Beruflich Dokumente
Kultur Dokumente
Hot Applications
Heating of Binder at 1650c
Heating of Aggregate at 150oc
Production of mix at 1550C
Tack coating at 1600C
Laying of mix at 1300C
Compaction of mix at 1200C
DRAWBACKS OF HOT MIX TECHNOLOGY
Environmental Degradation
High Energy Consumption
Increase in Carbon Footprint
Low Output for Mix Production
Low Laying Work in rains / cold
Limited Construction Period in a yr.
Oxidative Hardening of Binder
Heath / Safety Hazardous to Labour
Emulsion Based Cold Mixes
Overcome
Hot Mix Problems
BITUMEN EMULSION
A liquid product in which a
substantial amount of bitumen is
suspended in a finely divided form
of the size 4-10 microns in water in
presence of emulsifiers
TYPES OF EMULSIFIER
Anionic Emulsifier
RCOOH + NaOH = RCOO - + Na + + H2O
Cationic Emulsifier
RNH2 + HCl = RNH3+ + Cl -
TYPES OF EMULSION
Anionic Emulsion
Cationic Emulsion Emulsified Ions
+ +
+
BITUMEN
DROPLET
+
+
CATIONIC BITUMEN EMULSION
GRADES OF BITUMEN EMULSION
Rapid Set - RS-1 & RS-2
Medium Set - MS
Slow Set - SS-1 & SS-2
Bitumen Water +
+ 2% K.oil emulsifier
Bitumen Emulsion
colloid
mill
dosage dosage
pump pump
emulsion
Pilot Plant in CRRI
Property Value
Binder Grade (Pen) 80-100
Binder Level (%) 65
Emulsifier Level (%) 0.6
pH of Water Phase 2.4
(HCl)
Viscosity Saybolt 108
Furol Viscometer at
25C, Seconds
TESTING OF EMULSIONS (IS: 8887-2004)
Residue on 600 micron IS sieve
Viscosity by Saybolt Furol viscometer
Coagulation at low temperature
Storage stability after 24 hrs.,
Particle charge
Stability to mixing with cement,
Coating ability and water resistance
Residue Test
- Penetration
- Ductility
- Solubility in Trichloroethylene
APPLICATION OF COLD MIX TECHNOLOGY
Construction of BM, PMC, MSS & SDBC
Surface Dressing
Grouting-Penetration Macadam
Priming GSB/WMM & Tack coating
Crack Sealing (Black Seals)
Repair of Pot- Holes & Depression
Repair of Utility Cuts & Bomb Crater
Sub-Base & Base Courses (Sealing)
Slurry Seal Treatment / Micro surfacing
WORLD WIDE CONSUMPTION OF
BITUMEN EMULSION V/S BITUMEN
Country Annual Tonnage Percentage
Emulsion Bitumen
(i) Residue on 600 micron IS sieve 0.05 max. 0.05 max. 0.05 max. 0.05 max.
(% mass)
(ii) Viscosity by Saybolt Furol Viscometer,
seconds
At 250C - - - 30-150
At 500C 20-100 100-300 30-300 -
(iii) Coagulation of emulsion at low Nil Nil Nil Nil
temperature
(iv) Storage stability after 24 hrs. , %, max. 2.0 1.0 1.0 2.0
120
100
80
%age PASSING
60
40
20
0
0.09 0.18 0.355 0.71 2.8 5.6 11.2 13.2 22.4
I.S. SIEVE SIZE (mm.)
(iii) Determination of Premix Water Content
Quantity of emulsion ( P) is determined as :
P = 0.05A+0.1B+0.5C
Where,
A = Percent aggregate retained on 2.8 mm sieve
B = Percent aggregate retained on 90 micron sieve
C = Percent aggregate passing on 90 micron sieve
500
MARSHALL STABILITY
2.22 475
450
2.21
(g/cc.)
425
(kg.)
2.2
400
2.19 375
2.18 350
2.17 325
300
6 7 8 9 10 11
6 7 8 9 10 11
BITUMEN EMULSION CONTENT (%)
BITUMEN EMULSION CONTENT (%)
MARSHALL STABILITY
475
450
AIR VOIDS (%)
8.0
425
(kg.)
