Merco Bahrain Bapco PDF

Bitumen Manufacturing

Company

About Us

MERCO was establish in the Kingdom of Bahrain in the year 2004 under the patronage of H.H. Shaikh Khalifa Bin Hamad Bin Isa Al-Khalifa.

MERCO is the biggest Bitumen cut-back manufacturing facility in the Kingdom of Bahrain. Our state-of-the-art PLC controlled system help us to manufacture products to highest degree of accuracy. We have in-house quality control to serve our Clients better.

Our materials are packed in Drums, Flexi tanks and 1-Ton bags as per the requirements and needs of our Customers. Our special packaging facility is designed to lower the temperature of material before loading in Flexi bags.

MERCO is also into processing of Petrochemicals from SABIC for in-ternal use. MERCO also provide services like Plant maintenance, Oil Storage, Material Packing, Tank Cleaning and Oil Recycling throughout the world.

Middle East Recycling Company WLL

Our Products

Bitumen products: MERCO has become one of the leading manufac-turer of Bitumen Products in the Kingdom of Bahrain. Our Bitumen prod-ucts are manufactured using materials from BAPCO. Our Cutback manufac-turing facility can blend up to 1000 liters per minute.

Specialized Packing for BAPCO: We also specialize in the packaging of BAPCO Bitumen into Drums or Flexi Tanks for shipment throughout the world.

Specialized Packing for SABIC: We also provide packaging services for Petrochemical’s for SABIC.

We manufacture the following Bituminous Products:

1. Penetration Grades• Bitumen 40/50• Bitumen 60/70• Bitumen 80/100

2. Cutback Bitumen• Slow Curing (SC Grade)• Medium Curing (MC Grade)• Rapid Curing (RC Grade)

3. Bitumen Emulsion• Cationic Emulsion [K1-60, K1-40]• Anionic Emulsion

4. Polymer Modified Bitumen• PMB (PG 76-22) *• PMB (PG 82-22) *• PMB HiMD *

* The new products to be start soon.



Quality Policy Statement

The Quality Policy at MERCO basically defines our mission statement in fine print: “Promote a quality-in-all-we-do philosophy with a total company effort and commitment to continuous improvement”. MERCO is committed to QUALITY, ON-TIME DELIVERY and COST-EFFEC-TIVENESS, and is committed to:

• Provide products and services which meet customer needs and expec-tations:

• Manufacture products which meet customer specifications.• Strive to meet customer’s target values.• Monitor customer satisfaction.

• Deliver on-time:

• Ship on the date required by the customer.• Monitor on-time delivery performance.

• Reduce all costs to the lowest possible level:

• Establish and periodically review Cost Reduction Programs.• Monitor the Cost of Quality


To meet our commitment, we must:

• Foster a team approach to defect prevention and problem solving.• Emphasize appropriate training for all employees.• Recognize each employee’s responsibility for quality.• Empower employees to question processes which appear to produce discrepancies.• Treat fellow employees as both customers and suppliers.• Acknowledge employee’s self-improvements and contributions to the company.• Exchange expertise with suppliers and customers.• Use only Selected, Approved, Preferred or Certified suppliers.• Accept only conforming products and services from suppliers.• Elicit written corrective actions from suppliers.• Keep the Quality Department independent of, but a partner with, Manufacturing.• Reduce waste and inefficiency, wherever found.• Seek out technologies for assuring error-free work.• Continue to implement statistical approaches to reduce variation.• Draw on customer’s expertise in various areas.• Strive for complete understanding of our customers’ application re-quirements.• Earn customer recognition of our quality progress.• Develop and achieve Quality Improvement Goals.• Practice good housekeeping.• Never compromise safety.• Review and renew this Quality Policy on a regular basis

Bitumen and Product Specifications

Bitumen is available in a variety of grades. Specifications vary to meet the needs of the consuming industries and are based on a series of physical tests that define the safety, solubility, physical properties and durability of bitumen.

The physical properties are designed to define performance character-istics that are required under the climatic and loading conditions that the bitumen will experience in service.

Bitumen is graded according to the standardized testing methods. These tests also give rise to two commonly used terms which describe the method of measurement, rather than a “type“ of Bitumen.


