Workshop on Technologies for North East Region

and Implementation Framework

Bituminous Emulsion
Based Cold Mix
Technology

M.N.Nagabhushana
Principal Scientist
CRRI, New Delhi-110 025
6th September, 2013
Conventional Bituminous Mix Technologies

Hot Mix Technologies-Shortfalls

• Heating of binder at 150-170°C
• Heating of aggregates
at 185-200°C
• Production at 150-160°C
• Laying at 140°C
• Compaction at 120 °C
• Environmental pollution
• High energy consumption
• Limited work year
Solution…!!!
 Cold mix technologies using bitumen
emulsion as binder
 Cold Bituminous Mixes
 Cold mix technology eliminates heating of
aggregates, bitumen binder, uses cationic
bitumen emulsions
 Optimized composition of open graded premix
carpet, semi- dense bituminous concrete,
microsurfacing and bituminous macadam
 Is environment friendly, offer greater social
acceptance, increased paving period,
acceptable performance and cost effective
 Technology has found wide acceptance
 Advantages of Cold Mixes in Road Construction

 Non polluting process

 Contains anti-stripping agents
 Lesser manpower
 Increased work year
 Cold application
 Eliminates heating- Energy conservation
 Environment friendly
 Coats wet/damp aggregates
 What is Bitumen Emulsion ?
 An emulsion a mixture of two immiscible liquids, one of which is
dispersed in the other in the form of very fine droplets, using an
emulsifier.
 A colloid mill is generally used for the preparation of an emulsion
by dispersion of bitumen in water at 3000 rpm.
 Bitumen is dispersed throughout the continuous water phase in
the form of discrete globules, typically 0.1 micron to 50 micron in
diameter
 Bitumen in suspension by electrostatic charges stabilized by an
emulsifier
Emulsified
+ Ions
Double Layer
Bitumen + +- ++ : +- - + - -
+ -++ : -----+
+ + -+ : + - - - -+-
+
+- ++ : - - - -+- -
+ Interface Solution
 Constituents of Bitumen Emulsion

 Bitumen
 Penetration 60-200 (60%-70%)
 Softening point , max 40 o C
 Solubility in TCE, min 99 %
 Loss on heating , max 1 %
 Water (Potable) - 30%-40%
 Emulsifier (0.5 to 2 %)
 Kerosene (2 to 3 %)
 Hydrochloric acid (0.2 to 0.5%)
 Calcium chloride (0.2 to 0.5%)
Anionic Emulsions :
 asphalt particles have negative
charge
 adhere better with positive
surface charges (e.g., lime
stone)
 alkaline in nature
Emulsifier gives surface charge to asphalt
droplets suspended in water medium

Cationic Emulsions :
asphalt particles have positive charge
adhere better with negative particles(e.g. ,
silica)
acid in nature
also work better with wet aggregate sand
in cold weather
Structure of Cationic Bitumen Emulsion
 Aggregate Emulsion Interactions
For the purpose of predicting the performance of bitumen emulsion,
most rocks can be divided into two broad categories :
(a) “Oxide” rocks consisting of those with high ratios of silicon
oxide (Silicate) or metal oxide content, and
(b) “Carbonate” rocks consisting of those with high ratios of
Limestone or Dolomite type minerals.
Most of the igneous rocks and Slag fall into the oxide category,
while most of the sedimentary rocks fall into the carbonate
category. Metamorphic rocks can be in either category, depending
on their properties and composition.
Based on the above information and the general principle that using
emulsions and aggregate of opposite charges are beneficial, most of
the aggregates used worldwide for paving are silicate-based
(siliceous) and that is the reason why most of those areas specify
cationic bitumen emulsions. Anionic emulsions can be used with
Lime stone and Dolomite types of aggregates.
Emulsion production unit
 Tests to be conducted on bitumen emulsions
 Residue on 600 micron sieve
 Viscosity by Say bolt Furol viscometer
 Coagulation at low temperature
 Storage stability after 24 hours
 Particle charge
 Coating ability and water resistance
 Coating dry aggregate
 Coating after spraying
 Coating wet aggregate
 Coating after spraying
 Stability to mixing with cement
 Miscibility with water
 Tests on residue
 Residue by evaporation
 Penetration
 Ductility at 270C
 Solubility in tri-chloro-ethylene
Types and Applications of Bitumen Emulsion (IS: 8887)