400
375
7.0
350
325
6.0 300
6 7 8 9 10 11 6 7 8 9 10 11
BITUMEN EMULSION CONTENT (%) BITUMEN EMULSION CONTENT (%)
FIELD TRIALS IN DIFFERENT
CLIMATES
Available Specifications for Cold Mixes
IRC: 14-2004 Recommended Practice for Open Graded
Premix Carpets (Third Revision)
IRC:110-2005 Standard Specification and Code of
Practice for Design and Construction of
Surface Dressing
IRC:SP:81-2008 Tentative Specification for Slurry Seal /
Micro-surfacing
IRC: 82-1982 Code of Practice for Maintenance of
Bituminous Surfaces of Highways
IRC: SP: 20-2002 Rural Road Manual
1
Coagulation Test
2
Rolling Drum for Emulsion Mixing
PREPARATION OF COLD MIX IN MIXER
1 2
Charging of Aggregates Wetting of Aggregates
3 4
2
1
3 4
LAYING OF COLD MIX FOR PMC / MSS
1 2
Tack coating with emulsion Ferrying of cold mix
3 4
3
Spreading of cold mix Laying of cold mix in rains
PMC Surface Before Seal Coat
SEAL COAT ON PREMIX
CARPET
SAND SEAL COAT
Cold mix of fine aggregates mixture
with emulsion (SS-2)
Spread the mix on open graded
Compact with 8-10 Tonne roller
Spreading of Aggregate
The first layer of aggregate of 19 mm size
was spread over the tack coated area
The aggregate was compacted with 8-10
ton road roller
The newly laid road surface was allowed
to traffic after 4-5 hours.
Two Coat Surface Dressing
Second Coat
Over first coat , Tack coat applied
Tack coat
Bitumen emulsion (RS-2) with quantity @
13 kg per 10m2 area was applied with
perforated cans at 3mm hole apart
Spreading of Aggregate
The first layer of aggregate of 13 mm size
was spread over the tack coated area
The aggregate was compacted with 8-10
ton road roller
The newly laid road surface was allowed
to traffic after 4-5 hours.
CONSTRUCTION OF PMC WITH
MINI HOT MIX PLANT
AIZAWL ( MIZORAM) - May, 2008
13.2 mm & 9.5mm - 2 : 1
FINISHED SURFACE OF WBM
PMC SURFACE
Performance of PMC
FIELD PERFORMANCE EVALUATION
METHODOLOGY
VISUAL INSPECTION
DISTRESS MEASUREMENTS
BINDERs AGING
FUNCTIONAL CHARACTERISTICS
UNEVENNESS OF SURFACING
1 2
MSS with Bitumen after 4 yrs Mix Seal Surfacing with 20%
reduced emulsion after 5 yrs
Performance of MSS on NH-2
Service Life of Mix Seal Surfacings with Emulsion and Bitumen
100
90
80
70
Performance Points,%
60
50
MSS R MSS T-20
40
MSS T-15 MSS T-10
30 MSS T-5 MSS T-0
20
10
0
0 1 2 3 4 5 6
Service Life, Years
Pavement Distress with Time in Mix Seal Surfacings
91
81 MSS-R MSS-T-20
71 MSS-T-15 MSS-T-10
Pavement Distress,%
MSS-T-5 MSS-T-0
61
51
41
31
21
11
1
0 1 2 3 4 5 6
Service Life, Years
PERFORMANCE OF PMC WITH EMULSION ON NH-2
1 2
Premix Carpet with 10% reduced PMC with 5 % reduced emulsion
emulsion after 5 yrs service life after 5 yrs service life
3 4
PMC with bitumen PMC with 5 % reduced emulsion
after 4 yrs service life after 5 yrs service life
Performance of PMC with Bitumen and Emulsions
100
90
80
70
Performance Point, %
60
50
PMC R PMC T-20 PMC T-15
40
PMC T-10 PMC T-5 PMC T-0
30
20
10
0
0 1 2 3 4 5 6
Service Life, Years
PERFORMANCE OF COLD TCSD ON NH-2
1 2
TCSD with emulsion After 5 Years TCSD with emulsion After 5 Years
3
TCSD with Bitumen after 4 years
Performance of TCSD with Emulsion and Bitumen
100
90
80
Performance Points, %
70
60
50
20
10
0
0 1 2 3 4 5 6
Service Life, Years
Pavement Distress in TCSD with Time
4.5
3.5
Pavement Distress, %
3
TCSD-T-20 TCSD-T-15 TCSD-T-10
2.5
1.5
0.5
0
0 1 2 3 4 5 6
Service Life, Years
PERFORMANCE OF ROADS WITH EMULSION ON NH-44
1 2
SDBC with emulsion after PMC emulsion after 4 yrs
4 yrs
3
PERFORMANCE OF ROADS WITH EMULSION ON NH-1A
1 2
PMC with emulsion on H-S Rd PMC with emulsion after 5 yrs
