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Polymer Stabilized Hard Stands

National Highway

PMGSY

Gram Panchayat

Mine Haul Road

State Highway

Mineral Ore Stacking

Real Estate

Parking Lots

Warehouse

Registered Office
808-809, E Block, International Trade Tower,
Nehru Place, New Delhi - 110 019
Tel: +91-11-26423911/12, 41608688, Fax: +91-11-26447486
Email: ippl-delhi@ippl.net.in,
ippl-gurgaon@ippl.net.in

Manufacturing Plant
No. 162, 164-165, Raipur Industrial Area,
Bhagwanpur, Roorkee-247 661,
Uttarakhand, India
Telefax: +91-1332-235292
Email: ippl-plant@ippl.net.in

www.ippl.net.in

Economics of Alternate Roads

INDIA POLYROADS PRIVATE LIMITED


Upholding excellent innovative technology laced with capabilities and unbeatable
quality and workmanship for a future greener and cleaner long life Earth.
We contemplate a world equipped with a most advanced and sustainable global
road network!

India Polyroads Private Limited manufactures high quality polymer stabilization products for the road construction industry,
indigenously. Polymer Pavement personnel have been active in development of polymers for road stabilization for more than 5
years and has formed strategic development, testing & recognition alliance with leading National Govt. testing bodies of
Authority, in India over continuous up gradation and research for better roads.
Primary focus of IPPL is on research and development of industrial polymer based products for the Highway and other
infrastructure & construction industry. IPPL Design and Application Engineers will advise and assist partners & prospects in
site inspections, soil testing, alternate crust design, planning and the transfer of IPPL's product implementation methodology
knowledge. In order to consult engineers to familiarize themselves with the technology and alternate performance based

IPPL MANUFACTURING UNIT, ROORKEE, UTTARAKHAND - INDIA


design, IPPL has realized the need to provide an empirical alternate Highway design for their products with consultation and
un interrupted progress on the research involving the priceless support from the leading premier institute of international
repute- IIT Kharagpur, West Bengal, India.
IPPL products are indigenously produced in their State-of-Art workshop in Roorkee, Uttarakhand, India and product

In the coming 05 years, we intend to be one of the pioneer polymer


stabilization product manufacturing companies with the most advanced
technology, dedicated workforce and power to innovate for development and
match the need of world demand.

implemented far and wide in the country with varied soil types, thru customized alternate crust designs for durability, time
and cost saving proposition, yet meet the traffic & load stimulation and design life demands. Quality control is kept to the
highest standard with all products being manufactured to ISO 9001 and ISO 14001 standards & Certified by Nations'
Premier Research and Testing Authorities/Institutes:

Central Road Research Institute

BRO

01

WHAT IS A POLYMER
The word Polymer comes from the Greek word "poly"
means many, and "meros', means parts or units.
A polymer is a group of many units. You combine many
"monomers" (individual units) to create a polymer.
Mixing various monomers, results in a "copolymer"- such
is the IPPL SS-IX.
Polymeric materials are characterized by long chains of
repeated molecule units known as "mers'. These long
chains intertwine to form the bulk of the plastic. The nature
by which the chains intertwine determine the plastic's
macroscopic properties and binding strength.

WHY POLYMER STABILISATION?


Typically, the polymer chain orientations are random and
give the plastic an amorphous structure. Amorphous
plastics have good impact strength and toughness and
they do not mix with water. However, with other polymer
additives, the IPPL SS-IX polymer will use water as a
transport means to lubricate the soil particles at molecular
level. Under mechanical compaction, the chains of
IPPL SS-IX polymers are interlocked (see Diagram). The
more the compactions the stronger these bonds become
and the stronger the soil stabilization becomes. As the
water between the soil particles evaporate, a film bonding
layer is formed tends to hold back and bonds strong.

The traditional methodology of building layered roads &


then sealing it with a wearing course seal has been tried &
proven over a period of more than 2,000 years, dating
back to the Roman Empire.
Further stabilization of the base layer with cement, has
made traditional designed roads very strong with good
longevity. Notwithstanding, the good properties of
traditional designed roads, very little progress has been
made during the last 100 years to utilize technology in
reducing costs associated with bringing in borrow-pit or

IPPL POLYMER:
The use of high-tech polymer additives for road
stabilization, can bind waste materials that are normally
discarded materials into useful load bearing layers that can
be used in the road's base or sub-base road layers.

