2101CV622 Module 5 Introduction To New Technology

Highway Construction Technology
(2101CV622)
Module 5:
Introduction to New
Technology
Prof. Dhaval A. Jalalpara

Civil Engineering Department
Darshan Institute of Engineering & Technology, Rajkot
Dhaval.jalalpara@darshan.ac.in
7405239039
DU Syllabus-
 Highway Construction and Technology
 Teaching Scheme
Credi Practical
Teaching Scheme (Hours) Theory Marks
t Marks
Total
End
Mid Sem Term Marks
L T P C Semester Viva (V)
(M) Work (I)
Exam (E)
3 0 2 4 70 30 25 25 150
 Theory Exam : 70 Marks

 Mid Sem Exam: 30 Marks
 Term work :25 Marks
 External Viva : 25 Marks
Prof. Dhaval A. Jalalpara 2101CV622 ▪ Unit 5: Introduction to New Technology 2

DU Syllabus-
Chapte Contents No of %
r No. Lect. propo
Pavement Materials and Characterization 9 20
Soil: Characterization for Earthwork, Subgrade. Effective CBR, Concept of Modulus of resilient of
subgrade.
Aggregate: Granular Subbase and Base layer -road aggregates used for WBM, WMM, Aggregate
used in Bituminous layer, Its characteristics, gradation- Fullers equation, physical properties
1.
requirements for rural road and high-volume road., Concept of Modulus of resilient of sub base and
base course as per IRC 37.
Bituminous material: Bitumen, Emulsion, Modiƒed bitumen, bituminous mix design–Volumetric,
concept of modulus of resilient per IRC 37, Quality control and Quality Assurance plan for
highway.
Construction of Pavement - Flexible 9 20
Flexible Pavement: Construction procedure of embankment, subgrade, Sub base (Granular, sub
base), Drainage layer, ƒilter /separation layer, Base course-WBM, WMM, Lime stabilized, cement
2. stabilized (Granular layer-Cement Treated Base-CTB, Cement Treated Sub-base-CTSB),
Bituminous mix – Binder course and wearing course, its selection, its gradation, compaction and
density requirements. Selection of different bituminous mix treatment as per functional and
structural requirements of Construction procedure as per speciƒcation of MORTH.

DU Syllabus
Sr. Contents No of %
No. Lect. propo
3. Construction of Pavement - Rigid
Rigid pavement: Earthwork, Granular sub base, drainage layer, Dry lean concrete as per IRC-49,
Pavement quality concrete construction requirements as per IRC:15 and IRC:58 and MORTH,
Importance of joints and its provision Interlocking, Concept of Un-Bonded and Bonded Concrete 9 20
Pavement.
Interlocking Concrete Block Pavement (ICBP) and Its procedure of laying, requirements, Pattern of
blocks, Strength requirement as per guidelines of IRC SP 63.
4 Maintenance of Pavement
Flexible pavement: IRC-82, need of maintenance, types, planning, system approach, types of defects,
symptoms, location, cause, severity level and treatment. Preventive and periodical renewals, its warrants 9 20
and treatments. Concept of Overlay, its suitable mix and thickness as per functional and structural need.
Rigid pavement: Distresses, Causes, Maintenance and its methodology as per IRC: SP:83.
5 Introduction to New Technology
Recycle aggregate pavement as per IRC:120 (RAP). Cold in place(CIP), Hot in place (HIP), plant mix
technology, Methodology of construction, Cold mix technology as per IRC SP-100, White topping –
9 20
Conventional, Ultra-thin white topping as per IRC SP-76, , Stone matrix asphalt as per IRC SP-79, Warm
mix asphalt as per IRC SP 101, Micro surfacing ,slurry seal as per IRC SP: 81.Aggregate other than
Natural resources-steel slag, copper slag, Iron slag.

