viscosity by saybolt furo! viscometer

Viscosity is defined as resistance to flow. The viscosity of emulsion is an important property
and it must meet the requirements of 1$:8887. The viscos ity of bitumen emulsion is measured

14
 IRC:5P:1QO.2014

at 25 Of 5O"C by using saybolt Furo! VISCOmeter depending 00 the grade of bitumen emulsion
as per tile test method giv en in 15 :3117. The results are reported in Say bolt Furo! seconds
{Fig. 3.1 ).

Fig. J 1 Saybolt Furo! Vosoos,ty Measurement

3.2.3 Coagulation at low temperature

Coagulation test at low temperature is performed to ensure the homogeneity and stability
of bitumen emulsion. if exposed or sto red at sub-zero temperature. In this lest, 20 ml of
previously siev ed homogeno us bitumen emulsion is transferred in to a boiling tube. The
temperature of this boiling tube is brought to 3O"C by plungi ng the tube inlo water bath
previously set at 3O"C with gentle stirring by a glass rod . Once the temperature of bttumen
em ulsiOn is constant at 3O"C. the tube is plunged into ice ba th Of rehigerator previously set
10 O"C with slow stirring by road . Once the temperature of emulsion reaches O"C, the tube
is transferred into refrigerator for 30 minutes previously set at -3 to -4C. Finally, the tube is
removed from refrigera tor and brough t to room temperature without any disturbance, The
emulsion is filtered through 600 micron IS Sieve and sieve is washed with distilled water and
checked fOf resfdual bitumen (coagulation ), if any. As per the test method , there should not
be any deposit Of coagu lation on the sieve. If emulsion is expect ed to expose below -4OC
cluring stora ge and transportation, the coagulation is checked after applying 3 freeze and
thaw cycles. The complete details of test are described in Annex-C of 15:8887.

3.2.4 Storoge stability

SIorage stab~ity is an importa nt property of bitumen emulsiOn and it renacts the tendency of
OlIUITJen globules settling down over a period of time. Storage stability of bitumen emulsion
oS determined after 24 h of storage, as per IS:8887. In this test. SOO ml homog enized and
previously sieved bitumen emulsion is taken into graduated cylinder of 500 ml capacity and
-eft undisturbed in the laboratory lor 24 h at room temperature , Tile samples. 5O:t 0.1 9 each,
are taken from the top and bottom of the cylinder into previously weighed beakers of 600 mI
capacity. Both the beakers are hea ted in an air oven at 163 2.8OC for 2 h. The beake rs are
removed from the air oven and left over residues are stirred and further kept in air oven for
1 h at the same temperature, so as to remove water from the resid ues . Both the beakers are
cooed and weighed to nearest 0 .1 g. The difference in the weight ofresidues should not be ITlC:lre
than 2 percent for R$-.-1 . S5-1 and S5-2 grades, whereas it should not be more than 1 pelceclt

15
IRC:SP:1()()..2Q14

for R5 -2 and MS grades of emu lsion as per 15 :8887. The compl ete de tails of test method
are given in Ann ex-O or 15:8887.

3.2.5 PartK:le charge

The signi ficance of th is test is 10 differentiate between the anionic, cat ionic and inverted
emuts-cns. In this test method . two steel plates, of size 25 mm X 75 mm, are immersed into
emulsion placed at a distance of 25 mm , which are connected to 12 volt DC Circuit through a
switch, rheostat and a mete!". In the test, 4 mA ClJJ1"erIt is passed between the electrodes for
30 min utes. At the end of e xpecment, the electrode plates are wa shed with distilled water
and inspected for an y bitumen deposition In case of cationic bitume n em ulsion, the particles
of cat ionic bitu men emulsion get deposited on cathode during the experiment (Fig. 3.2 ).
However, there is no deposition of bitumen particles on cathode in case of anion ic and
inverted bitumen emu lsions. The complete detail of the test method has been provided in
Annex-E of 15 :8887 specificatiOns .

.... 'L....
-.iI.. _._+

...Jj
FIQ. 3.2 Parbde Charge MeastM"ement

3.2.6 Coating ability and water resistance

The ob;ectiv e 01this tes t is to de termin e the ability of bitumen emulsion to (i) coa t lhe aggrega tes
thoroughly. (ii) withstand mu(ing action wh ile remaining as a film on agg regates. and (iii)
resist the washing action of water after the completiOn of mixing . This test is developed to
basically identity the medium setti ng cat ionic bitumen emulsion and to eval uate its suita bility
fot mixing with coarse graded calcareous aggregates and is no t app licable for rapid setting
and slow sening bitumen emulSionS. In this test. 460 gm of aggregate (pass ing throug h
19 mm IS sieve and retained on 4 .75 mm IS sieve ) is coa led with calcium carbonate du st
(4 g) and then mixed with bitumen emulsion (35 g) in a pan. About hall of the mixture is
then placed on absorbent pap er for vis ual inspection of surface area of aggregate coated
with bitum en emul sion. The leltov$' mixture in the pan is sprayed with wa ter and rinsed with
water until the nnse water runs clear. This material is placed on an absorbent paper and
inspected for status of coating. 'Good' status means the aggrega tes are fu lly coa ted with
bitume n except the pinho le and sharp edg es of aggrega te. 'Fair' status means the higher
surface area is coated in comparison to the uncoated surface area whereas 'Poor: status
means lower surface area is coa l ed in comparison to the uncoatect surface area.

16
 IRC: SP: 1QO-20 14

The second test is repeated in the same ma nnef as above with a dIfference that the
aggregates are wet w ith water (9.3 mll before mixing with bitumen emulsion allCl the n are
viSUall y inspected foe" coating .

3.2.7 Stabimy to mixing with cement

This test roocates the ability of slow se tting bitumen emulsion to mix w ith a high surface are a
material without break ing . In the field , slow setting grade of bitumen emulsion (5 5-2) is often
used with aggregates conta ining appreciable am ount of fines and dust. In th is test. bitumen
emulsion sam ple (that ha s to be tested) is diluted w ith water so that it has bitumen content
equt valent to 50 percent. This sample ( 100 g) is mixed with cem ent (50 g, already sie....ed with
150 micro se ve)with steel rod for 1 minute. At the end of mi xing . 150 ml boiled water is added
and mixed for 3 minutes. This mixture is finally w ashed o....er 1.4 mm sie.... e. The material
retained on the sieve should not be more than 2 percent of bitumen present in the emulsion
as per 15 :8887 specifications. The complete details of test method are given in Annex-G of
15:8887.
3.2.8 Miscibility WIth water
The purpose of this test is to ide ntify the types of bit umen emulsion Le. bitumen in water or
wat er in bit umen. Normally, cationic bitumen emulsions irrespective of the grades are miscible
with water, whereas an in.... erted emulsion (5 5-1 grade) is immiscible in w ater. In this test,
150 ml waler, is mixed in 50 ml bitumen emulsion with constant stirring at room temperature.
The mixture is allowed to keep for 2 h. As per 15 :8887, there shou ld not be any coagulation
of bitume n after 2 h. Th e tes t method is detailed in Annex -H of 15 :8887.
3.2.9 Residue by evaporation
Residue by e v aporation provides a fair idea of bitumen con tent present in the bitum en
emulsion. This test is co nducted on all grades of cationic bitumen emulsions e xce pt for inv ert
em ulsion (55-1 grade). In this test , 50 g sample is heated for 2 h in a two litr e beaker a t
163 2.8"C in air o ven. At the end of thi s pe nce. the re sidue of beaker is stirred we ll and
further heated for 1 h at 163 2 .8"C in air o....en . The weight in perce ntag es of the res idue
is determined after- cooling the beaker at room temperature . The details of test method are
given in Annex-J of 15:8887.
3.2,10 Tests on residue
Tests such as Penelration , Ductility and Solubility in Trichloroethylene are also applicable
" the res idue of bitumen emulsion as it has to perform the sa me functlOO as bitumen after
coagulation , followed by ev aporation and drying of water The penetration. ductility and
solubility in trich loroe thylene tes ts are conducted on residues as per the procedures given in
15: 1203. 15 :1208 and 15: 1216 res pectively.
3.2.11 Distillation test
Distillation test is performed on Slow Setting grade 01 Emulsion (S5~ 1) in place of 'Residue
by E....eccreuco', as it contains higher concentration of org anic distillates along with water in
com pariso n to other grades of em ulsion. The residu e, obtained after distillation at 36O"C,
should not be less than 50 percent. as per 15 :8887. The complete details 01test method are
given in 15:1213.

17
IRC:5P:1QO-2014

3.2.12 Wale r content

w ate r content is determ ined only in 5 10w grade of setting grade of Emulsion (55-1) by
follow ing Dean Stark test method given in IS:1211. The water conten l in 5 5 -1 should not be
more than 20 percent, as per 15:8887.

3.3 Sam pling of Emulsion

The emulsion supplied by manufacture at site shall be collected from drums 01tankers as per
procedures describe in 15:8887 and 15:1201. In case of tanker. sample of emulsiOn st\a.II be
Iaken (Fig . 3.3) using a 3 kg container mounted on a woodier rode (75 em length and 2 ern
in dial . In case of drum s . these have to be rolled to and fro 5-6 times at a distance of
4-5 meters. Sample (2 kg) from the drum will be taken using a pump 01 lilting drum at
6O"C angle. One sample f0l10-2O tonne in case of tanker and 5-10 tonne in case of drums
shall be taken at site for evaluation of quality at site.

---
e

--
----iii

-'-~"'"
-=
FlQ_3.3 Sampling of Emulsion

18
 IRC: S P.'0l).201 4

4 Quick Tests for Quality of B itumen Emulsion at Site

t e Eng ineers are alw ays co ncerned abo ut the Quality of bitumen emulsion rece ived at site .
following tes ts shou ld be carried out at site to ascertain the Quality of bit umen emulsion
jed at site .

i) Res idu e on 600 micron IS sieve, as per test procedure described in

section 3.2.1.
ill Binder con ten t as per test procedure desaibed in section 3.2.9.
iii) Viscosity by now type viscometer as per test procedure described in
section 3.2.2.

4 SPECIFICATION AND TESTING OF AGGREGATES

.t Introduction

understandi ng of aggregates mineralogy and its impact on the performance of emulsion

ased mixes is important. Th is section provide general informa tion 's on the composition of
too'"'"and their interactio n with different type s of emu lsions , and som e of the basic tests that
used to determine !tie su itability of aggregates for use in emulsiOn based cold mi xes are
i\ten be low

.2 Aggregate - Emulsi on In t eractio ns

For!tle purpose of predicbng!tle performance of billlmen emulsion, rocks can be divided into
two broad categories . The "oxide" roc ks consisting of those with high ratio s o f silicon oxide
(Silicate) or metal oxide co ntent. and the "ca rbon ate" rocks consisting of those with high ratios
of Ume stone or Dolomite type minerals. Most of !tie igneous rocks and Slag fall into the o xide
category, wh ile most of the sedimentary roc ks fall into the carbonate category. Metamorphic
rocks can be in either ca tegory. depending on their properties and composition .

Based on the above informabon and the general pri nciple that using emu lsions and aggregate
of opposite ch arges are beneficial, most of the aggregates used worldwide for paving are
silica te-based (siliceo us) and that is the reason why mo st of thos e areas specify ca tion ic
bitUme n emu lsions. An ionic emulsions ca n be used w ith lime stone and Dolomite types of
aggregates.

4.3 Testing

The following tests are considered enpoetant for deciding suitability of aggregates for cold
mixes .
Sand Equivalent Value Test
Methyleoe Blue Tes t
Shape Test
Gradation Test

19
IRC :SP;100-20 14

Soundness Test
Aggreg ate Impact Value Test
Water Absol'ption Test
Stripping Test
The significance and brief of various tests are described below:

4 .3.1 Sand equivalent value test

This test is used 10 dete rmine the amount of fine clay particles. This test is dooe as
ASTM 02419 (AAS HTO T 176) Of 1$:2720 (Part 37 ). The value of sand equivalent sI1aI
minimum SO.

4.3.2 Mertlyfene blue test

Th is test is a measure o f the relative su rface are a and su rface reactivity o f an aggregate 's
fraction . A measured amount of me l hylene blue dye is mixed with aggregate fines until
noes can roo longer absorb additional dye. The amount of dye necessary to surface sa
the fines is an indiCation of surface area and reactivity. Th is test is a good melhod of
control . As aggregates are supplied for a job. a sleady Methylene bIoe value is an ind"....
that the clay fines content is unchanging . The tesr sha ll be done as per ISSA procedure
in EN 933-Q9.

4.3.3 Shape test

The mineral structure 01 rocks plays a big role in determini ng the shape of aggrega te
crushing For example, the minerals that contain certa in pla ner crystalline structures
fracture into flat pieces. The sh ape 01 aggregale is determined by using nakioess
elongalloo ind e x tests , as per 15:2386 (Part-IV ). The va lue of combined FI + Et shall
exce ed 35.

4.3.4 Gradation test

Gradation les t is conducted as per 15:2386 (Part l) for conformity of co nstruc:bcJII

specifications.

4.3.5 Soundness test

The tes t procedure is described in 15:2386-1963 (Part-V). Th is test indica te s the susceptibility
of aggregates to disintegration und er the ac tion o f water containing sod ium and magnesium
sulpha tes . Washed and dried aggregates of specified sizes are imme rsed in saturated
solution of sodium su lphate or magnesium sulphate for 16 to 18 hours. This is then removed
and dried 10 constant weight. This forms one cyde. The test is repeated lor 5 cycles. Aftet
5 cyeses. the sample is washed . dried in an oven and re-se vec on those very sieves which
were used before the test. The weight 01 material retained on each sieve is recorded. The
cumulative difference betwee n the amounts weight of material on each sieves before and
after the test is the loss due to disintegration and is e xpressed as percen ta ge of tot al inillal
 IRC:SP:100-201 4

weight of the sample. The permissible values fOf loss in sod ium sulphate and magnesium
sulpha te after 5 cycles are 12 percent and 18 peeceot respectively. If the loss is more. then
ee agg regates are lik.eIy 10 disintegrate by water con taining such sans . The test result is 10
be used as caution rather tha n as a definite evidence for rejecbon of the aggregates. The
sest is carrec out wilen adequate information is not available from service record of the
aggregates actually exposed to sucn weathering cooeucos.

' .3.6 Aggregate impact value test

Aggregate Impact value lest is a measure of resis tance of aggrega tes 10 the disintegration
due to impact. wh ich in some aggregates d iffers from characteristics value 0 1 resistance
to crushi ng under slow compressive load . In the aggregate impact value test, as given in
1$ :2386- 1963 (Part IV) 12 .5 to 10 mm sized clean dry aggregates of specified volume are
subjected to 15 blows by as 13.5 to 14.0 kg hammer falling from a height of 380 5 mm. The
weigh t of sample of aggreg ate passing 2,36 mm sieve obtai ned after the test is expres sed
as a perce ntage of the or iginal weight of aggregate and is the aggregate impact value. Th e
agg regate impact values spe cified lor base. binder and surface courses are 30, 27 and
24 percent respectively.
' .3.7 Water abSfJrption test

Water absoepnon is the difference in weigh t of aggregates between 24 hours water saturated
surface-dry condition and oven-dry condition expressed as percentage of the latter. The test
procedure is given in 15: 2386-1963 (Part-Ill). Water absorption is high 'or porous aggregates.
The maximu m value of water ebsoepnon is restricted to 2 cercent fOf aggregates to be used
1"1 road construction.

' .3.8 Stripping test

Stripping is the displacement of bitumen film from a coated road agg regate partide in the
presence of water. The details of lest procedure are given in 15:624 1. In this test. 200 g of
12.5 to 20 mm sized agg regates are coated WIth 5 percent bitumen under specified cond itions
and immersed in distilled water at 4O"C fOf 24 hoUrs . The average percent uncoated area is
ooserveo under water. The amoun t of stripped area . expressed as per cent. is the stripping
value. A higher stripping value irKlicates posslbdity of loss of adhesiOn between aggregates
and bitumen in the presence of water, The degree of stripping is related 10 the type of
aggregates. shape. size. grain-siZe. surface texture . mineralogical composition, presence of
dust or cla y. moistu re. acidity or alka linity etc.

If there is fourKl to be any sligh t evidence of stripping either by Qualitative estimation or

by quantitative measureme nt, incorpor ation of commercially available anti-stripping agent in
bitum en is recommended. It is also recommended to carry out water sensitivity test (Retained
Tensile Strength, as per ASTM D 4867) if the minimum retained coa ting in the test is less than
95 %, meeting the requirement of MoRT&H standard .

21
IRC;SP:100-2014

5 SPRAY APPUCATION5

5.1 Prim e Coat

Prime coat is an application of a low viscosity bitumen emulsiOn on a compacted granular

base course which penetrate into the base (>8mm). A prime coat performs several important
functions as given below:

Coats and bonds loose mineral particles on the surface of the granular
bas
Hardens or toughens the surface of the base
Wat6fP"OOf the surface of the base by pluggi ng capillary or interconnected
vocs
Provides adhesion or bond betwe en the base and the bituminou s mixture.
The emulsion grade like 5 5 -1 (Inverted Emulsion ) has bee n developed for priming. The
amount and sire of VOids in the granular base. temperature. sunshine. and wind will influence
the penetration process. In case of very dense surface. it may be necessary to make multiple
applications . This is done to improve penetration (>8 mm ) and prevent runoff and pudd ing
of the emul sion. For bette r pen etration and reduced tyre pickup carronc emulsion . additives
may also we used .

The choice of a biluminous prilTlef shan depend upon the porosity characteristics of \he
granular surface to be primed as class ified in IRC:16. These are esteo below:
i) Surface of low porosity: Wet Mix Macadam (W MM) and Water BouncI
Macadam (WBM)
ii) Surfaces of medium porosity; Mecha nically stabijized soil base ,
cement stabilized soil arld lime cement base
iii) Surface of hig h porosity: Gravel base. Cru sher Run Macadam (CRMI
Crushed Roc k Base
The type and viscosity of the primer shall com ply with the requi rements of 15:8881
sampled and tested tor- 5 5-1 grade in accordance with standard. The quantity of 5S-1
bitumen emulsiOn foe' verccs granular surface shall be as per Table 5.1.

Ta ble 5.1 Quant ity of Bitumen Emulsion as Primer lo r Various Surface Types

Type of Surface Rate of Spray (kgl10 ....

Low porosity (WMMIWBM) 1 to 10
Medium Porosity (Medlanically stabilized sea base . limel 9 to 12
cement stabilized so~ and lime cement base)
High porosity (Grave l Base . Crusher Run Macad am (CRM) 12 to 15
and Crushed Rock Base )

22
 IRC:SP: l00-20 ' ,!

Primer shall nol be applied during a dusl storm or when the weather is foggy, rainy or windy
or when the temperature in the shade is less then 10"C . Surfaces to receive emulsion as
primer shall be damp, without standing water. The applicat ion of prime r in prog ress is shown
in Ph otos 5.1 and 5.2 The detail s of prime coat application are given in IRC :16.

