TKSubhaash

Head Technical - Hincol

TKSubhaash
 Three Hard Truths have significant impact on
how Bitumen industry will shape up in future
➢More roads
➢Demand move up
➢Urban mobility challenged and rural
Demand connectivity
➢Budget constraints
➢Pavement Structural & Functional Design
Changes

➢More Coker & Reduced Bitumen Supply

➢Crude diet changes - greater variability in
Supply
quality
➢Constrained supply of quality aggregates

Climate ➢PhysicalRisk to Pavements

Stress ➢Regulatory Risks

TKSubhaash
 Approach: Technology Innovation is one of the key ways to
address cost and engineering challenges going forward

Products Applications Standards

Specifications Pavement Design /

Mix Designs Practices
Selection of
Quality Asphalt Plants &
Products /
Laying
Technology

TKSubhaash
 Pavement Performance : Dilemma

Traffic Demand
Climate

Rut depth
Pavement Structure
Asphalt Slab

Stiffness Stiffness
Reduce Reduce
Rutting Cracking
Pavement condition

Asphalt Operations
Material Supply bitumen bitumen
penetration penetration

TKSubhaash
 Components of Flexible Pavement
TKSubhaash

TKSubhaash
 Wheel Load Distribution

Flexible Rigid

TKSubhaash
 Pavement Design Concept

Tensile
Strain

Compressive
Strain

TKSubhaash
 Products for Various Layers - Highways

Cold
Recycling
PMB / CRMB /
BC / SMA VG40

DBM RS1 (Tack)

WMM / GSB CRMB / VG40

Compacted SS1 IS (Prime) /

Subgrade RS1 (Tack)

SS2 Stab
Natural
TKSubhaash

Subgrade
SS2 Stab

TKSubhaash
 Products for Various Layers - Rural

CRMB / VG40
RS2 Emulsion
Seal Coat

OGPC RS1 (Tack)

WMM / GSB CRMB / VG40 /

Premix Emulsion

Compacted SS1 IS (Prime) /

Subgrade RS1 (Tack)

SS2 Stab

Natural
TKSubhaash

Subgrade
SS2 Stab

TKSubhaash
 Maintenance Solutions for Wearing Course

Bitugrip

Microsurfacing /
Slurry Seal

Surface
Dressing

Fog Seal

Roadbond

Jetpatcher
SAMI
TKSubhaash
 Pavement Materials – Bitumen Emulsion
Viscosity is Critical
Application Conditions require bitumen to behave as a mobile liquid

• Environmental Pollution
Heat - Bitumen
• Risk to workmen

Dissolve in • Fire Hazard

Solvents -
• Slow Curing Rate
Cutback

• Easy and Safe

TKSubhaash

Emulsify - • Workable at Ambient

Emulsion • Environment friendly
• Strong Bonding

12

TKSubhaash
 Pavement Materials – Bitumen Emulsion
Emulsions
The bitumen is dispersed
Bitumen
throughout the water phase in the
form of discrete globules, typically
0.1 to 50 micron dia
Water Emulsion

Emulsifier

Anionic

Cationic
TKSubhaash

Non ionic

1
3
TKSubhaash
 Pavement Materials – Bitumen Emulsion
Emulsion Types
Material Cationic Anionic
emulsion emulsion
Electropositive Neutralizing Attraction
materials reacting
(limestone, Breaking
basalt) Breaking

+ + + + Forming of Forming of
+ + insoluble amine insoluble amine
++ + +++ carbonate carbonate

Adhesiveness
Adhesiveness
Electronegative Attraction
materials (silex, No
quartz, granite) Breaking neutralizing

- - - - Forming of reaction

- - insoluble amine No attraction

- - - - -- silicate
Adhesiveness

TKSubhaash
 Pavement Materials – Bitumen Emulsion

Dispersed Phase RS1

- Bitumen RS2
- Diluent MS
Emulsion to SS1
Dispersion Phase Storage tank SS2
- Hot water
- Acid
- Emulsifier

Bitumen Emulsion
Breaking
Heating Required Not Required Curing
Pollution High Nil Setting
Coating Good Excellent
TKSubhaash

Surface Coverage Poor Excellent

Application Difficult Easy
Antistripping Good Better
Execution Slow Fast
TKSubhaash
 Tack Coat – Bitumen Vs Emulsion

To promote the bond between pavement layers.