HEAT / COLD
IPPL SS-IX polymers contain (Poly/methyl metha crylate PMMA) are hydrophobic and do not dissolve in water. Water merely
acts as a transport mechanism in assisting the polymer in lubricating the soil particles. Once the water had dissipated the IPPL
SS-IX polymer performs throughout the ambient temperature.

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layer. IPPL Stabilizer polymers are water based.


After compaction, the stabilized layer will gradually gain
strength as water evaporates and the polymer chains bind
tighter. Strength Parameters used for design and
construction, like Resilient Modulus and Unconfined
Compressive Strength (UCS) tests show substantial rise
even after 7 days of curing. These tests have been
replicated numerous times by independent testing
authorities worldwide, confirming polymers ability to
produce above standard road bases.

Saves

Natural Aggregates | Crust Layers | Time of Road Execution

Suggests

Alternate & IRC: 37 compliant, Crust Design over specific Soil & Design Life

Eliminates :

WMM | DBM / BM

Improves

Soil CBR | Resilient Modules | Durability

Welcome

Lowering Project Costs | Convenience | Save Earth | Enjoy Better Durability

POLYMERS - REDUCE CONSTRUCTION COSTS SIGNIFICANTLY

AASTHO

molecules are also polymeric. All plastics are polymers, but not all polymers are plastics.

BENEFITS

Polymer stabilized pavements, with the correct selection


of materials and road designs, will exceed the international
standards IRC, AASHTO, ASTM and BS codes load
bearing capacities for the specific road design. Efficient to
stablise various sub base layers in addition to the baselayer. The polymer product, mixed with water will also
gravitate downwards and will form a further semi-bound

Polymer is often used as a synonym for plastic, but many biological and inorganic

quarry materials for road construction. Severe


environmental damage is caused by extracting road
aggregate from borrow-pit sand quarries. Even with
borrow-pits being leveled or filled to a certain degree, the
evidence is always there. Many Countries are limiting the
use of aggregates from borrow-pits and quarries and are
actively researching and encouraging contractors to
consider the use of alternative materials such as waste
materials, slag or in-situ materials in the road
constructions including innovative and green technologies
available with IPPL.

Equivalent Single Axle Load (ESAL) based on AASHTO Road Test results, the most common
approach is to convert wheel loads of various magnitudes and repetitions ("mixed traffic") to
an equivalent number of "standard" or "equivalent" loads. The most commonly used
equivalent load in the world is the 80 kN (18,000 Ibs/ 8Tons) equivalent single axle load
(normally designated ESAL).
FHWA Class9 Five-Axle Tractor- Semitrailer (18 TyresTotal) A typical tyre load is 18.9
kN(4,250 Ibs/2 Tons- 8 Tons per single axle)with an inflation pressure of 689 kPa (100 psi.)
and a tyre footprint of 20cm x 50 cm.

03

IPPL SS-IX
POLYMER ROAD STABILIZER

PRODUCT OVERVIEW
ITEM PRODUCT
1.

DESCRIPTION

IPPL SS-IX

IPPL SS-IX Polymer is used for the stabilization

Polymer Soil

of base and sub-base layers. It reduces the


crust layers and roads can be built three times
quicker with a substantial saving compared to
the traditional roads.

Stabilizer

IPPL SS-IX Polymer is a third generation road stabilizing


polymer and a dust suppressant.
It is the flagship product of IPPL to be used extensively for
stabilizing the base and sub-base layers of roads, Mine
Haul Roads, Parking Lots, Hard Stands and Container
Depots.

The product has been widely used since inception, in the


sectors covering Defence, NHAI, SH, Ware House
management, Container Handling segments etc in the
country with good performance and durability.
The product gains excellent strength from mechanical
compaction and is an excellent solution for heavily
trafficked roads and hard stands.

Can be used for: Roads, Hard Stands,


Container Depots and Airstrips.

2.

IPPL AT-X

Polymer based "asphalt" - apply thinner seals


and reduce costs.

COMPARISON:
TRADITIONAL DESIGNED ROAD CRUST
BITUMINOUS CONCRETE

BITUMINOUS CONCRETE
SAMI / Aggregate Interface Layer

DENSE BITUMEN MACADAM

SOIL STABLIZED BASE

No bleeding, in the heat. Cold applications.