Photos 5.1 aod 5,2 Priming in Progress Uslng BiWmen Emulsion

5.2 Tack Co at

Tack coa t is a light application of low viscosity liquid brtuminous material like emulsion to an
e}\isting surface (bituminous/cement concrete/primed granular su rtace) to facilitate a bond
between the surface being paved and the overlaying course. Th e tack coat is recommended
for all types of overlays. Th e only poss ible exception might be when an overl ay is to be placed
within 48 hours on a fre shly laid bituminous surface that has not bee n subjected to any traffic
or con taminated by dust. Bitumen emulsions commonly used for tack coat are RS-l , SS-
1h. CSS-1 and C5S-1h. The de tailed reqcsements of tad<. coal are given in IRC:16. The
recommended rare of appIicalion of tack coa t is given in Tab le 5.2 .

Table 5.2 Rate of Application of Tack Coat

s . No. Type of Surface Rate of Spray (kgl10 ml)

,I Bituminous surface 2.0 to 3.0
2) Gr anular surface treated with primer 2.5 to 3.0
3) Cement concrete pavement 3.0 to 3.5
'The test results of lack coat are obtained if it is applied whil e the pavement surface is wet
and the surface temoeature is normally above 25"C . 'The surface to be tack coated must be
dean and free of loose mineral material. A good lack. coat results in a very thin but uniform
coa ling of residual bin.men on the surface. when the emulsion has broken . After spraying
the tack coat. sufficien t time musl be allowed before an over1ay is placed for the complete
breaking of the emulsion (brown to black colour).

The tack coat distri butor shall be a self propelled or towed bitumen pressure sprayer.
equipped for spraying the material uniformly at a specified rat e. Sma ll area s, inaccessible to
!he pressure distributor, or in narrow strips, may be sprayed with a pressure hand sprayer.

23 Devendrn)(uma(
SQ)J.E,LBG
IRC :$ P;100-2014

The details of applica tion of tack coat are given in IRC :16 . T he tack coat sp raying in prog re ss
is shown in Ph o t o 5.3. The view of good tack coal is shown in Photo 5.4. The quality of tack
coat can be quantitatively determined by measu rement of bond strength (by shear test) on
cores taken out from test section. A shear strength value of 2.0 kgfcrrr is acceptable for good
tack coat. A procedure for tes ting of bond strength is given in Append ix-l .

Ptlolos 53 & 5.4 Application 01 Tack Coat USIng Bitumen EmuIslon alld V_ of Good Tad< COiIt

Speed additives may be used for quick setti ng and reduced tyre piC!<. up.

5.3 Crack Seali ng

Cracking in the bituminous surface occurs in many forms varying from small hairline cracks
(less lhan 1 mm) to wide cracks having a width of 6 mm or more_large or severe cracks may
not atways be correctable by crack se aling using bitUmen emulsion. Cracks generally fan into
one of the following categories.
A lligator Cracks : Interco n nected cracks forming a series of blocks
resembling to skin of allig ator or chicken wire .
Ed ge cracking : Crack ing that occurs along the outer edge of the pa vement.
usually within 300 10 600 mm of the edg e. Such cracking occurs when cevee
shoulders do not ex ist.
RenfICtive cracks : Cracks in bitumen overlays and surface treatments tnat
re flect the crack pa ttern 01 the underlying cevementtayers.
Shrinkag e or block cracks: Interco nnect ed crac ks forming series of large
blocks. usua lly w ith sharp corners or angles.
Slippage crac ks : C rescent shaped creeks that point in the direction otlhe
thnJsl of the wheels on the paverreot surface.
U near cra ck s : A crack that may be parallel or transverse 10 the center line.
ar randomly located in the pavement surface.
If cracking results from a d eflection beneath the pavement surface. it is always doubtful tnat
seal ing the cra cks by emulsion wil l pro vide a longer lasting solution.

24
 IRC: $ P:1QO-201 4.

The besllime of sealing cracks is as soon as these develops. A crack ca n continue 10 widen.
so crack se aling must be done at Ihe earliest. The failure 10 seal crac ks pro perly ca n lead 10
further and more sev ere pavem ent da mage due 10w ater intrusion Of" freeze-thaw. Sealing of
caces with bitumen emulsion is relatively Simple and inexpensive and can dela y or postpone
major main lenance. Before cracks are to be fined. loose materiel in Ihe crack should be
blow n out using compressed air. The left out of foreign materia l in cracks not removed by air
blowing should be rem oved by steel wire brush or compressed in .

Small and medium cracks. less than 6 mm width, are diflia.lh to seal effectively_ For large
crac ks. bitumen emulsion ($S-2) mixed w ith sa nd , should be forced into the crack until It
is about 3 to 6 mm from the surface. After curing has OCCUlTed. finish sealing by filling the
remaining de pth by lig ht a ppecaton of dry sa nd to prevent pickup of material by tra ffic. The
recommended bittlmen emulsion grade to be used for crack sealing is S$-2 or its equivalent.
A pressure distributor or sprayer ma y be used for application of bitumen emulsion. The
Table 5.3 provides recommen ded criteria for cr ack sealing .

n,ble 5.3 Recommended Crrten., for Craek Sealing

Cra.;k cn.ractertstlcs _ ~ _ C....... T.... tmenl Ac:tMty
- Crack Sealing Crack Filling
WOdlh. mm
_.)
Edge detc<iorabon (i.e. spak.

Annual horizoIUI mo'o'ef\'lerlI. mrn

-
Mo:1irnalIQ

)
510 19
None (S 25 pett:enl d

aa
~-
5 10 25
Mode<a'" 10 None (s 50 perren!
)
<3
Type of cra ck Transverse Th ermal Crac ks Longitudinal Reflective Cracks
Transverse aenecsve Cracks Loogrtud'na1 Cold JOil'l1 Crad<s
Longilu:Iinal ReIlective Crad<s L.ong;\udln8I Edge Cracks
Longitudinal Cold joinl: Cr'ad<$ Ch$tantly Space Bk:x:k Cr.Kl<s

5.4 Fog Sea l

Fog seal is defined as "a light application of diluted ($ 5-2 or taik>r made ) bitumen emulsion
used primalily to seal an e xisting bitumen surface to reduce ravel ing and en riCh dry and
wea thered surface s. Fog se al is a method of inco rpo ration of bituminous binder to an existing
pavement to impro ve its wat erproofing cha racteristics. preventing further stone loss by holding
aggregate in place. rejl1Venating surface and improving the surface appearance. However.
its inappro priate use can result in a slICk pavement. During appl ieation, bitumen emulsion
wets the surface of the aggregate. Cationic emulsion can displace water from the surface of
binder on the aggregate and existing binder film. The rate 01 breaking emulsion is dependent
on several factors including we ather conditions (e.q . w ind . rain, temperature . elc.).

RejlNenating emulsion has oils that help in softening ol ltte oxid ized binder in existing scrtace.
thus redu cing its visco sity. Th is also improves lhe f1e ~ ib il ity of the binder. wh ich red uces the
possibility of COhesive failure Th is may be ben eficial in situations wh ere the surface has

25
IRC :5P;100-2014

an open textu re and the existing bind~ has become hard and bottle due to aging. As with
conventional emul sions, if these do oot pene trate the surface. they may crea te a surface
pron e to skiddi ng after they brea k. Fog seals are also useful in chip seal applicati ons to hold
chi ps in place in fre sh seal coa ts. These are referred to as flush coats. This can help prevent
vehicle damage arising from flying chips.

A Fog seal is
,. Designed to coat. protect. and/or rejuvenate the existing oxidiseal bitumen
binder.
,. Improve the waterproofing of the surface.
,. Reduce aglllg susceptibility 01 the surface by lowering permeability 10 water
and air,
,. To renew an old bituminous surface that has become dry, brittle and hungry
with age.
,. To seal small cracks and surface voids
,. To inhibit raveli ng and whip-off chipping by traffic on freshly laid surface
dress ing
Properly calibrated truc k mou nted distributors shall be used to apply the emulsion. Spray
nozzles with 4 to 5 mm openings are recom mended . The emulsion may be heated to maximum
5O"C. altho ugh. generally the emulsion is sprayed at ambient tempera ture . The emulsion is
sprayed at a rate that is dependent on the surface conditions. A test section representative of
the entire surface should be chosen to oecoe application rate . The Iotal quantity 01 emulsion
in fog seal is normally from 0.5- 1.0 11m" of diMe<! 55 emulsiOn ( 1:1 dilution). The surface
condition or texture, dryness and degree of cracking of the pavement determine the quantity
required, Excessive applicatioo of the fog seal must be avoided as this will result in pickup of
bitumen by vehicl es leading to a slippe ry surface. When excess emulsion is applied. a light
application of fine sand on the affected area may be applied to prevent formation of sliding
surface. Ph otos 5.5 & 5.6 show Fog Seal application .

Photos 55 & 5 ,6 Fog Seal in Progress on a Oxidized Surface

26
 IRC:SP:1QO-20 14

Lmrtatioos of Fog Seal : These are given below

') Fog seals are not useful as seal coats on clos e graded surfaces without the
additi on of aggregates as they may crea te a slippery surface.
2) Fog seals should not be used on Rubbe riZed Asphalt Concrete (RAG) or
polymer modified mixes unless the pavements are over five years old as
these binders age at a different rate .
3) The appli cation of fog seals is also limited by weather. It should be ensured
that the emulsion should fully cure before freezing cond itions are encountered.
In addition , seal coats applied in the winter have less time 10 penetrate the
pavement and are more prone to cause sliCk surface conditions.
4) Over awlicatioo of the fog seal resists in the pickup of the bitumen by
vebces and poss ibly a slippery surface. When excess emulsion is applied,
a light applica tion of fine sand on the affected area may correct the
problem .

6 SURFACE TREATMENTS

6.1 Introduction

Surface treatmen ts, involving the use of bitumen em ulsion. are vital from routine as well as
preventive maintenance point of view. The thin surface treatments are used primarily for the
t:lIowing applications:
,. To provide an ecooomical, al-weather surface for light to medium traffic.
When polymer modified emulsion and high quality aggregates are used,
surface treatmen ts may also be used for high volume traffic appl ications like
National Highways.
,. To provide a wa terproof barrier that prevents the intru sion of moistur e into
undertying layers
,. To provide a skid-resistant surface for the pavements that have become
slip pery because of bleedi ng or poli shing of aggregates.

,. To reju venate dry and weathered surface. A weathered and raveled

pavement surface can be restored to use ful service by application of a single
()f' multipl e surface treatments.
:.- To provide tempora ry surface f()f' a new gra nular or bituminous base
cou rse.
,. To rejuvenate old pavements that have deteriorated because of aging .
shrinkage ()f' cracking. Such treatments have little ()f' no structural slreflgth

27
IRC:SP:1QO.-2014

but can preserve the existing structural value by water proofing and serve as
stop-gap measure until the regular reha bilitatiOn is done.
The need fOf a stroog base or sound pavement under surlace treatments cannot be
overemphasized since surface treatment s are not designed to correct a pavement strength
that is structurally deficien t. The various types of surface treatments. involving the use of
bitumen emulsion. are discussed in the following sub-sections .

6.2 Sea l Coat

Seal coat is an application of bitumen emulsion based thin layer to an existing bituminous
surface. This type of maintenance treatment is applied primarily to improve the existing
pavement surface by providing a uniform treatment of seal coal to the surface and to improve
its resistance to water percolation. Therefore . seal coat provides an imperviou s membfane
that w~l slow down the rate of wealhing of bituminous layer. The types of bitume n emulSiOn
that can be used f()( seal coat are $$-2, R$-2. SS-1, $$- 1h. CS$-1 and CSS~ 1h. Seal ooats
are dassified in two categories. as given under.
1) Sand seal coat
2) liquid seal coat
Sand seal coat wilh bitumen emulsion many a time is problematic due to lump formalion
during mixing of sand with emulsion in mixer. Therefore. liquid seal coat should be preferred
over open graded prem ix carpel For liquid seal coat, bitumen emulsion of RS-2 grade @
12-14 kg per 10 m' area shall be spread over premix carpet and then 6 .3 mm passing
aggregate shall be spread over it. The aggregate tayer shall be comp acted with 8-10 lonn e
roller immedia tely after the spreading of aggre gates 10 get the finished surface . The details
of this techn ique of construction are given in IRC- 14.

6.3 Sand Seal

Sand seal is a spray applica tion of bitumen emulsion followed by light cover of fine aggr egates.
such as d ean sand or screenings . Cold mixed sand seal can be useful in correcting a number
of surface defects. Usually. RS-l , CR$-1 , M$-1 or HFM5-1 emulsions are applied at a rate of
about 0.70 to 1.251iIerlor. This is foDowed by applicatiOn of eccct s.s to 12 kg/or of sand or
screenings cover. In some location s. sand seals are used when good sources of aggreg ates
f()( ch ip seals are not available. The cold mixed sand seal is used primarily fOf following
applications.
Enridl a dry. weathered Of oxidized surface. The sand seal will helpto prevent
loss of material from the old surface by traffic due to abrasion.
Prevent the intrusion of moisture , when an existing pavement surtace begins
to crack , moisture may pass into the underlying pavemen t structure thereby
reducing its load bearing ability. A sand seal can prov ide a barrier to prevent
this intrusion.

28
 IRC SP:100-201 4

Develop a skc-resistant surface te xture . By selecting sharp and ang ular fine
aggregate, a highly skid-resistant surface can be provided.

6.4 Surface Dr es sing

Surface dressing consists of application of bitumen emulsion on to an el(isting road surface .

bllowed by the application of a single-sized cover aggregates, The aggregates are applied in
a single thickness over the em ulsion layer and are then rolled in order to 's ear the aggregate
particles in the residual bitu men. This application may also be don e in two or multiple layers.
SIJCh seals are produced with large aggregate in the bottom layer and prog ressively smaller
aggregate in the upper layers. The aggrega te size. number of layers, and binder type are
chosen based 00 the projected traffic loading and the condition of existing surface.

Surface Dressing is applied 10 an existing road surface as an economical maintenance

eeann ent. This should be used on roads that are in good structural conditions but are at a stage
lfl their life cycle. where stre sses are developing. Surface Dressing will seal the underlying
layer from water intrusion, corr ect the surface cracking. ravel ing, surf ace hardening, and
woul d be able to imp rove the skid resistance. Normally. surface dressing will not be able to
correct the full depth cracking, rutting. or conditions caused by base failures or incorrect mi.
design reflect ed by sl'loving or bleeding_

The emulsion is appl ied by a mechanical spraydislributor truck and aggregates are appli ed by
a specialized chip spreader. The application rates of emulsion and aggregate are determined
by a laboratory design method. The ultimate objective is to achieve 60 percent depth
embedment of aggregate in the cured residual binder layer with 40 percent of aggregates
remaining exposed. Some illustrations of surface dressing are show n in Photos 6. 1 & 6.2.

For Surface Dressing either rapid selling cationic or anionic (including high noat) or modified
emulsions can be used. Clean aggregates con taining very low fines usualy require rapid selling
types. while lower quality agg rega tes with higher water absorp lion may require meclium selling
types emulsion to allow proper binda adhesion 10 the aggregate. For high traffic road s or in
more severe dimatic ccooucne. tatex or polymer modified bitumen emulsion may be used.
Since mos t of availab le aggregates are siliceou s, cetooc type s emclaoos are preferred fo r
desired adhesion, while anionic including high floa t emulsions may provid e better adhesion
with calcareous aggregates under high temperature. The emul sions are of typically higher
viscosities wh ich allow them to resist running off and to maintain an appropriate thiCkness
prior to the addition of aggregate. Emu lsions offer several advantages over other" types of
bituminous material as binder for surface dressing:
Emulsion can be used with damp aggrega te
The y do not need elevated temperatures for applica tion
They eliminate the fife hazard associated with cutback bitumen
They eliminate pollution assoc iated with cutback bitume n
The y provide quicker chip retention than the cutback bitumen

29
IRC:SP:1OCJ-2014

Photo 6.1 Views of Surface Dressing Work

,

Photo 62 IllustJ'alJons 01 Surlace Dressing Using Bltumen Emulsion

One of the most important aspects of good performance of surfac e dressing using emulsion
lies in the selec tion of correct type, grade . and appl ication rate of emulsion as well as the
aggregates. When a proper grade is selected, bitum en emulsion for the surfa ce treatment
wi ll have the following benefits.
Be nuid enou gh during application to spray properly and to cover the surfa ce
unif ormly

30
 I RC S P; 100-20 ' ~

Retain proper con sistency after application to wet the surface be ing trea ted
and the aggregate applied
Cure and develop adhesion to the aggregate and surface quicll.ly
Hold aggregates tightly to the road su rface after rolling and cu ring ; prev enting
loss of aggregate
Not bleed or strip w ith changi ng weather co nditions when applied at the
correct rate

Table 6.1 presents the types of bitumen emulSiOn recommended for surface dressing. Hig h
volume traffick ed roads may requi re a poly mer mconeo rapid-setting emusco. For modified
emul sion. the aqueous phase of emulsion may be modified by 3 percent latex or SBR or
Natural Rubber. Table 6.2 gives the nominal ap plication rates both for emulsion and chipping.
The use of these ma terials with relatively low temperature produces significant energy-sa ving
For traditional surface dressi ng , RS-2 type cationic bitumen emu lsion co nformi ng to 15:8887,
IS recommended. Type and grades of bitumen emu lsion and the corresponding temperatures
recomme nded for SpFclying are given in Table 6.3 .

Table 6.1 Types of Bitumen Emuls ion Recommended for Surface Dressing

Specification Descrfption and Uses Construction Typical BItumen

Guidelines Emulsion
Single Coa t
Surface
This is the most important low
cost maintenance treatment.
Spray-applied

layer-. Mao, types 01
O~ R$-2 , Modified

Dressing It produces an all-weather textures available . Keys

surface. renews weathered to success: Use cu bical
pavements. improves
"'~ aggregates, Coordinate
res istance.
,,'" seals
pa veme nt e ffectively.
"'. "0'
co nstruction, Use hard
clean aggreg ate,
aod pro perty calibrate
spray equipment.
Dou ble Coat Two ap plications of bi nder and Spray ap plied m two RS-2 , HFRS2
Surface aggregate . The second ch ip laY""
Dres sing application uses a smaller size
stone than the firs\. It is du rable ,
provides some leveling aod
is available in a m.m ber of
te xtures.
Triple Coal Three applica liorJ of bind er and Spray-applied in three RS-2 , HFRS-2
Surface three sizes of aggregates/chips laY""
Dressing are applied . It provides upto
about 20 mm thick surface .
Note : IRC:110 reo;lfTVTIell(I the use of RS-2 grade d bitumen emulsion, manly because d
lack of availabi lity of other grades 01bitlJmen emulsion in India.