To prevent slippage between pavement layers.

Vital for structural performance of the pavement.

Too much tack coat can create a slippage layer

Bitumen Emulsion
0.7 Kg/m2 0.25 kg/m2
Cold
Hot Application
Application
Uniform
Poor coverage
coverage
23 Rs/m2 7.6 Rs/m2
@ 30467 Rs/T @ 32996 Rs/T

TKSubhaash
 Bitumen Emulsion – Tack Coat

RS1 (Tack)

RS1 (Tack)

0.25 – 0.35 kg/m2

½” Deflection, 1/4” Deflection, Interlayer Bond Condition

25 kg load 100 kg load
Surface Binder Base % Life
Full 100
Partial Full 84
TKSubhaash

Poor Full 69
Partial 64
Unbonded Fully bonded Poor Full 40
Poor 13
TKSubhaash
 Bitumen Emulsion – Prime Coat

Penetration depth of a Interfacial bond

SS1 prime coat material strength
(Prime)
1. Penetration Test 2. Bond Strength
SS1 Emulsion penetrate SS1 prime coat
on WMM surface to a sustained a load of
level of 10 – 15 mm. 185 kg ; Others
sustained a load of 30
Coats and bonds loose kg
mineral particles on the
surface of the base 3. Tracking
Nature:
Hardens the surface of the No Tire pick up
base with SS1 as per
IS 8887 as
TKSubhaash

Waterproof the surface of emulsion for

the base by plugging priming Visual test to check the
capillary or interconnected tracking nature
voids
TKSubhaash
 Bitumen Emulsion – Prime Coat

MoRTH Section 500, Clause 502: Prime Coat: The primer shall be cationic bitumen
emulsion SS1 grade conforming to IS:8887 or medium curing cutback bitumen conforming to
IS:217 or as specified in the Contract.

MoRTH Section 500, Clause 503: Tack Coat: The binder used for tack coat shall
be either Cationic bitumen emulsion (RS 1) complying with IS:8887

IRC 16 : STANDARD SPECIFICATIONS AND CODE OF PRACTICE FOR PRIME

AND TACK COAT The bituminous material to be used as primer should be such that
it can penetrate deep into base course (about 10 mm depth). Cationic bitumen
emulsion SS-1 grade conforming to IS:8887 shall be used as primer. The binder used
for tack coat shall be either Cationic Bitumen Emulsion (RS- 1 ) conforming to IS: 8887
TKSubhaash

IRC SP 20: Rural Roads Manual: The primer shall be a slow setting bitumen emulsion
complying with IS:8887, or medium curing cut-back as per 1S:217-1983
Tack Coat : Rapid or medium or slow setting type emulsion (IS: 8887- 1 995

TKSubhaash
 Bitumen Emulsion – Fog Seal
Fog Seal Arresting raveling and
(Hinmat) adding binder back to
aged surfaces

Improve Sealing or
waterproofing

Improve the surface

appearance

Typical Heavy Duty Pavement

Surface 40 mm 0.5 – 1 kg/cm2

Binder 50 mm,

Base 60 mm

Sub Base
TKSubhaash

TKSubhaash
 Bitumen Emulsion – Fog Seal

Fog seal
Fog Seal surface preventing
after 4 years water intrusion

Fog seal

No fog seal

TKSubhaash
 Bitumen Emulsion – Fog Seal
Airport References

MES Airport, Jammu MES Airport, Gwalior MES Airport, Jalandher

BIAL, Bangalore MES Airport, Jodhpur MES Airport, Arakkonam
DIAL, Delhi MES Airport, Kutch MIAL & HIAL Airports

