MICROSURFACING AS ECO FRIENDLY

TECHNOLOGY FOR MAINTENANCE

Dr. Sangita
Senior Scientist
Flexible Pavement Division
CENTRAL ROAD RESEARCH INSTITUTE
NEW DELHI
PURPOSE OF MAINTENANCE
Improvement of Riding Quality
Retardation of Deterioration Process
Extension in Service Life of Pavement
Saving in Road User Cost
Reduction in Environmental Damage by
Reduced Fuel Consumption
Avoidance of Large Capital Investment for
Reconstruction
 SUGGESTED NORMS

To prevent noise and air pollution when road

maintenance is in progress
Utility levels to be kept at the existing levels
(increase in height of pavement to be discouraged)
General road users should not be disturbed while
maintenance is in progress
Keeping in view above points microsurfacing
is an environment friendly maintenance
technology.
 MICROSURFACING
Microsurfacing is a mixture of Polymer Modified
Emulsified Bitumen, Dense Graded Crushed Mineral
Aggregates, Mineral Filler (normally Portland Cement),
Water and Chemical Additives to facilitate early setting
of mix.

Microsurfacing in Progress
 Microsurfacing Process
Emulsifier
Bitumen & Chem. Water Polymers Quarry
Source Additives Source

Emulsion Plant
Chemical
Emulsion Aggregate Water Cement
Retarder
Chemicals
Service Lab Mix Design
Marketing
Tools
Critical components Microsurfacing Machine

Production and Application On Roads

ADVANTAGE OF MICROSURFACING
Quick setting
Early opening to traffic
Higher resistance to abrasion
Can be used for Medium volume traffic corridors
Fast construction
Less air/noise pollution
Cost effective
ADVANTAGE OF MICROSURFACING (Contd.)
Prevents reflective cracking
Seals wide cracks effectively
Delays in hardening of bitumen due to environment
Better visibility at night
No rolling and compaction is required
Preservation of pavements structural strength
 ADVANTAGES OF MICROSURFACING

Marginal raise in pavement height

Least environment pollution
Increased skid resistance
Faster laying process
High durability due to polymer / rubber
additives
 APPLICATIONS

Preventive and periodic maintenance

Rut filling with the help of special rut box
Improvement in skid resistance and friction on a
concrete road
Filling up of minor irregularities on surface
Quality Control Tests
Polymer Modified Emulsion
Storage Stability
Grading of Filler.
Grading of Aggregate
Binder Content.
Grading of Aggregate Recovered from Mix
Residual Bitumen Content, % Wt. of dry
aggregate
Application Rate of dry aggregate
PROPERTIES OF MODIFIED EMULSION FOR
MICROSURFACING
Requirements Test Method Limits
Viscosity Say bolt furol at 250C, Sec. IS:8887 20-100
Particle charge IS:8887 Positive
Storage stability (24 hours), %, max. IS:8887 1.0
Residue by evaporation, %, min. IS:8887 60
Test on Residue
Penetration, 0.1mm at 250C IS:1203 40-90
Softening Point, 0C, min. IS : 1205 60
Elastic Recovery, %, min. IRC : SP : 53 20
Ductility at 50C, cm, min. IS:1208 20

Plasticity interval, min, 0C IS : 9881 75

 REQUIREMENT OF AGGREGATES

Requirement Test Method Limits

Sand Equivalent value ASTM D 2419 65% Minimum

Soundness IS: 2386 Part-5 15% Max. using Na2SO4

25% Max. using MgSO4

Abrasion Resistance IS: 2386 Part-4 30% maximum

 GRADING OF AGGREGATES FOR
MICROSURFACING
Sieve Size Type-II, Percent Type-III, Percent Stockpile
Passing Passing Tolerance
9.5 mm 100 100 --

4.75 mm 90-100 70-90 5%

2.36 mm 65-90 45-70 5%

1.18 mm 45-70 28-50 5%

600 micron 30-50 19-34 5%

330 micron 18-30 12-25 4%

150 micron 10-21 7-18 3%

75 micron 5-15 5-15 2%

Mix Composition & Application Rate
Property Type II Type III
Residual Bitumen Content, 7-13 5.5- 8.0
% Wt. of dry aggregate
Application Rate of dry 6-11 8-12
aggregate
Composition (by Weight of Aggregate) of various ingredients