31
IRC:SP:100-2014

Table 6.2 Nominal Application Rates for Bi nd... and Chippi ng

Nominal Chipping Emulsion (Residual Binder) Chips (cum/m'l

Size (mm) (Kg/m l )
19 0.0 15
1.0 0 .010
10 0.9
6 0.75 0004
Tabl<t 6.3 Recommended Spraying Temperature for Various Bitumen Emulsions

Type and Grade of Emulsion Spraying Temperatul"9 '"C

CR5-2
RS-2 50-85
HFRS-2 50-85
Modifi ed 55-85
The aggregate's quality used on the surface is subjected to the abrasive action of traffic.
If aggregates are not hard enough to resist wear and tear, the pavement may become a
skid hazard when wet. Most of the hard aggregates can be used succe ssfully fOf surface
treatments . The aggregate selected must also meet the job requirements in terms of size.
shape. and deanliness. The gradi ng requ iremen ts are given in Table 6.4
Table 6 .4 Grading Requirement for Surface Dressing

IS Sieve Designation Cumulative Pereent Passing by We ight of Total

Aggregate Nominal Size (mm)
(m m ) -
I 19 13 10 6
26.5 100
19.0 85-100 100
13.2 D-4O 85-100 100
9.5 G-7 D-4O 85-100 100
63 G-7 G-35 85- 100
4.75 G-1O
335 G-35
' .36 G-2 G-' G-' G-1O
0 60 G-'
0 .Q75 0-1.5 0-1.5 0-1.5 0-1.5
The tem perature of emulsion shall be 50,75OC using whirling spray jets and 5Q-70"C using
slot jets. The complete details of chi p seal/surface dressing are given in IRC :110.

32
 IRC :SP :100-201 4

Open Graded Premix Carpet

nie bitumen emulsion of MS grade shall be used for preparation of cold mixed ope n
fa<,:" premix . The materials sh all be propo rtioned as per the Quantities given in Tables 6.5
6.6 lor aggregate and bitumen emulsion respectively.
eXISti ng pavement surface shall be cleaned off dirt. dust and loose ma terials. The cold
ad open graded premix carpet sha ll be laid when tack coat turn s black from brown.
blended agg regates of 13.2 mm and 11 .2 mm nomi nal sizes in 2:1 ratio. as per the
jfied requi reme nt. shan be cha rged in the hot mix plant which sha ll be used without
tlng arrangement and suitable modification for trcorporanon of emulsion. The optimum

""'0' co nte nt 1 percent b y weight of aggregates (if needed) shalilhen be added to wet the
tes. The emu lsion of M$ gradelSS gradelSpeOaI grade in required Quantity
ximately (7 percent by wt. of aggrega tes ) sha ll then be added into wet gradually
""reo; ate and mixed for two minutes 10 get uniform ooating. Prolonged mixing shall be
ad as it will oecoat the aggregates.
cold mix shall be transported 10 laying site and shall be spread manually for loose
oie::k11esS of about 30 mm over the tack coated area. Rol ling shall be done as described in
: 14. The surface shall be opened afief 2-3 hours.
Table 6.5 Quantities of Aggregate for 10 m' Area

s. No. Premix Carpet

Coarse aggregate of nominal 13.2 mm size: passing 15:22.4 mm 0.18m'
sieve and retained on 15 .11.2 mm sieve
bl Coarse ag gregate of nominal 11.2 mm size: passing 15:13.2 mm O.09m>
sieve and retained on 1$ :5.6 mm sieve

Table 6.6 Quantities of Bitumen Emulsion per 10 m' of Ann

AI For Premix Carpet (M5 ) 20 to 23 kg

BI For Seal Coa t
i) For Liquid sea t coat (R5 -2) 12 t0 14kg
ii) For Premix seal coal (5 S-2) 10 t0 12kg

The cold mixed open graded premix carpet may also be prepared in a concrete mixer. For
this purpose, the blended aggreg ates of 13.2 mm and 10 mm size in 1:2 ratio s shall be
cI1a rged into con crete mi xer. The premi xing water content @ 1 to 2 percent by w eight of
aggreg ate shalt be added into lhe mixer and uniforml y mi xed 10 wet the aggregate surface.
The requi red qua ntity of emulsion of M$ grade Of tailormade shall then be added and mixer
with aggregates 'Of two mi nutes . Prolong miJCing (move then one minute) shall be avoided
as it tends 10 de -coat the binder fro m aggregate. The col d mix whil e indicating brown colour
shall be discharged into trolleys to transport to the construction site. Tack coating. spreading
of cold mix and compaction of cold mix with 8-10 tonne roller shall be carried out to ge l the
I'lnished premix carpet surface. The deta ils of construction are given in IRC:14 .

33
IRC :SP :1QO-2014

6.6 Mix Sea l Su rtacing

Cold Mixed Mix Seal Su rtacing (MSS), w hich is a continuous graded mixture, may be used 8S
renewal coat on low trafficked roads . This sub-section deals w ith the materials and con structio n
procedure for laying ook:I mixed mix seal su rfacing using cationic bitumen emulsion.

For Pfemixing, the binder shall be Slow Setting (SS-2)fSpecialgrade complying with 15:8887
standard or tauor made to be compatible with available ag gregate . For tack coat, Rapid
Setting (RS-l) grade of cationic bitumen emulsion, complying with 15:8887 standard will be
used The coarse aggregates shall satisfy the entire physica l req uirements as speci fied in
Section 4. The fine aggregate shall be the fraction passing 2.8 mm sieve and retained on 90
micfOrl sieve . It sha ~ be d ean, ha rd. durable, uncoated and free from soft or flaky and organic
or oeeteoous matter the gradation of aggregates as given in Table 6,7 shall be us ed .

Table 6.7 Gradat ion of Agg regates lor Cold Mixed Mix Seal Surfacing

Sieve size % Passing by we ight

Type A Type B
13.2 mm 100
11.2 mm 100 88-100
5.6mm sa-ee 3 152
2.8mm 1438 5-25
O.09O mm 0-5 0-5
Note ; The coarser side of ltle grading IS desirable.
The quantity of aggregate shall be 0.27 m' for 10 m' are a. The quantity of bitumen emulsion
(5$02) sha ll be 30 kg for Type A and 33 kg lor Type B grad ing.

The base ov er whiCh ook:I mixed MSS is to be laid shall be completely free from du st and
mud. Whefe the exisllng base is having potholes or nrtting, defects sh all be rectified before
laying MSS . For tack-coat, bitumen emulsion of Rap id Selling (R S-1) grade shall be used .
The bitumen emulsion is applied on an ex isting pavement, preferably on damp surface, at the
rate of 2-3 kg per 10 sq.m erea. In case of dry and hungry surtace. emulsion shall be used at
the rate of 3.5 kg pet" 10 sq .m. The tack coa t with emu lsion shall be applied not eartier than
30 minutes before laying the ook:I mix. The ook:I mix sh all be Iaiel when tack coa t bind er turns
black from brown colour. It is imperative to prepare the cold mixed MSS usi ng con ventional
hot mix plant switch ing off heating arrangement or cold mix plant or any othe r su itable mixer
of adequate capacity. The plant ma y be either a batch type or a continuous type having
two-stage mixer. The bitumen emulsion shall be added into the mixer by having a separate
outlet from emu lsion tank_

The aggregate shall be chargoo first into the mixer/p ug mill follo wed by the addition of
optimum w ater co ntent (approximately 1-2 percent) to mixer and then adding the req uired
quantity of bitumen emulsion. The above ingroo ien ts shall be mi xed for about one minute 10
achieve the uniform coating. The ook:I mixed MSS sha ll be discharged for transportation 10

34
 IRC:SP:1QO-201 4

laying site. The cold mixed MSS sha ll be transported from plant site by tippe r trucks 10 the
laying site and spreading wi ll be done preferably by means of a selt-p m pelled mechanical
paver at an approp riate speed capable of spreading, tamping and finishing the mix, true to
the proper grade, line and cros s-section. The mix shal! be spread in such a manner thai , after
compaction, the required thickness of layer is laid uniformly for desired thickness.

Longiludinal joints and edges shall be const ructed true to the line marking parallel to the
centre line of road l ongitudinal jo ints shou ld be offset by at least 150 mm from those in
binder course . if any, and transverse joints or const ruction joints shall be placed in the origina l
thickness of previously laid mix. The vertical cut face shall be painted with bitumen emulsion
prior 10 the laying of fresh mix against it.

The cold mixed MSS laid wit h the paver, after change of colour from brown to black due
to breaking of emulsion on surface of coat ed aggrega te, shall be thoroughly and uniform ly
com pacted through a set of rollers at a speed not more than 5 km per hour. The initial or
break down rolling shall be done with a- tztonnes three wheel steel roller followed by final
rolling with 8-10 tonnes tandem roller. Before finishing with tandem roller. break down rolling
shall preferab ly be followed by an intermediate rolling by smooth wheel pneumatic roller of
15 to 30 tonn es having a tyre pressure of 7 kg./sqcm.

The joints and edges shall be rolled with 8-12 tonnes three wheel roller. All the com paction
operations t.e. breakdown rolling, intermediate rolling and final rolling shall be accompl ished
by using a vibrato ry roller of 8-10 tonnes weig ht. During final rolling . the vibratory system
shall be switched off and wheels of roller shall be kept mo ist to prevent the mix from sticking
to them. Rolling shall commence longitudinally from edges and progre ss towar ds the centre
except on super elevated portions where it shall progress from lower to the upper edge.
Rolling shall be continue till the des ired density is achieved and all roller marks are eliminated.
Traffic shall be allowed after 3-4 hour s provided the mix has been set and does not stick to
tyres of vehicles.

Adequate quality control at every stage of the wor k is essential. A field labor atory shall be
set up to ensure the controls. Sieve analysis 01each typ e of aggregate at feeder end should
be made to see tha t the gradation of aggregate reasonably follows the speci fied designed
gradation. The number of samples per day would depend upon the bulk supply of aggregates
made in a day at the plant sue. The characteristics of these materials shall be determined at
the rate of one lest for every 50-100 m' of aggregates . Periodic checks on emul sion covering
binder content, viscos ity and res idue on 600 micron sieve should be done , in accor dance
with 18 :8887. The emu lsion should be thoroughly mixed by rolling the drum to and fro to a
distance of 10 metre for about 5 minutes before using emulsion for premixing with graded
aggregate. At least one samp le for every 100 tonne of cold mix discharged at the pug mill
chute or a minimum of one samp le per plant per day shall be collected and necessary tests
carried out. Bitumen shall be extracted from about 1000 gm of the mix and bitumen content
determined Sieve analysis of aggregates after the bitumen is extracted shall be done to
determine compliance 01 standard gradafion.

35
IRC :S P:100-2014

6.7 Slurry Seal

Slurry se al is a mixture o f dense graded aggregate , emulsified bitumen , fil ler, additive and
water. The mixture is applied as su rface trea tment on the ex isting surface. Slurry seal ca n
be used for both preventive and corrective ma intenance needs. T his treatment dose not
increase the structural strength o f a pavement. A pavem ent wtlidl is structurally weak. should
be repaired first for structural defic iency befor e applying slull)' se al . Ruts, humps, distressed
pav ement edges , cro wn deficiencies , or other surface irregularities tha t affect riding qu ality
shoul d be co rre cte d befo re placing slurry seal. Slurry seal Is co nsidere d to be a ve ry effective
m aintenance techniqu e for the surfaces of older pave ments. It w ill fill the su rface cra ck s. stop
raveling and loss of matrix, impro ve skid re sistance , gen erally protect the pav ement, redu ce
water and o xidative deterioration, and finally extend the overall pavement se rvice life . Slu rry
sea l has the following major advantages :

Rapid application and quiCk retu m of traffic to the pavement

Ex cellent surface texture and friction re sistance
Ability to correct mi nor surface irregularities
MInimum loss of kerb height
No need for manhole and other structure adjustments
Ex ce llent low cost treatment for u rba n streets
Slurry seal is applied in a ve ry thin layer o f 3 to 6 mm. The grade of em ulsion to be used is
SS-2 co nforming to IS:8887 or tailor made . The mac hine used for mixing and eppncano n
is a se lf-contained . ccnno uous-now mixing unit. w hich a ccu rately deli vers materials (pre-
determined amount 01 aggreg ate. miner al filler. additive . water. and bilum en emulsion) to
the mixing ch am ber. Tables 6.8 and 6.9 gives the specifica tion requirements for slur ry seals
and properti es of aggrega tes to be use d in srury seal and Table 6.10 de scribed mix d es ign
criterion fo r slurry se al mix. Th e details of slurry seal applica tion and construction proc ed ure
are given in IRC: SP:81.

Table 6 .8 Specifieations Requirements foI' Different Ty pes of S lurry $ea l Treatments

so.naoce ernd<s less than

1 mm
\ 1-3

CVPO)
rrrn ~
...
an:! prevenIiveo' (3-6 rrrn ) and ple.e, "'.e.
renewal trealmenIlUI:*> 4 50 r.-al Irt!atment (lJpto 1500
CVPO)
84109.8 10.1/01 2

Resid ual binder 1010 16 4 .510 13.5 6.510 12

tpercenI by we;ghl
or dry aggregale)

By weight 01 dry aggregale only

.. Indicative only
CV PD + Comm ercial Vehicles Per Day

36

-
 IRC:SP:1QO-201.

Table 6.9 Properties of Aggreg ates

Properties Test Method Speclficatiofl

Sand Equivalent Value 15:2720 (Part 37) Min. 50
Water AbsorpIiOn" 15 :2386 (Part 3) Max. 2.0%
Soundness (with Sodium Sulphate) 15:2386 (Part 5) Max. 12%
Soundness (with Magnesium Sulphate) Max . 18%
In case wa ter absorption exceeds 2 percent bu! IS less than 4 percent . the same may be
permitted sulJ1ect to conformity of soundness test and wet stripping test.
Table 610 Mix Desi gn Criteria for Slurry Seal Mix

Requirements Specification Test Method

Mix Time. Minimu m 18", Appendix-2
Consistency, Maximum 3an Appendix-3
Wet Cohesioo (within 60 min ). Minimum 20 kg.em Appendix-4
We t Stripping , value minimum 90 Appendix-5
We t Track Ab rasion Loss (one hour soak). Maximum 800 glm2 Appendix-6

6.8 Microsurfac ing

6.8.1 Introduction
The Miaosurfac:ing shall oonsist of mixture of modified (Polymer or Ru boer Latex) bitumen
emul sion. wel l gra ded mineral aggregate, water . lil~ and additive (if needed) pro portioned.
mixed and uniformly spread ov er a pr operty prepared surface. The final ly laid microsurfadng
shall have a homogelleOUS mat ad here firmly to the prepared surface and provide friction
resi stant surface texture throughout its servce life . The mix is to be a quick setting system
i.e. it should be able to receive traffic after a short period of time pretera bly within about one
hours of its laying depending upon weather conditions.

It is applied on an e xisting pa vemen t surface wh icll is structurally sound but is showing the
signs of functional distress such as loss riding quality. cracking and polish ing . Generally.
microsorfac:ing is laid in single layer, but when the e xisting surface is highly pol ished and!
or cracked. it is advisable to apply it in two or more layers. Micmsurfacing can be used for
surface tr eatment on roads. taxi wa ys and runways. Norm<Illy two lay ers of microsurfacing
are advisable on cement coocrete su rface.

As a surface treatment, micro-surlacing impa rts protection to the underlying pavement and
prov ides rene wed surface. Special emulsifiers in mlcro-surtecnq emulsions contribute to the
qu ick setting chara cterist ics. Minor re-protumq can be achieved with multiple applications.
Special equipment permits the filling of wheel ruts up to 40 mm deep in one pass.

37

~
IRC :SP :100-2014

6.8_2 Benefits of mIcrosUrfadng

The major ben e fits of microsurfacing tech nolog y are given as und er:
,. Quick applica tion (One lane- km in 35 minutes)
,. Minimum traffic hold up (work is done in lane wise mannef) quick opening to
trae c
,. life sp an ex ceed s t he life sp an 01 ordinary Bituminous Concrete
,. Non-pollu tin g for environme nt since no heating or hot paving is req uired
,. Does not require se nsor paver or compaction eq uipm ents
,. Longer life SInce o xidalion is red uced
,. Waterproof Surface - Prolection from rains
,. Ideal for surface se aling treatm ent since it improve s sk id re sistance and
pr ovides surface durab ility
,. Does not increase pavement heig ht sig nifica ntly (T his saves from water
logging . drainage and other assocetee problems)
,. Cost e ffective as compa red 10 Ho t-Mix (Almost 4D% saving in Cost )
,. Redu ces noise caused by movement of tr affic
,. En vironment friendly (red uced emissions)
,. No change in road furniture or drainage
,. Savings in natural resources
Microsurfacing helps in pre serv ation of paveme nt st reng th and can be used beth as a
preventive maintenance treat ment or and periodic renewal treatment on a preferably low,
medium or heavy traffic. It can be used for pavements in urba n and rural areas. primary
and inter-slate routes . residential streets. highways, and toll roads. It can also be used on
the top of single coat surface dressing (Cape Seal), on open graded premix carpet without
se al coat and also on Dense Bituminous MacadamfBitumi nous Macadam. Various ty pes of
microsuriacin g thai can be used for different applications : quantity of micro surlacing mix and
the residu al binder con tent in each type are pr ese nted in Table 6.11.

Tabkl6.11 Different Types of Microsurfaci l'g

Applicabons For roads in urban and nJral areas, Fo r primary and inlef.-slale routes.
resklcnlial slreels. as prevenl lve highways and runways 10 give max imum
aod renewal treatment 1500 skill resistance. poeowlive and renewal
CVPD) treatment o 1500 CVPD)
Ouanbty" of UIctosurfacr,g 8." 10 10,8 11.1 to 16.3

"""'"
Residual birldef (perCl!f11 by
.w eighl of dry aggregat" L' _--l
6.5 10 10.5
--l
5.5 10 10 5
.J
By we;ghl of dty aggregate
Indicative only

38
 IRC:S P. l 00-2O": ,(

6.8.3 Constituen t materials

Bitumen emulsion sh all be a modified (polymer modifiedllatex modified ) conforming to

requi rements, as specified in Tabl e 6.12. Th e mod ifier shall be polymer! rubber preferably
synthetic or natural rubber latex blended into bitumen or aqueo us phase of emulsion prior
10 or durin g the emul sification process. It may also be required to be specifically desfgned
bitumen emulsioo for a particular with reg ard to the quantity and grading o f aggregates. The
gading of aggregates is presented in Tab le 6.13.

