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CONSTRUCTION OF RURAL ROADS WITH CATIONIC BITUMEN EMULSION
BASED COLD MIX TECHNOLOGY
Dr. N.K.S. PundhirSenior Principal Scientist E-mail: [email protected]
CSIR- Central Road Research Institute,New Delhi-110025
Hot Applications Heating of Binder at 1650cHeating of Aggregate at 150oc Production of mix at 1550CTack coating at 1600CLaying of mix at 1300CCompaction of mix at 1200C
CONVENTIONAL METHOD FOR ROAD CONSTRUCTION
HOT MIX TECHNOLOGY
DRAW BACKS OF HOT MIX TECHNOLOGY
Environmental Degradation High Energy ConsumptionIncrease in Carbon Footprint Low Output for Mix Production Low Laying Work in rains / coldLimited Construction Period in a yr.Oxidative Hardening of BinderHeath / Safety Hazard to Labour
Emulsion Based Cold Mixes Overcome
Hot Mix Problems
BITUMEN EMULSIONA 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 -
+
+
+
+
+
CATIONIC BITUMEN EMULSION
BITUMEN
DROPLET
Emulsified Ions
TYPES OF EMULSION• Anionic Emulsion• Cationic Emulsion• Non Ionic Emulsion
+
GRADES OF BITUMEN EMULSIONRapid Set - RS-1 & RS-2Medium Set - MSSlow Set - SS-1 & SS-2
RS-1 : Tack-Coating , Penetration Grouting
RS-2 : Surface Dressing,
MS : Premix carpet, Patch Repair
SS-1 : Priming
SS-2 : SDBC, BC, BM, Slurry Seal,
PMB/Latex Emulsion : Micro-surfacing
Bitumen Emulsion ProductionBitumen Emulsion Production
BitumenBitumen+ 2% + 2% K.oilK.oil Water + Water +
emulsifieremulsifier
colloid colloid millmill
dosagedosagepumppump
dosagedosagepumppump
emulsionemulsion
Bitumen EmulsionBitumen Emulsion
TESTING OF EMULSIONS (IS: 8887-2004)Residue on 600 micron IS sieveViscosity by Viscosity by SayboltSaybolt FurolFurol viscometerviscometerCoagulation at low temperatureStorage stability after 24 hrs.,Particle chargeStability to mixing with cement,Coating ability and water resistanceResidue Test
- Penetration- Ductility- Solubility in Trichloroethylene
Physico-chemical Properties of Cationic Bitumen Emulsion as per IS:8887- 2004
60 min.60-12050 min.98 min.
65 min.60-15050 min.98 min.
67 min.80-15050 min.98 min.
60 min.80-15050 min.98 min.
Test on residue : (a) Residue by evaporation, % (b) Penetration, 250C/100 gm/5 sec.(c) Ductility, 270C/cm., (d) Solubility In Trichloroethylene, %
(ix)
NoCoagulation
NoCoagulation
NoCoagulation
NoCoagulation
Miscibility with water (coagulation)( viii)
2Nil-NilStability to mixing cement, %coagulation
(vii)
----
GoodFairFairFair
----
----
Coating ability and water resistance(a) Coating, dry aggregates(b) Coating after spraying water(c) Coating, wet aggregates(d) Coating after spraying water
(vi)
+ve+ve+ve+veParticle charge(v)
2.01.01.02.0Storage stability after 24 hrs. , %, max.(iv)
NilNilNilNilCoagulation of emulsion at low temperature
(iii)
30-150-
-30-300
-100-300
-20-100
Viscosity by Saybolt Furol Viscometer, secondsAt 250CAt 500C
(ii)
0.05 max.0.05 max.0.05 max.0.05 max.Residue on 600 micron IS sieve (% mass)
(i)
SS-2MSRS-2RS-1
Requirement of IS:8887- 2004Properties of Bitumen EmulsionS.No.
