Nanotechnology for Water Resistant

FDR - Stabilized Bases & Bituminous Layers

IRF Global Road

Achievement Award (2013)
 GLOBALLY PATENTED TECHNOLOGY

International Road Federation Marico Innovation Foundation’s CII Innovation Award recognizing
(IRF) Global Road Achievement India’s Best innovation Award that Zydex Technology
award (2013) (2014) innovation (2018)
 Zydex Technology Impacts

 Builds water resistant, Nano flexible stabilized Subbase and Base layer

 Protects bituminous layers against moisture damages

 Superior design, allows higher drainage coefficient of 1.3 – 1.4

 Enhances sustainability, reduces use of aggregates 50 - 70 %

 Technology validated over a time in different weather conditions since 2017

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Stabilized Sub Base / Base Nanotechnology Additives

Terrasil – Organo Silane nanotechnology, UV & heat stable reactive soil nano
modifier reduces swelling and imparts water resistance;

Zycobond - UV & heat stable, cross-linkable 70- 80 nm nano acrylic co-

polymer, imparts flexibility and reduce incidence of cracking along with cement

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Reduced Water Permeability & Improved Soil Compaction

Charge shielding & oil (alkyl)  Increase of CBR with nano (70-80 nm) polymer along
lubrication with cement, enables use of local soils, by saving
transportation cost and time.
Enables optimum
compaction

 Reduces swelling by > 90% to impart dimensional

stability

 Makes soil surface water-impermeable. Permeability

drops to 10-7 cm/s (100 days resistance) from usual 10-5
cm/s (1 day).

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Nano Bonding with Flexibility, Durability & Improved Strength

Cement Soil Stabilization Silane + Nano Polymer + Cement

Cement
Particle

ZycoBond
Particle

Cementitious bonds degrade with time and lose Unaffected by wet and dry cycles due to
strength due to wet and dry cycles - Low hydrophobicity - High durability
durability

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 Siliceous Layer
on Aggregate

NORMAL
AGGREGATE

Silanol
Groups
-OH Groups make aggregate
surface hydrophilic (water loving)

Particle
Surface

Aggregate / Soil / Clay Sand

Surface Silicate Structure
 Hydrophobic Layer on the
Aggregate

Aggregate Treated
with Organosilane

Organo-silane creates molecular level 4-6 nm of Alkyl

hydrophobic zone (water repellent) Siloxane Surface

Particle
Surface

Aggregate / Soil / Clay Sand

Surface Silicate Structure
FDR / Stabilization with Recycler
Machine
 FDR – Execution

1. Shoulders: Excavation and removal of 8. Cement quantity check kg per sqm –

material Plate test
9. Recycling and additives mixing
2. Scarification with Recycler of existing road
10. Grading
3. Grading and mixing with grader 11. Compaction with padfoot roller
4. Compaction with Soil Compactor 12. Grading (to fill up the holes of
padfoot roller)
5. NMC check
13. Compaction with Vibratory
6. Solution Preparation : Terrasil, Zycobond compactor and PTR
and Water in water tanker 14. Water curing
7. Cement Spreading with fully automatic
spreader
1. Shoulder Excavation & Material Removal
2. Scarification with Recycler
3. Grading and Mixing with Grader
4. Compaction
6. Solution Preparation : Terrasil + Zycobond + Water

5. Solution Preparation : Terrasil + Zycobond + Water

6. Cement Spreading with Automatic Cement Spreader
7. Recycling and Additive Mixing
8. Grading after Recycling of Mix
9. Compaction with Padfoot Roller
10. Grading for final finishing of Stabilized Surface
11. Compaction with Vibratory Roller and PTR
12. Water Curing
13. QC Testing
Execution Video
 Nanotechnology for Prime & Tack Coat
and SAMI Layer

TerraPrime additive to Cationic Bitumen Emulsion CSS1 for faster curing &
increased bond strength

Nanotac additive to Cationic Bitumen Emulsion RS1 for stronger adhesion of

bitumen emulsion to create bonded paving fabric of SAMI Layer

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14. Prime Coat @ 1 Kg/sqm with CSS1 & Terraprime
(CSSI 100 Kg + Terraprime 1 Kg + Water 100 Ltr )
15. SAMI Layer with CRS emulsion @ 0.6 Kg/sqm with NanoTac
0.1% by weight of emulsion over Prime Coat
16. PTR for Adhesion of Paving Fabric followed by second Coat of CRS
emulsion @ 0.6 Kg/sqm with NanoTac 0.1% by weight of emulsion
16. BC 40 mm
17. BC - Core Cut
 Andaman NHIDCL 20 MSA (Ch:107+000 – Ch:129+000)

