Field Trails

for the
Development
of the
Cold Mix Technology
for
Road Construction
and
Maintenance
• Bituminous Macadam
• Dense Carpeting
• Semi dense carpeting
• 20 mm Carpeting with seal coat
• Unpremixed Surface dressing
• Slurry Sealing and Microsurfacing
• Patch Repairs with Ready Mix
• Spray Patch Repairs
• Water Proof Coatings

OMIL
Central laboratory at Zuangtui for establishment of
job mix formulations

Sieve analysis and job mix formulations started

 Testing facilities

The Central Laboratory

at PWD Mizoram
 Results of the Marshall tests

Bituminous Maccadam Semi Dense Carpeting

Binder Moisture Density Stability Flow Binder Moisture Density Stability Flow

6% 5% 2.18 - - 8% 6% 2.19 3866 3.5

7% 5% 2.2 1901.46 1.9 9% 6% 2.20 4062 3.2

8% 5% 2.2 2477.66 4.0 10% 6% 2.15 3468 3.2

Aggregates :-20mm 40%, 10mm 40%, Dust 15% Aggregates:- 10mm 65%, Dust 35%

Quote CRRI :- the test results are excellent far better than expected
 Trial Mixes

Aggregates contained a lot of dust in the form of clay

Quality of the Aggregates

Trial Mixes BM

Coating was excellent with no Emulsion run off

OMIL Representative
Dr Pundhir and Dr Sarma CRRI
 10th JUNE
TEST TRACK
 10th June

Plant Trails taken on Bituminous Macadam

Drum mix plant
670sq meter laid stretch

Emulsions from OMIL

Paver Laid Primix being unloaded to paver

 With Dr Pundhir. Dr Sarma, Mr Dushaka and
World Bank rep MR Kevin from Vic Roads
at work site

CRRI Personel and Mr Dushaka

With Mr Kevin VIC ROADS

World Bank Consultant
 Results on the mix quality and
quality of paver laying

• Coating was good

• Laying was uniform there was no sticking on the

skrid , no hold up in the skrid

• As the moisture content in the atmosphere

was high it took time to set

• It started to rain after the mix was laid and continued

raining heavily for nearly 3 days

Comments on the laid stretch by MR Kevin , World Bank and CRRI

• Mixing and laying was good

• Longer Setting time was attributed to the high
percentage of dust ( clay like particles) in the aggregates
11th JUNE
Demonstration on
Patch Repair Work For Mizoram PWD

In
I Front of NBCC office Mizoram
n

F
 Trial on Plant mixing and laying
Laid Stretch 670 sq meters
Semi- dense Carpeting
• Laying and mixing good

• No hold up in the skrid

l
• No sticking to the skrid
Rolling semidense carpet
• Rolling done after 45 mins
Dr Pundhir
• Setting time very long

• Longer setting time was

attributed to the
atmospheric conditions
Rolling semidense carpet
and the high percentage
Rolling semidense carpet of dust in the aggregates
Comments CRRI and
others

OUR OBSERVATIONS!!!!!! Atmospheric conditions should not affect the setting time significantly it is the
dust ( clay like particles ) which was the cause of the problem !!!!!!!!!
 Presentations
and
interactions

At the Engineers Club

Engineers Club

Laboratory

Over Lunch

In the Laboratory

Mr Dushaka giving the presentation

Mr Vinay Nath gave the presentation on behalf of OMIL
and Preetam Rajkhowa handled the interactions and the
question and answer session
OUR FINAL OBSERVATIONS
• Aggregates were not properly graded and contained
excessive fines and could not be screened due to wetness

• It was the dust which created the problem in setting

• Mixing and laying was perfect

• Laboratory tests have given excellent results on Marshals tests

• By altering the mixing technique very good results were obtained

in field scale trials in our factory site using aggregates
from Meghalaya which are similar to the ones available
in Mizoram

• Cold Mix technology is cost effective and can be taken up on

a large scale using all variety of aggregates with slight
modification in the drum mix system

• MR. Dushaka has been informed about our success in achieving the
correct setting time using aggregates similar to the ones available in
Mizoram ………even with excessive dust !!!!!!!!!
 Work at Assam Carbon
Using
Natural Rubber Modified Emulsions
 Work at Assam Carbon
using
Natural Rubber Modified Emulsions

Water puddles after rain

Tack coat
No Rolling was done
Rolling was just by the wheels
Manual mixing manual Of traffic
laying
Work at Factory site
using aggregates
from Meghalaya
almost similar to
the ones used in Mizoram
 Work at plant site using Lots of clay
aggregates from Meghalaya In it
almost similar to the ones
used in Mizoram

Dust

DUST Lots of clay

10 mm

12 mm 20mm
Bamboo Shuttering material
 Work at factory site using
aggregates from Meghalaya
almost similar to the ones
used in Mizoram

Adding water
Mixed with emulsions
Semi Semi
Densedense
Mix Mix

Wood Laminated with Bamboo

Laser Cut Bamboo

 Work at plant site using
aggregates from Meghalaya
almost similar to the ones
used in Mizoram