3.

WET MIX MACADAM


IPPL PT-V

Normally a pre-packaged cold application used


to repair potholes.

POLYMER STABILIZED ROAD CRUST

GRANULAR SUB BASE


SUB GRADE

GRANULAR SUB BASE


EMBANKMENT
SUB GRADE
EMBANKMENT

IPPL DT-II

Eliminate dust. Cost effective seal. Simple mix


with water and spray over the area. A film is
formed over the soil, binding the fine particles.
A colour tint can be applied to the product.

Bonding: IPPL SS-IX Polymer mixed with water is sprayed into the soil to be stabilized using standard water
browser. On compaction the polymer molecules bind together with the soil increasingly with running traffic, the
polymer atoms bind tighter and tighter as water molecules evaporate and the road becomes tough and stronger.
Lab tests: Have consistently shown increased structural strengths over a period of time. Due to the flexible nature of

Helicopter landing in dust-free environment.


IPPL Polymer is re-applied every 18 months or
so, subject to actual wear and tear. Can be used
on mines and dirt roads.

the polymers, the pavement surface allows a certain amount of flexibility on the road and does not become brittle.
The maintenance on IPPL SS-IX stabilized roads are dramatically reduced in comparison to traditional other
stabilized roads.
Structural Guarantee: All IPPL SS-IX applications are guaranteed to exceed the AASHTO structural load bearing
axle capacity. Road base/sub-base will be tested for its binding capacity and if necessary, will be modified to meet
the standards as per road design.

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IPPL- STA

RCC Crack, Roof Nailing Gaps, Expansion


Joins etc. for sealing and water proof filling.

Construction Speed: Stabilize up to one kilometer per day using traditional equipments, see pictures. Alternatively
one can use soil stabilizing/pulverzing machines to stabilize up to three kilometers per day.

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IPPL SS-IX
POLYMER & ESSENCE IN LIFE STYLE ...
1. Asphalt Roads: Ideal for stabilizing base & sub-base layers. In most instances, the in-situ soils in the area can be used for
stabilization. The stabilized road is opened to heavy traffic within 72 hours after construction, as the additional traffic on the
stabilized road actually assists in dissipating the water in the base and sub-base, thereby speeding up the polymer
binding process and the structural strength of the road. After checking the moisture content, prime coat applications
followed by bituminous wearing course is undertaken.

IPPL SS-IX
TEST REPORTS PRIOR TO DESIGN PROCESS
To guarantee that we will exceed AASHTO structural load bearing axle capacities, it is important to consider various
pertinent factors before applying IPPL SS-IX stabilization polymers, adequate representative soil samples should be
taken and tested for:
Geo-Technical Report (Gradation, F.S.I., L.L., P.I., MDD, O.M.C, Gradation & C.B.R.) of the
carriageway to be stabilized.
In case of formation; F.S.I., P.I, and C.B.R. of the soil to be used for the subgrade.

2. Rural Roads: IPPL SS-IX is ideal for providing a tough base layer. Cost effective aggregate seals can be applied as a
wearing course.
In some instances, due to economic reasons, the rural roads may be left unsealed- with no wearing course. In this instant,
a light clear polymer binder can be sprayed over the existing stabilized road as a cost effective interim measure. It may be
necessary to apply a diluted polymer spray over the stabilized area every 6 months pre monsoon.

3. Mine Haul Roads: IPPL SS-IX can be used over the specific crust designs for unsealed polymer stabilized layered roads
that will provide the structural load bearing capacity of these heavy haul vehicles.

4. Railway Embankment: IPPL SS-IX can stabilize Railway Embankment / base to its best requirement of load bearing
capacity of the tracks.

5. Shipping Yards, Container Depots, Helipads, Airstrips & Parking Lots: IPPL SS-IX with its flexible base and sub-base
layers provides excellent strength for stated applications, which thereafter can be paved as per requirement.

IPPL SS-IX
DESIGN PROCESS
A pavement design is formulated based on the following:

IPPL SS-IX POLYMER


OVERVIEW
Many years of lab and field development have
resulted in IPPL SS-IX using a combination of
nanotech polymer molecules, mainly
consisting of two sizes- 5m and 0.1m.
The 5m polymers bind the aggregate in the
base-layer while the 0.1 m nano-polymers
migrate deeper into the sub-base layer,
thereby stabilizing another layer, although only
one layer may have been stabilized. This dual
nano-technology is unique to IPPL SS-IX.