Tat. 6.12 Requiremen ts of Modified BitlI....n Emulsion for Micr05urfacing

Requirement Specification Method of T" t

Residue 0fl600 pm IS Sieve (Percent by mass ). maximum 005 IS:8887
V1scosity by SayboltF~oI VISCOmeter. at 25"C. second 20-'00 IS:8887
Coagulatiorl of emulsion at low temperature 15:8887
5torage Stability after 24 h (l68h). %. maximum "'
2(4) 15:8887
Partide charge, + ve ' ve ." 15:8887
Tests on Residue:
.) Residue by evaporation, % minimum 60 IS:8887
b) Penetratlon a125"C 1100 g/5 s 40-'00 IS:1203
oj 0udiIity at 27"C. ern. minimum 50 IS:1208
d) Softening Point "C. minimum 51 tS:1 205
. ) Elastic Recovery*. %, minimum 50 15: 15462
I n SoIub~rty in Trichloroethylene. %. minimum 97 15:1216
.
In case. elastic recovery IS tested for TOl"SlOflat Elastic Recovery as per Appendl,,_7. ee
minimum value shall be 20 percent
Table 6.1 3 Grading Requirements f or Micro5urb cing and Slurry Sealing

Sieve Size (m m ) Percent age by Mass Passing (M inimum Layer Thickn ess)
Typ e I Type II Ty pe: III
9 .5 . - '00
6.3 - ' 00 91-100
4 .75 ' 00 90-'00 7G-90
2 .36 90-'00 65-90 45-70
1.18 65-90 45-70 28-50
0.600 4G-65 30-50 19-34
0.300 25-42 18-30 12-25
0.150 15-30 10-21 7-18
0.Q75 10-20 5-15 5-15

The mi neral aggregate sha ll consist of cru shed stone dust, clea n hard. durable, uncoated .
dry particles and shall be free from dust. so ft particles. org ani c matter or other deleterious

39
IRC :SP:100-201 4

substances. Miner<1I filler shall be Or dinary Portla nd Cement (OPe). The quantity o f filler
shall be preferably in the range of 0.5 to 2 perce nt by the weight of dry aggregate. The water
shall be potable, free from harmful sans and contaeeoants. The pH value of wa ter shall be
in the range of 6 to 7. Chemical additive may be used to accelerate or retard the break-set
time of the micro-surfacing mix or to Improve the resu lbng finished surface. The Q,uantlty of
adQi\",e , 1I used. shall be eeccee by undertaking the mix oe slgn and is 0 be adjusted as pe r
the field/clima te coromons such as hu midity and temperature at site . The specifica tion of
additive needed shall be suppl ied by suppliers of em ulsion . The add itive and emu lsion shall
be compatible w ith ea ch other.

6.8.4 Design of microswtacing mix

The mix design of Microsurfacing shall be prepared in a fully eQuipped laboratory and
the Job Mix FQmlula so evolved shall be approved by the client. The compatIbility of
aggreg ate. emulsion. filler and additive shall be vented by mix design for the selected
grading (Type II Of Type Ill). as specified in Tab le 6.14. The indica tion values allhe ingradients
for Microsurfacing mixture is specified in Tabl e 6.15 and proposed Microsurfacing mixture
sha ll conform to the req uire ments speci fied, when tested in accordance with specified tests,
The mix de sign report shall clea rly show the proportions o f aggregale, filler. water. and
residual bitumen con ten t based on the dry weighl of aggregates and additive used (if any).

T;oble 6.14 Milt Design Criteria for Microsurtac ing Mix

Reqlll......ent Specific.atlor\ Method of Test

MI X Time. m NlIm um
Con sistency. m aximum
"'"
,=
Appendlx2
A(lpendix-4
Wet Cohesion. within 30 min. minimum 12 kg.em Appendix3
Wet Cohesion. WIthin 60 min. rninirruTI 20 kg,em Appendix 3
Wet Slrwing ....... 'ilo mnrrun Appeoodox ~

'M!It Trad< Aboasioo. Loss (one hoo.r soaI< ). fTI;IXIm.JfTI Appe"dix_7

Table 6.15 Indicative Limits of Ingredients in Mix

Ingredients Li mits (Per cent by weight of aggregate)

Resid ual Bitumen 6.5 to 10.5 for Type II 5.5 to 10.5 tor Type til
Mineral Filler 0.5 to 3_0
Additive As needed
W ate- As neeoec
Aggregate, modified bilumeo emulsion, water and additive (if used), shall be proportioned by
weig hl of aggreg ate utilizing the mix design appro ved by the Eng ineer-in-Charge. lf more than
one ty pe of aggreg ate is used, the correct amo unl of each type of aggregates which ha ve
been used 10 produce the requ ired grad ing. shall be proportioned separately prior to adding
other mate rials of the mixture, in a manner that will result in a uniform and homogeneous
blend. Fina Vco mp leted mixture, after addition crwatee and any additive, if used, sha ll be such

40
 IRC; SP:l00-201 4

that the micro surta on q mixture has proper worka bility and permits traffic with in one hour
depending upon the weather conditions , w ithout occurrence of raveling and bleeding. Tnal
mixes shall be prepared and laid for the designed mix and observed for breaking time and
setting time . The wet track abrasion test is used to determine the mimmum residual bitumen
conlent Procedure for calibration o f microsurfac ing machine is given in Appendix-8

Details o f Microsu rfacing application are given in IRC :SP:81.

6.9 Cape Sea l

Cape seal invo lves application of a slurry se al or micro-surfaci ng to a newty-ccostructed

sing le coat surface dres sing treatment. The slurry or microsurfacing application helps to
fill the voids between the chips. Cape seals provide highly durable surface treatment The
slurry or microsurfacing bonds the chips to prevent loss of the chips due to traffIC abrasion.
For a successful cape seal. it is important to have single coat surface treatment wrth lower
residu al bitumen cont ent tha n a tradi tio nal ch ip seal. Th e most critical element to avoid in a
cape seal is an excess of sl urry that eliminates the desired knobby surface texture. Curing
time of four 10 ten days should be allowed between placement of the orooneo surface after
surface dressing and before appl iea tion of slurry seal or microsurfacing to remove loose
co ver material or other foreign material that would prevent adheren ce. Tab le 6.16 gives
Quantities of bitumen em ulsion and aggregates req uired to execute a cape seat. For surface
dressing RS-2 emulsion sha ll be used. For slurry seal SS-2 grade emulsion shall be used.
Polymer mOOified emulsion shal l be used if microsurfaCing is used as top layer.

Ta ble 6.16 Quantities of Bitumen Emuls ion and Aggregate for Ca pe Sea l

ThIckness 01 C
Se,,1
.,. NomInal SIze 01
Aggregate
Quantity 01 Quantity of
Emulsion (kg/m' )
Slurry M,xtufa
Aggregate (kg/m'l (Type 1l. kglm'

125 rrnl Tl-:lc 9 .5 10 2.36 rnrn 14 16 1.4--2.0 2 7-4.5

.,..,." (0.30-0.45) (6- 10 )

19.0 mm Thiel< 19 .0 109.5 mrn 2227 1.8-2.3 3.5-5.5

(4D-SO) (0.40-0.50) (B-12)

Details of construction o f ch ip seal and sluny seal are given in IRC:110 and IRS :S P;8 1.
~~

7 COLD MIXES

A cold mix is defined as a mixture of bitumen emulsion and aggregate that is miXed tog e\hel"
at ambient temperature . Bitumen emulsion being liquid at room tempera ture. thefe is no
need to heat Of dry the minerai aggreg ate . Cold mi~ is usefu l in the area s, where there is
long distance between the job site and plant and temperature of dimate is low and mod erate
(<4 O"CI Further. the versatility of cold mix aHows it to be miXed in-pl ace at the job site as well
as at a plant site and then subsequently tran sported to the;oo site. Cold mix may be used
11 bituminous base (BM), binder" course (B M/SOBC) as well as wearing course (SOBe) at

41
IRC :SP :100-2 014

fle xible pavemen t These mixes ma y be designed for a broad range of bitumen emulsion s,
aggregates , field conditions and tailored to specific performance requiremen t The cold
mix should be desig ned to meet the pe rformance requ irements whieh incl ude workability,
coating. strength de velopmen t. and other applicable targets. The quality of resid ual bitumen,
aggregate. and climatiC conditions should be taken into account

The important elements for design 01 an acceptable cold mix are described below:
a) Coa ting : The emulsion shou ld have ability to coat the agg rega te effectIvely
without oo l1ing of lines. Sometimes , the quality of emulsion, mi xing wa ter and
aggregate may also influenc e the coating .
b) Workability : The mixtur e must mai ntain its wo rkability during produ ction,
laying and storage (in case of stockpiled mixes) prior to its application.

c) Run-off : The design should ensure that emulsion ren-ee from mixture will
not ecce. For open graded mixes, it is important that emulsion does not
drain down through the voids in aggregate.
d) Aggregates quality : The sand equivalent value test shall be carried OUIto
ens ure that d ay con tent is not in excess. A sand equivalent value (as per
15:2720) of 50 and above is preferred.
e} Bitumen content : The amount 01 residual bitum en requ ired in the mix is
determined based on the surface area of the aggr egate an d typ ically varies
between 4 to 6 percent residual bitumen by weight of dry aggregate depending
upon gradation selected.
f) Moisture s usceptibility ; For moisture susceptib~ity of the mix to intrusm
of wa ter. boiling or im mer3ion tests may be used in conjunction with coa ting
by vis ual ob serva tions.

g) Stre ng th : Progres sive strength gain can be determined using Marshall

Stability Test. Minimum strength requ irements will be set by the design
criteria depending upon the type of mixture (open graded/dense graded).
This section deals with the differen t types of cold mi xes wh ich may be used for consuu cton
and maintenance 01 road s .

7.1 Cold Mi xed B itum i nou s Macadam (CMB M)

Bituminous Macadam (BM) is an open grad ed bituminous mixtu re suitable tor moderate
traffIc roa ds used for con struction of bituminous base cou rse as well as for strengthening
of fle xible pavements. Cold Mixed Bituminou s Ma cadam (CMBM) shall involve cons truct ion
of one or mo re COurses 01 compacted mixture prepared with bitumen em ulsion and min eral
aggregate, laid imm ediately after mixing to required grade and camber using appropriate
machinery.

42
 IRC:SP :1DO-20 14

, 7.1.1 Propertie s of materials

The agg regates shall consi st of crushed stone, crush ed slag, crushed grave l (shin gle ) Of
other suitable, The aggregates shall be clean . strong , durab le and fair ly cubica l, free from
clay and disintegrated pieces, organic and other deleterious matter. The coarse aggregates
shall be crushed material retained on 2,36 mm IS sieve while fine aggregates shall be fract ion

, passing , 236 mm sieve and retained on 75 micron sieve. Th e aggregate shall satisfy the
physical requirements as given in Tab le 7.1 with sand equivalent value of more than 50. The
requirement of filler (material passing 75 micron sieve) in CMBM shall be met from stone
I
dust, ceme nt, hydrated lime or any other non-plastic mineral matter. The blended aggregates
for CMBM shall satisfy the grading given in Table 7.2.

Table 7.1 Requireme nts of the Agg regates for Cold Mix

Property Test spectncenon Method of Test

Cleanliness (dust) Grain size analysis Max 5% passing 0.075 15 :2386 Part I
mm sieve
Particle shape Combined Flakiness Max 35% IS:2386 Part I
and Elongation Indices"
Strength Los Angeles Abrasion Max 35% IS:2386 Part IV
Value or Aggregate Max 27%
Impact Va lue
Durability Soundness either' Max 12% IS:2386 Part V
Sodium Sulphate or Max 18%
Magnesium Sulphate
Water Absorption Water Absorption Max 2% IS:2386 Part III
Stripping Coating and Stripping Minimum retained IS 6241
of Bitumen Aggregate coating 95%
Mix
Water Sensitivity Retained Tensile Min, 80% MSHTO 283
Stref"lgth""
Fine clay particles Sand Equivalent Value Minimum 50 15 :2720 (part 37)
Surface reactivates Methylene blue Max 10 ISSA

Bitumen emulsion for preparation of CMBM shall be Medi um Setting (MS). Slow Setting
(5 5 -2 ) grade or a tailor made for compatibility with availa ble mineral aggregates, conforming
to IS:8887 or other international sta ndard (ASTM or MSHTO ). The actua l grade of the
emul sion to be used would depend on the cha racteristics of the agg regates. If the sand
equivalent value of the aggregates is between 50 to 70. use SS -2 grade of emulsion and for
sand equivalent values more than 70. use MS grade of emulsion. The Rapid Setting (RS~ 1)
grade of bitumen emulsion. conforming to IS:8887 shall be used in Tack Coat.

43
IRC :SP :1ClO-201 4

Table 7.2 Grading of Aggregates for Coml)3Cted Thic kness of 50 mm CMBM

Sieve eee, mm Pe~ nt paning by _ight

265 '00
19.0 90-'00
13.2 se-se
9.5 20-55
4,75 ' &-36
2.36 4-19
030 2-10
0.075 ,-4
Sand E uivalent value ASTM 024 19 50 Minimum
Percent Crushed Faces 75% Minimum
Bitumen Emulsion % by Weight of Mix 5% MInimum
Minimum residual bitumen 3.5 percent
7.1.2 Quantifies of matenals

The approximate quan tity of mineral aggregates required for 50 mm compacted thickness
of CM BM shall be 0.60 to 0.75 m l for 10 rrr area. Bitume n emulsion (M5,55-2 grade or any
other suitable grade) required for premi xing of bituminous Macadam shall be added at the
rate specified rate depending on the grada tion of aggrega tes after adding premi xing water
(1 to 3 percent). The quan tity of emulsion may be slightly higher for an absorptive type of
aggregates (water absorption exceeding 2 percent). R5-1 grade shall be applied fo r tack
coat@ 3.0 kgl10m' on primed WaterBound Macadam(WBM)orWetMixMacadam(WMM)
surface . In case. CMBM is to be laid over the existing bituminous setece. the lack coa t of
R5-1 grade shan be applied @2. 5 kgl 10 rrr area wh ich should also meet the requirement of
bond strength. as determined by the method given in Appendix.' . The CMSM shall be laid
when !he color of tack coa t tums black from its original brown colour.

7.1.3 Mlxturedesigrl

The detailed procedure for de termining the job mix fOllTlUIa for CMSM is given in
Append ix-9 .The irldiCalive design cnteria for CM SM is given Fabte 7.3.
Table 7.3 Ind icative Design Req uirements fo r CMBM

i) Number of compaction blows on each side of Marshall spec;men 50

ii ) Marshall Stability at 250C in kg (minimum), after curing the specimen in air 350
(72 hours)
iii) Marshall flow (mm) at250C Max 8
iv) Per cent voids in mixture 10-14
Binder content (residual bitumen) by weight of total mix (%),min 35
"
vi) Retained indirect tensile strength at 25C after conditioning for 72 hours in air and 50
24 hours at 4O"C, in water %.

44
 IRC: SP: 1OQ-201 J.

7.1.4 ConstnJc;:t;ofIofCMBM

CM BM shall not be laid during rai ning or w hen the granular ba se course is wet or when the
atmospheriC temperature in the shade is below 8"C . All equipment necessary fOf the proper
oonstruetion worX shall be av aila ble at the WOf1l; site in good working condition. Adequate
provisions for safe movement of ve hicular traffic shall be made in ad vance. The underlying
surface on wh ich CMBM is to be laid shall be pr epared , shaped an d conditioned to a uniform
grade and cam ber. Depeesscos. ruts Of potholes shall be repaired in advance at least before
ItIe da y of layin g The surface of underlying course sh all be thoroughly swept. made clean
free from the dust and foreig n materials. If the e xisting base is extremely uneven, a profile
correction course ma y be considered. The tack coat with emulsion shall be applied not earlier
than 10 minutes before laying the co ld mix.

It is imperative to prepare cold mix of proper and uni form quality by using a cold mix plant
or a modified hot mix plant switching off the heating . The produdton of high quality cold
mixes requires a well-con trolled operation. The se t up for a central cold mi x plant may vary
depending on the Quality req uired and the type of mix. It is recommended that the pla nt
shall have ( 1) a twin shaft pug mill. (2) a la nk for emulsiOn slorage, (3) metered pumps fo r
emul sion tra nsfer to pug mill and water, valves and spray bars, (4) aggregate feeder bins . (5)
conve yor belts for moving aggregate and mix, and (6) a powe r source. The pug mill should
allow a variaoon in the mixing time to ensure proper coating of aggregate with emulsion .
The use of a surge bin or storage silo is desirable for continuous mixing and improved mix
unifo rmity. Batch type pug mills ca n be used but the pr oduction of cold mixes is ideally suited
for cootinuous type mixers . The ingredients shall be mix ed for about one minute to achieve
the unifOlTTl coating of bitumen 00 mineral aggregates. Excessive mixing may un-coat lila
aggreg ates.

For planl produced cold mixes. the pavi ng procedures are sim~ar to those used for hot
brtumioous mixe s. The self-propelled pavers are recommended . Cold mixes are generally
stiff er than hot mixes or not as w ork able as hot mi xed materials, w ith open-graded mixture
being the most difficult to place . Proper paver operation is tbus very crit ical lor obtaining a
uniform and smooth ma t This includes keeping the paver speed as con stan t as possitne and
the level of mix on the augers at a nearly constan t dep th. If the mix sticks to paver screed Of
teari ng of the ma l CMX:Urs, a change in the mixing tim e or the water content should be effected
whidl would eliminate the problem. The screed should not be heated.

For an open-graded mix like the CMBM , the breaking of bitumen emulsion usually occurs
quickly. With open-graded mixes. rolling may oormally begin immediately behind the paver.
Vibratory rolling for open-graded mixes is not recommended because fracture of aggregate
and bit umen debo nding may occur. A light "choke" or "blotter" of a coarse sand or fine crusher
screening s may be applied after steel-whee led rolling, The choke or blotter permits rolling
with a pneumatic-tired roller and prevents pick.up of mix and damage of com pacted cold mix
laye r by the traffi c. Properly des ign ed uniformly cold mix shall be discharged to the tippers
for lransportation to site. The spreading of cold mix w ill be done preferably by means of a se lf
propelled rrecrencer paver at a su itable speed capable of spreading , tamping and finishing

45
IRC: SP:l 00-20 14

to the proper grade. line and cross-se ction . The mix shall be spread in such a ma nre-
afte r compaction, the req uired thickness of surfacing layer is achieved. The paver lac
mix, after becoming black from original brown colour due to breaking of emulsiOn on
of aggregate. sha n be thoroughly and uniformly com pacted by a set 0 1 rollers at a soeee
more than 5 km pe r hour. The break down rolling sha n be done with 8- 12 toone th ree
steel roller and the fina l rolli ng shall be done w ith 8 to 10 ton ne ta ndem roller. Before fi~
rolling by tandem roller, break dow n rolling shall prefera bty be followed by an imerrreo,
rolling with smooth wheel pneumati c roll er of 15 to 30 tonne capacity having a tyre pr
of 7 kg/cw . The wheels of the roller sha ll be kept mo ist to prevent the picking up of
Rolling shall co mmence longitudinally fro m edges and progres s towards the centre excece
su per elevated portions. where it shall progress from lower to the upper edge. Rol ling
be continued til1 lhe specified density is achieved and all roller marks are eliminated. T
shall be allow ed after 2-3 hours. when the cokt mix is well set and is not picked up by
vehicles.