Penetration Graded Bitumen

Bitumen is classified by the depth to which a standard needle will pene-trate under specified test conditions.

This “pen” test classification is used to indicate the hardness of bitumen, lower penetration indicating harder bitumen.

Specifications for penetration graded bitumen’s normally state the pene-tration range for a grade, e.g. 50/70.

Other tests are used to classify the bitumen for specification purposes, such as softening point, solubility, flash point etc.

PG Grade Bitumen - TYPICAL SPECIFICATION

PROPERTYGRADES BITUMEN STANDARD

40/50 60/70 80/100 85/100 120/150 200/300 ASTM

Penetration @ 25 °C for 5 Sec 40/50 60/70 80/100 85/100 120/150 200/300 D-5

Flash Point °F 450 450 450 450 450 350 D-92

Ductility @ 25 °C - cm/min 100 100 100 100 100 100 D-113

Solubility in Trichloroethyl-ene 99 99 99 99 99 99 D-2042

Retained penetration after thin film oven test 55+ 52+ 47+ 47+ 42+ 37+ D-175

Ductility @ 25 °C - cm/min after thin film oven test - 50 75 75 100 100 D-113

Package 1000 Kg / 500 Kg Meltable Jumbo bags loaded in Containers.

Quantity Available 2500 MT / Month


Cutback Bitumen

Cutbacks are bitumen preparations in which the viscosity of the binder has been reduced by the addition of a volatile solvent, nor-mally derived from petroleum.

Cutback products are typically used for spraying and some mix-ing applications. The advantage of cutbacks over emulsions is much higher residual bitumen content, typically over 80% com-pared with over 40-65% for Bitumen emulsions.

The result is more Bitumen left on the roadway after curing, for the same volume of binder applied.

TYPICAL SPECIFICATION

PROPERTYCutback Bitumen

MC 30Cutback Bitumen

MC 70 STANDARD

Min Max Min Max ASTMKinematic viscosity @ 60°C,Cst 30 60 70 140 ASTM D2170

Flash Point ( Tag Open- Cup), °C 38 - 38 - ASTM D3143

Distillation Test, (% of Total Distillate to 360 o C)

- To 225 o C - 25 - 20 ASTM D402

- To 260 o C 40 70 20 60 ASTM D402

- To 315 o C 75 93 65 90 ASTM D402

Residue from distillation to 360 °C,% wt 50% - 55% - ASTM D402

Test on residue from distillation

Penetration at 25 °C, 100g, 5 Sec 120 250 125 250 ASTM D5

Ductility at 25 °C (cm) 100 - 100 - ASTM D113

Solubility in Trichloroethylene, % wt 99.90% - 99.90% - ASTM D2042

Water content, % Volume or mass 0.0% - 0.0% - ASTM D95

Package Flexi Bag Containers.

Quantity Available 5000 MT/ Month of any of the two grades.


Fluxed Bitumen

Fluxed bitumen’s are bitumen preparations where the viscos-ity of the binder has been reduced by the addition of relatively non-volatile oils. Typical fluxants include gas oil and vegetable based oils.

MERCO fluxed bitumen is prepared from Bitumen 60/70 grade, fluxed with non volatile light fuel oil.


PROPERTYGRADES STANDARD

BFO ASTM

Physical State Viscous Liquid -

Appearance Opaque -

Flash point –Open cup, °C >65 D-92

Initial Boiling point, °C >120 D-86

Water content (wt)% 0.5 MAX D-6304

Residue content (Wt) % 50 MAX D-86

Kinematic Viscosity @ 50 °C, Cst Max <450 D-445

Solubility in CS@ (wt)% 98.5 MAX D-4

Spot Test NEGATIVE -

Density @25 °C <0.991 D4052

Package Flexi Bag Containers

Quantity Available 1200 MT/Month


Bitumen Primer

Bitumen Primer is a locally manufactured bitumen solution suit-able for sealing and priming porous and non-porous surfaces.

TYPICAL SPECIFICATIONPROPERTY STANDARD

Type of solvent Kerosene

Solid Content >50%

Specific Gravity 0.9

Flash Point, ° C 36 - 38

Film Thickness Wet: 100 microns and Dry: 54 microns

Application Temperature range, ° C 5 - 55

Drying Time BS3416/6949:1991 About 4 -6 hours

Finish BS3416/6949:1991 smooth, Opaque and free from sags or runs.

