CONSTRUCTION OF RURAL ROADS
WITH CATIONIC BITUMEN EMULSION
BASED COLD MIX TECHNOLOGY
Dr. N.K.S. Pundhir
Senior Principal Scientist
E-mail: pundhir.crri@nic.in
CSIR- Central Road Research Institute,
New Delhi-110025
CONVENTIONAL METHOD FOR ROAD
CONSTRUCTION
¾ HOT MIX TECHNOLOGY
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
DRAW BACKS 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 Hazard 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
Emulsified Ions
• Cationic Emulsion
+ +
• Non Ionic Emulsion +
BITUMEN
DROPLET +
+
CATIONIC BITUMEN EMULSION
GRADES OF BITUMEN EMULSION
Rapid Set - RS-1 & RS-2
Medium Set - MS
Slow 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 Production
Bitumen Water +
+ 2% K.oil emulsifier
Bitumen Emulsion
colloid
mill
dosage dosage
pump pump
emulsion
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
Physico-chemical Properties of Cationic Bitumen Emulsion as per IS:8887- 2004
Properties of Bitumen Emulsion Requirement of IS:8887- 2004
S.No.
RS-1 RS-2 MS SS-2
(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
(v) Particle charge +ve +ve +ve +ve
(vi) Coating ability and water resistance - - Good -
(a) Coating, dry aggregates - - Fair -
(b) Coating after spraying water - - Fair -
(c) Coating, wet aggregates - - Fair -
(d) Coating after spraying water
(vii) Stability to mixing cement, Nil - Nil 2
%coagulation
( viii) Miscibility with water (coagulation) No No No No
Coagulation Coagulation Coagulation Coagulation
(ix) Test on residue : 60 min. 67 min. 65 min. 60 min.
(a) Residue by evaporation, % 80-150 80-150 60-150 60-120
(b) Penetration, 250C/100 gm/5 sec. 50 min. 50 min. 50 min. 50 min.
(c) Ductility, 270C/cm., 98 min. 98 min. 98 min. 98 min.
(d) Solubility In Trichloroethylene, %
APPLICATION OF COLD MIX TECHNOLOGY
¾ Construction of BM, PMC, MSS & SDBC
¾ Surface Dressing
¾ Grouting-Penetration Macadam
¾ Priming GSB/WMM & Tack coating
¾ Crack Sealing (Black Seals)
¾ Repair of Pot- Holes & Depression
¾ Repair of Utility Cuts & Bomb Crater
¾ Sub-Base & Base Courses (Sealing)
¾ Slurry Seal Treatment / Micro surfacing
COLD MIX DESIGN
Cold mix design of MSS, SDBC / BM :
¾ Evaluation of Bitumen Emulsion
¾ Gradation and Properties of Aggregates
¾ Premixing Optimum Water Content
¾ Preparation of Marshall Specimens
¾Testing of Marshall Specimens
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
Fix quantity of emulsion, P,
Prepare cold mix with varying water contents
( 2,3,4,5 %) and visually examined for coating value
and workability
Premix water content is determined as water
content at which coating and workability is maximum
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 MIX
PROPERTIES OF COLD MIX WITH EMULSION (SS-2)
S. No. Properties Bitumen emulsion
Content,%
6.0 7.0 8.0
I Bitumen residue, % 3.8 4.4 4.9
ii Bulk density, gm/cc 2.26 2.27 2.25
iii Air Voids, % 9.1 7.81 7.92
iv Stability, kg. at 250C 480 560 530
v Flow, mm 6 3.5 6.5
OPTIMIZATION OF EMULSION CONTENT
3 day curing (40C oven) 3 day curing (40C oven)
2.23 500
D R Y B U L K D E N S IT Y
M AR S H A L L S T AB IL IT Y
2.22 475
2.21 450
(g /c c .)
425
2.2
(k g .)