Adequate quality control at every stage of the worll: is essenti al. Therefore . field labora
must be set up . Periodic sieve analysis of each type of mineral agg regate sha ll be do ne
ensure that the gradation of ag gregate follows close 10 the original gradation o f desig
job mix. The number of sam ples to be taken per day wo uld depend upon the bulk supply
aggregates made in a da y at the plan t sile. The characteristics 0 1 mi neral aggregate s
be determined at the rate of one test for every 100 m3 of aggregates. Period ic checks
the propertie s of erreiso n such as residue con tent. viscosity and residue on 600 micron IS
sieve shall be done in flE!ld, in accordance to 15:8887-2004 At lea st one sample for every
100 tonnes of co ld mix discharged at the pug mill chu te or a minimum of on e sa mp le per plart
per da y shall be collected and various tests shall be carried out. These specimen s sha ll be
tested for den sity. Residu al bitumen sha ll be e xtracted fro m mix after ClJ ring and emulsion
shall be determined.

For the compacted su rface of every 700 rrr or less, one field de ns ity lest shan be conducted
to determine the de nsity of mix as laid and compacted . The density sh all Il()( be less than
95 percent 0 1 the maximum laboratory density. The longitudinal pro file of the fin ished su rface
shal t be tesled by 3 m str aight edge. parallel to the cen tre line, and the transvers e pro file by
a camber temp late . Any irregularity greater tha n 6 mm sh all be corrected.

7.2 Col d Mi xed Semi Dense Bitum ino u s Concrete (C MS DBC)

Semi de nse bitumloous coocrere (5 DBC) is a continuously grad ed milt, which can be used
as binder coe-se or we aring course in a flex ible pavement. This section deals with the design
and construction of 40 mm th ick Cold Mixed 5DBC using cerooc bitumen emu lsiOn.

7.2.1 Properties of materialS

CMSDB C shall consist of coarse aggregate, fine aggregate and filler (Conforming the
req uirement given in Table 7.1) in su itable proportion mixed with suffi cient quantity of mlx in9
water an d cationic bit umen emulsion . Representative sa mples of aggregates , proposed to be

"
 I RC : S P: 100-20 1 ~

used for the speer'fie job . shall be tested in the laboratory and prope r blend of aggregate shaI
be wortIed ou t so that the grada tion of final aggregate mix will satisfy the specified gradatiOn.
set forth in Tab Ie 7.4 ,
Table 7.4 Gradation of Agg regate in CMSDBC

Sieve Size (mm) Percent Passing by We ight

13 .2 100
9.5 90-100
4. 75 35 -51
2 36 24-39
1.18 15-30
0.300 9-19
0.075 2-8
Sa"" Equivalent Value (ASTM 0 241 9) 50 Min.
Percent Crushed Faces 75 Min .
Bitumen Emu Ision(SS-2 or tailo r mad e ) by Weight of Mix 8-10%

The optimum bitu men emulsion content (OBEC) shall be arrived at by Marshall method of mix
oesign wor1Ied out in the laboratory and by using 5S-2 grade of catooc bitumen emulsion.

Coarse ag greg ate shall be the fraction retained on 2.36 mm sieve and fine aggregates shall
be the fract ion passing 2.36 mm sieve and retained on 75 micron sieve. The se shall consi st
of crushed screenings. natural sand or a midure of both and shall be clean. ha rd. durable.
uncoated and free from injurioos. clay, soft Of flaky pieces. crqenc or oee teoccs matter. The
aggreg ate sha tI satisfy physical requirements given in Table 7.1. The shelf life of bitumen
emuls ion shall be such that it meets the phy sical requ irements. as given in earlier Table 3.2,
at the time of its use, The da tes of manufacture and expiry sha ll be clearly indicated on the

"""".
7.2.2 D6signofCMSDBC
Design cr iteria torC MSDBC is given in Table 7.5. The laboratory mix design gives proportions
of different miner al aggregates in tetTTIS of individual sieve size. for the purpose of actual
construction in the field , Blending of two or more sizes of aggregates (each size having
with in it a range of individual sieve sizes) would be necessary The blending ratio is obtamed
on a weight basi s. giving the percent weight of coarse aggregate , fine agg regate and filler
needed to give the uhimate gradation based on unit weight or boIk density of aggregates
SlJpplied _ The m ineral aggregate in combination with the optimum premixing water content
and bitu men e mulsion con tent, as determi ned in the laboratory. constitutes the job mix
formu la for implementation during the construction. The cold mix design shall be worked out
based on a correet and truly representative sample of materials tha t will actually be used in
the given con structiOn project. The deta iled procedure evolved for mix design of CMSOBC
using cationiC biIturren emulsion, is given in Append ix -9.

4'

IRC: SP :100-20 14

Table 7.5 Requirements of Cold Mixed SOSC

i) Xumbcr of compaction blows on each side of \l arshall specimen so

ii, \ lafShatl Stal>ihl)' al 25"(' in kg (mini mum). afteT curing !he specimen al 500
room rcmpcratcrc for 72 hours
iii) Mar:;hatl li nw (mml \1a\.8
i,-j

"
Per cent voids in mL\ IUre
fl indcr ~...-nk'lll (residual bitumc:n) by '" eighl u f total mi 'l ty.).mi n ..,
6 - 10

vi] Retai ned indirecl tensi1c slrength at 25"C after cornlilinning fur n hours in ts
air and 72 hours at 40"C. in water %

7.2.3 ConstrudJon of CMSDBC

Same as described in seoco 7. 1.4.

7.2.4 Quality control

The quality con trol tests and freq uency are give n in A nnex ure-l l.

7.2.5 PrecautiOns in laying of cok1 mixes (8M and SDSCJ

Follo wing precaution s should be taken to en sure successfu l laying of co ld mixes and to
achieve good pe rfor mance

Cold mix.es generally have good resistance to detrimef1tal e ffects o f w ater

damage during construction. Howevef. if rain occurs be fore the mix.ture is
cu red , traffic should be kept off . until the mix is cured and the necessary
co mpaction is acco mpiished.
The mixing wa ter content should be just sufficient requ ired 10 adequately
e'scerse the emulsion and achieve good workability
Mixtures shou ld be mixed only enough 10 property disperse the emulsiOfl.
Exce ssive mixing may cau se the emu lsion to break prematurely or strip fro m
the mi neral aggregates
FOf taster QJring. place the cold mix. in several th in laye rs rath ef than in a
single thick layer.
If case ra veling observed due to tra ffic, the loose material should be broomed
off as so on as possible to prevent further damage to the surface. If the
raveling co ntinues. the surface should be fog sealed w ith a lighl appliCation
of a slow-se tting em ulsion diluted with soft water 10 1:1 rsto.

7.' B ituminous Co ld Mixes (Incl uding Gravel Emulsion)

Thi s includes providing cold mix consisting of mixture of unheated minerai aggregate and
bitumen emulsion . laid in a single layer of 25-75 mm. De taas are given in Clause 518
tscececesco for Roads and Bridges WorXs). s-' Revision 2013
ea

--
 IRC:SP:1QO-2014

8 HALF WARM MIXES

Half warm mixes are those mixes in which the bitu minous binder is either a bitum en emulsion
or foamed bitumen, which is mixed with warm aggregates (100 10" C), laid and compa cted
at te mperature betwee n BO-9O"C .

Half wa rm mixes are considered as low energy mi xes, wh ich can be used for coosnucto n
and maintenance of bituminous courses for all climatic and tratfic cooetcos. The production
of a half warm mix using bitumen emulsion as the brnoer is comparable to prod uction of
hoi mi x using hot and melted paving bitumen. However, the mixing time is less in case of
half warm mix and the plant operahng temperatures are also low er. The prime adva ntages
d produciflQ half warm mixes (DBM, SOBC and BC ) using warm agg regate and ca tion ic
bitUmen emulsiOns are as under:
, Reduced mixing lime
, Ability to coat large size aggregate al lower temperature
, Reduction of bitumen harden ing duri ng mixing

8.1 Material s for Ha lf Warm Mixes

The half wa rm mixed dense bitu minous macadam, semi-dense or d ense bituminous concrete
shaN consist of coarse aggregate, fine agg rega te and fitler in suita ble proportion mi xed with
sufficient quantity of cationic bitumen emulsion. Represen tative samples of the aggregates
proposed 10 be used for the specific job sha ll be tested in the labora tory and a proper blend
d the aggregate shall be WOI'ked out so that the gradation of final aggregate mix will satisfy
specifi ed aggregate gradaoons , of OBM , SDBC and BC.

Half warm mixes shall consist of coarse aggregate, fine aggregate and filler (Conform ing the
requ irement given in Tabl e 7.1). The bitumen emulsion shall be catiomc 5S-2 grade confi rm ing
k) 15 :8887 spec ificati on or a tailor made for the aggregate to be used in con struction . The
requirements of bitumen emctslo n are given Tab le 3.2 (Section 3). Desig n of half warm
aggregate ba sed mix prepared with bitum en em ulsion shall be don e by Marshall Method.
The design criteria is given in Tabl e 8 .1.
Table 8.1 Requiremenb o f the Wann Mix PTep;llM with Bitumen Emu lsion

i) Number of compaction blows on each side of Marshan Specimen 75

il) Marshall Stability at 6QOC in kg (minimu m) , after aJring the MarshaU 900
Specimen fo r 24 h
iii) Marshall flow (mm) Max . 5
iv) Per cent Voids in Mix 3-6
v) Binder conten t (Residual Bitumen) by weight of total mix (%),min 45
vi) Reta ined Marshall Stab ility, Ratio 80

49
IRC:SP:1 00 -2014

8.2 Preparation of Mixture

The mixing plant may be eittler a batch or- drum mix plant. Incase of balch plants, the pug
mill mi xing chamber snould be vented to allow for the steam to escape. The discharge end
of the bitumen emclson circulating pipe should be kepi below the surface of the emulsion
in the storage tank to prevent foaming. The bitu men transfer system mus t allow tum ing
off or reducing the heat on all line s, pump s and jacketed bitumen we igh buckets. The
tem perature of the emul sion should never reach 90"C and it should be kep t about 75 to
85OC. Th e minimum mixing lime needs to be established and shall be based on the amount
of coating of aggrega te particles as de termined by ASTM D 2489 , "Test for Degree of Particle
Coaling of Bitumi nous-Agg rega te Mixture", The minimum acceptable percen tage of mated
partiCles will vary with agg rega te gradation, partJde shape. surface textu re . bitu men conten t
and use of the wa rm Of jot mixed material. Warm bitumen emulsion mixes are prod uced
at a temperature between 80 to 85"C. The terrtperature of agg rega te is kepi in between
95 to 105"C.
8.3 Construction Procedure
Procedure for construction shall be same as for cold mixes . Warm or hot emulsion mi xes
typica lly are spread with a self-prope lled sensor paver. For warm emulsion mixtures. a
minimu m delay should QCOJr cereeen d ischarge from the mixing plant and placement of
mixture 10 prevent it from becoming stiff and difficu lt 10 spread. However, some warm emulsion
mixtures , produced with emulsions having very soft bitumen residue and a small quantity of
solvent, may be stockpiled and placed cold. For wa rm emulsion mixes. compaction should
begin whe n the mix will support the ro ller without shoving. For warm mixes, the breakdo wn
rolling can be completed with a self-propelle d pne umatic or double drum (tandem) vibratory
roller fo llowed by finish rolling with a steel wheeled roller.

8.4 Quality Control

The de tails of Quality con trol may be referred to Anne xure" l

9 MAINTENANCE MIXTURE S USING BITUMEN EMU LSION

9.1 Introduction
Maintenance is essen tial for upkeep of the road. The most lime consuming and neglected
maintena nce activities include patching , filling potholes and repair of other failed local areas
or the pavement. It is well known that the use of. hot mix is pre ferred for palch work. The
quality hoi mi x is not available throughout the year at many locations like areas of ooId climate
and high r3infall. Therefore , patchi ng may be accomplished using cold mi xes. Mainlenance
mixes con sest of !he following types;
1) Mixes for Immed iate Use
2) Storable Mi xes
3) Maintenance mixes using RAP
4) Ready Mad e Mixes

50
 IRC:SP:100-20 1..l.

9.2 Maintenance Mixes for Im mediate Use

Such emul sion-aggregate mixes can be mi xed in a pug mill or in a concrete mi xer and
transported to the site where these are to be used. The heating of the aggregate is norma lty
not necessary, In cold wea lher cond itions. warm aggregates and emulSiOns heated upto
50 to 85"C can be used for better worItabi lity. Precautions to be takef1 during heating of
emulsiOn are givef1 in Section 2.8 . Proced ure fOf preparation of mix for immediate use and
storable mi xes is given in Appendix-10 .

The bitumeo emulsions recommended lor p<ltching mixes are MS. 55-2 grades or ta ilor-
made. Aggregates should meet the requirements specified previously in Secti o n 4 , The
aggrega te gradation recommended is given in Table 9.1. Bitumen emulsion con taining sma ll
amoun ts of solven ts genera lly prod uces the acceptable patching mixes ro- immediate use .

Table 9.1 Grading for Maintenance Mixe.

Sieve Size Percent Passing

9.5 100
4.75 40-100
2.36 10-40
1.18 0-10
0.075 0-2
The quan tity Ofemulsion Shall be 7 to 8 percent by weight of agg regate.

9.3 Storable Maintenance Mixes

During the cold weather and rainy monms. most of the maintenance mixes used are those
which may be stored/stockpiled. which can be produced in late summer or earty rrcems
of winter. transported and stored lor later use Such mix es are usable fOf periods up to six
months and are workable without the use of heat. These must be cove red by porytrene or
tarponne The production of stock pile maintenance mix is simple and includes a pug mill
type mixer. Slow selting (SS-2) grade or taWor made emulsion is to be used for thIS purpose.
The agg regate gradation for stockpile mixes is same as given in Tabie 9. 1. The duty mixed
material shall be stored in a clean . covered area to prev ent contamination and not stored in
a low area or depression where water cou ld get into the mix. For prolonged stockpiling alld
to be usable at lower te mperatures. a high neat medium setting emulsion is recommended.
These mix es may contain residual bitumen in the range of 4.5 to 5.5 percent depending on
gradation and surface characteristics of aggregates .

9.4 Maintenance Mixes Using RAP (MMRAPj

Many bitumen pav ement oveney projects include cold milling of bituminous surface and can
produce large quantities of Reclaimed Asphalt Pavement (RAP). There are a number of uses
lor RAP in pavements appliCation. and an increasing one is to use it in maintenance mix.

51
nevendro Kumar
SQME.LBG
lRC:SP:1ClO-2014

It is reoommended that, wheo possible, cold mining be used wIlich produces RAP m-.
in small pieces so thai it would not require further crushing, Bitumen emu lsion is ~:;:~
incorporated to the RAP by plant mixing . Special emulsion formulations have been deY<
for preparing RAP maintenance mixes, since softening of the aged RAP asphalt binder
de sired, Emulsion contents in the ran ge 011.5 to 2-5 percent by dry weight of RA P are ""...
rce eese mixes . RAP maintenance mixes are stored in stockpaes and their handling is
similar 10 traditional emulsion merntenaoce mixes, Normally extra slow SS-2 emulsiOn
more soIvoot is useful. These mi xes may be used successfully for both thin and deep pa. ....,
including potholes repa ir, In area wtere coa rse, crushed aggregates are oor av ailable
use of RAP usually results in su per ior maintenance mixes to those produced from
aggregates.

9.5 Readymade Mai nten an ce Mixes

Rea dy 10 use proprietary cold mix patching materials are also effective for insta nt f~
of pot hol es on road s under incl ement weather and operating co nditions. These mixes . .
e xpec ted to con tain 5 to 6 percent of residual bitumen and continuously gra ded aggregates.
A ty pical grading for such mixes is given in Table 9.1. Such mixes ca n be stored upto
months from date of manufacture.

9.6 Quality of Mai n t en ance Mixes

The follow ing tests Shall be ca rried out fOf as se ssment of the Quality of mai nten ance mixes
Test procedures are give n in Appendics 11 t o 13 The procedure for ca rrying out the bcJnC
test is given in Appendix 1 .
... Water resistance test
:..- Workabij ity test
... Binder co ntent
... Bond test

9.7 Procedure f or Repair of Poth oles Usi n g Mai ntenan ce Mix es

9.7.1 Preparation of pot/'IoIes

Pothol e shall be cleaned of loose material and dust with a stiff w ire brush . Pothole need
not be dry. However, e xce ss water. it any in the pothole, shalf be removed A tack coat sha ll
be applied to WMMl granul ar su rface before placing the mix to ensure good bond at the
boIlom

9.7.2 Placing mix in potholes

The mi x is intended for filling pot holes up to 75 mm deep. For deeper pot holes (more than 75
mm). pat ching mix shall be pla ced and com pacted in 2 or more layers of 25 to 75 mm. Initia lly
the pothole may be filled using Crusher Run Macad am (C RM) con for ming to the grading
given in Table 9.2,

52
 IRC:S P :1 00-201 J.

, Sieve size
Tab le 9.2 Gr ading of Crush er Run Macadam

% Passing by weight
,
d
53 mm Max. Size 37.5 mm Max. Size
63mm 100
,, 45mm 87-1 00 100
22.4 mm 5085 90-100
5.6mm 25-45 35-55
710 mm 10-25 10-30
90mm 2-5 2-5

9.7.3 Compaction of the mixes

First the outs ide edge or periphery of the patch shall be compacted with a hand ramm er and
men compaction shall proceed inwards. To pre vent initial pick up of the loose mix by the hand
rammer either co ntinue 10 wet th e hand rammer with water or place empty plastic lined bags
on the loose mix. For deep pothol es. place the patching mix and compact in 75 mm thick
layers. After compaction, the compacted patch shall be about 10 mm higher than the existing
road surface to allow for furthe r com paction by traffic. If there are numerous closely spaced
patches, it is preferred to use a sm all roller rather than a hand rammer. If a roller is used. the
compacted patch shall be about 3 mm highe r than the existing road surface .

Befo re opening the compacted patch to traffic. sufficient amount of cle an sand shall be
sprinkled on the patch to prevent pick up by traffic . The quality control shall be done as per
An nexu re-II.

10 COLO RECYCLING USING BITUMEN EMULSION

10.1 Introd uction

Recycling is defin ed as "the proce ss involving the reuse of material that al ready has
performed its first-intended use". In relation to bituminous pavement recycl ing , there are
several methods available. Therefore. projects being con sidered for recycling of pavement
must be carefully evaluated to decide the most appropriate recycling technique. The factors to
be considered should include (1) existing pavement condition (2) existing pavemen t material
quality. specifications and layer thickness (3) structural integrity of pavement (4) availability
of recycling additive and (5) recycling machinery. The Asphalt Recycling and Reclaimi ng
Association (A RRA) recognized five type s of recycl ing tor bituminous pavements:
a) Cold Planning : The bitum inous pa vement is removed to a specifie d depth
and the surface is restored to a desired grade and camber. Surfac e shall be
free of humps, ruts and other surface irregulari ties. The milling of pavemen t
is done with a suitable self-propelled rotary drum and co ld planning mach ine.
The Reclaimed Asp halt Pavement (RAP) materials are then trans ferred to
tippers for transportation to site of work .