 RS-1 is used for tack coat

 RS-2 is used for surface dressing
 MS is used for open graded premix
 SS-1 is used for priming
 SS-2 is used for slurry sealing, seal coat
and semi dense and dense mixes
Applications of bitumen emulsions
 Tack coat & priming
 Crack filling and sealing
 Repair of pot- holes & depression
 Surface dressing
 Premix Carpet
 Bituminous Macadam
 Semi Dense Bituminous Concrete
 Microsurfacing
 Slurry Seal treatment
 Repair of utility cuts
 Soil stabilisation
 Recycling
 Warm mixes and half warm mixes
Construction specifications using cationic
bitumen emulsion

 IRC:110-2005-Standard specifications and code of

practice for design and construction of surface
dressing
 MoRT&H (5th edition) specification for prime coat,
tack coat, surface dressing, open-graded premix
surfacing, slurry seal, fog spray and bituminous
cold mix
 IRC: 14-2004-Open graded surfacing using cationic
bitumen emulsion
 IRC: SP: 81-2008- Tentative specifications for slurry
seal and microsurfacing
 IRC “Rural Road Specifications’ 2004
Emulsion as Primer
 Waterproof surface of base
 Plug capillary voids
 Coat and bond loose mineral particles
 Harden and toughen the surface
 Promote adhesion between base and new
bituminous layer
 SS1, CSS1 or MC grade cut-back can be used
 Quantity depend upon porosity of base layer
Application of inverted emulsion
 Combines the best properties of emulsion & cutback
for priming application

 Widely used in countries like South Africa and India

 SS1 belongs to this category

 Excellent penetration of base course (10-12 mm)
 Application at room temperature (no heating required
unlike cutback)
 Non- inflammable
 User/environment friendly
Factors responsible for promoting interest in
use of Bitumen Emulsions
• The energy scarcity and crisis
• Use of Bitumen emulsions without additional
heating
• Concerns about reducing atmospheric
pollution
• The ability to use cold materials at remote
sites
• Ability to coat damp aggregate surface which
eventually reduces the fuel requirements for
heating and drying aggregates
 Factors responsible for promoting interest in
use of Bitumen Emulsions
• Availability of a variety of emulsion types which have
led to development of new formulations and improved
laboratory procedures in order to satisfy the design
and construction requirements
• The applicability of emulsions for use in preventive
maintenance so as to increase the service life of
existing distressed pavements
• Success stories of the use of warm mix and cold mix
technologies in construction and maintenance of rural
roads
• Health of construction workers
Variables affecting Quality of Bitumen
Emulsion
 Chemical properties of bitumen
 Consistency and quantity of bitumen
 Particle size of bitumen in the emulsion
 Quality and concentration of emulsifier
 Manufacturing conditions such as temperature,
pressure, and shear rate
 Ionic charge on the emulsion particles
 Order of addition of the ingredients
 Equipment used in manufacturing of emulsion
 Properties of chemical modifiers or polymers
 Quality of water particularly the hardness
 Properties of Bitumen Emulsion
 Stability
 Viscosity
 Breaking and Curing
 Adhesion
 Precautions for Storing and Handling
• Store preferably between 10 °C and 50 °C.
• Should not be heated above 85 °C, as elevated temperatures
evaporate water and thereby, changing the characteristics of
emulsion, which may lead to breaking.
• Do not allow freezing. Freezing below 4 °C may cause
breaking of emulsion leading to separation bitumen from
water. The result may be two having distinct layers in the tank.
• Do not use jet of air to agitate emulsion, as this may cause
emulsion to break.
• When heating bitumen emulsion, agitate it gently to eliminate
or reduce skin formation.
• When diluting bitumen emulsion, check the quality and
compatibility of water with the emulsion by testing a small
quantity. If possible, use warm and soft water for dilution.
 Precautions for Storing and Handling
• Always add water slowly to the emulsion (not the
emulsion to the water).
•Remember that emulsions with the same grade
designation can be very different chemically and also
in performance.
• Do not mix different classes, types, and grades of
emulsions in tanks and distributors.
•Do not dilute rapid-setting grades of bitumen
emulsion with water. Medium and slow setting grades
may however be diluted, but always add soft water
slowly to the bitumen emulsion.
•Do not load bitumen emulsion into storage tanks,
tank cars, tank transports, or distributors containing
remains of incompatible materials.
 Application of Tack Coat(TC)
 Bitumen emulsion of RS-I grade
 Quantity @ 2-3 Kg per 10 m2 area
 Pressure distributor or mechanical
sprayer
 Cleaning of cavities with water before
TC
 Turns black from brown in 10-15
minutes
 Wetting of road surface required, if
dry
 Adequate bond strength is needed