Ingredients Type II Type III

Aggregate 100 100

Cement, % 1.5 1.5

Water, % 14 14.5

Emulsion, % 13.5 13

Additive,% As required As required

Calibration of machine
Capt Gaur Road 29 K N Katju
Marg Marg
Out Flow / Calibration
Aggregate 600kg/min 600kg/min 600kg/min
Emulsion 78kg/min 81kg/min 81kg/min
Cement 9kg/min 9kg/min 9kg/min
Additive 9kg/min 9kg/min 9kg/min
Rate of Application on Capt Gaur Marg

Length = 254.60 m
Width = 2.60 m
Travel Time = 11.19 sec
Area = 661.96 Sq.cm
Aggregate Consumed = (11+ 19/60)*600kg/min = 6790 kg
Emulsion Consumed = (11+ 19/60)*78kg/min = 883kg
Cement Consumed = (11+ 19/60)*9kg/min = 102 kg
% Emulsion = 883/6790*100 = 13.0
% Cement = 102/6790*100 = 1.5%
Rate of Application = 6790kg/661.96 Sq.m = 10.26 kg/Sq.m
 REQUIREMENT OF MIX
ISSA Test Description Specification

ISSA TB-139 Wet Cohesion

@ 30 Minutes Minimum (Set) 12 kg-cm Minimum
@ 60 Minutes Minimum (Traffic) 20 kg-Cm Minimum

ISSA TB-109 Excess Asphalt by LWT Sand 540 g/m2 Maximum

Adhesion

ISSA TB-114 Wet Stripping Pass (90% Minimum)

ISSA TB-100 Wet-Track Abrasion Loss

One hour Soak 540 g/m2 (maximum)
Six-day Soak 800 g/m2 (maximum)

(ISSA technical manual for slurry sealing and microsurfacing)

REQUIREMENT OF MICROSURFACING

TEST STANDARD UNIT LIMITS

Consistency ASTM D:3910 Cm 23

Set time ASTM D:3910 Minute 15 240

Cure time ASTM D:3910 Minute < 480

Loss on ASTM D:3910 G/m2 < 500

WTAT
USAGE OF MICROSURFACING

Useful on Flexible as well as Rigid Pavements

Application in thin layer (3-4 mm thick)
On top surface of flyovers and bridge decks
Approaches of junctions and roundabouts
BASIC CONDITIONS FOR APPLICATION
OF MICROSURFACING

Pavement should be structurally sound for future traffic

Wide alligator cracks, transverse cracks should be repaired
prior to application of microsurfacifng
All deep ruts in excess of 8mm shall be filled up before
application of microsurfacing
THE QUANTITY OF TREATMENT DEPENDS UPON :
Pavement Distress
Traffic
Loading
 Guidelines for Application of Microsurfacing

Serviceability Indicators Urban (Heavy Traffic) Urban (Light Traffic)

Preventive Periodic Preventive Periodic
Deflection*, mm 0.8 (max.) 0.8 (max.) 1.2 (max.) 1.2 (max.)
Distress, % 5 (max) 10 (max.) 5 (max.) 10 (max.)
Roughness, mm/km. 2500 (Max.) 3500 (max.) 3000 (max.) 4000 (max.)
Rutting, mm 8 (max.) 16 (max.) 8 (max.) 16 (max.)
Thickness, mm 5-6 7-8 3-4 6-7
Quantity of aggregate, kg/m2 10-12 14-16 6-8 12-14

Type of grading (ISSA)** III III II II

*as measured with Benkelman beam, **International slurry seal association.