53
IRC:SP:1lXl-201 4

b) Hot Recycling : RAP is combined with virgins aggregates. bitumen and

recycl ing agent to produce a usable bitumlllOUS milo:. Although balch type hot
mix plants are used, drum mix plants may also be used to produce the mix
containi ng RAP. Most 01 the RAP is produced by cold planning. milling and
crushing. The mix placement . compacting equipments and procedures are
same as used hot mix bituminous construction.
c) Hot In-Place Recy cling : This type 0 1 recycl ing is perfomled on-site; in-
place. The aged pave ment is typically reworIl.ed to a depth in the range of
20 to 40 mm . The bituminous pavement is heated. softened and scarified. A
bitumen emu lsion or other suitable recycl ing agen t is added. The three hoi
in-place recycli ng methods are defined as heater-scarification , repavmg and
remmnq.
d) Co ld Recy cling ; The cold recycling is perform ed using the cenlral or mobile
plant. The most commonly used method is cold in- place recycling. In this
type of recycling. the depth of pavement may be in the range of 50 to 100
mm . The pa vement is pulverized and the reclaimed material is mixed with a
bitumen emulsion or emulsified recycl ing agenl, Spread and compacted to
produce a base course layer. Cold recycl ed base requires a fresh bituminous
surface over it. The pavements w ith less traffic may use a bitumen emulsion
feN" surface treatment. Higher traffic pavements may use a modified bitumen
emulsion or a surface treatmen t of hot bitum inous mix.
e) Full-Depth Reclamation : In this category, all of the pa vement sections,
and in some cases. a predelennined amount of un6el1ying material. are
mixed with bilumen emul siOn 10 produce a stab~ized base course. FuMdepth
reclamation consists of siKbasic steps such as pulverization, additive and/or
emu lsion incorporation. spread ing , compacting. shaping, and placement 01
new bituminous surface ,

10.2 RAP Material for Co ld Recycli ng

The term 'RAP' is given 10 bituminous material that is recovered from an old existillQ pave ment.
There are two wa ys that RAP materia l can be used in road construction:
a) In-situ Trea tme nt : The existillQ bituminous miK can be reclaimed and
simul taneousty treated usillQ 'cold in-place recycli ng" technology (also
referred to as CIR or partial dep th recydillQ ). This process uses a large
truck-mounled recycler to recover the upper portion of bituminous layer of
the eKisUng pa vement (normally betw een 100 mm 10 150 mm depth) and
simult aneo usly RAP in m ixed with additives.
b) In Plant Treatment : The milled bituminou s mixture is stockpiled locally and
treated in a suitable mixing plant. The treated RAP material is then return ed to
site and paved back in the areas that were milled . The "col d in plant recycling"
technology introduce s flexibility into the recycling process by separating the

54
 IRC:SP:10Q..2014

recovefY and reuse operations . In addition , where required, this process

provides the opportunity 10 crush and/or- semen RAP material . as well as
blend it with fresh aggregate (eg., graded crusbed stone ). if required. before
it is recycled.
The quality of RAP is mos t important. From a cold recycling perspective, it is
most important to know whe ther the bitumen in the RAP material is "Active or
Inactive. RAP maybe a "Black Aggregate" (Inactive) with properties similar
to those of graded crushed stone or- it may be a 'Sticky Material" (Active) with
inheren t coOesiveness due 10 the less brittle bitumen in the RAP material.
This is important since !he stale of the binder in RAP w~l have a sign ifican t
influence on how the recycled materia l will behave whe n it is reused .
The followi ng observations will indicate inactive RAP :
a) Visual appearance : The RAP is dull grey in colour with no black shining
surfaces.
b) Btittleness ; Achunk of RAP bf"eaks cleanly irllo pieces.
c) Adhesion : Pieces of RAP (at ambienttemperalure) do oot st ick to the
hand. whe n a sample is firmly sque ezed .
In case, there is a doubt as to whether or not the RAP can be classified as
Active or Inactive, a representative sample may be tested in a laboratory to
de term ine following properties:
a) The amount of bitumen in the RAP material (percen tage by mass),
b) Rheological properties of the recovered bitumen (Penetration, Softening
Point. Shear Modulus and Viscosity )_
c) Chem ical composition of bitu men (asphaltenes. aromatics. resins and
saturates)

10.3 Cold Recycling

The cold recycling process has numerous applications for maintena nce and rehabilitation of
old bitu minous pav ements. However. each application will be a proj ect specific. The following
three factors are cons idered responsible to decide process of recycling :
" The type 0 1 pav ement and the distress that needs to be addre ssed
" The qua lity of malerial in ellisting pavement
" The service life exoectatcos after recycling
The materia ls involYed with !he cold recyding process can be classified in to two types;
;.. 100 percent Recl aimed Asphalt Pavement (RAP ) mateoai. where the depth
of recycling is rest ricted to bituminous layers
;.. Blend of RAP and Granular material , wh ere the recycl ing depth includ es
granular layers also. Such RAP iflCludes bituminous materials . crushed
stone and natural gravels. as well as materials previously stabilized.

55
IRC:SP :l 00-2014

,. Cold recycling may involve use of foam bitumen as well as bitumen

emulsions.

10.4 Recycling Using Bitumen Emul si on

The use of bitumen emulsion s as binder in cold recycling and full depth redamation process
is well known. The essential part for seectco of a bituminous pavement rehabilitatiOn method
is the determinatiOn of the existing pavement condition. The type and area of pavement
surface de fects need to be scienllfically evaluated. The strength of the cerent pavement
struct ure and its material needs are 10 be examined. The current and future traffic needs
must be investigated. The steps and methods for evaluation of pa vement mateoais for cold
recycling is given in Table 10 .1.

Table 10.1 Evaluation Procedure fo r Cold Recycling and Full Depth Reclamation

Characteristics Method of Test

ASTM 'S
Bitumen content in bituminous mixt ure 02 172 .
Recovery bitumen from a bituminous paving mi xture (by 018561 .
Abson Recovery method or Rota ry Evaporator) D 5404
Sieve ana lysis of fine and coarse aggregates C 136 15 :2386
Amou nt of materials finer than 75 IJm sieve in mineral C 11 7 15 :2386
Liquid limit plastic limit and plasticity index of soil 04318 15:2720
Sand equivalent value of soil or aggregate 0 241 9 15 :2720
Penetration of bituminous malenals D5 15:1203
VISCOSity of asphalt by vacuu m capinary viscometer 02171 15:1206

For bitumillQUS materials. testi ng typically inCludes bitl.men extraction for bitumen con tent
aggregate Quality sieve analysis of agg rega tes. For cold recyc:ling . a solvent or "Abson
Reco very (A5 TM 0472 and 1856)" method may be adopted which incl udes to de termine
the bitumen properties. Chemical Composition (aspha ltenes. resins. saturates and paraffins)
Penetration as 25"C . Absolute VISCOSity at 6O"C. For aggrega te bases and sub grade seas.
a wet sieve analysis and sand equivalent value or plasticity index are necessary done_A
mixtu re design is requ imd to determine the type . grade and amount of bitu men emulsion
10 be added in mixture. The premixing water con tent. the stability and streng th (modu lus)
properties of the recycled mixture tests are needed to be investigated.

10.5 Mix Design Procedure

Considering the number of variables that need to be add ressed and the amount of material
requ ired to study these variabl es. the mix desig n procedure involves several steps depending
on the magn itude of design traffiCand life. The mix design procedure always begin with testing
of the material to be stabilized (preliminary tests ) to detennine wheth er it is suitable for treating

56
 IRC:SP:1ClO-2Q14

with bitumen emu lsion and, if not. the type of pre -treatment required 10 make it suita ble
Once lhe suitability of the material has been proven, the actual mix design procedure beg in
those provides an indication o f the application rate of bitumen emulsion and filler (if necessary )
required to achieve the d ass of mix. Thereafter, depending on the design traffIC (structural
capacity requirement). additional tests are undertaken to reline the application rate of bitumen
emulsion and ga in confidence in the perfoonance potential 01the treated malerial. Procedure
described in Asphalt Academy (May 20(9) Tech nical guideline : Bitumen Stab~ized Material.
A guideline for design and con struction of bitumen emulsion and foam bitumen stabilized
mate rial (TG-2) ma y be used for mix design. In summary. the mix de sign procedure consists
of following steps.
a) Preliminary Tests : These include standard labo ratory tes ts to determine
lhe grading. moisture, den sity relationships and Atterberg limits , whe re the
result s indicate that some form of pre-treatment is requ ired , accncnanests
must be undertaken aft er such pre-treatment to ensure lhat the desired
benefits were ecnevec.
b) Level 1 Mix Design : level 1 Mix design begin with the preparation of
samples that will be used to prepare the specimens requ ired fof an levels of
mix design. 100 mm diameter Marshall Specimens (Marshall Specimen ) are
prep ared and cured for Indirec t Tensile Strength (ITS ) tesnnq.Test results are
used to :
, Ident ify the preferred sta bilizing agent
, Indicate the target bitumen coueru
, Identify the need for filler.
level 1 mix design is sufficient for lighter and medium tra ffIC roads with
a limited structural capacity of 5 msa Where the structural capacity
requirements exceed 5 msa , the mix design procedures described as levels
2 and 3 should be undertaken.
c) Level 2 Mix Design : This proc edure uses 150 mm diameter by 127 mm
higth specimens (Proctor spe cimens) prepa red using vibratory compaction,
cured at the eq uili brium moisture co ntent and tested for Indirect Tensile
Streng th. This level is recommended for road s carrying !Taffic up to 10 rnsa.
Test resu lts are used to:
, Optimize the required bitumen content
~ Obtain ITS values for increased ccoeoeoce
d) Level 3 Mix Design : This procedure uses biaxial testing on 150 mm
diameter by 300 mm high specimens for a higher level of confidence. This
level is reco mmended lor desig n traffic exceeding 10 msa.
e) Materials Selection Criteria; The guidelines are given be low :
The PI of materiel to be treated with bitumen emulsion should be less
- than 8.

57
IRC:SP:100-2014

ii) Bitumen emulsion must coat coars e particles. not only the fines
iii) Fines content of 2 percent is sufficie nt.
iv} Material at a temperature of 15"C or higher ca n be treated with bin.r-
emulsion
v) The selection of the correct grade or category of bitumen emulslQO
each app lication is essent ial
These are listed below:
i) Slow set cation ic bitumen emutsions are exclusively used worldwide ~
bitumen emu lsions or tailormade emulsions having longer workability
ensure good dispersion and are formulated for needed mix stability
ii) A number of developments in bitumen emulsion techn ology are haPl)e!'1lll
10 improve stability without prolong ing the breaking time . These emuls.:-
are typically slower setting than the traditional 55 products, and should
used on projects where the treated layer can be cured for a shorter pero;
before opening to traffic. During the mix design , and on site before full-sea;,
application begins, the brea king rate should be tested with represe ntav.
samples of materia l, active filler, water at realis tic temperatures.
iii) The selection of the bitumen emu lsion type and grade is influenced by
type of material and climatic condition that is to be treated. Certain malere
types are not suitable for treatment with anionic bitumen emulsions. Trese
are the acidi c rocks with silica conte nts above 65 percent and alkali conteres
below 35 percent such a quartzite, granite, rhyolite, sandstone, syenite ~
felsrtes. Treatment of such materials requires a cauonc bitume n emulsion.
iv) Manufacturers normally recomm end that undiluted bitum en emulsi on rna,
De heated to 50 and 60"C to prevent premature breaki ng due to the increase
in pressure and sheari ng action while pumping and injecting through ee
spray bar on the recyc ler.
v) The pH levels of the water must be checked for the compatibility of the
bitumen emulsion and the water.
vi) Breaking is the separalion of the bitumen from the water phase througtl
floccu lation and the coalescence of the bitumen dro plets to produce films
of bitumen on the individual particles of the material. The rate at which the
bitumen droplets separate from the water phase is referred to as the breaking
time.
vii) The breaking process with anionic bitumen emulsions is a mechanical
process (evaporation), whereas cationic bitumen emulsions produce a
chemical break. For dense mixtures, more time is needed to allow for mixing
and placement besides slowe r breaking times. As the bitumen emulsion
breaks , the colou r changes from brown to blac k. Although this can De
observed with the naked eye, it is recommended that a magn ifying glass
may also be usee .

58
 IRC :SP: 1QO-2014

viii) Curing is the d isplace ment of water and the resutlant increase in stiffness
aod tensile strength of the mix. This is important as a mix needs to develop
sufficient stiffness and cohesion between particles before tra ffic is opened.
ix) Rate of absorption of water by such materia ls is also important. Rough-
textu red and porous materials reduce ItIe breaking and setting lime of
emu lsion mix by abso rbing water contaoec in the bitumen emulsiCNl.
x} Moisture content of the mix prior to mixing influen ces breaking time. Wh ile
moisture co nte nt of the mix aft er compaction influences cu ring rate.
Ili) Gradi ng of the material and voids content of the mix also influence setting
process
xii) Type. grade and quantity of the bitumen emulsion also influence settlflg
""""'".
xiii) Mineral composition olltte material pray a vital role. The rate of cure may be
a ffected by physico- chemical interactions between the bitumen emulsion
and the surface of the individual material particles.
xiv ) Quantum of electrical cha rge on the material particles in relation to that of the
bitumen emerson also influence breaking as wel l as selting.
xv) Active filler addition. the amount of ce me nt Of ~me also influence seltiog.
xvi ) Temper ature of material and air: The hig~ temperature. the quicker the
bit umen emulsion breaks and cur es .
xvii) A minimum of 1 to 2 pe rce nt moisture is req uired in the mineral material prior
to adding the bitumen emulsion .

11 EQUIPMENT FOR B ITUMIN OUS ROAD CONSTRUCTION

USING EMU L SIO NS

11.1 Introduction

Th is section deals wi1h the basic information of eq uipments reQuired fof construction and
maintenance 01 100 road s using bitumen emulsion in cold and warm miKes besides other
application. Th e follow ing equipments are dealt in this Section.
1) Emulsion sp rayers 6) Rollers
2) Pressu re distributors 7) Microsu rfacing machines
3) Chip spreaders 8) Cold recycling ma chines
4) Cold mix plants 9) Patch ing machines
5) Pavers

11 .2 Em uls ion Sprayers

The hand operated as w ell as mechan ized bitumen emulsion sprayers may be used for
sprayi ng bitumen emu ls ion for small are as . These sprayers are avail able in diffe rent sizes

(25 liters to 500 liters) capacity.A picture of ha nd operated spra yers and mechanized bit umen
emulSion sprayers are given in Photo 11.1 .

59
 Ptloto 11 .1 OffIerent Type 01 Bitumen Emulsiorl Sprayers

11,3 Pressure Di stributors

The bit umen emulsioo drsllibulor is the most important equipment used in tack coat. prime cost
and other su rface treatments (Phot o 11.2). It is used 10 uniformly apply the bitu me n emulsior1
ov er the surface at the specified rate. The distributor co nsists of eith er a truck-mounted or
trailer-mounted insula ted tan k w ith co ntrols to se t the bitumen emulsion application ra tes. A
spray bar eq uipped w ith nozzles through which the bitumen emulsion forced under pressure
on lO the pavement surface is placed at the end of tan k. Spray bars ca n COVet widths of 3
to 9 m in a single pass , depeodillg on ne pump capacity. A tla nd sprayer ma y be used to
apply the emulsion to areas that cannot be reacnec with the spray bar. The distri butor tank,
ty pically has a capacity of 3,000 to 20,000 liters . The tan k shall contai n a circulating system
Pressure genera ted w hen a non circulating or nol bypassed spray bar is shut o ff can cause
the emulsion to brea k and plug the unit with bitumen. The tank is also equipped with OOE
or more heaters used to bring the bitumen emulsion to the desired spraying temperature
Extreme ca re is requ ired when using thes e heat ers whi le emu lsion is used as material
Premature breaking of the emu lsion ma y occur. if hea ting temperatu re is too high (>7O"C
and heaters are 10 be used. the em utsion should remain cifculating while heal is applied anc
e xcessive temperalures shou ld not be allowed. Two extremely important adjustments are
the spra y nozzle angle se lling and spra y bar height. The angle of the nozzle openings must
be adjusted so that the spray showers w ill not interfere w ith each oth er. The recommended
angle , measured from the spray ba r a xis, is from 15 to 30 degrees. To ensure a unifonr
sp read , the spray ba r must be set and maintained at the proper height above the pa vemEl!"l
surface. If it is set too high. distortion of spray fa ns ma y occur. The best res ults ~
are achieved with an exact dou ble coverage, but triple coverage can sometimes be used
with spray ba rs with 100 mm nozzle spac ing Fig.11.1 illustrates the heights o f the spray
bar necessary to achi eve thes e co verage. Three co ntrols are sta ndard eq uipment on most
distributors. One is a valve sys tem that governs the !low of bitumen enersoo . Another is ;0
pressure gauge that reg isters pump output. The third is a bitumen emulsion with an odome1er
that indica tes the number or me ters per minu te and the total distance traveled . Des pite the
precise controls on a distributor, it is alw ays advisable to chec k the ra te of application .:>
the field. Thi s can be done w ith a shallow metal tra y e xactly one SQua re me ter in the area
If a tray is 1'101 av ailable, a sheel of heavy pa per or ca rdboard can also serve the intenoec
purpose. The tray is weighed and placed on the surface to be sprayed. Immediately after ~

60
 IRC,SP:1QO-2014

distributor has passed . the tray is removed and weighed again . The difference between tne
two is the weight of the bitumen emulsion applied on the surface in one sq. meter area .

Photo 11.2 Emulsion Sprayer

s_ . ......'&

Fig , 11,1

11.4 Aggrega te Sp reade rs

The aggregate spreader is an important equipment for surface dressing. It applies a uniform
aggregate cover at the specified rate. Spreaders range from the simple vane type attached
to a truck. tail gate to the highly efficient self-propelled type . Tail gate spreade rs are usually
of two types. One is a steel plate to which is attac hed a series of vanes to provide coverage
across the lane. Another is a truck-mounted hopper with a feed roller activated by small
wheels driven by the truck wheels, In each case , the truck backs up to spread the stone.
This prevents the freshly applied bitumen emulsion from being picked up by the truck tires.
Mechanical aggreg ate spreade rs contain hoppers and a built in distribution system to ensure
a uniform spread of the cover aggregate across the entire Jane width . Mechanical spreaders

61
IRC :SP :1QO-2014

are either truck-att ached or self-prop elled. In bot h ty pes, the aggregate is du mped from a
truck into a receiving hoppe r for spreading. The truck attached spreader typi call y co ntains an
auge r and a roughened spread roll in the hopper that ensures a positive and uniform feed of
ma terial. The self-propelled unit has a similar feed mechanism. One difference is that the self
propelled spceeoer con tains a scalping screen over the aggregate receiving hopper. Anott1eI'
is that there ca n be a sloped screen that allows the larger partides to drop into the asphalt
film first with the finer particles failing afterward s through the screen. This system ensures
that the larger partc e e are sufficiently embedded in the asphalt to hold them in place. The
self-prope lled uni t ha s the advantage of being able to closely follo w behind the bitumen
emul sion distributor. with minimum stopping to change ag greg ate trucks. Mec han ical self
propelled agg regate spreaders should be ca librated to ap ply the designed qua ntity of cover
stone fOt any given project. The req uired eq uipme nt can be very simple and may consist
on ly of several sneers of ca nvas. each exactly one square meter (sq uare yard), and a sca le
By ma king se veral runs at differe nt speeds and ga te openings ever the sheets o f canvas
and carefully we ighing the agg rega te de posited on them , the gate opening and spreadef
speed required to apply the cover stone at the specified rate pel" sq uare me ter can be quiCkly
determined. A typical chip sprea der is shown in Photo 11 .3.