TKSubhaash
 Bitumen Emulsion – Fog Seal
Product offered & Key Specs

Hinmat Benefits of Tests on Residue

Key Specifications
Hinmat

Benefits
Emulsion is a Hinmat Residue by evaporation >60
specially Emulsion when Penetration @ 25 oC 40-100
formulated used for Fog
Modified Bitumen Seal: Softening Point (oC) >57
Emulsion for high • Seal very small Elastic Recovery, % >50
performing cracks and
applications. It Ductility at 27C >50
surface voids
allows for faster
paving • Renew old
applications and asphalt
improved overall surfaces those
pavement have become
strength dry and brittle
over age Hinmat
• It can help conforms to
delay the need IRC SP 81
for major
maintenance
TKSubhaash

when applied in
a timely
manner

TKSubhaash
 Bitumen Emulsion – Cold Mix
Seal Coat
RS2 Emulsion

OGPC
Premix Emulsion

1929 COLd ASphalt

Performance validated by CRRI in three climatic

conditions, namely Hot, Cold and Heavy Rainfall

Demonstrated performance records throughout India

More than 90 years of global expertise of designing

emulsions and constructing roads.
TKSubhaash
 Bitumen Emulsion – Cold Mix

• 3 Kg/MT • 21
Reduction of emissions
Kg/MT with Cold Mix process
CO2
100
Hot Mix
Cold Mix 80
at 160C 60
Eq. CO2 Dust SO2
Eq. CO2 40
20
Hot Mix 0
Cold
at 160C
Mix
Energy
TKSubhaash

MJ/MT Nox VOC

MJ/MT
• 36 • 277
MJ/MT MJ/MT
CO
HMA

TKSubhaash
 Bitumen Emulsion – Cold Mix
TKSubhaash

TKSubhaash
 Bitumen Emulsion – Microsurfacing
Structurally Prior repair Prior repair Chemistry and selection of
sound of all cracks of Potholes emulsion components
pavement
Emulsion properties for good
and durable road performance
Microsurfacing Cost Effective
Understanding aggregate
quality,
Minimize Oxidation

Application machinery and Reduce Water

operators competence Infiltration
Provide Skid Resistance
Construction procedures and
management Improve Aesthetics
Good

1 here ... Correct Raveling

Pavement Condition
Average Life : 5 – 7
HINMAT 4-10 here?
years

Poor
Base Base
TKSubhaash Time (Years)
 Bitumen Emulsion – Microsurfacing
HINMAT

TKSubhaash
 Bitumen Emulsion – Roadbond

Roadbond

~100 kg / m2 (40 mm depth)

TKSubhaash
 Bitumen Emulsion – Stabilization

Stabilization is the process

Subgrade CBR of mixing a stabilizer
(emulsion) with soil or

Resilient Modulus aggregate to produce a

Tensile
Strain material whose strength is

Tensile / greater than that of the

Compressive
Strain Compressive Strain unbound material

TKSubhaash
 Bitumen Emulsion – Stabilization

Virgin RAP
WMM / Resilient
Chemical Stabilizer
Content
BSM Modulus
Composition

Moisture Degree of
Content Compaction
IS Sieve WMM Resilient Modulus
53.00 mm 100
45.00 mm 95-100
Reduction
Less Environ
Cost 600
Energy mental 26.50 mm -
Less Pace of 22.40 mm 60-80
Aggregate Noise
mix construction
11.20 mm 40-60 250
Less
Bitumen Dust Durable 4.75 mm 25-40
heating
2.36 mm 15-30 WMM EMULSION
STABILIZED WMM
0.600 8-22
Resilient Modulus
TKSubhaash 0.075 0-5
 Bitumen Emulsion – Stabilization

Cold
Recycling

SS2 Stab

SS2 Stab

Conventional,
640 mm With Stabilized Cost, Cr/Km
Bituminous Layer, 540 mm
Design 130 mm BC 40 mm
Stabilized
• 19 MSA WMM, 150 3.11 2.56
• 6% CBR mm
• Width 5 - Granular CT Sub base
200 mm WMM EMULSION
10m 510 mm STABILIZED
WMM
Granular
150 mm Cost, INR - Cr/km

TKSubhaash
 Bitumen Emulsion – Stabilization

IRC 37 : 2018

Test Specimen Dia BSM1

ITS dry 100 mm > 225
ITS wet 100 mm > 100

TKSubhaash
 Bitumen Emulsion – Stabilization : Case Study
Fatigue & Rutting Life evaluated to be 102 Stabilization shall used at places when
and 178 MSA respectively against design life poor drainage, less crust pavement
of 19 MSA thickness is a concern