Syllabus Content
1. Recycle aggregate pavement as per IRC:120 (RAP), Cold in place (CIP), Hot
in place (HIP), plant mix technology,
2. Methodology of construction, Cold mix technology as per IRC SP-100,
3. White topping – Conventional, Ultra-thin white topping as per IRC SP-76
4. Stone matrix asphalt as per IRC SP-79
5. Warm mix asphalt as per IRC SP 101,
6. Micro surfacing ,slurry seal as per IRC SP-81

IRC GUIDELINES

Irc:120-2015-Recycle aggregate pavement

What is Recycling of pavement
 Recycling of pavement is the process in which the existing pavement materials are
reclaimed and re-used after reprocessing for either
 (a) resurfacing, or
 (b) repaving, or
 (c) reconstruction of pavement
 Selection of pavement for recycling that depends upon
 the condition of the existing pavement,
 the nature of the reclaimed materials,
 the method of reprocessing, and
 the treatment that the pavement requires

Candidate pavement for recycling




Recycling of pavement
 The justification for reclaiming the pavement materials, consisting mainly of aggregates and
bituminous binders, is both environmental as well as economic.
 The aggregates existing in the pavement are part of natural resources drawn from the
environment and should not be simply dumped at dump sites if a pavement fails or becomes
unserviceable because it will cause damage to the environment, which will be further
accentuated by extracting more virgin aggregates from the environment in replacement of the
wasted materials.
 Economic justification comes from the utilization of the bitumen already existing in the
pavement, which reduces the requirement of expensive virgin bitumen.

Classification of recycling methods

Pavement
recycling
Central
In-place Full depth
Mostly In plant
recycling reclamation
India it is
in practice recycling
Cold
Hot Process Hot Process Cold Process
Process

1. In place recycling – Hot Process (Hot In-place recycling -HIPR)
 In HIR, a train of equipment is used with capabilities to perform different functions such as
a) infrared heating of the pavement surface to soften it,
b) milling the softened hot pavement surface,
c) transferring the milled materials into Pug mill mixer of the Recycling equipment
through a belt conveyor,
d) adding fresh mix/binder/rejuvenator as per requirements of design into the pug mill,
e) discharging the remixed materials into integrated paving screeds for paving the re-
mixed output, rolling and compaction of the paved material.
 In HIR, 100 per cent of the reclaimed material is utilized.
 However, its limitation is that no more than 50 mm thick bituminous layer can be
satisfactorily recycled (maximum 75 mm if softer binder was used in the original
construction).
2. In place recycling – Cold Process (Cold In-place recycling -CIPR)
 In this process, milling and mixing are simultaneous processes accomplished by a single
equipment or a train of equipment capable of milling and conveying the milled material to be fed
to a pug mill, with parallel supply line for feeding fresh aggregates also, and separate feeding
lines to the pug mill for bitumen emulsion, and rejuvenator.
 Where foam bitumen is to be used, there has to be separate feeding line for hot bitumen and
water to produce the foam bitumen and then feed into the pug mill.
 The mixed material is discharged into the paver hopper closely following the recycling equipment
or train of equipment, then paved and compacted.
 This type of recycling is considered suitable for depth up to 150 mm and the use of reclaimed
material is also of the same order (typically 30 to 50%) as in HIP.
 Another variant of cold in-place recycling is Full Depth Reclamation, where the thickness of
pavement to be recycled is greater than typically 150 mm.
 The pavement is ripped, the material pulverized and stabilized with lime, cement or cementitious
materials and compacted into base layer of the required strength.
This method is most
preferable treatment
3. Central Plant Recycling – Hot Process
 This process involves production and laying of hot mix materials but not with virgin aggregates and
binder but with a combination of reclaimed stockpiled aggregates already coated with binder and
additional virgin aggregate and fresh binder to meet the requirements of the design.
 Usually, some rejuvenator is used to soften the old hardened binder in the reclaimed aggregates.
 Heating the reclaimed binder coated aggregates may release unacceptable fumes while feeding them
cold directly into the pug mill may reduce the mixing temperature.
 The hot mix production process, therefore, has to be suitably modified.
 In all other respects, hot in-plant recycling is just like normal hot mix construction.
 Not more than 50% of the reclaimed material is used, though a widely accepted percentage is only 30)
and the thickness in which it can be laid is typically 100 mm.
4. Central Plant Recycling – Cold Process
 The process involves production of the mix in a plant using either emulsion or
foam bitumen and laying and compaction in the usual manner.
 A rejuvenator is to be added in the mixing process to soften the hard binder in the
reclaimed material.
 The application range in terms of depth of recycling and use of reclaimed materials
is typically the same as for cold in-place recycling.