QUALITY CONTROL GUIDELINES

Prior inspection and rectification of defects

Inspection of machine and materials
Calibration of machine
Control of flow rate of ingredients as per mix
design at site
Removal of drag marks with rubber squeegee
Control of joints (desirable 50 mm overlap)
SUGGESTED QUALITY CONTROL FREQUENCY
Test Frequency

Quality of aggregate One test per source

Grading of aggregates and One test per lot (100 tonne)

moisture content

Flow of aggregate from the Daily

machine
Quality of emulsion Regularly per lot (10 tonne)

Binder content in mix Once per day

Grading of washed aggregate Once per day

Quality of water and cement Once per source

 WEATHER LIMITATIONS

Not applicable for air temperature below 100C

Applicable when pavement and air temperature are

above 80C and rising

Not applicable when the finished product freezes

within 24 hours
Tack Coat
Required only in case of extremely dry surfaces or
concrete pavements
Tack coat should consist of one part emulsified
bitumen / three parts water
Emulsified bitumen shall be slow setting grade
Should applied with a standard distributor
Distributor shall be capable of applying the diluted
emulsion at a rate of 0.2 to 0.3 litre / m2
COST ASPECTS OF MICROSURFACING IN
COMPARISON WITH CONVENTIONAL HOT MIX
RENEWAL PER LANE KM (3500 M2 ) IS :
40 mm Thick Bituminous Concrete ~ 5 lakhs
8 mm Microsurfacing ~ 3 lakhs
SAVINGS IN LAYING OF MICROSURFACING
Aggregates ~ 75 %
Unit cost/m2
8 mm thick Microsurfacing ~ Rs.100
40 mm thick BC ~ Rs.
Savings ~ 35 %
WORKS EXECUTED IN DELHI
The Microsurfacing technology has been recently
introduced in India and following roads in Delhi has
been resurfaced with this technology:
Prithvi Raj Road
Windsor Palace Roundabout
August-kranti Marg
Outer Ring Road Number 26
Joseph Tito Marg
Ashram Flyover
Obrai Hotel Flyover
VIEW OF ORR 26 BEFORE MICROSURFACING
FRESHLY LAID MICROSURFACING ON ORR 26
 MICROSURFACING ON ORR 26

ONE WEEK

SIX MONTHS
 Roughness Progression with Time

4500

Prithvi Raj Road

4000 3775
Windsor Palace Roundabout
3500 3260 3265
3243 3250 3255 3255 3255
Roughness (mm/km)

2991

3000
2688
2555
2455
2315 2400
2500 2276 2276

2000

1500

1000

500

0
BT 0 3 6 12 18 21 27
Nov. 2000 March 2001 July 2003
Time (Months)
 Roughness Progression with Time
2760
2750
Ashram Flyover

2740
Roughness (mm/km)

2720
2720

2700

2685

2680

2660

2640

0 (Dec. 2002) 3 7 (July 2003)

Time (Months)
STUDY FINDINGS

There is improvement in riding quality

Growth of roughness with passage of time is
arrested
Prevents moisture ingress
Development of distress delayed
Provides a sort of laminated layer on top of the
existing road surface
SURFACE CONDITION OF NH-44 BEFORE TREATMENT
CALIBRATION OF MICROSURFACING PAVER IN PROGRESS
LAYING IN PROGRESS
TEXTURE OF FRESHLY LAID MICROSURFACING
SURFACE CONDITION AFTER 24 HOURS
 TYPICAL COMPOSITION OF
MICROSURFACING MIX

NR Latex Modified bitumen emulsion 12 %

Aggregates 100 %
Cement 2%
Additive 1.5 %
Water 12 %
 COMPARISON OF HOT MIX AND COLD MIX
TECHNOLOGY
Item Microsurfacing Hot Mixed Bituminous
Concrete
Noise Level Low High
Production of Toxic Fumes None High
Dust Low High
Worker Hazard None High
Energy Consumption Low High
Ease of Application Very Easy Not so
Ability to Resist Weathering High Low
Flexibility of Product High Low
Ability to Apply in Damp Condition Yes No
Thickness of Layer 4-16 mm 25-50 mm
Cost per m2 Rs. 100 Rs.
Life Time Expectancy 4-6 Years 4-6 Years
 PWD has decided to resurface number of roads in Delhi
using Microsurfacing.
So far, the work has been executed on the following roads.
Siri Fort Road
Link Road between NH-8 & Samalkha Chowk,
Ambedkar Road New Delhi
Road No. 29 Pashim Vihar
Dr. K.N. Katju Marg Rohini
Rao Tula Ram Marg
Nizzamuddin Bridge to Noida More
Road No. 42A Deepali Chowk, Rohini.
Ashram Chowk to Nizzamudin
Rajghat (Ring Road)
Captain Gaur Marg
 Properties of Designed Mix
Requirements ISSA Limits Contract Test Value
Document