APPLICATION OF COLD MIX TECHNOLOGYConstruction of BM, PMC, MSS & SDBC Surface DressingGrouting-Penetration MacadamPriming GSB/WMM & Tack coatingCrack Sealing (Black Seals)Repair of Pot- Holes & DepressionRepair of Utility Cuts & Bomb Crater
Sub-Base & Base Courses (Sealing)Slurry Seal Treatment / Micro surfacing
COLD MIX DESIGN Cold mix design of MSS, SDBC / BM :
Evaluation of Bitumen Emulsion
Gradation and Properties of Aggregates
Premixing Optimum Water Content
Preparation of Marshall Specimens
Testing of Marshall Specimens
Quantity of emulsion ( P) is determined as :P = 0.05A+0.1B+0.5C
Where,A = Percent aggregate retained on 2.8 mm sieveB = Percent aggregate retained on 90 micron sieveC = Percent aggregate passing on 90 micron sieve
FFix quantity of emulsion, P, ix quantity of emulsion, P, Prepare cold mix with varying water contents Prepare cold mix with varying water contents ( 2,3,4,5 %) and visually examined for coating value ( 2,3,4,5 %) and visually examined for coating value and workabilityand workabilityPremix water content is determined as water Premix water content is determined as water content at which coating and workability is maximum content at which coating and workability is maximum
Determination of Premix Water ContentDetermination of Premix Water Content
Preparation of Marshall Specimens
1100g Blended Aggregates
4 % water content Mix for wetting
Addition of emulsion 7,8,9% into
aggregates Mixing for uniform
coating Cold mix in mould
Compaction with 75 Blows on each face Specimens Marshall Specimen Curing for 3 days at 400C Testing for Bulk Density, Stability, flow , Retained Stab. at 250C
TESTING OF COLD MIXTESTING OF COLD MIX
PROPERTIES OF COLD MIX WITH EMULSION (SS-2)
6.53.56Flow, mmv
530560480Stability, kg. at 250Civ
7.927.819.1Air Voids, %iii
2.252.272.26Bulk density, gm/ccii
4.94.43.8Bitumen residue, %I
8.07.06.0
Bitumen emulsion Content,%
PropertiesS. No.
2.172.182.192.2
2.212.222.23
6 7 8 9 10 11BITUMEN EMULSION CONTENT (%)
DR
Y B
ULK
DEN
SITY
(g
/cc.
)
3 day curing (40C oven)
300325350375400425450475500
6 7 8 9 10 11BITUMEN EMULSION CONTENT (%)
MAR
SHAL
L ST
ABIL
ITY
(kg.
)
3 day curing (40C oven)
6.0
7.0
8.0
9.0
6 7 8 9 10 11
BITUMEN EMULSION CONTENT (%)
AIR
VO
IDS
(%)
3 day curing (40C oven)
300325350375400425450475500
6 7 8 9 10 11BITUMEN EMULSION CONTENT (%)
MAR
SHAL
L ST
ABIL
ITY
(kg.
)
3 day curing (40C oven)
OPTIMIZATION OF EMULSION CONTENT
FIELD TRIALS IN DIFFERENT FIELD TRIALS IN DIFFERENT CLIMATESCLIMATES
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
No Specifications for MSS, SDBC, BC & BM with cold mixes
On NHOn NH--1A Jammu1A Jammu--Srinagar National Highway Srinagar National Highway in J&K under snow bound area in J&K under snow bound area
On NHOn NH--44 near 44 near SilcharSilchar on Jowai on Jowai -- Badarpur Road Badarpur Road in Assam under high rainfall area in Assam under high rainfall area
On On HanumangarhHanumangarh--SangeriaSangeria Road in Rajasthan Road in Rajasthan in desert climate in desert climate
On NHOn NH--2 near Agra from km2 near Agra from km--228228--230 in hot climate 230 in hot climate
On Approach Road to Secratariat, On Approach Road to Secratariat, AizwalAizwal in wet climate in wet climate
DantaurDantaur--KhajuwalaKhajuwala Road in RajasthanRoad in Rajasthan--desert climate desert climate
ByBy--pass pass AizawlAizawl, High rainfall ( June,2007), High rainfall ( June,2007)
NHNH--1A Jammu1A Jammu--SrinagarSrinagar Road ( Sept., 2007) Road ( Sept., 2007)
Rural Roads in Assam ( Feb. 2012)Rural Roads in Assam ( Feb. 2012)
TEST LOCATIONS OF BRO / LOCAL TEST LOCATIONS OF BRO / LOCAL PWDsPWDs
Tack CoatingBitumen Emulsion of RS-1Quantity @ 2.5 – 3.5 kg per 10 M2 areaPressure distributor / or manuallyCleaning of holes with water when tack coating discontinued Spread Cold Mix when Tack coat turns black from brown Wetting of road surface required, in Summer
CONSTRUCTION OF ROADCONSTRUCTION OF ROAD WITH COLD MIXWITH COLD MIX
PREPARATION OF COLD MIX IN MIXER
Charging of Aggregates
Discharging of Cold Mix
Wetting of Aggregates
Bitumen Emulsion for Cold MixBitumen Emulsion for Cold Mix
1 2
3 4
PREPARATION OF COLD MIX IN TRAY
1 2
3 4
LAYING OF COLD MIX FOR MSS / PMC
Ferrying of cold mix
Laying of cold mix in rainsSpreading of cold mix
Tack coating with emulsionTack coating with emulsion1 2
3 43
Preparation of road surfacePreparation of road surface•• Pavement surface cleaned of dirt, dust Pavement surface cleaned of dirt, dust •• PotPot--holes and minor irregularity ratified holes and minor irregularity ratified •• Half width taken for surface dressingHalf width taken for surface dressing•• The road was divided into segment of The road was divided into segment of 10 m10 m22 area. area.