I,
I

Photo 11.3 A Typical Chip Spreader

11.5 Cold Mix Plants

Cold bituminous mix invotving use of bitumen emulsion as binder is manufactured in a pug
mill, w hich blend w ater based bitume n emulsion with pre wetted ag gregates according 10
a laboratory job m ix formu la The aggreg ate may be virgin , or RA P and may be used 10
prod uce a low cost and low energy pavi ng materia l. These cold mixes may be manufacturea
by a ce ntrally located or by mobile plan t. The mixes may be used for base, binder. le veling
or wearing co urse or structural overla ys. The resi liency o f cold mix products 10 self-heal wiU1
moveme nl rrom freeze thaw cycles ma kes Ihem ide al. The key benefi ts of cold mix pa~

62
 IRC:SP: 100-2014

are desaibed below :

, Flexible but strong to withstand temperatu re fluctuations
, can be mixed at a central plant or portable at remote locations
, Eco-frlendly materials used at ambient temperatures be reduce emissions,
Energy secu rity
, Cold bituminous mixes minimizes transportation and materials cost
, Cost-effective paving for upgr ading rural roads far from a hot mix plant
, Small jobs can be dooe using concrete m ixes.
A typical cold mix plant compriSeS various parts as listed below :
1) Cold aggr89ate feeding system
2) Dryer system
3) Combustion system
4) Hea t material hoi sting system
5) Dust remover system
6) Vibrating screen system
7) Weighing system
8) Mixer system
9) Powdery material feed ing system
10) Main body of mixing plant
11 ) Compressed air supply system
12) Electrical control system
13) Bitumen emulsion spraying system
14) Bitumen emulsion supply system
15) Finished product bin
i ypical cold mix plant are shoWn in Photo 11.4 .

Pholo 11 .4 Centrally Located and Mobile Cold Mo. Planls

63
IRe SP;1OQ-Z014

11.6 Pavers

For plant produced emu lsion mixes, the paving procedures are similar to those used for hot
mixed materials. Base courses may be laid with self-propelled base spreaders or even with
a blade. However, self-propelled pavers are recommended for surface courses. Cold mixes
generally are stiller than hot bituminou s mi x, with open-qreded mixtures being the most
difficult to place Proper paver ope ration is very critical for obtaining uniform and smooth
mat. This includes keeping the paver speed as constant as poss ible and the level of mi x on
the augers at a nearly consta nt depth. If mix SlickS to the paver screed or tearing 01 the mat
occu rs. chan ge in the mixing lime or the water content can eliminate the problem. The screed
should not be heated. Ptant produced emulsion mixes are placed in lifts of 100 mm or more
but compaction and cunng proceeds quicker with lifts of 50 to 75 mm. Foropen-graded mixes ,
the breaking of the bitume n emulsion usually occu rs quickly, With open-graded mixes , rolling
normal y may begin immed iately behind the paver. However, the emulsion in dense-g raded
mi xes typically ODes not break for some time. Because of the higher moi sture contents for
mixing, a delay in the compaction of dense-g raded mixes is usu ally required. The amount of
delay is dependent on the litt thick ness and the curing cond itions of air tem perature, humidity
and wind . The rate of water loss controls when compaction may beg in.

Because-of the extreme tacki ness of open-graded mixes and an initial low stability until
ob taining some aggregate interlock, the breakdown roPing is best accomplished with a static
steel--wheeled roller. Vibratory rolling of open-graded mixes is not recommended because
fracture of aggregate and asphalt bondi ng can occur. A ligh t ' choke" or "blotter" of a coarse
sand or fine crusher screenings may he applied after steel-wheeled rolli ng. The cho ke or
blotter permits rolling with a poee matc- tired roller and prevents pick-up and dam age by
traffic. The sand or screenings is app lied with a ccrrectonet self-propelled ctliP spread er or
sand spinner at the rate of 3.30 to 06 6 kgl1 0 rn",

11.7 Ro llers

Rolli ng presses the aggrega te dow n into the bituminous binder, promoting better adhesion.
Unless the cover aggregate is properly embedded in the bitumen film, there is a good
possibility that some may be lost through traffic abrasion. For single surface tre atments,
pneumatic-tired fillers produce best results. They force the aggregate firmly into the bitumen
binder without crushing the particles. The tires press into small depressions to better seat
the particles . Steel wheeled rollers tend to bridge over such depressions and may fracture
the aggregate. If the roller speed is too high , the roller may dislodge the aggregate. Diff erent
types of rollers are shown in Photo 11.5 ,

64
 I R C: S P: 100-201 ~

Photo 11.5 Different Type of Rollers

11 .8 Micr osurfacing Mach ines

The machine shall be specially desig ned for application of slurry microsurfaclng mixture. It
shall be a se!f-propelled equipment, truck mounted, consisting oftha following sub-assemblies
used to man ufacture and simultaneously spread these mixes on the surface. (Photo 11 .6)

':: :' T
Microsurfllclnll ProcH '
,- ;;:~ ';;;;;~
~_=. L-

.. ~-

Photo 11.6 Microsurfacing in P10gles5 and Mic:rostnacing P10c ess

Aggregate Bin
Fijler Bin
Water and Emulsion Tanks
Additive Tanks
Aggregates and filler conveyors to supply the mixer box
Pump or comprassed air system to supply the emulsionlwa ter
Mixer Box
Spreader Box to place the mixed slurry on the job

11.9 Co ld Recy clin g Mach ines

A view 01 cold recycling machine is given in Photo 11.7. Such machines are useful for surface
and full depth recycling involving use of bitumen emulsion.

5
IRC:SP:1(lO201 4

Photo 11.7 Cok:I RecydlO9 Mac::tW>e

11.10 Patching Machines

A v1ew of various patching machines is given in Photo 11 .8

f'tloto 11.8 A VIeW of Patching f.lactWles

66
 IRC: SP :100-2014.

Annexure "

Choice/Selet;ti o n of Cold Mix Treatments for Different ClimatefTraffic Conditions

(Warrants )

TItle of Treatment Traffic ICVPOl Climate ChoIce of

. -
Temperature Ranlfall
Emulsion

Prime Coal No limit No Lim it No Lim it SS-1

Tack Coat No Limit No Limit No Lim it RS-'
sea ccet <' 500 No Lmit No Limil SS-'
sand Seal <' 500 No Limit No l..in1it 58-,
cap Seal -aooc No Limit No Limit RS-2 SS- 2 and
Mod,fled

Chip Seai <1500 Avoid in Cold No limit RS-2, Modified

Climate

S1uny Seal
MicroslJfacirlg
<1500
No Lmil.
No Limit
No Limit
No Limit
No limit
""" ...
58-,

OGPC <'500 Moderate & cold

d lmate (maximum
air temperature
Medium
."
MSlSS-2

Tailormade
'OOC,
MSS <1500 Moderate & cold Low MS/SS 2
dimate (less tha n
<O"C, .""
Tailormade

8M <' 500 Moderate & cold ,~ M8'SS-21

climate (maximum Tailormade
air temperature
.OOC,
SDBC -cooo Moderate & cold L~ SS-2!Taikmnade
climate (maximum
air tem perature
<O"C,
Half Warm MIX <4500 Moderate & cold No lind 5S-2!Taik:lrmade
(08M, SOBC . Be) climate (ma xirrlu'n
air temperature
<O"C,
COld Recycling No lim it Moderate and co ld No limit SS-2!Tailormade

T
._
duna!e

Pat ching No Limi t No Limit No limit MSlSS-21

6T
IRC:SP :100-2014

Annexure-II
Quality Control Tests for Emulsion and Cold Mixes

Pnme Coal/Tack CoaV Number of samples (two

Fog Seal per lot of 20 toone
Ii) Rate 01 Spread of Tray tesl One test per 500 m' anll
Emulsion not less than two tests per

coevswrece '"
" Seal
Dressing
i} Quality 01 Emu lsion IS:8887 Same as mentIOned under
Senal NO. 1
ii) Aggregate Impact Value IS2 386 (Part IV) One test per 50 m' of
aggregate
iii) Flakiness I nde~ and IS2 386 (Part I)
Ekmgatl on Index
iv} Stripping vatue 01 15 ;6241 Initially one set of 3
aggregates representative specimens
lo r each source 01 supply.
Subsequenlly when
warranted ~ change in lhe
aggregates source
v) Water absorption 01 IS:2386 (Part III) One test per 50 m'
aggrega tes aggregate
vi) W" ler sensitivrty of mi~ AASHTO T283 Inrtially one set of 3
representative spec;mens
for each SOUrce 01 supply,
Subsequently when
warranted by changes in
the Quality of aggregales
(il required)
vii) Grading 0/ aggregates 15:2386 (Part I) One test per 25 m'
viii) Soundness (Magnesium 15 :2386 (Part IV) Initially, one determination
and Sodium SUlp hate ) by each method lo r each
source of supply. then as
warranled by change in the
quality of the agg regates.
ix) Rate 01 spread of One tesl per 500 m' of
materials WOfk, and I10l less than
two lests per day
x) Sand EQu ivalenl Value IS2 72() (Part 37) One lesl lor 50 m' by
agg regate

" OpBn-graded Premix i) Quality of Emulsion

S u rl a c i n g f C l o se - I~-+~_~~_~~~-+~~~
graded Premix ii} Aggregate Impact Value lS:2386
15 :8887 Same as mentioned under
t"'''''''''-.~_~~_
Seria l No , 1
Same as menl ioned under
Surfacing Serial No , 2
iii) Flakiness Index and 152386 (Part IV) -do-
Elongation Index

68
 IR C: $ P .100-201 J.

'No Specification Method.

'HB
w) Stripping value IS;6241
''''''''''
same as mentioned I,I'Vjer
Seria l NO. 2
- ) Water at>sorptoon 01 IS:2386 (Part III) same as mentioned under
aggregates Serial Nl.>. 2
.) Walet sensitivity of mD< MSHTO T-283 same as "lei iIIOo oed uno:ler
SenalNo.2
vii) G<ading of aggrega tes IS :2386 (Part I) Same as me<'Cioned under
Senal No. 2
vi;i) Soundness (Magnesium IS:2386 (Part V) Same as ment ioned under
and Sod ium SoIphaIe) Serial No, 2
. ) TemperBtln 01 binder at - AJ. regular dose intervals
""0::. ..to,
. ) BInder con ten t Appen<!ill-13 One Ie5I per 5000 m> and
i10I less tha n two tests per
d.,
xi ) Rale of spread of milled . Rl:I9ular control throug h

., Bi1I.minous My.... _ I)
material
0uaIity of EmuIsiorl 1$8887
checks of layer lhic:I<.ne&s
Same as meollliol oed under
SeniII No. 1
(Cold Mixed )
ij) Aggregate I~ V3Iue IS:2386 (Part III) Same as n.......... oed under
Senal No. 2
;ii) Flakiness Inde, .00 IS:2386 (PM I) Same as menlioned ul'\der
Elongation Il'\dell Serial No.2
') Stripping Value IS :6241 Same as menlloned under
Serial No. 2
- ) Wate< --.s.tiv'tV of lTllJl AASHTO T-283 .....
. ) Grad'ng of aggregates 152386 (Patt I) ,~
IH"
"".,d"" ""
plant boltl on \he tfldividual
mi,ed

-
constitue nts
aggrl:l9ate form the dryer
w ) Water
.",.,..
viii ) Sout d
'" 1$;2386 (Part I)

1M ll",esOum IS:2386 (Part III)

same as in Serial No.2

Same as "",",boned under

and Sodium SlJlphale) Serial No. 2
i,) Binder content .00 A ppe"d ill_U Periodic , 9<lbj&c1 10
min;mum of two tests per

-
aggregate grading

. ""'...
) Rate of spread of lTIIJled
day per pla nt
R.....
~ """'"
of ~ lhK:l<nes:s

5) SlUrry seal u
...."""'" '"
, i) COl'

Quality of Emulsl on
Ieo1 .

IS:8887 -
One test per 250 m' of

Same as mentioned uil(\er

Serial No. 1

""--
ij) Sand Equivalent value of 15 :2720 (Part 31) One test for 50 m'

69
IRC:SP:100-201 4

~
..
Ii}

iii)
~nnl""ate ~radln"
Recovered
[oeeenauon
,
Repave)
sta b~ity
blnc\Ar -

(Remlxl .
25 m' of ree cled mat
Min,mum of one test
50 m> nf mat_
For each 400 IOnnes. /I
mill recycled. a set eX

.......,
Mil"""'" -....,
specomeIlS 10

51a1:*ty, 1bro<. density . .

-
w;d oonlenl $I !bled 10
minimum eX !\OO 6els CJ

Cold MI. (8 M1S06C) Quality of Emutsoon r.ncllIr1

" 'j lS8887 same as menboned
Sef'lal No , 1
ii) Aggreg.ale Impact V81ue 15:2386 (Parl IV ) Same as mefl\io<led u,""""
Serial No. 2
>-
iii) Flakiness
~nl nrleX
5
Index

Value
'"' IS:2386 (Part I)

15 :6241 -oo-
" Waler 01 mi. AASHTO T-283 -oo-
Gt'ading of aggregates

-
. j 15:2386 (Pall I) ,~

'" '''' ""

,~

plant boIh on the irolfrv;d ....

"' ...
oonsbluenls an """eo

-,
=-,--
w Sand Equillalent YaIue ~2nO Part 24 Test for' 50 m'
. Two IesI per (lay pet pIanl

"'-, w.~ d 15: 2386 (f'aIllIl ) same in 5enal No,2

te
Sound ness (Magnesium 15:2386 (Pa rt III) same as menl","&<! under
and Sodium Sui hal~l seoer No . 2
. i) binder conlenl
aggreg ate grading .'"
Appendi 13 PerKxlic. subject
minimum of two tests per '"
cav per n1anl
xii) Mix stability For each 400 Ionnes of
mill produoI:od. one set of
3 UshaI sp ec:i"'e,, s to
be prepared ..., tested b"
stabiity. 1bro<. density and
(lid oonlenl $I " 10 a

' j Patch ing Mix

"
B,",n~

oJ WQrl<ablllty
Append ix-1

Append ix.12
~",-"
oee
~~j
,~

'"
..,
rrinrnum of two sets of

uo
(W
One O!S;est PO'
toeres

"" . (W
Appen-d ix-13 ,~ tests let
iii) 8 iooor COnle nl
~~,

Waler Resistance Append i~ -11

>~est p,
' j One
~~ '"
70
 IRC :SP :l lXl- 201"

Test Meth od for Determination of Bond Strength

$(;ope : This test method is irlteoded 10 determine the bond strength between two
superimposed bituminous layers 01 field and laboratory prepared sa mples

Apparatus : Marshall Testing Ap paralus. Hammer and Shear Mould

Method :

a) Test on sa mples from field

The co res of the two superimposed bituminous layers suc h as BC over BC

or Be over DBM shall be taken out fro m the field using the core cu tting
machine. The core shall be allowed to cure in the laboratory fo r aneast 24
hours. After the curing ?8fiod. the sample shall be placed in the shear mould
and tested in the Ma rsh all testing machine at 25C. The failure load is noted
down and shear str ength shall be ca lculated as follows :

Load [at Failure)

Shear Stren gth = -;-:,.,--;-:":-"'''"'''C='''''''--,,~-C'
Area o f jhc surlocc (n.-sisli ng I"" load)

b) Test on labora tory sam ples

In the laboratory. Marshall Samples are to be pre pared by 50 blows on one

side, such tha t the thiCkness of the sample is about JO..35 rTWTI. Once the
samples are taken out from the mould, tack coa t is applied at the specified
rate on the samples and alklw'ed to cu re for 24 hours at room temperature.
After the curing period, the other half part of the Marshall sample is prepared
by applying 50 blows. The sample should be such tha t half 01 the sa mple is
of the one type of material and the other superimposed half is of other type of
the material and tack coat membrane is inter1ayer between two layers. The
sample is taee n ou t and allowed 10 cure for 24 hours . Aft er the completion
cu ring peood . the sample shall be placed in the shear mould assembly
Marshall testing machine . Test setup lor tes ting of bond strength of tack coa l
between two bituminous layers is showing in Photo 1.

71
 IRC:SP:100-20 t4

I
r ""'"
...
......
So
>------j
-.- I -- - -

--
I

-
-+- r---- I

,"-
---
-
"
...
,
,
...
I '----

.
I Photo 1 Test Set up for Testing of Bond Strength 01
Tack Coal Between Two Bituminous Layers

72
 IRC:SP:1QO-2014

Appendix-2

Method for Determination of Mixing Time

Scope : This test is intended 10 determine breaking time of ermAsiOO in a slurry seal or
microsurfacing mixtur e.

A pparalus : Stainless SleeI Bowl. Spatula . Beakers, Measuring Cylinders. Spoon,

Balance.

Method : Take 1000 g of the graded aggregate and needed cement in a bowl, mixed genUy.
Add required quantity of mixing water cootaining required dose of additive (if needed), to the
aggregate and cement mixture . Mix the cements in bowl vigorously with the help of spatu la
so that a homogenous paste is fanned . Add requisi te quantity of emulsion and then mix
the conten ts in bow l with the help of spatula till the emul sion commences oreaking (colour
turns brown to blackish brown ) and mix beqms ceasing its work.ability. The lime required for
initiation of breaking emulsion is known as mixing time.

Report : Minimum time in seconds required for initial breakmq of emulsion is reported as
"Maximum Mixing Time".

73
IRC:SP:100 -20 14

Append ix -3

Method for Determination of Consistency

Scope: This Test is used to determine the consistency of slurry sea l and microsurfacing
mixture
sa
Apparatus: Mould of metal. in the form of a frustum as a cone . 38 mm in diameter at top
89 mm in diameter at the base and 76 mm in height. The centre of 228 mm metal plate G
inscribed with a circ le of 89 mm in diameter. Three to four addition al circles each 13 mn:
greater in diameter than the preceding cird e are inscribed on the metal plate around Ihf.
centre.

Method: Mould is loosely filled with slurry seal/microsurfad ng mixtu re and struck off. The
mould and contents are then inverted in the centre of the metal plate by placing the mscnoee
surface of the metal plate on the slurry frlled cone. Which while holding cone and plate fi~
together, is Quickly inverted . The mould is removed and contents allowed to flow over the
inscribed circl es until flow of the slurry stops.