Fresh Bituminous Layer

Existing Layer
Production of Cold Mixes with HMP

Adding Pre-mix Water Adding Emulsion in Drum Mixer

Cold Mix on Conveyer Belt Discharge of Cold Mix to Dumper

 Preparation of Cold Mix

Charging of Aggregates Wetting of Aggregates

Emulsion for Cold Mix Discharging of Cold Mix

Transportation of cold mix
 Cold mix shall be discharged in trolleys/wheel barrow
 Cold mix shall be transported to site by wheel barrow/tippers
 Avoid newly laid surface or tacky road surface while ferrying

Spreading of cold mix

 Spread cold mix in half the road-width
 Required thickness with spreader
 Cold mix turned black from brown
 Cold mix aerated for about one hours

Compaction
 Compacted with 8-10 ton road roller
 Wetting of wheels
Performance of PMC with
emulsion

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
 Micro Surfacing: Solution for Faster Maintenance
Microsurfacing mixture consist of :
• Dense-graded crushed fine aggregate
• Polymer / latex modified emulsion
• Water
• Mineral filler (cement)
• Chemical additive

Composition of Designed Mix

Ingredients Percent by weight of aggregate
Aggregate 100 %
Emulsion 13 %
Portland Cement 1.5 %
Additive 0.5%
Water 14 %
Average flow of mix was 12 kg/sq.m. with Emulsion Content at 13.0%
MICROSURFACING IN PROGRESS
 Uses and Merits
 Preventive and periodic maintenance
and renewals on structurally sound
pavement
 Surface with satisfactory riding quality
 Surface defects like cracks and
polished surface of various types may
be treated
 Can be used for delay of reflection
cracking as cap seal
 Improvement of skid resistance and
rejuvenation of hungry surface
 Surface treatment suitable on National
highways, expressways and airfield
pavement
 Skid resistance and noise reduction on
concrete and bituminous pavement
 Fastest construction technology
A View of Microsurfacing Treatment on Delhi Roads

Kamal Attaurk Marg

Brigadiar Hoshiar Singh Marg
( Single Microsurfacing) , March’09
(DBM + Microsurfacing) , March 2007

Janpath Rajaji Marg

( Double Microsurfacing) , June’07 ( SDBC + Microsurfacing) , Jan’08
 Why Warm Mix Technology
Warm mix technology is emerging  WMA is produced in the temperature
technology, which allows the range of 120 °C to 135 °C
mixing, lay down, and compaction  Half WMA is produced in the temperature
of bituminous mixes at lower range of 80 °C to 100 °C
temperatures compared to Hot Mix

 Energy saving
 Decreased emissions
 Reduced fuel costs WMA (110 °C)
 Reduced aging of binder
 Lower fumes and odor emissions
 Cool weather paving
 Compaction aid for stiff mix
 Extend paving window
 Generation of carbon credit
 Increase use of RAP
 Cold Mix and Half Warm Mix: Imperatives
 Cold mix is prepared using bitumen emulsion as binder
 Bitumen emulsion as binder may be used in half warm mix
 Successfully used for construction of rural roads in Assam
 Performance of these roads is found acceptable
 Successfully used for construction of bituminous structural layers

+
Bitumen +

+
+
 Types of Warm Mix Technologies
 Several process have been developed to improve mixture workability
allowing lower production and lay down temperatures
 WMA technologies can be classified broadly as (a) those that use water,
(b) those that use organic additive or wax (c) those that use chemical
additives or surfactants.