INSTITUTIONAL RECOGNITION

Type and nature of traffic use of the pavement


Percentage of heavy vehicles and axle loads
Life span of road
Current traffic use
Cumulative increase in traffic load over life of road
Environmental conditions
Type of material to be stabilized and its testing
Testing for strength capability (Unconfined Compressive Strength / Resilient Modulus) of the Soil after
addition of IPPL SS-IX
Based on the above results-Stress- Strain Analysis of the designed pavement for its Crust Reduction
The Dosage of IPPL SS-IX varies based on the above criteria. However, optimal polymer dose
@ 0.5% of the stabilizing material by weight is treated / consumed, in all probability.
OPC grade 43 may be applied @ 1-2% by weight of the stabilizing material on specific cases only

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07

IPPL SS-IX
SOIL TESTING PRIOR TO CONSTRUCTION

CONSTRUCTION OVERVIEW

Establish plasticity Index of the Original ground / Material to be stabilized. Incase PI is more than
10%, modify the material by adding Non Plastic Material.

Pavement is outlined and pegged to get proper alignment.

Establish C.B.R. of soil.

Based on the OMC established at site, add IPPL SS-IX to

Establish Maximum Dry Density and O.M.C. of soil- to ensure optimum compaction.

the Water in the Browser.

Modification of soil is undertaken (if required).

This Admixture of IPPL SS-IX and water at 1% above OMC, is


sprayed to the ripped pavement and evenly distributed throughout
the pavement material.

Tiller for Pulverization

Pulverization on the SSB Pavement after applied the IPPL SS-IX


admixture.
Pavement is profiled (to design alignment).
Pavement compacted to min. 98% of maximum dry density (MDD)
and verify in-situ with FDD test.
Pavement is open to traffic after 3 days.

IPPL SS-IX MOD Applicatio Ratio

Wearing surface - Bitumen layer is added within 5-7 days.

CONSTRUCTION MACHINERIES & EQUIPMENTS


Hydraulic Motor Grader with back-end ripper
Tractor with Ripper/Cultivator optional to Hydraulic Motor Grader
with back-end ripper or Pulverizer Machine
Water Browser with min. carrying capacity of 4000/12000 litres
with attached sprinkler pump
Vibratory soil compactor 11 ton capacity

Vibro Roller (10-12 tons)

Survey equipment set


D.C.P., N.D.G. testing equipment and Moisture meter

PAVEMENT PREPARATION

Grader and Spreader

Scarify the existing surface and remove tree roots, stumps and
vegetation.
Remove loose debris if any.
Dump & Spread the SSB Mix material over the Subgrade /GSB top
layers as required.
Remove loose debris if any.

SOIL PARAMETERS

Rip/Furrow the surface to desired depth.


Remove all particles above the standard grading analysis.

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Tipper / Dumper

09

APPLICATION OF IPPL SS-IX

ENVIRONMENT FRIENDLY

IPPL SS-IX as per the specific design requirements is added to water tanker
complying to the OMC requirements of the stabilizing pavement layer.
Water tanker evenly sprays the IPPL SS-IX & Water Admixture over the
stabilizing surface.

Polymer based soil stabilizer is an innovative technology of road construction


and is based on the concept of minimal usage of scarce natural resources,
machinery & equipments. It is a cold mix technology.
Polymer Sprinkler

MIXING IPPL SS-IX POLYMER


Using the motor grader, furrow the pavement surface upto a specified layer
thickness using the ripper attachment. Alternately, a tractor attached
Ripper/Cultivator can also be used for small works.

SMOKE

This can also be done by a conventional Reclaimer/ Stabilizer machines.

PROFILING & COMPACTION

Through the awareness of the issue concerning global warming and its impacts
on the environment and society, India Polyroads Private Ltd is striving towards
reducing every possible impact on the environment through
their methods of road construction and is also preparing for
future low-carbon economics. Polymer Pavements has
shown a commitment to utilizing a carbon footprint
assessment towards resolving these issues.

Tiller for Pulverization

FREE

After mixing IPPL SS-IX admixture into the approved soil, profile the formation
with a motor grader.