Tack coat Tack coat •• Bitumen emulsion (RSBitumen emulsion (RS--2) with quantity @ 2) with quantity @ 17 kg per 10m17 kg per 10m22 area was applied with area was applied with perforated cans at 3mm hole apartperforated cans at 3mm hole apart
Spreading of AggregateSpreading of Aggregate•• The first layer of aggregate of 19 mm size The first layer of aggregate of 19 mm size
was spread over the tack coated areawas spread over the tack coated area•• The aggregate was compacted with 8The aggregate was compacted with 8--10 10
ton road roller ton road roller •• The newly laid road surface was allowed The newly laid road surface was allowed
to traffic after 4to traffic after 4--5 hours. 5 hours.
INEXPENSIVE SURFACE DRESSING WITH EMULSIONINEXPENSIVE SURFACE DRESSING WITH EMULSION
CONSTRUCTION OF CONSTRUCTION OF RURAL ROADS WITH RURAL ROADS WITH
COLD MIX TECHNOLGY COLD MIX TECHNOLGY IN NORTH EAST REGION IN NORTH EAST REGION
Work Shop at Agartala on 4 / 5.02.2012
2
3
4
1
CONSTRUCTION DEMO IN AGARTALA (5.2.2012)
2
43
1
21
3 4
CONSTRUCTION OF RURAL ROAD IN CONSTRUCTION OF RURAL ROAD IN ASSAMASSAM-- Feb. 6, 2012Feb. 6, 2012
PERFORMANCE OF RURAL ROADS WITH COLD MIXPERFORMANCE OF RURAL ROADS WITH COLD MIX--Under Under PMGSYPMGSY IN BONGAGAON (2012)IN BONGAGAON (2012)
2
3 4
1
PERFORMANCE OBSERVATIONS PERFORMANCE OBSERVATIONS CONDUCTED IN ASSAMCONDUCTED IN ASSAM
A.A.RajkhowaparaRajkhowapara Road to NHRoad to NH--5252
B.B. BongsharBongshar to to SolalkucheSolalkuche Road.Road.
C.C.KayajanKayajan to to PatkataPatkata Road.Road.
D.D.BezeraBezera--MandaktaMandakta RoadRoad..
MECHANISED CONSTRUCTION MECHANISED CONSTRUCTION IN VARYING CLIMATESIN VARYING CLIMATES
•• Desert (Rajasthan)Desert (Rajasthan)•• High Rainfall (High Rainfall)High Rainfall (High Rainfall)•• Cold & Snow Bound (J&K)Cold & Snow Bound (J&K)
PRODUCTION OF COLD MIXES WITH HMP
Adding PreAdding Pre--mix Watermix Water Adding Emulsion in Drum MixerAdding Emulsion in Drum Mixer
Cold Mix on Conveyer BeltCold Mix on Conveyer Belt Discharge of Cold Mix to DumperDischarge of Cold Mix to Dumper
1 2
3 4
LAYING ROAD WITH COLD MIX IN RAJASTHANLAYING ROAD WITH COLD MIX IN RAJASTHAN
1
3
2
4
LAYING OF ROAD WITH COLD MIX IN J & K
43
21
Laying of Road with Cold Mix in Mizoram
1
3 4
2
Materials and Energy Requirement for Materials and Energy Requirement for Different Type of RenewalsDifferent Type of Renewals
Specification Aggregate
(cu.m.)
Bitumen(Kg.)