 Aspha-min®
 Sasobit®
 WAM-Foam® (warm asphalt mix foam)
 Evotherm
 LEA (low energy asphalt)
 Rediset WMX
 REVIX
 Double barrel green WMA system
 Emulsion based
 Foam bitumen based
Production and Laying of Warm Mixes
 Foamed Bitumen: Binder and Stabilizer
 Deficiencies of bitumen in RAP using cold
recycling may be corrected by bitumen
emulsion/foamed bitumen
 It improves strength of material and
reduces the detrimental effect of water
 Produced by injecting water into hot bitumen
 Explosively transformed into vapour, trapped in
thousands tiny bitumen bubbles
 Foam bitumen collapses in less than a minute
 Greater the volume of the foam better
distribution of bitumen into aggregate
 On compaction, the bitumen particles in the
mastic are physically pressed against the large
aggregate particles resulting in localized non-
continuous bond
 Effectively rejuvenate bitumen in RAP
Problems faced and experiences gained

 Ball formation observed with dusty aggregates

 Lump formation with aggregates having more fines and clay
 Concrete mixer was not found appropriate for graded cold
mixes
 Long setting time and tenderness of dense cold mix
 Sand seal coat on PMC was observed problematic due ball
formation during mixing of emulsion and sand
 Rich mix formed with emulsion and fine aggregates stick to
the bottom of concrete mixer
Remedial measures
 Regular cleaning of mixer say after an hour work by tapping
with wooden hammer
 Addition of fines after coating of coarse aggregates with
emulsion
 Laying of Cold Mix MSS / PMC

Tack Coating with Emulsion Spreading of cold mix

Compaction of cold mix Laying of cold mix in rains

 Two Coat Surface Dressing

Tack Coating with emulsion Spreading of Aggregates

Spreading of Emulsion Compaction of Aggregates

 Structural Layers can also…….

Production of cold mix for SDBC Laying of BM with Emulsion at Aizawl

Compacting SDBC A 5 year old Surface

Production of Cold Mixes with HMP

Adding Pre-mix Water Adding Emulsion in Drum Mixer

Cold Mix on Conveyer Belt Discharge of Cold Mix to Dumper

Laying & Compaction of Cold Mix
Laying with Cold Mixes in J & K
Laying with Cold Mixes in Mizoram
 Cold mix has been successfully
used for construction of rural roads
in Assam
 Performance of these roads is found
acceptable
2 yrs Old Road PMGSY Package No – As -01-62
2 yrs Old Road Location: Patsala, Barpeta
2 yrs Old Road Location: Simaluguri, Sivsagar
3 yrs old road
Location :
Bongaigaon
Road name : Kuma
kata to Sankarghola
3 yrs old road
Location : Mirza , Kamrup
 Workshop on Non-conventional
Materials/Technologies- 18.02.2012
Prime Recommendation of Workshop on
Non Conventional Technologies/Materials

 Use of cold mixes to be

enhanced
for construction of rural
roads in North East,
Chattisgarh, Orissa, Bihar,
Zharkhand, West Bengal etc.
Workshop on Sustainable Technologies for
Road Construction in Jorhat 19.09.2011
CRRI has
already
provided a
cold mix
based
technology
license to
M/s
Bitchem
 Rural Roads for North-East
 India has extensive road network of nearly 4 million kms
 Efficient transport system needed for growth of rural economy
 79.8% comprise rural and low volume roads
 PMGSY aims to provide all weather connectivity to habitations of
500 and above
 Hilly, desert and tribal areas with habitations of 250 and above to be
provided with all weather roads
 Bharat Nirman envisages connectivity to over 66,800 unconnected
habitations through building over 1,46,000 km of new roads and
upgradation of about 1,94,000 km of existing road network
 Flexible pavement is the preferred pavement type
 Conventional construction materials are depleting fast
 Network to be extended to all terrains, environment and social
sectors
 Climatic condition and terrain of North East is uncongenial to
progress using conventional materials and technologies
 Needed Action Plan