Existing Road

Sub Grade 500 mm, Stabilized Base 340

mm*, SAMI Layer, BC 40 mm

*Granular material 30-35%, Borrow area soil

65-70%, Cement 5%, Terrasil & Zycobond
1.2Kg each per cum
Borrow Area Soil Dumping & Spreading

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 Final
Compaction

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Curing

Post Rain Surface

Monsoon 2021 – 80 Inch Rains…

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 Chemical Bonding - Complete Coating -
Consistent Compaction
 Eliminates moisture & frost damages,  Combined Warm Mix and Antistrip
prevents stripping in bitumen layers  Enables lower mixing and compaction
 Enhanced Durability temperatures
 Odor Free  Allows paving at lower ambient temperatures
 Low Dosage
Chemical Bonding and Moisture Resistance

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 Boil Test Retained Coating 98 % of ZT mix v/s control 65 %

Control

Treated

Test 30 minutes (BIS 14982-

2017)
Mix made with VG 30
Bitumen Granite Aggregates

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Chemical Bonding and Moisture Resistance
Due to permanent nature of chemical bonding, the antistrip does not deplete with time.
Extension of test protocols demonstrates long term performance and durability

BIS 14982-2022

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 Bitumen Mixes Faster Coating at Lower Temperatures
Control With Organosilane

Bitumen binder
Air Interphase Pinhole free surface with jet
black look
 Faster coating, wetting & saturation of bitumen in micro pores & 30 % reduced Coating time 47 sec against 67 sec
crevices of aggregates and fines Innovationsgesellschaft
 Eliminates air interface at aggregate surface – higher oxidation Technische Universität
Braunschweig mbH
resistance

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Compaction at Lower Temperature

Compaction temperatures for unmodified PG 58-22 in the range

of 131-136 0C in Nova Scotia, AMEC Americas Ltd

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Bituminous Layer with ZycoTherm Nanotechnology (HMA)
Terraprime added to CSS1 water based cationic bitumen emulsion ensures quick
set (1 to 2 hour) penetrative priming thereby allowing faster construction. It gives
water resistant, reduced tyre pickup.

Mixing Ratio and Spray Rate

Terraprime CSS1 Water Litre Spray rate

kg KG litre/sqm
1 100 200 1

 Net saving approx. Rs 63,000 per km (3.75 m width)

 Enables bituminous work on same day.

 Prime Coat with Terraprime Nanotechnology

Quick Priming
Spraying CSS1 Solution – 1
Penetration 8 - 9 mm WBM Surface CSS1 : Water: Terraprime ltr/sqm
CAPEX Negative

Waterproofed –
open to traffic

Surface after 30 minutes Cured Surface

 Track Resistant Bonded Tack Coat

 Water Resistance  Higher Inter layer Bond Strength

 Finer Droplet Size  Higher Penetration Depth
 Uniform Coverage  Lower Residual Bitumen
 Reduces tire pick-up & Slippage  Reduced Stickiness to Equipment
 Tack Coat: Surface Preparation & Bitumen Emulsion Spraying

Bitumen emulsion:
C60 BP3 ZM 33.5%

Nanotac: 0,5%
into bitumen
emulsion

Additional
water: 66%

Spray Rate: 0.3

kg/sqm (0.2kg/sqm)

Air temperature: 5°C

 Bituminous Layer with Nanotac Nanotechnology (CMA)

Spreading Compaction Compacted Surface

 Surface Dressing with Nanotac

Priming Emulsion Spraying Chips Spreading

Chips Spreading Compaction Final Surface

 Bitumen Layers – Eliminate Potholes
ZycoTherm added to bitumen binder chemically converts aggregate & fines
from hydrophilic to hydrophobic surfaces, eliminates stripping. Imparts
enhanced workability in paving even in lower ambient temperatures.

Nanotac additive to Cationic Bitumen Emulsion for stronger adhesion of

bitumen emulsion to aggregates and eliminate stripping in Cold mixes and
Surface dressing’s

 Compliance to BIS Code IS 14982-2017 for retained coating of bitumen mixes

(HMA & CMA) will help in ensuring and also extending design life

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THANK YOU

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