Energy(Kilo /Cal×108)
Hot Cold
Hot Cold Hot Cold
Two Coat Surface Dressing
85 70 9800 7280 0.99 0.74
Premix Carpet + Seal Coat
116 116 9100 8645 1.02 0.91
Mix Seal Surfacing 95 95 8700 8580 1.16 0.92
Semi-Dense Bituminous Concrete
134 134 11000 11000 1.63 1.32
Comparative Cost of Bituminous Surfacings With Emulsion vis-a-vis Hot Bitumen
104.76Emulsion20PMC4168.84Bitumen20PMC3276.21Emulsion25SDBC2324.08Bitumen25SDBC1
Cost / m2, Rs.
BinderThickness, mm
SpecificationS. N.
FIELD PERFORMANCE EVALUATION FIELD PERFORMANCE EVALUATION
METHODOLOGYMETHODOLOGY
VISUAL INSPECTIONVISUAL INSPECTION
DISTRESS MEASUREMENTSDISTRESS MEASUREMENTS
BINDERBINDER’’ss AGING AGING
FUNCTIONAL CHARACTERISTICSFUNCTIONAL CHARACTERISTICS
UNEVENNESS OF SURFACINGUNEVENNESS OF SURFACING
BENKELMAN BEAM DEFLECTIONBENKELMAN BEAM DEFLECTION
Mix Seal Surfacing with 20% Mix Seal Surfacing with 20% reduced emulsion after 5 yrsreduced emulsion after 5 yrs
MSSMSS with Bitumen after 4 yrswith Bitumen after 4 yrs
PERFORMANCE OF MSS WITH EMULSION on NHPERFORMANCE OF MSS WITH EMULSION on NH--22
1 2
10 % Binder economy 10 % Binder economy iisiis achieved in achieved in MSS, PMC and TCSDMSS, PMC and TCSD
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6
Service Life, Years
Perf
orm
ance
Poi
nts,
%
MSS R MSS T-20MSS T-15 MSS T-10MSS T-5 MSS T-0
Service Life of Mix Seal Surfacings with Emulsion and BitumenService Life of Mix Seal Surfacings with Emulsion and Bitumen
1
11
21
31
41
51
61
71
81
91
0 1 2 3 4 5 6
Service Life, Years
Pave
men
t Dis
tres
s,%
MSS-R MSS-T-20
MSS-T-15 MSS-T-10
MSS-T-5 MSS-T-0
Pavement Distress with Time in Mix Seal SurfacingsPavement Distress with Time in Mix Seal Surfacings
PMC with 5 % reduced emulsion PMC with 5 % reduced emulsion after 5 yrs service lifeafter 5 yrs service life
Premix Carpet with bitumen Premix Carpet with bitumen after 4 yrs service lifeafter 4 yrs service life
Premix Carpet with 10% reduced Premix Carpet with 10% reduced emulsion after 5 yrs service lifeemulsion after 5 yrs service life
PERFORMANCE OF PMC WITH EMULSION ON NHPERFORMANCE OF PMC WITH EMULSION ON NH--22
21
3
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6
Service Life, Years
Perf
orm
ance
Poi
nt, %
PMC R PMC T-20 PMC T-15
PMC T-10 PMC T-5 PMC T-0
Performance of Premix Carpet with Bitumen and Performance of Premix Carpet with Bitumen and different Emulsion Contentdifferent Emulsion Content
PERFORMANCE OF COLD TCSD ON NHPERFORMANCE OF COLD TCSD ON NH--22
TCSD with emulsion After 5 YearsTCSD with emulsion After 5 Years
TCSD with Bitumen after 4TCSD with Bitumen after 4 yearsyears
TCSD with emulsion After 5 YearsTCSD with emulsion After 5 Years
21
3
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6
Service Life, Years
Perf
orm
ance
Poi
nts,
%
TCSD T-20 TCSD T-15 TCSD T-10
TCSD T-5 TCSD T-0 TCSD R
Performance of Two Coat Surface Dressing with Emulsion and BitumPerformance of Two Coat Surface Dressing with Emulsion and Bitumenen
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0 1 2 3 4 5 6
Service Life, Years
Pav
emen
t Dis
tres
s, %
TCSD-T-20 TCSD-T-15 TCSD-T-10
TCSD-T-5 TCSD-T-0 TCSD-R
Pavement Distress in Two Coat Surface Dressing TimePavement Distress in Two Coat Surface Dressing Time
SDBC with emulsion after SDBC with emulsion after 4 yrs4 yrs
PMC emulsion after 4 yrsPMC emulsion after 4 yrs
PMC with emulsion after 5 yrsPMC with emulsion after 5 yrs
PERFORMANCE OF ROADS WITH EMULSION ON NHPERFORMANCE OF ROADS WITH EMULSION ON NH--4444
21
3
