PERFORMANCE OF COLD IN PLACE

RECYCLED PAVEMENTS (CIPR)

NH-2 & NH-5
CHALLENGE IS NOT TO CONSTRUCT FAST,
CHALLENGE IS TO CONSTRUCT SUSTAINABILY
National Highway from Varanasi to Aurangabad at NH-2,
Six lane National Highway with heavy traffic(180MSA)
DISTRESSED PAVEMENT
 Pre Project Investigations
Test pit observations, Coring of bituminous mixes, Deformation evaluation, Traffic
volume survey, Collection of milled material, RAP design
COLD IN-SITU RECYCLING USING FOAM BITUMEN

For RAP mix design

Optimum foamed bitumen content- 2.25%
Optimum moisture content – 6%
Optimum foaming characteristics were
achieved at temperature of 180°C and
foaming water content of 5%.

Foaming was done with VG-30 binder

1% cement OPC 43 grade was added to
improve the stability and better dispersion
of foamed bitumen in fine particles of the
mix
BSM Samples
 Sample No Indirect Tensile Strength, kPa
2.0% Foamed Binder 2.25% Foamed 3.0% Foamed
Dry ITS Values Content Binder Content Binder Content
1 272 390 327
2 332 408 339
3 273 401 330

Sample No Indirect Tensile Strength, kPa

2.0% Foamed Binder 2.25% Foamed 3.0% Foamed
Wet ITS Values Content Binder Content Binder Content
1 201 302 227
2 233 307 242
3 203 309 219
Resilient Modulus, MPa
Sample No 2.0% Foamed Binder 2.25% Foamed Binder 3.0% Foamed Binder
Content Content Content
25C 35C 25C 35C 25C 35C
Resilient Modulus
1 1597 1043 2649 1499 2296 1481
2 1508 926 2506 1389 2343 1619
 Pavement Design
Existing Layers Conventional Overlay CIR

• Granular Sub Base • Granular Sub Base • Granular Sub Base

(GSB)+ Granular Base (GSB)+ Granular Base (GSB)+ Granular Base
(WMM) : 450mm (WMM) : 450mm (WMM) : 450mm
• Total Bituminous crust • Dense Bituminous • Bitumen Stabilized
245mm Macadam (DBM): material (BSM):
185mm 175mm
• Bituminous Concrete • Dense Bituminous
(BC): 50mm Macadam (DBM):
70mm
• Bituminous Concrete
(BC): 50mm

By using foam stabilized technique, app 80% of recycled aggregate was used and
about 60% less bitumen have been used for construction of pavement.
RECYCLED PAVEMENT : 2016-17
2020-2021
Samples packed and transported to CRRI
FIELD CORES IN CRRI LAB
Resilient Modulus Values of Field Cores

Chainage Height (mm) Diameter (mm) Mr, Mpa @ 35C

788+410 62.4 93.6 4889
790+100 64.7 93.7 3608
790+240 63.9 93.7 4798
795+020 65.6 93.6 4614
805+780 62.8 94.0 3232
815+770 62.7 94.3 2203
832+560 62.9 93.4 2690
849+420 64.6 92.4 5274
790+100 65.4 94.0 5598
805+780 60.8 94.2 1834
815+770 63.4 94.1 4913
815+830 60.3 93.3 5034
BC has not been laid at
some chainages till date
and the pavement is
performing only with
BSM-DBM
National Highway from Rajahmundry-Tuni NH-5, 30 MSA
 Pre Project Investigations
Test pit observations, Coring of bituminous
mixes, Deformation evaluation, Traffic volume
survey, Collection of milled material, RAP design
 Foam binder content, % Resilient Modulus at 35ºC , MPa

2.0 1037
2.5 1109
3.0 1361
3.5 1198
Foam binder Dry Indirect Tensile Strength, Wet Indirect Tensile Strength, kPa
content, % kPa 80% of RAP material, 10%
2.0 257 214 coarse aggregate, 9% stone
dust (SD) and 1% cement is
2.5 335 215
blended to meet the gradation
3.0 415 259 requirement of IRC 37: 2012
3.5 302 205
Layer Specification Thickness, Modulus Value
mm Considered, MPa
Granular Sub Base (GSB)+ 350 229
Granular Base (WMM) 210 229
Bituminous Concrete (Existing after milling) 160 1700
BSM layer 100 800
Bituminous Concrete (BC) 40 3000
Jan-2021
Resilient Modulus Values of Field Cores

Chainage Height (mm) Diameter (mm) Mr, Mpa @ 35C

867+800 43.3 99.5 2433
867+800 55.9 99.8 2095
868+200 50.5 99.7 2132
869+000 48.1 99.5 2194
870+350 51.6 99.9 2553
Resilient Modulus Values of Field Cores at
Different Temperatures
Site Name Chainage 25C 35C 45C

788+410 9383 4889 2099

790+240 7434 4798 3025
NH2
795+020 7730 4614 2706
849+420 6903 5274 3047
867+800 4010 2433 1926
867+800 4586 2095 1774
NH5
868+200 4431 2132 1555
869+000 7208 2194 1187
 ITS Values of Field Cores

SECTION CHAINAGE ITS,KPa

NH2 795+020 1270
849+420 1070
790+240 1215
NH5 869+200 854
867+350 797
867+800 889
 Conclusions
• NH2 section – CIPR was done in 2016-17, performance check was carried out in
2020 December . The pavement performance is found satisfactory, irrespective of
the fact that for a traffic of 180MSA the pavement thickness was not sufficient, since
BC is not given at many chainages.
• At few locations damage is found in terms of rutting and cracks. Core were taken
from such locations and it was found that the damage is restricted to DBM layer.
There is no damage in BSM layer.
• As per the pavement design given by CRRI, over 175mm of BSM (CIPR) layer, 70
DBM and 50BC was to be given. But there was delay in giving BC layer and till date
at some locations there is only DBM over BSM.
• NH-5 section CIPR was completed in July 2019, performance check was carried out
in January 2021. The pavement performance is found satisfactory.