after 2 yrs
Performance of Test Section on N.H. 44 (Assam)
in High Reinfall Area
FIG 10 : PERFORMANCE OF TEST SECTIONS (SDBC) ON NH-44 FIG 12 : CRACKED AREA IN SDBC WITH SERVICE LIFE ON NH-44
100 50
SDBC (Emulsion)
90 SDBC (Bitumen)
% CRACKED AREA
40
PERFORM ANCE, %
80
30
70
60 20
50
(Emulsion) 10
40 (Bitumen)
30 0
0 1 2 3 4 5
20
SERVICE LIFE IN YEARS
0 1 SERVICE
2 LIFE IN YEARS
3 4 5
Performance of Test Section on N.H. 1A (J&K)
in Snow Bound Area
Premix Carpet Specification
Semi Dense Bituminous Concrete
Visual Inspection
PERFORM ANCE, %
100 90
PERFORMANCE, %
90 80
80 70
70
60
60
50
50 (Emulsion)
40 40
(Bitumen)
30 30
20 (Emulsion) 20
10 (Bitumen) 0 1 2 3 4 5 6 7
0
0 1 2 3 4 5 6 7 SERVICE LIFE IN YEARS
SERVICE LIFE IN YEARS
1-d
% CRACKED AREA
70 SDBC (Bitumen)
% CRACKED AREA
PMC (Bitumen)
25
60 SDBC (Emulsion)
PMC (Emulsion) 20
50
15
40
10
30
20 5
10 0
0 0 1 2 3 4 5
SERVICES LIFE IN YEARS
0 1 2 3 4 5
SERVICE LIFE IN YEARS
Fig. 1: Performance of PMC and SDBC with service life in years on J-S Road (NH-1A):
a) PMC with emulsion and bitumen; b) SDBC with emulsion and bitumen ; c) Pavement
distress in PMC with emulsion and bitumen; d) Pavement distress in SDBC with emulsion and
bitumen
90
80
70
60
(Emulsion)
50 (Bitumen)
40
0 1 2 3 4 5
100
Penetration, dmm
80
60
40
20
0
1 2 3 4 5
1 2
3 4
CONSTRUCTION OF RURAL ROAD (PMGSY) IN
ASSAM- Feb. 2012
1 2
3 4
PERFORMANCE OF RURAL ROADS WITH COLD MIX-
Under PMGSY IN BONBOIGAON (2012)
1 2
4
3
MECHANISED CONSTRUCTION
OF BM, SDBC & MSS
IN VARYING CLIMATES
Desert (Rajasthan)
High Rainfall (High Rainfall)
Cold & Snow Bound (J&K)
Gradation of BITUMINOUS MACADAM
Proportioning of Mineral Aggregate Blend
Sieve Size, Specified mid
mm gradation
Combined
% passing % passing % passing gradation of
20mm 10mm stone dust blended agg
40% 45% 15% 40:45:15
40 45 15 100
26.5 100 100
45 95
19 40 15 100 90-100
44 72
13.2 19 15 78 56-88
24
4.75 0 1.5 15 17 16-36
11.5
2.36 0 0 15 15 4-19
6
0.300 0 0 6 6 2-10
4
75 0 0 2 2 0-8
PRODUCTION OF COLD MIXES WITH HMP
1 2
Adding Pre-mix Water Adding Emulsion in Drum Mixer
3 4
Cold Mix on Conveyer Belt Discharge of Cold Mix to Dumper
LAYING ROAD WITH COLD MIX IN RAJASTHAN
1 2
3
4
LAYING OF ROAD WITH COLD MIX IN J & K
1 2
3 4
Laying of Road with Cold Mix in Mizoram
1 2
3 4
Laying of Road with Cold Mixes
2
1
4
3
PERFORMANCE OF
SDBC &MSS IN RAJ.
SDBC with Emulsion After Two Year Service Life
1 2
3 4
Reasons for Durable Road
1 2
3 4
PROCESS OF REPAIR WITH COLD MIX
11 22
4
3
REPAIR DEMO IN MUMBAI ( Jan. 9, 2012)
1 2
4
3
REPAIR DEMO IN AGARTALA ( Feb. 5, 2012)
1 2
3 4
APPLICATION OF SLURRY SEAL ON
VIP ROADS
What is Slurry Seal
The slurry seal shall consist of :
6 MONTHS 6 MONTHS
SIGNING OF MOA FOR TRANSFER OF COLD MIX TECHNOLOGY for N.E.
REGION TO M/S BITCHEM. ASPHALT TECHNOLOGIES GUWAHATI ON
27.12.2011
SIGNING OF MOA FOR TRANSFER OF COLD MIX TECHNOLOGY FOR
EAST PART TO M/S BITCHEM. ASPHALT TECHNOLOGIES GUWAHATI
ON 13.6.12
WORK SHOP JORHAT 19 SEPT. 2011
TRANSFER OF TECHNOLOGY FOR
SDBC & BM AT GUWAHATI ( MAY-2012)
11 2
Adding Pre-mix Water Cold mix for belt
3 4
Cold Mix on Conveyer Belt Cold Mix in Dumper
LAYING OF COLD SDBC IN GUWAHATI
1 2
3 4
LAYING OF SDBC WITH COLD MIX
2
1
4
3
LAYING OF BM WITH COLD MIX
Drafted Specifications for Development of Cold Mix
Technology and under IRC consideration
Guidelines for Patch and Pot hole Repair with Emulsion Based Cold
Mix Technology
Production of Half Warm Mix at Rajkot
Production of Half Warm Mix at
Temperature 80-90oC
Laying of Test Section with Half
Warm Mix at Rajkot on NH-27
THANK YOU