PERFORMANCE OF PMC ON HPERFORMANCE OF PMC ON H--S ROADS S ROADS (RAJASTHAN)(RAJASTHAN)
PMC with emulsion after 5 yrsPMC with emulsion after 5 yrsPMC with emulsion on HPMC with emulsion on H--S Rd S Rd after 2 yrsafter 2 yrs
1 2
PERFORMANCE OF SDBC ON NHPERFORMANCE OF SDBC ON NH--1A (J&K)1A (J&K)
SDBC with emulsion after 5 yrsSDBC with emulsion after 5 yrsSDBC with emulsion after 5 yrs SDBC with emulsion after 5 yrs
1 2
PERFORMANCE OF BM +PMC AFTER 5 yrs PERFORMANCE OF BM +PMC AFTER 5 yrs ON NEW APPROACH ROAD AIZAWLON NEW APPROACH ROAD AIZAWL
2
43
1
•• There is chemical interaction There is chemical interaction between emulsion / aggregatebetween emulsion / aggregate
•• The Cationic Emulsion is The Cationic Emulsion is positively chargedpositively charged
•• Surface of Siliceous Surface of Siliceous aggregates is having aggregates is having Negative Charge Negative Charge
•• The strong bond formed The strong bond formed between emulsionbetween emulsion--AggregateAggregate
•• Emulsion contain Anti Emulsion contain Anti --stripping agent which reduces stripping agent which reduces water damageswater damages
Reasons for Durable RoadReasons for Durable Road
Benefits of Emulsions Based Cold MixesEnvironment Friendly and Energy EfficientConstruction feasible in rains/wet and cold weather Extends construction period During a yearFast Production of Cold Mix 4-5 times Faster Construction by Cold Mix15-20 % Cheaper RoadsContain in built ant-stripping agentPrevent oxidative hardeningConsume targeted Budget in timeLabour Intensive - Creates Jobs for Villagers
- MNREGALabour Friendly Technology- Health, Safety
GHG Emission Per Ton Laid MaterialGHG Emission Per Ton Laid Material
Energy Consumption Per Ton Laid MaterialEnergy Consumption Per Ton Laid Material
REPAIR OF POT- HOLE Make rectangular shape
Clean the pot- hole area
Track coating the edge and area
Prepare cold mix
Charge the aggregate 11 mm down in concrete mixer
Add 2 % Water and mix
Add 5-6% emulsion & mix uniformly
Pour mix in pot hole/depression
Compact with road roller
PREPARATION OF COLD MIX FOR REPAIR
2
43
1
PROCESS OF REPAIR WITH COLD MIX
11 222
43
1
REPAIR DEMO IN MUMBAI ( Jan. 9, 2012)
2
43
1
REPAIR DEMO IN AGARTALA ( Feb. 5, 2012)
2
43
1
APPLICATION OF SLURRY SEALAPPLICATION OF SLURRY SEAL
ONON
•• DISTRESS ROADSDISTRESS ROADS-- CRACKEDCRACKED
•• VIP ROADSVIP ROADS
What is Slurry SealThe slurry seal shall consist of :
• cationic bitumen emulsion(SS-2) • mineral aggregate • water
Grading of Aggregates
5-155-1510-2075 micron7-1810-2115-30150 micron12-2518-3025-42300 micron19-3430-5040-65600 micron28-5045-7065-901.18 mm45-7065-9090-1002.36 mm70-9090-1001004.75 mm90-1001006.3 mm
1009.5 mmType III(6-8 mm)Type II (4-6 mm)Type I (2-3 mm)
% Passing (Minimum Layer Thickness)Sieve Size
APPLICATION OF SLURRY SEALAPPLICATION OF SLURRY SEAL
PERFORMANCE OF SLURRY SEALPERFORMANCE OF SLURRY SEAL
6 MONTHS6 MONTHS6 MONTHS6 MONTHS
Drafted Specifications for Development of Cold Mix Technology and under IRC consideration
Proposed Tentative Specification For Semi-dense Bituminous Concrete Using Cationic Bitumen Emulsion
Proposed Tentative Specification of Mix Seal Surfacing (Dense-Graded Premix Carpet) With Cationic Bitumen Emulsion
Proposed Specification for Bituminous Macadam (Base & Binder Course) with Cationic Bitumen Emulsion
Guidelines for Construction of Roads with Emulsion Based Cold Mix Technology
Guidelines for Patch and Pot hole Repair with Emulsion Based Cold Mix Technology
THANK YOUTHANK YOU