Cold Mix Technology-IRC:SP:100-2014
 COLD MIX TECHNOLOGY IN CONSTRUCTION AND MAINTENANCE OF
ROAD USING BITUMEN EMULSION FAMILY OF BITUMEN
Disadvantages of hot mix
technologies: Bitumen Cutback Emulsion
 Emission of green house Rapid Setting (RS)
gases
Rapid Curing (RC)
 High level of noise and air VG-10 Medium
Medium Setting(MS
pollution VG-20 )
Curing(MC)
Slow Setting (SS)
 Compromise with the VG-30 Slow Curing (SC)
durability of bitumen due to VG-40
aging during heating Application of cold
 High energy consumption mix technology is with
 Unsafe for maintenance crew Emulsion
 Results obtained from field trials conducted by CRRI and oil companies on
cold mixes and bitumen emulsion Several factors that have lead to the increasing
use of bitumen emulsion in road construction and maintenance are listed below:
 The energy scarcity and crisis
 Bitumen emulsions do not require petroleum solvent to make it liquid
 Bitumen emulsions can generally be used without additional heating
 Concerns about reducing atmospheric pollution
 The ability of certain types of bitumen emulsions to coat damp aggregate
surface, which eventually reduces the fuel requirements for heating and
drying aggregates
 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 ability to use cold bituminous materials at remote sites
 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 and cold mix technologies in construction
and maintenance of rural roads
 Health of construction workers

 The uses of emulsion in construction and maintenance applications covered in
these guidelines are given below
Surface Treatment Including Maintenance Including Periodic Treatments Other Applications
Preventive and Corrective Other Applications
Maintenance Cold Mixes Warm Mixes
Fog Seal Patching Semi-Dense Prime Coat

Pothole Repair Mixes Tack Coat
Sand Seal Cold Recycling Dense Mixes
Slurry Seal Bituminous Macadam Crack Sealing
Microsurfacing Premix Carpet Soil Stabilization
Mix Seal Surfacing
Cape Seal
Semi-Dense
Chip Seal Bituminous Concrete

White topping – Conventional, Ultra-thin white topping as per IRC SP-76
 What is Whitetopping ?
 Whitetopping is defined as a Portland Cement Concrete (PCC) overlay constructed
on the top of an existing bituminous pavement
 Whitetopping is thus PCC resurfacing (overlay) as a rehabilitation or structural
strengthening alternative on bituminous pavement
 The PCC overlay may or may not be bonded to the layer below
 Why Whitetopping?
 A PCC overlay is commonly applied where rutting of bituminous pavements is a
recurring problem
 Concrete overlays offer the potential for extended service life, increased structural
and functional capacity, reduced maintenance requirements, and lower life-cycle
costs when compared with bituminous overlay alternative

Advantage of Whitetopping
 Low life-cycle cost
 Rutting and cracking predominant in case of bituminous pavements is normally
absent with concrete surfaces of Whitetopping
 Whitetopping improves structural capacity of existing bituminous pavement
 Whitetopping is quite cost-effective
 Occurrence of cracks is also relatively much less in case of Whitetopping
 Concrete is relatively light in colour -lower contribution to heat in environment
 Fuel consumption on concrete roads has been found to be less than the
bituminous roads

Types of Whitetopping
 Whitetopping is classified into three types. This is based on the types of interface
provided i.e. degree of bonding between the underlying bituminous layer with PCC
overlay and the thickness of the overlay
Types of As per
Bonding Thickness
Bonded Unbonded Partial bonded Conventional Thin Ultra Thin

interface interface interface Whitetopping Whitetopping Whitetopping
(TWT) (UTWT)
Thickness 200 Thickness

Thickness less
mm or more more than 100
than or equal
mm and more
to 100 mm
than 200 mm