Chemical & water resistance

Resistance to: most salt solutions, dilute acids/ alkali’s, water and alcohol.

Non Resistance to: oils, solvents and some detergent solutions.

Effect on potable water BS3416/6949:1991/ BS 6920:2000 Passed. Suitable for use in contact with potable water.




Bitumen Emulsion K1-40

Bitumen emulsion consists of three basic ingredients: bitumen, water, and an emulsifying agent. Based on specifications it may contain other additives, such as sta-bilizers, coating improver, anti-strips, or break control agents. It is well known that water and asphalt will not mix, except under care-fully controlled conditions using highly specialized equipment and chemical additives.


Say-bolt furol viscosity @ 25 °C (sec) 25 Min. ASTM-D244

Sieve test (%) 0.1 Max ASTM-D244

Particle Charge Test Positive ASTM-D244

Residue from Distillation (%) 38 Min. ASTM-D244

Test on residue from

Distillation

Penetration on residue @ 25, 100g. 60 Min. 200 Max ASTM-D5

5 sec (0.1mm)

Solubility in Trichloroethylene ASTM-D2042

(% Mass) 97.5




Bitumen Emulsion SS-1h

A tack coat is a very light spray application of diluted asphalt emulsion. It is used to create a bond between an asphalt overlay being placed and the existing surface. A tack coat is recommended for all overlays. The only possible exception might be when an additional course is placed within two to three days on a freshly-laid asphalt surface.


PROPERTY STANDARD

Test on emulsion D-244

Viscosity, Say-bolt Furol @ 25 °C sec 20-100

Storage stability test 24 hr. % wt 1.0 Max

Cement mixing test % wt. 2.0 Max

Sieve test % wt. 0.1 Max

Residue by distillation % wt. 57 Min

Particle charge test -

Tests on residue from distillation

Penetration @ 25 °C 100gr. 5sec 40 - 90 ASTM-D5

Ductility @ 25 °C sec 40 Min ASTM-D113

Solubility in Trichloroethylene 97.5 Min ASTM-D2042




Rapid-Curing (RC)

Rapid-Curing asphalt is a volatile solvent or light distillate, generally in the gasoline or naphtha boiling point range.


PROPERTY STANDARD

Kinematic viscosity at 140 °F CST ASTM-D2170

Flash Point ASTM-D3143

Distillate test: Distillate % of total dis-tillate to 360 °C

To 225 °C To 260 °C

To 316 °C

35 Min.

60 Min.

80 Min.

ASTM-D402

Residue from distillation to 360 °C 65 Min.

Test on residue from distillation Viscosity at 60 °C Ductility at 77 °F Solubility in Trichloroethylene % Water

60 Min - 240 Max

100 Min.

-

0.2 Max

ASTM-D2170

ASTM-D113

ASTM-D2042

ASTM-D95




Cationic Slow Setting Asphalt Emulsion (CSS-1h)

Asphalt Emulsion CSS-1h is a cationic slow setting asphalt emulsion. The base asphalt for emulsification is derived from specially selected crude oils via carefully controlled refining processes.


Say-Bolt Furol viscosity @ 25 °C sec 20 Min - 70 Max ASTM-D244

1 Day Settlement (% difference) 1 Max ASTM-D244

Sieve Test (%) 0.1 Max ASTM-D244

Particle Charge Test Positive ASTM-D244

Residue (% Mass) 60 Min ASTM-D244

Penetration on residue @ 25 °C 100gr. 5sec 60 Min - 200 Max ASTM-D5

Solubility in Trichloroethylene (% Mass) 97 - ASTM-D2042




Our Services

We also provide the following services:

• Waste Oil Recycling• Waste Oil Storage• Tank Cleaning• Oil Recycling• Plant Repairs and Maintenance


MERCO

North Askar Industrial Area - Kingdom of BahrainP: +973 77052250 - +973 36310109 - +973 39947333 • F: +973 17910039

www.merc.company • [email protected]

Documents

Merco Bahrain Bapco PDF