Design Parameters

Consistency (mm) 20-30 20-30 24

Set Time, minutes Max 240 15-240 18

Cure Time, minutes Max 480 Max 480 90

Loss on Wet Track 538 (max) 500 (max) 43

Abrasion Test ,
g/m2
 Properties of Polymer Modified Emulsion used at various locations
S.No. Test Test Value Road Test Value Specified Test
No. 29 Pashim DR. K.N. Value as per
Vihar. Katju Marg contract
Rohini document

1 Residue on 600 micron IS 0.48 0.12 0.05, Maximum

Sieve, percent by mass

2 Viscosity by Saybolt furol 21 23 20-100

Viscometer, Seconds at 250
C

3 Coagulation of Emulsion at Nil Nil Nil

low temperature

4 Particle charge Positive Positive Positive

5 Miscibility with water No Coagulation No No Coagulation

Coagulation
Tests on residue
6 Residue by 63.2 65 60 Minimum
evaporation,
percent,
7 Penetration 44 45 40-90
250C/100g/5Sec

8 Ductility 50C/cm, 17 26 10 Min

9 Solubility in 98.1 98.5 97.5

Trichloroethylene,
percent by mass,
Min
10 Elastic recovery at 20 28 12 Minimum
250C ,%
S.No. Test Link Road Ambedkar Specified Test
between NH 8 & Road Value as per IS
Samhalka Chowk 8887:2004

1 Residue on 600 micron 0.04 0.05 0.05, Maximum

IS Sieve, percent by
mass

2 Viscosity by Saybolt 23 20 20-100

furol Viscometer,
Seconds at 250 C

3 Coagulation of Nil Nil Nil

Emulsion at low
temperature

4 Particle charge Positive Positive Positive

5 Miscibility with water No Coagulation No No

Coagulation Coagulation
Tests on residue
6 Residue by 62.3 61 60 Minimum
evaporation, percent,

7 Penetration 40 48 40-90
250C/100g/5Sec

8 Ductility 50C/cm, 15 13 10 Min

9 Solubility in 97.8 98 97.5

Trichloroethylene,
percent by mass, Min

10 Elastic recovery, 21 16 12 Minimum

250C ,%
Grading obtained for mineral filler (Cement)

Sieve Road No. 29 Pashim DR. K.N. Katju % Passing

(mm) Vihar Marg,Rohini (specified)

% Passing (obtained)

0.600 100 100 100

0.300 100 100 95-100

0.075 91 93 70-100
Sieve (mm) Link Road Ambedkar Marg % Passing
between NH 8 & (specified)
Samhalka Chowk

% Passing (obtained)

0.600 100 100 100

0.300 98 96 95-100

0.075 99 92 70-100
Gradation of aggregate (Type II) received from site
Dr. K.N. Katju
Sieve Road No. 29 Pashim Vihar.
Marg,Rohini
(mm)
% Passing (specified)

% Passing (obtained)

9.5 100 100 100

4.75 96 97 90-100

2.36 62 69 65-90

1.18 56 65 45-70

0.600 42 50 30-50

0.300 20 25 18-30

0.150 14 17 10-21

0.075 8 11 5-15
 Sieve Link Road Ambedkar road Percent Passing
Size (mm) between NH-8 and (specified)
Samhalka Chowk

% Passing (obtained)

9.5 100 100 100

4.75 96 96 90-100

2.36 65 63 65-90

1.18 56 54 45-70

0.600 47 44 30-50

0.300 29 28 18-30

0.150 16 14 10-21

0.075 9 8 5-15
Results of gradation of aggregate recovered from manufactured mix and Wet Track Abrasion Test