SMA-STONE MATRIX ASPHALT-IRC:SP:79-2008

Stone Matrix Asphalt
 SMA is a gap graded aggregate asphalt hot mix that maximizes the asphalt cement
content and coarse aggregate fraction
 SMA provides a stable stone on stone skeleton that is held together by a rich
mixture of asphalt, cement, filler and stabilizing additive
Mix is composed of
• High Quality aggregate
• Asphalt rich mortar
• Mineral filler
• Cellulose fiber

Characteristics of different mix
GAP GRADED MIX /STONE
DENSE GRADED MIX OPEN GRADED MIX MATRIX
• Well distributed • Have large • Gap graded or
aggregate volume of air Stone matrix
gradation voids asphalt
throughout (typically 18 to • High coarse
entire range of 22%) aggregate
sieves used content(70 to 80%)
• Used in binder • Water will • High asphalt
and surface drain through content > 6%
course • High filler
• Superpave, • Used as open content @ 10%
Marshal and graded friction by weight
Haveem course (OGFC) • Durable mix
methods • stone to stone
designing dense- • Provide skid content
graded mixes resistant • Rut resistant mix
Stone Matrix Asphalt

ADVANTAGES OF SMA OVER MASTIC ASPHALT
1. 50 % cheaper than mastic asphalt
2. Faster ,mechanized and pollution free construction
3. Better durability and rideability
4. Better skid resistance
5. Reduced noise pollution
6. Less wear and tear of tires
7. Rut resistant mix
 Area of application
1. Intersections
2. Bridge deck slab
3. High volume traffic road
Warm mix asphalt IRC:SP:101-2014

Warm Mix Asphalt
 Warm-mix asphalt is the generic term for a variety of technologies that allow the
producers of hot-mix asphalt pavement material to lower the temperatures at which
the material is mixed and placed on the road
Why Warm Mix Asphalt
• Reduce production temperatures
• Reduce lay down temperatures
• Reduce fuel costs
• Reduce aging of binder
• Lower fumes & emissions
• Cool weather paving
• Compaction aid for stiff mixes
• Extend paving window
Warm Mix Asphalt
 The basic principle of this technology is that by adding certain additives at the final
stages of the mix production, the coating of the aggregates by the binder is greatly
enhanced
 Can be achieved at a considerably less temperature (typically 30°C less) compared
to the hot mix process wherein bitumen is heated to a sufficiently high temperature
to make it fluid enough to surround the aggregates and coat their surfaces

Warm Mix Asphalt
 Currently there are more than 30 different WMA technologies, using patented
processes and products, which have capabilities of bringing reduction in mixing,
lay down and compaction temperatures of bituminous mixes in one of three
different ways
1. Water based technology
 Foaming
2. Chemical additives
3. Rheological modifiers
4. Hybrid technologies
5. Other technologies

Benefits of warm mix asphalt
1. Environmental Benefits: The single most important justification for use of this
technology is that it reduces the emission of green house gases by around 25 to
30 percent and controls thereby global warming. This would earn tradable carbon
credit.
2. Health Benefits: The fumes from hot mix asphalt are known to be potential health
hazards, especially for the construction workers. Reduced temperature of the mix
avoids this health hazard.
3. Technical advantages: Lower mixing temperature, Much improved workability,
Reduced rate of cooling of the mix
4. Cost benefits: WMA is most likely to have long term cost advantages,

SLURRY SEAL AND MICROSURFACING

What is Microsurfacing ?
 Microsurfacing is a mixture of
 Polymer Modified Emulsified Bitumen
 Dense Graded Crushed Mineral Aggregates
 Mineral Filler (normally Portland Cement)
 Water and
 Chemical Additives to facilitate early setting of mix

APPLICATIONS OF MICROSURFACING
 Preventive and periodic maintenance
 Rut filling with the help of special rut box
 Improvement in skid resistance and friction on a concrete road
 Filling up of minor irregularities on surface
 Why Microsurfacing?
 Micro-surfacing helps in preservation of pavement strength and can be used both
as a preventive maintenance treatment or and periodic renewal treatment on a
preferably low, medium or heavy traffic
 It can be used for pavements in urban and rural areas, primary and inter-state
routes, residential streets, highways, and toll roads