Report : The outflow of slurry is measured at four points 900 apart from each point. The
average value is reported in em.

74
 IRC:SP:1DO-201 4

Append lx-4

Method fo r Determination of Cure TIme

Scope : This Test is intended to detetmine axe time of slurry seal and miaosurfacing mix
for complete cohesion.

Appa ratus: Cohesion Tester capable to apply varying pressure to a slurry pad, air compressor
(0 to 700 kPa). Torque meter (35 kg.em tOfQue), 60 mm dia. Steel mould of 6 mm and
10 mm thickness. 4.75 mm and 8.00 mm size sieves. mixing pan , spatula. balance. bituminous
roofing felt of 10 em' size and 13,6 kg weight,:zo.30 mesh standard Ottawa sand , 3-M brand
sand paper.

Proce dure : A suitable number of identical specime ns of mix are cast in the 6 mm or
10 mm ring mould centered on the bituminous roofing fell base of shape. Specimen shall
be uniform. whose surfaces are horizontally parallel . A template is recommended to obtain
uniform thickness of sJurrylMiaosafacing mixture mat. After setting of slurry mat it is placed
beneath the pneumatically actuated rubber foot (25.4 mm dia.) of the calibrated cohesion
tester. A pressure of 193 kPa considered to be equivalent to the pressure exerted by lyres of
vehide is appl ied. The torque measurements are made at intervals of 30, 45, 60, 75. 90, 120,
180 and 240 min after casting of samples by means of a torque tester, till highest and stable
torque reading is obtained.

Report : The time required to reach constant and max imum torque or rubber foot rides freely
over slurry mat without dislodgement of aggregate particles is recorded as the Curve Time,
In case of quiCk traffic system. a cohesion torq ue of 20-21 kg.em is required to reach within
60 min. For a quick - set system, a cohesion torqee of 12-13 kg.em is required to reach
within 30 min.

75
IRC:SP:1 ClO-2014

Appendix_5

Meth od f or Wei Strippi ng o f Cured o f S lur ry

Scope : The purpose of this test is 10 help in selection of compatible sl urry seaVMiCfosurfacing
sys tem with a given aggregate. This is genera lly useful for screening of emu lsion formulation.
fillers and add itiveS by e xamination of ability 01 sys tem to rema in coated under the specified
test condition.

Apparatus: 600 mI beaker, hot plate with adjustable temperature. high wet strength paper

Procedure ; 400 ml o f cemeeeeaseo tap WOller or distilled water is added to the 600 In
beaker placed on the hot pla te and brought to a vigorous boiling condition. 10 gm mixture 01
cured slurry is dropped in to l he bo iling w ater for three minu tes duration. After three minutes
beaker with mixture is removed Irom the hot plate and allowed to cool up to room temperature
Subsequently, cold tap wat er shall be appl ied on the surface of the wa ter beaker and continued
until any free bitumen on the surface of the water flows over the sides of the beaker. The
wat er is then decanted an d the co ntents removed from the bea ker are placed on the white
absorbent paper/towel. After drying . the samp le shall be examined for uncoated areas.

Report : Report the estimated coa ted area of the aggreg ate surface with bitumen as a
percentage of the Iotal aggreg ate surface.

90 percent retai ned coating is satisfactory.

75 percent to 90 percent retained coating is judged as ma rginal.
Below 75 percent retained coa ling is unsatisfactory,

76
 JRC:SP: 1QO-201 "

Appendix....(j

Met hod for Wet Track Abra si on Test

Obj ect ive: This tes t procedure is used to determine the resistance to abrasion 01 slurry seal!
microsurfacing layer and to establish minimum permissible bitume n emulsion con tent in the
microsurfaci ngfslurry seal mixture.

Appa ratus : The req uired apparatus are as under:

i) Bala nce : Ca p able of we ighing 5000 9 within 1.0 g .
ii) Planetary Type Mechanical Siner : such as the Hobart Model N-50. Model
C- l00 or Model A-120 made by the Hobart Manufacturing Cc.. Troy. Ohio)
equipped with a we ighted rubber hose hokl ing device hav ing free up and
down movement in the shaft sleeve.
iii) Flat bottom Metal pan. Appro ximately 330 mm in diam eter with 51 mm
vertical side walls having four eqcis paced screw clamps capable of securing
285 mm d iameter specimen 10 bottom of pan.
iv) Suitable Heavy Gauge round bottom bowl: to cootae the sample during
mixes.
v) Long handled serving Spoon: of suecent length to pro;ect 101 mm Of more
out of the round bottom bowl dunng stirring.
vi) Circular Disks: Metal Circular disk 01286 mm diameter and 6 mm and 8 mm
thick.
vii) Oven: Forced draft constant temperature thermostatically conuoaeo at
60 a-c.
viii) water Bath: Constant Temperature , controlled at 25 1e.
Sam ple Preparat ion :
i) The op timum rat io of Portland cement, additives. water and bitu men
emulsion to the dry weight of the aggregates shan be predetermined in the
Iabora lory.
ii) Dry the agg regates in the oven at 105"C to 11O"Capproximately tor 16 hours.
until con stant weight is obtained.
iii) Remove the aggregates from oven and cool to room temperature.
iv) Weight the sufficient Quantities of the individual components in compliance
to mi x design to obtain a sample of about 1000 g.
v) Place the weighed aggregates and the filler in to the mi xing bowl.

77
IRC:SP: 1QO-2014

vi) Aft er proper mi xing 01 O'y aggregates in mixing bowl, add predetermined
qua nlily of water and additive (if required) and mix agaIn for one minute until
all aggregate partICles are uniformly wetted .
vii) Add predete rmined quantity of bitumen emulsion and mix for a period of no!:
less than 30s and rot more than 180s_
viii) Cenlrelhe specimen mould on a fell dISC. Immediately pou r the Microsurfacing.
slurry seal mix in specimen mould placed on fell disk.
ix) Screed the slurry level on top of the mould and discard excess material.
x) Remove the mould without disturbing the casted sample and place !t'e
moulded specime n in the oven for 24 n. at 6O"C to obtain constant weight
xi) Cool the dried specimen up to room temperature and de termi ne its weight

Test Prcced ure :

Lock the rubber hose abrasion head on the shaft of the mixing machine. A new hose surfaw
shall be used for each tesl. Place the speci men in 330 mm diameter flat bollom pan. oar-
the spec imen to the pan and mount plate by tightening the quick release clamps. Ensure
the specimen is prop erly centered and the rubbe r, hose will not run close to the edge
water at 25C to the pan to cover the specimen to a minimum dep th of 6 mm. Elevate
bowl resting on the platform of the mixer until the rubber hose bears freely on the "",-
of the spec imen. Operate the mixer at its low speed selti ng and abrade the scecme-
five min utes. Remove the specimen from the pan after the abrasion cycle and wasr
specimen till it is free trom debris . Place the washed test specimen in the oven at 6O"C
dry to constant weight Determine the loss in weight of the specimen expressed in grart!
sqm and report it as the wea r value or WTAT loss value.

Report : Report the we ar value (WTAT Loss) in gram per square metre.

78
 IRC :SP:100-2014

Appendix -?

" Test Method for Determination of Torsional Elastic Recovery of Residual Binders

001 Sco pe : The test method is intended 10 determine torsional elastic recovery of modified
res idue using a simple OO/l: and cu p assembly.

Apparatus : Bolt assembly - The bolt has a cylindrical head WIth diame~ of 28.6 mm and
thickness of 9.52 mm and threaded shank of the bold is 44. 5 mm long . A metal spider w ith
three radi al pms and two nuts can be used to centre the assembly. A pointer is requ ired lor
angle measurement in the absence of the spider Sample tin of 85 ml capacity and internal
cta merecot 5 110 52 mm; ang le measuring device and sa mple clamp a ssembly or an alternativ e
means of damping the samplelboll as sembly and determining the initial and recove red angle.
The recommended device shal comprise a scale of 80mm radars gradualed in degrees
around CIt least ha lf its Circu mference and a clamp capable of holding the sample cup within
3 mm of its centre and without defonning the cu p by more than 3 mm in an y di rect ion: wafe r
bath capable to operate at 25 "C filled wi th thermom eter; forced co nve ction oven _ capable
of opera ting in ue rallQ6 6O"C to 2()()OC: slop watch , span ner 10 suil bolt a ssembl y.

Meth od : The torsional elastic recovery appa ratus operates by manually rotating an aluminum
bah previOuSly embedded in a cup containing modified b~ through an angle of 180" and
measuring the e xtent of recovery of the original applied ro tation. Init ially 180" twist is applied
wi th a spanner for period of 10s. The recovery after 30s is measured.

Pour the re sidue into lhe cup of assembly until it begins to Iorm a meniscus on the top surface
of the boll. Allow the assembly with sample 10 cool for one hcu by allowing i1to sta nd at room
temperature and adjust the a ssembly height to keep the top surface of the bah flush with the
surface of Ihe sample. PI<lC6 the assemb ly at coostant iemoerature of 25"C in a wa ter bath
for one hour, Adjust the sp idElf to <I pos ition 7 mm aoo ve the rim and return the assembly to
the bath. PI<lC6 the sample assembly on the base plate and fit t he pointer to the 180" pos itio n
wilhout disturbing the sa mple , With the help of span ner. turn the bolt moving the pointer from
the 180" position 10 Zero d egree position using a steady motion fc)( 10s Release the bah
when the ponte- reaches the zero position and commence liming. Record the recovered
angle after 308 . The torsion ela stic recovery in percentage is calculated by following :

100 x Al180,Where A is recovered angle in degrees

Report : Report the torsional elastic recovery as mean of three re sults logethe r w ith
teeoerature of lest and recovery lime.

79
IRC:SP:1ClO-201 4

Appendill.-8

Ca li b ration of Slurry Sea l and Micro surfaci ng Mach ine Mol

The purpose of these guidelin es is to familiarize both the users of the slurry seal mach ine!
microsurfacing machine as we ll as the client regarding the basic featur es of modem slurry
seal machine Both slurry seal and microsurfaci ng system have three main ingredients te.
aggregates . bitumen emulsion and cement as filler. Apart from these, water and additive, if
used are other ingredients for the purpose of W(Il1mb~ity of the mix. Unlike conventional hot
mix W(lI1(s wherein one crew is involved in miXing of the materia ls and the other in using it, the
same crew uses machine to proportioo and mix up all the ingredients while laying the finished
product. The modem traffic systems are very senSitive to changes in any of the ingredients as
the same can cause an unsatisfactory rnix , This in tum oeceeeaeiec the accurate calibration
of the mach ine ,

Each slurry seal/microsurfacing machine to be used for execution of this worll shall be
calibrated prior to constru ction . The machin e is equipped with suitable mean s of accu rately
mete ring each individual material and is cap able of delivering a predetermin ed proportion of
agg regate. water. emulsion. cement and additive to the mixture . Since all fee<ling mechanism
is con tinuous. fed and proportioning remains con stant at all the time. This mechanism allows
the accurate calibration of the machine so that the exact quantities of materials use during
any period can be estimated.

The calibration document shaQ include indIVidual calibration of each matenal at various
settings . wh id'l can be related to the machines metering devices, Normally, cou nters are
provided on the machine lor the purpose of calibration. Weig ht per min ute is calculated at a
particular setti ng to determine the tota l outflow of individ ual materia l at the setting. Precisely.
the calibrations of machi ne for aggregate is done first as other components are related to the
quantity of aggregates. Based on the job mid fonnula approved for the work. the ca libration
of mach ine for other ingredients i.e . bitumen emulsion. cement . water and additive (if any)
is done in the proportion set out the rein after making adjustment to the outflow of these
ingredients at different settings to ge t the desired results . Bitu men emulsion is adj usted first
followed by cement, wa ter and additive. Flow chart diagram of outflow of variou s ingredie nts
is made for future reference . Once calibrated. the con tractor as well as the clien t notes the
setting of counters fa( vsrocs ingredients and period ical check is made to control the qua lit)o
of the milt

80
 JRC:S P:10Cl-201 4

Method for Desig n of Co ld Mixes

Presently. a standard desig n procedure is not available for design ofeold mixed BM Ot SOBC .
The eoId mix design procedure iovolves opt imization of water as wea as content of bitume1l
emulsion lOt the aggregates in the mix , The aggregates are made moist with water to wet its
surface and then coated with cenon c bitumen eme s oo. The different sizes of aggregates are
blended in proportions to achieve the best standard gradation of 8M or SOBC, The following
steps are necessary to design cold mixed 8 M or S08C with cation ic bitumen emulsion.

a) Testing of aggregate ; The aggregates supplied are subject ed to sieve

analysis and other physical tests for determining the properties such as
specific gravity. aggregate impact value. water absorption and sand equivalent
value.
b) Testing of bitumen emulsion : The samples of slow setting bitumen
emuls ion (5 5-2) to be used for construction of 8M shall be tested as per IS:
8887 . The coating test of aggregates shall also be carried out as per ASTM
o 2397 or AASHTO M 208.
c) Determination of premix ing wat er con ten t ; For determination of optimum
water content for prem ixing , the quantity of bitumen emulsion is first
determ ined using the following equation.
P::o.05A+O.1B+O.5C ... (1)
_ e,
P :: Quantity of bitumen emulsion (%)
A :: Percent aggregate retained on 2.36 mm sieve
B :: Percent aggregate passing 2.36 mm sie ve and retained on 90 micron sieve
C :: Percent aggregate passi ng on 90 micron Sieve

Different samples of aggregates aod emu lsion mixes are prepared keeptng the quantity of
bitumen emulsion constant (as determined from EquatiOn 1) and vary ing the water conten t.
The coated aggregates are then visually observed for coated area of the aggregate by the
binder.The optimum wate r conten t is the water content at which maximum co<ltingof aggregate
occur. This water content is taken as premi xed water content in designing the cold mixed 8M
or cold mixed SDBC. The optimum water content for BM or SOBC is norm ally foun d to be 2 to
3 percent by weight of aggregate. However. this quantity may vary depending on the weather
condition (temperature, hum idity and wind velocity) and properties of aggregates.

6'
lRC:SP:100-2014

Determination of Optimum Binder Content

The procedur e for the design of cold mix utilises standard Marshall equipment. Marshall tes
specimens in triplicate are prepared with different binder content (bitumen emulsion). Differert]
sizes of aggregates are blended to achieve the specified aggregate gradation. About 11 00
gm of graded aggregates are made wet uniformly with optimum water content. The differerl,
percentage of bitumen emulsion, say 5 percent by weight of aggregate, are then added to
the aggre gates and mixed for 1-2 minutes for achieving uniform binder coating. The mixture
is dried for about 1-2 hour s using a fan. The cold mix is then kept in oven at 40"C for 2 hours
The cold mix is then transferred into the Marshall mould with a filter paper on base plate and
compacted with 50 blows of Marshall hammer on both faces. Similarly, the Marsh all specimen
are prepared with optimum wate r content and bitumen emulsion contents of 5, 6, 7. 8 and
9 percent by weight of aggre gates. The Marshall specimens are then extracted from the
mould after 24 hours and cured in air oven at 40"C for 72 hours before subjecting to differer1
Marshall Stab ility Tests. Marshall specimen are subjected to different tests viz . bulk densit)!.
stability and flow values. Marshall stability and flow values are determined in dry state aI:
25C . Different properties of the mixes are determined and other design parameters like
voids content, voids filled with binder etc. are calculated .

...

82
 IRC:SP:1(X)..2014

Appendlx.10

Preparation of Storable Mixture at Site (FOT Immediate Use)

Materials ; Aggregate conforming to standard and grading . MS or 5 5 -2 grade emu lSiOn

conforminq to 15: 8887, water potabl e.

Eq uipm ents : Measuring buckets, balance, concrete mixer/pug mill type mixer or cold mix
plants .

Procedure ; Charye blended aggregate meeting standard grading to pug min or cold mix
plant or concre te mixer followed by adding mixing water@ 1-2 percent to wet the aggregate.
mix cont ents for 1-2 minutes_Add reqc rsrte quantity of MSlS5- 2 emu lsion @ 7 percent by
weight of aggregate and mix for 1 minute . DiSdlarge mix when it is brown and then use .

Preparation of Storable Mixture at Site (For Storage)

Materi al : Aggregat e conforming to standard and grading. 55-2 emulsion with higher solvent
in res idue, water potable .

Eq uipments : Same as above

Procedure ; Same as above

Storage : Store mixes in shade at dry place in U shaped concrete boxes (2 m x 2 m x 4 m).
Mix shall be covered with a cover of polymer sheet to reduce exposure of mix to air, rain and
sunlight.

83
IRC :SP :1QO-2014

Appendix -11

Water Resistance Test

Fifty grams of patdling mix , shall be heated at 12O"C., a labofatory oven for 4 hou's
then cooled to 95"C in laboratory by air. and then placed in 400 mJ of bo~ ing water
~l glass beaker and stirred about 95"C with a glass rod at the rate of 1 re""'....
per secooc for 3 minutes . The watef shan be decanted and the mix shan be spread
an absorbent paper for visual obsetvation of the coating. The aggregate shall be at
90 percent coa led with a bitu minous film.

84
 lRC:SP:1002014

Appendix -1 2

Wor kability Test

and Approximately 2.5 kg of the patching mix shall be cooled to - ?OC in a freeze r. After cooling ,
Ina the mixture shall be capable of being broken up readily with a spatula that has a blade
bon length of approximately 200 mm. This test shall be performed when the mix is produced
on and thereafter anytime during storage. If the mix is not workable at _7C, it shall be rejected
st and the comp osition of the mix shall be properly modified (for example, by increasing the
bitumen content and/or grad ation changes). This test is also applicable in areas with hot
climate because it amplifies the workability characteristics of the mix by using a lower test
temperature.

85
IRC:SP:100-2014

Appendix -1 3

Binder Content in Cold Mixes

Take 600 gm of cold bituminous mixture in preweighed bowl and place in a hot air oven for
4 hours at 120"C, Cool the mix to room temperature and weigh to nearest 0.1 gm. Place cooled
mix in a tray at 100"C for about 1 hour and take 500 gm (W l) of mix in a bowl of bitumen
extractor, while the tempe rature of mixture is 50-60C. Close the lid of extraction bowl and
allow the contents to remain is submerged condition in solvent (TCF) for about 1 h. Repeat
this process till TCE is clear of Colour and aggrega te is free from bitumen. Dry aggregate
in an oven at 120"C for about 2 h. Take the weight of bowl+ aggregate for determination of
bitumen content (W2). The difference in W1 and (1M2 + we ight of filler) indicate weight of
residual bitumen in mixture .

86
 IRC:SP :100-201 4

REFEREN CES
"A Basic Asphalt Emulsion Manual", MS-19 , Third Edition , Asphalt Ins titute, USA.
MoRT&H , "Specifications for Road and Bridges W()l1(s", Fourth ReviSiOn, Ministry
of Road Transport and Highways , Indian Roads Congress, New Delh i, 2001.
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87 llevendm Kumar
SOM E,LBG