o Identification of thrust areas

o Increase domain competence
o Knowledge pooling from all around
o Effective Dissemination
o Modified specifications
o Ensuring ground utilization
 New Material and Technologies: Policy Framework
• Incorporation of specifications for proven materials and
technologies in MoRTH, BIS and IRC specifications
Fly ash, ultra thin white topping, modified bitumen, multi grade bitumen,
Geo Textiles, micro surfacing, Stone matrix asphalt, Recycling

• Ongoing specification development

Plastic waste, Warm mixes, Modified emulsions, patching mixes, Industrial
waste, New pavement design, use of fibers in concrete pavement etc.

• Need of new specification

Performance based bitumen specifications, Nano technology, new
generation additives for soil stabilization, Performance based design, half
warm mixes using bitumen emulsions and foam bitumen, thin surfacing for
rural roads, Membranes for bridge deck surfacing etc.
 New Material and Technologies: Policy Framework
• IRC has accreditation wing (committee) for identification
and recognition of new materials and new technologies
for construction and maintenance of road infrastructure.
• IRC has so far accredited 69 new materials/techniques
• NHAI and planning commission permitted use of new
materials technologies and design by concessionaire in
PPP (DBFO) projects for sustaining infrastructure
development and saving of materials
 New Material and Technologies: Shortcomings
o Rigid policies at implementation stage
o Insufficient knowledgebase
o Subjective decisions
o Missing/Inadequate need based judgments
o Resistance to transformations
o Cost related issues
o Unskilled/untrained workforce
o Accreditation related issues
o Specification related issues
o Apprehensions of failures
o Lack of field performance data
 Technology Innovations and Implementation in
Road Sector is Required
• Achieving cost effectiveness and speed in construction,
durability and performance
• Providing technical underpinning to evolve new
standards
• Developing man force with adequate knowledge in new
technologies
• Materials and energy conservation
• Reduced carbon foot print
New Material and Technologies: Recommendations
• Agencies should enhance budgetary provisions for
faster evaluations of new materials and technologies
by the national facilities like APTF and other state of art
facilities available at R&D institutions like CRRI and IITs
• The cumbersome process of approval of pilot projects
involving new materials and technologies should be
simplified for rapid disposals
• Concessioners should be given incentive for pilot
projects involving materials and technologies saving
energy and materials besides adding to carbon credit
New Material and Technologies: Recommendations
• The knowledge of technical persons with
interdisciplinary background having batter
understanding of the behavior of new materials and
technologies should be effectively tapped
• Requirement of equipments for implementation of new
technologies should be procured and effectively used
by construction agencies
• Development of specification for new technologies
should be expedited
• Sufficient allocation of funds for upgradation and re-
engineering of technologies for Indian conditions
The Main goal of these TECHNOLOGIES is to
Achieve :
•Conserve Natural Material Resources
•Explore Alternative Technologies
•Conserve Fuel & Energy Sources
•Enhance Environmental Quality
•Improve Road Safety
•Evolve Better Pavement Designs
•Build Sustainable Assets
Recognition for Technology by-
 Incorporating in DPRs
 Bringing awareness through
appropriate forums, demos etc.
 Have a technology management
arrangement
 Document and disseminate
Sustainability is the next
great game in
transportation.
The game becomes
serious when you keep
score.

Greenroads keeps
score.
Tell me and I will forget, show
me I may not remember. Involve
me and I will understand”
– Native American saying

Hence, Let us understand by

involving ourselves
“The future is not a result of
choices among alternative paths,
but is one that is created –created
first in mind and will, created next
in activity.”John Schaar.

Let us create Green Roads with

sustainable techniques for our
rural masses