400
2.19 375
2.18 350
2.17 325
6 7 8 9 10 11 300
6 7 8 9 10 11
BITUMEN EMULSION CONTENT (%)
BITUMEN EMULSION CONTENT (%)
3 day curing (40C oven) 3 day curing (40C oven)
9.0
500
M ARSHALL STABILITY
475
450
A IR V O ID S ( % )
8.0
425
(kg.)
400
7.0
375
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
¾ No Specifications for MSS, SDBC, BC & BM with cold
mixes
TEST LOCATIONS OF BRO / LOCAL PWDs
On NH-1A Jammu-Srinagar National Highway
in J&K under snow bound area
On NH-44 near Silchar on Jowai - Badarpur Road
in Assam under high rainfall area
On Hanumangarh-Sangeria Road in Rajasthan
in desert climate
On NH-2 near Agra from km-228-230 in hot climate
On Approach Road to Secratariat, Aizwal in wet climate
Dantaur-Khajuwala Road in Rajasthan-desert climate
By-pass Aizawl, High rainfall ( June,2007)
NH-1A Jammu-Srinagar Road ( Sept., 2007)
Rural Roads in Assam ( Feb. 2012)
CONSTRUCTION OF ROAD WITH COLD MIX
Tack Coating
Bitumen Emulsion of RS-1
Quantity @ 2.5 – 3.5 kg
per 10 M2 area
Pressure distributor / or
manually
Cleaning 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
PREPARATION OF COLD MIX IN MIXER
1 2
Charging of Aggregates Wetting of Aggregates
3 4
Bitumen Emulsion for Cold Mix Discharging of Cold Mix
PREPARATION OF COLD MIX IN TRAY
2
1
3 4
LAYING OF COLD MIX FOR MSS / PMC
1 2
Tack coating with emulsion Ferrying of cold mix
3 4
3
Spreading of cold mix Laying of cold mix in rains
INEXPENSIVE SURFACE DRESSING WITH EMULSION
Preparation of road surface
• Pavement surface cleaned of dirt, dust
• Pot-holes and minor irregularity ratified
• Half width taken for surface dressing
• The road was divided into segment of
10 m2 area.
Tack coat
• Bitumen emulsion (RS-2) with quantity @
17 kg per 10m2 area was applied with
perforated cans at 3mm hole apart
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.
CONSTRUCTION OF
RURAL ROADS WITH
COLD MIX TECHNOLGY
IN NORTH EAST REGION
1 2
4
Work Shop at Agartala on 4 / 5.02.2012
CONSTRUCTION DEMO IN AGARTALA (5.2.2012)
1 2
3 4
CONSTRUCTION OF RURAL ROAD IN
ASSAM- Feb. 6, 2012
1 2
3 4
PERFORMANCE OF RURAL ROADS WITH COLD MIX-
Under PMGSY IN BONGAGAON (2012)
1 2
4
3
PERFORMANCE OBSERVATIONS
CONDUCTED IN ASSAM
A. Rajkhowapara Road to NH-52
B. Bongshar to Solalkuche Road.
C. Kayajan to Patkata Road.
D. Bezera-Mandakta Road.
MECHANISED CONSTRUCTION
IN VARYING CLIMATES
• Desert (Rajasthan)
• High Rainfall (High Rainfall)
• Cold & Snow Bound (J&K)
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
Materials and Energy Requirement for
Different Type of Renewals
Specification Aggregat Bitumen Energy
e (Kg.) (Kilo /Cal×108)
(cu.m.)
Hot Col Hot Cold Hot Cold
d
Two Coat Surface 85 70 9800 7280 0.99 0.74
Dressing
Premix Carpet + Seal 116 116 9100 8645 1.02 0.91
Coat
Mix Seal Surfacing 95 95 8700 8580 1.16 0.92
Semi-Dense 134 134 11000 11000 1.63 1.32
Bituminous Concrete
Comparative Cost of Bituminous Surfacings
With Emulsion vis-a-vis Hot Bitumen
S. N. Specification Thickness, Binder Cost / m2,
mm Rs.