CLASSIFICATION OF MICROSURFACING
Item Type-II(4 to 6 mm) Type III (6 to 8 mm)
Application Preventive and renewal Preventive and renewal treatment
treatment
Traffic < 1500 CVPD 1500 to 4500 CVPD
Quantity of mix 8.4 to 10.8 Kg/m3 11.1 to 16.3 Kg/m3
Residual binder (percentage 6.5 to 10.5 5.5 to 10.5
by weight of dry aggregate)

Pavement maintenance



Benefits of microsurfacing
 The major benefits of microsurfacing technology are given as under:
1. Quick application (One lane- km in 35 minutes)
2. Minimum traffic hold up (work is done in lane wise manner) quick opening to traffic
3. Life span exceeds the life span of ordinary Bituminous Concrete
4. Non-polluting for environment since no heating or hot paving is required
5. Does not require sensor paver or compaction equipment’s
6. Longer life since oxidation is reduced
7. Waterproof Surface - Protection from rains
8. Ideal for surface sealing treatment since it improves skid resistance and provides surface
durability
9. Does not increase pavement height significantly
10. Cost effective as compared to Hot-Mix (Almost 40% saving in Cost)
Benefits of microsurfacing
11. Reduces noise caused by movement of traffic
12.Environment friendly (reduced emissions)
13.No change in road furniture or drainage
14.Savings in natural resources

Microsurfacing
 https://www.youtube.com/watch?v=dH7PjBR0_EY
What is slurry seal..?
 The slurry seal shall consist of a mixture of
 slow setting cationic bitumen emulsion,
 mineral aggregate, water and
 additives (if needed)
 proportioned, mixed and uniformly spread over a properly prepared surface.
 The finally laid slurry seal shall have a homogenous mat, adhere firmly to the
prepared surface and provide friction resistant surface texture throughout its
service life.
 This treatment shall be used only for preventive maintenance and renewal
treatment as substitute of surface dressing, open graded premix carpet and mix seal
surfacing for low traffic roads.
 Slurry seal can also be used for repair of minor surface defects like hair line and
fine cracks. https://www.youtube.com/watch?
v=3HhecRcknHw
Different Types of Slurry Sealing
Type I Type Il Type III
Items
(2-3 mm)** (4-6 mm)** (6-8 mm)**
For filling surface cracks For
For filling surface cracks
For filling hair filling surface cracks
(3-6 mm) and preventive
cracks on (1-3 mm), and preventive
Applications renewal treatment
surface less renewal treatment
renewal treatments
than 1 mm. renewal treatments (Upto
(Upto 1500 CVPD)
(Up to 450 CVPD)
Quantity* of Slurry 4.3 to 6.5 8.4 to 9.8
10.1 to 12
(kg/m)
Residual binder
10 to 16 75 to 13.5
(percent by weight 6.5 to 12
of dry aggregate)

What discussed
 Recycling of  Whitetopping  Microsurfacing ( Cold
pavement • As per bonding Mix)
 In plant • Bonded • Mixture of aggregate
• Unbonded • Polymer modified
 Hot Process • Partial bonded binder
 Cold process • As per thickness • Filler
 In place • Conventional • Cellulose fiber
 Hot Process • 200 mm tk • Higher Bitumen
• Thin Whitetopping content
 Cold process • 100 to 200 mm • Improve
tk  functional
Slurry seal
 Stone matrix asphalt • Ultra thin • Mixture of aggregate
performance
 Gap graded mix  WarmWhitetopping
Mix Asphalt • • SS Cationic
Maintenance
• < 100 mm tk emulsion
treatment
 Rut resistant mix • Need less temperature @ 30⁰ C
• Pavement
• Energy saving
 Used in high stress preservation
• Need some additives
area
Prof. Dhaval A. Jalalpara 2101CV622 ▪ Unit 5: Introduction to New Technology treatment 51
References
 IRC Guidelines


2101CV622 Module 5 Introduction To New Technology

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Highway Construction Technology

Prof. Dhaval A. Jalalpara

 Theory Exam : 70 Marks

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 The hot mix production process, therefore, has to be suitably modified.

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Fog Seal Patching Semi-Dense Prime Coat

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Bonded Unbonded Partial bonded Conventional Thin Ultra Thin

Thickness 200 Thickness

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