Semi Dense Mix

Tack coat/Priming
Rona

Rolling can be done in 45min-1hour

Storable Mixes

ZUPER COTE PC
 ZUPER COTE PC
• Storable Mixes • Can be stored in bags
• Suitable for patch repairs for atleast 1-2 months
• Sets instantly on application

Using a
Concrete
Mixer for Very
little
the MIX Emulsion
runoff

SEMI DENSE MIX Mix does not stick Showing the flow of mix from the mixer
to the mixer

Packed in cement bags

The open end tied

with a rope
Bituminous Macadam MIX
 •Storable Mixes ZUPER COTE PC
• Manual Mixing

Bags being filled

Premix Being bagged

Mixed Negligible emulsion run off

manually

Bags being taken for storage

 APPLICATION

ZUPER COTE PC
Storable Mixes
Application

Cutting the bag open

Out of the bag

Breaking the lumps Slight Ramming

Spreading
 Zuper Coter PC
Storable Mixes

Storable Mixes
Zuper Cote PC
Coarse Sand

Open to Traffic immediately

Zuper Cote PC 6mm aggregates
ZUPER COTE PC

Storable Mixes
Application

Ramming

Opening to traffic immediately

after ramming

No displacement
of gravels
even at high speeds
 Mr Rajkhowa with Eric

Eric being demonstrated

ready mix PC
Mr Bajaj ,Eric and plant personnel in the production capsule
Zuper Cote WP
Water proof paint
Zuper Cote PC

Water Proof Paint On

• Steel
• Asbestos
• Wood
• Concrete

Coated with
aluminium paint
on top

Brushed
Can be sprayed as well
• ZUPERCOTE
POLYMIX

• ZUPERCOTE
POLYMIX
Modified Premix
using
a
Mini Spot Mix Plant
Semi Dense Carpeting
Premix using a Mini Spot Mix Plant

Mini spot mix plant

i ed
ote dif
o
e rc M
p
Zu
ix
l ym Zuper cote
Po Polymix Modified
 Premix using a Mini Spot Mix Plant

Zuper cote
Polymix Modified
Zuper cote
Polymix Modified
 Premix using a Mini Spot Mix Plant

Zuper cote
Polymix Modified
Zuper cote
Polymix

Zuper cote
Polymix
 Premix using a Mini Spot Mix Plant

Laid Seal Coat

Preemix Seal Coat manual

Zuper cote
Polymix
Seal Coat being laid

Rolled Surface after seal coat

 Gravels from Mizoram
(similar to the ones available in Meghalaya)

Lots of clay particles Dust

Dust

Dust

10mm
20mm
10mm
 Gravels from Mizoram
(similar to the ones available in Meghalaya)

Mixed with water

and cement

Emulsion added

Semi dense Mix

Negligible emulsion run off

Mixing Laid premix…. Rolling after 1 hour

Road can be opened to traffic immediately aftr rolling
 Production Capsule at OMIL

Products
Zuper Cote

• RS
• MS
• SS
• Cut Back

Zuper Cote

• Polymix
• Polymix
modified

Zuper Cote PC

• Storable
Mixes

Zuper Cote WP

• Water proof
paint
Zuper Spray
Emulsion Sprayer

Being fabricated at site

Mobile Emulsion Sprayer
Zuper Spray
 Tractor loaded with
Zuper cote barrels aggregates and poly mix bags
being unloaded to decanter And the Zuper spray

Punj Loyd

Tractor Trolley, Zuper

for patch repairs Zuper Spray
Punj Loyd
with
near
the
Factory Site
National Highway
Polymix bags being
dropped along the road Polymix being
spread on the pot hole

Being Rolled

Rangia with Punj Loyd

 Storable Mixes
Polymix

Rangia with Punj Loyd

 Application of tack coat
Using a sprayer

With Punj Loyd

Rangia

Semi Dense patch

Using sprayer and
manual mixing
 Spray Patches

Spray Patches

NH near Rangia
For
Punj Loyd
Work Speed :- 2 kilometers in 4 hours
of heavy patchwork
With Punj Loyd Spray Patches
Tractor, trailer, Sprayer Chain

At the factory site

With
Punj Loyd

Spraying the road surface

Showing the original road surface

Spreading aggregates
Rolling the first layer
With
Punj loyd Showing the original surface
Spray prior to seal coat

Two coat unpremixed surface dressing

Spreading Seal Coat aggregates

 Two Coat un premixed surface dressing

With Punj Loyd

 Ganeshguri Flyover
Guwahati
Assam PWD
Semi Dense Patches/
Carpeting
Dense Bituminous
Concrete
For
The
Indian Railways
Mixer Machine for
MixerCold
being developed
Mix
In house
MICROSURFACING MIXES

MANUAL/MACHINES

MANUAL LAYING
Adding emulsion
Adding Cement
Manual Laying
Micro surfacing Mixes

Laid Surface can be opened

to traffic in 1-1.5 hours
Laid Surface can be opened to traffic in 1-1.5 hours