Road No. 29 DR. K.N. Katju

Pashim Marg,Rohini
Vihar Percent Passing (specified
Sieve Size (mm)
Type II)
Percent Passing (obtained)

9.5 100 100 100

4.75 97 98 90-100

2.36 69 69 65-90

1.18 65 68 45-70

0.600 51 50 30-50

0.300 25 23 18-30

0.150 17 17 10-21

0.075 11 12 5-15

Residual Bitumen,conent% 8.6 8.1 7-13

17 19
Wet Track Abrasion Test g/square meter 500 g/square meter max.
 Link road Percent Passing
Ambedkar
between NH 8 & (specified, Type
Sieve (mm) road
Samhalka Chowk II)

Percent Passing
9.5 100 100 100

4.75 96 97 90-100

2.36 66 65 65-90

1.18 54 53 45-70

0.600 44 46 30-50

0.300 28 28 18-30

0.150 14 15 10-21

0.075 8 10 5-15

PercentResidual 7.6 8.1 7-13

Bitumen,Conent
QUALITY CONTROL AT THE JOB SITE

Road No. 29
Dr.K.N.Katju Paschim Specified Limits
Property tested at Marg,Rohini Vihar.
site

Residue in 66.48 % 64.61 60 Minimum

Emulsion

Sand equivalent 70.90% 71.1 % 65 minimum

The specified grading and grading of stacked aggregate
Sieve % Passing (obtained) Dr. % Passing % Passing
(mm) K.N. Katju Marg,Rohini (obtained)Road (specified)
No 29 Paschim
Vihar

9.5 100 100 100

4.75 97 95 90-100

2.36 74 67 65-90

1.18 64 70 45-70

0.600 43 49 30-50

0.300 30 20 18-30

0.150 16 15 10-21

0.075 5 10 5-15
 EXPERIENCE GAINED DURING EXECUTION
Precautions:
(i) pre-matting of surface
(ii) homogeneous mix to prevent segregation of the emulsion
and aggregate fines.

Difficulties experienced:
The residue retained on 600-micron sieve is higher than
the specified limit.

Remedial measure:
A 600-micron sieve should be used at the time of
application.
Filler conforms the required specifications.
The gradation conducted on washed aggregate is within
the specifications band except on 2.36mm sieve, it is
slightly on the coarser side.
 Polymer modified emulsion needs special care during
storage and transportation.
The hose used to pump the emulsion were ensured to
be free of any materials that may contaminate emulsion.
Since, the storage stability of modified emulsion is
relatively less as compared to conventional bitumen
emulsion, it was used within a week from the date of
production.
Materials like aggregate, water and emulsion were
checked for compliance of specifications.
Continuous traffic flow caused hindrance in achieving
desired output of machine in peak hours. Therefore the
work could be executed between11 AM and 4.30 PM or
during night
KN Katzu Marg
Before Microsurfacing
KN Katzu Marg
Microsurfacing Execution
KN Katzu Marg
After Microsurfacing
Road No.29
Before Microsurfacing
Road No.29
After Microsurfacing
The technology has been demonstrated on
eleven sections and various locations laid in
Delhi.
Area covered; 6.0 Lakh Sqm,
Length ; 30 Km. approx
Performance of these sections will be monitored
for three years as a part of an in-house R & D
project
CONCLUSIONS
The ingredients and manufactured mix have
complied to specifications cited in the contract
document finalized by PWD, Delhi as well as ISSA
specifications.

Effective quality control plays a vital role in

success of Microsurfacing projects.

Microsurfacing could be an alternative to thin hot

mix renewals in maintenance of urban roads in
environment friendly manner and to save energy.
CONCLUSIONS
Its an environmental friendly technology
Energy efficient road maintenance technology
Savings in the materials
Cost effective application
Completely mechanized operation
Widely applicable for urban roads due to its ability
in thin layer application
Can cover large lengths in a day (a typical M.S.
Machine can lay about 3.5 lane Km in 8 hours)
Life expectancy is about 4-6 years
THANK YOU