The auditing process in which Ergomax complies, which is set out according to the international
reporting framework of the World Resource Institute and the World Business Council for

Compact the treated surface with a vibrating roller (not less than 11 tons
capacity) to reach maximum Dry Density (MDD).
The rolling pattern must be 2 plain passes from low camber towards high
camber. Then compact the treated surface again from low camber in a low
vibration amplitude and in the reverse direction the compactor must be in a non
vibratory mode.

The present carbon footprint assessment investigated the


carbon emissions involved in the construction of road 1000 meters by 7 meters using two different
methods, the India Polyroads Private Ltd method and the conventional cement stabilizing method.

Sustainable Development known as the Greenhouse Gas Protocol.

Grader and Spreader

If surface cracks are visible, skim the formation surface with a grader at desired
O.M.C.

Polymer based soil stabilizer mixed with water is sprayed on the soil, is thoroughly mixed in the soil with the help of motor
grader followed by compaction by soil compactor. Resulting in formation of a comparatively (in comparison with conventional
method) stronger pavement. It reduces the total number of layers from minimum of three in conventional method to one layer
(varied from design to design) The concept of polymer based soil stabilizer is environment friendly across three levels.

Do the final compaction with vibrating roller.

Micro - Direct impact on construction site

Vibration mode in one direction and non-vibratory in the reverse direction.

Macro - Usage of natural resources

After compaction, leave the pavement closed for minimum 72 hours and then
open to traffic. The pavement may be required to be closed for longer in case of
any rain.

Universal - Carbon footprint and emissions


Finished SSB Layer (Bearing Course)
Fuel Consumption Emission

SEALING THE PAVEMENT


Road to be left unsealed for a period of minimum a week for the moisture to
evaporate.
Apply Prime/ Tack coat.

Alternatively, incase to be left unsealed, a diluted mix of IPPL SS-IX can be


sprayed at a ratio of 250ml of IPPL SS-IX mixed with a further 3 parts
water (750ml) and applied at a mixed ratio of 1 liter/m2 as per engineers
decision and reapplying of sealing may require as per in C2 conditions and can
be re-applied in 6 month intervals.

10

ent

vem

Lay the wearing course as per design requirements.


S-IX

S
PPL

Po

lym

a
er P

Other
Stabilization
Onsite - Operations

I
BT Wearing Course

IPPL SS-IX Polymer Pavements


Other Stabilization

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ENVIRONMENT FRIENDLY
It does not have any adverse impact on the surrounding flora, fauna and human life. The product is cold mix and it does not
involve any fumes and heat. The involvement of dust particles is minimal as it is in liquid form and it binds the soil particles
without any effect of the sub-soil water and includes formation of only one layer compared to three layers in conventional
method. It is based on the usage of in-situ soil for the construction pavement. It uses minimal aggregates if the soil conditions
are not suitable for the usage of the polymer. Consequently, it consumes 40% less amount of aggregate consumed in
conventional method. It requires just 3000 liters of water for 100m long road with 7 m width which is half of the water required
in conventional method.
The usage of polymer requires 100 liters of diesel for construction of pavement of dimensions mentioned above. It utilizes the
basic machinery of road construction like motor grader, water tanker and compactor. There is a substantial difference in the
usage of diesel from what it is in conventional method. The requirement of bitumen is reduced by 50 - 60% as the pavement
requires just one thin layer of wearing coarse (Depends on Volume of Traffic) as the pavement is 5 - 6 times stronger than the
conventional pavement and is water resistant as well.
Several studies done regarding carbon footprint involved in the process including manufacturing of the product to road
construction reveal that Carbon dioxide emission in case of polymer is 1211 tons compared to 50450 in other i.e. a 98% less
carbon emission.

WHY IPPL
Faster and cost saving road construction
Substantial reduction in natural & rare road
Construction materials

COMMERCIAL HIGHLIGHTS
Savings of Man , Machine & Material in Road Construction

Better road Durability and performance


Substantially increases the SSB strength
by a minimum of 5 times
High tensile strength yet flexible
Time saving- save up to 40% construction
time
Reduction in equipment wear and tear
Plausible application of Non specialized
equipment
Minimal human resources
Quick and easy skills transfer
GREEN product-Environment friendly

SCARIFY & SPRAY IPPL SS-IX

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MIX THROUGHLY

COMPACT WELL & OPEN


TO TRAFFIC FOR 5 DAYS &
SEAL WITH ASPHALT

BT COATING