1 SDBC 25 Bitumen 324.08
2 SDBC 25 Emulsion 276.21
3 PMC 20 Bitumen 168.84
4 PMC 20 Emulsion 104.76
FIELD PERFORMANCE EVALUATION
METHODOLOGY
VISUAL INSPECTION
DISTRESS MEASUREMENTS
BINDER’s AGING
FUNCTIONAL CHARACTERISTICS
UNEVENNESS OF SURFACING
BENKELMAN BEAM DEFLECTION
PERFORMANCE OF MSS WITH EMULSION on NH-2
10 % Binder economy iis achieved in
MSS, PMC and TCSD
1 2
MSS with Bitumen after 4 yrs Mix Seal Surfacing with 20%
reduced emulsion after 5 yrs
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
Premix Carpet with bitumen
after 4 yrs service life
3
Performance of Premix Carpet with Bitumen and
different Emulsion Content
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 Two Coat Surface Dressing with Emulsion and Bitumen
100
90
80
Performance Points, %
70
60
50
40 TCSD T-20 TCSD T-15 TCSD T-10
30 TCSD T-5 TCSD T-0 TCSD R
20
10
0
0 1 2 3 4 5 6
Service Life, Years
Pavement Distress in Two Coat Surface Dressing Time
4.5
3.5
Pavement Distress, %
3
TCSD-T-20 TCSD-T-15 TCSD-T-10
2.5
2 TCSD-T-5 TCSD-T-0 TCSD-R
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
PMC with emulsion after 5 yrs
3
PERFORMANCE OF PMC ON H-S ROADS
(RAJASTHAN)
1 2
PMC with emulsion on H-S Rd PMC with emulsion after 5 yrs
after 2 yrs
PERFORMANCE OF SDBC ON NH-1A (J&K)
1 2
SDBC with emulsion after 5 yrs SDBC with emulsion after 5 yrs
PERFORMANCE OF BM +PMC AFTER 5 yrs
ON NEW APPROACH ROAD AIZAWL
1 2
3 4
Reasons for Durable Road
• There is chemical interaction
between emulsion / aggregate
• The Cationic Emulsion is
positively charged
• Surface of Siliceous
aggregates is having
Negative Charge
• The strong bond formed
between emulsion-Aggregate
• Emulsion contain Anti -
stripping agent which reduces
water damages
Benefits of Emulsions Based Cold Mixes
¾ Environment Friendly and Energy Efficient
¾ Construction feasible in rains/wet and cold
weather
¾ Extends construction period During a year
¾ Fast Production of Cold Mix
¾ 4-5 times Faster Construction by Cold Mix
¾ 15-20 % Cheaper Roads
¾ Contain in built ant-stripping agent
¾ Prevent oxidative hardening
¾ Consume targeted Budget in time
¾ Labour Intensive - Creates Jobs for Villagers
- MNREGA
¾ Labour Friendly Technology- Health, Safety
GHG Emission Per Ton Laid Material
Energy 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
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
• DISTRESS ROADS- CRACKED
• VIP ROADS
What is Slurry Seal
The slurry seal shall consist of :
• cationic bitumen emulsion(SS-2)
• mineral aggregate
• water
Grading of Aggregates
Sieve Size % Passing (Minimum Layer Thickness)
Type I (2-3 mm) Type II (4-6 mm) Type III(6-8 mm)
9.5 mm 100
6.3 mm 100 90-100
4.75 mm 100 90-100 70-90
2.36 mm 90-100 65-90 45-70
1.18 mm 65-90 45-70 28-50
600 micron 40-65 30-50 19-34
300 micron 25-42 18-30 12-25
150 micron 15-30 10-21 7-18
75 micron 10-20 5-15 5-15
APPLICATION OF SLURRY SEAL
PERFORMANCE OF SLURRY SEAL
6 MONTHS 6 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 YOU