Stabilization with Emulsion us much easier The stretch should be allowed to cure
for at least 48 hours with light traffic
being allowed.
Normal to Medium Traffic can be allowed
after few hours over emulsion stabilized
layer
Minimum thickness shall be 75 mm
Execution and Quality Control is easier

TKSubhaash
 Bitumen Emulsion – Recycling
- Hot-in-Place New
- Cold-in Place pavements
Aggregate and asphalt binders form a (emulsified)
previous pavement structure - Portable or centralized
Resurfacing
hotmix plants
Produced by milling, breaking and existing roads
grinding old pavements
RAP is then blended with new (virgin) Usually between 10 to 25 Subbase
pavements % used in mixes. materials

50 % is Max Shoulder
recommended paving and
widening

Can save 10 to 25%

25% RAP usage neutralises the carbon foot print

TKSubhaash
of a HMA plant
 Bitumen Emulsion – Recycling

• Avoid contamination
IS Sieve BSM • Don’t over crush. Only crush
50 100 oversize RAP
37.5 87-100 • Fractionation helps for design of
26.5 77-100 high RAP mixes
19.5 66-99 • Watch the weather when
13.2 67-87 processing
• Cover stockpiles
9.6 49-74
• Free moisture in the RAP can
6.7 40-62
cause caking of RAP (blinding
4.75 35-56
of screens) Intermediate & base courses
2.36 25-42
• Building steep sided stockpiles < 15% R> 30%: AP: Must be screened but
1.18 18-33 will create segregation
0.6 12-27 not necessary to fractionate into different
sizes
0.425 10-24
>15%<30% : Must fractionate into different
0.3 8-21
sizes
0.15 3-16
Aged binder must be < 30% of new mix
0.075 2-9

TKSubhaash
 Bitumen Emulsion – Stabilization
Case Study – KIIFB
Computed Strains
Tensile Subgrade
Strain Compressive Fatigue Rutting Allowable BC – PMB70V
Characteristics
(1) (BT) Strain Criteria Max Criteria Max Traffic in BC – VG40; -10;
Design
Traffic (3) (4) Allowable Allowable msa DBM – VG40 DBM – VG40
Traffic in msa Traffic in msa Minimum of Rs/sqm
9% CBR (msa) Rs/sqm
(2) (5) (6) (5) & (6)

Scenario 1
BC (40) + DBM (100) + WMM
(250) + GSB (200)
55 1.87E-04 3.15E-04 55 105 55 2600 2666

Scenario 2
BC (40) + DBM (50) +
WMMEmulsion (150) + GSB (300)
55 1.54E-04 3.56E-04 118 60 60 2144 2210

Scenario 3
BC (30) + DBM (50) +
55 1.39E-04 3.60E-04 180 57 57 2922 2972
WMMEmulsion (150) +
WMMEmulsion (225)

Scenario 4
BC (30) + DBM (50) +
55 1.38E-04 3.64E-04 181 55 55 2472 2522
WMMEmulsion (150) + CTSB (225)

TKSubhaash
 Synthetic Emulsion – Bituclair
Bituclair – Coloured Bitumen

Cycle Track @ Lucknow

TKSubhaash

TKSubhaash
 Bitumen Emulsion – Chip Seal

A Chip Seal
provides a little
heavier seal and
consists of a spray
applied bitumen
emulsion and then
aggregates added
to it.

TKSubhaash
 Bitumen Emulsion – Chip Seal
Chip Seal

TKSubhaash
 Services
Pavement
Mix Design Design Application
Competitors Customers
Offerings Needs

Marshall Resilient
Training
Modulus
Superpave Application
CBR
Hincol Support
Capabilities

Performance Grading Superpave

Dynamic Shear Wheel Tracker

Rutting & Fatigue Rutting Resistance
Rheometer
Four Point Bending
RTFOT & PAV Binder Ageing Beam Fatigue Resistance
Bending Beam Gyratory
Low Temp Cracking Compactor Field Compaction
TKSubhaash
Rheometer
TKSubhaash