KHRI - Webinar (11-04-2020) - Sustainable Solutions For Flexible Pavements-Er. T K Subhaash - KHRI - Assistant Director KHRI
KHRI - Webinar (11-04-2020) - Sustainable Solutions For Flexible Pavements-Er. T K Subhaash - KHRI - Assistant Director KHRI
KHRI - Webinar (11-04-2020) - Sustainable Solutions For Flexible Pavements-Er. T K Subhaash - KHRI - Assistant Director KHRI
TKSubhaash
Three Hard Truths have significant impact on
how Bitumen industry will shape up in future
➢More roads
➢Demand move up
➢Urban mobility challenged and rural
Demand connectivity
➢Budget constraints
➢Pavement Structural & Functional Design
Changes
TKSubhaash
Approach: Technology Innovation is one of the key ways to
address cost and engineering challenges going forward
TKSubhaash
Pavement Performance : Dilemma
Traffic Demand
Climate
Rut depth
Pavement Structure
Asphalt Slab
Stiffness Stiffness
Reduce Reduce
Rutting Cracking
Pavement condition
Asphalt Operations
Material Supply bitumen bitumen
penetration penetration
TKSubhaash
Components of Flexible Pavement
TKSubhaash
TKSubhaash
Wheel Load Distribution
Flexible Rigid
TKSubhaash
Pavement Design Concept
Tensile
Strain
Compressive
Strain
TKSubhaash
Products for Various Layers - Highways
Cold
Recycling
PMB / CRMB /
BC / SMA VG40
SS2 Stab
Natural
TKSubhaash
Subgrade
SS2 Stab
TKSubhaash
Products for Various Layers - Rural
CRMB / VG40
RS2 Emulsion
Seal Coat
SS2 Stab
Natural
TKSubhaash
Subgrade
SS2 Stab
TKSubhaash
Maintenance Solutions for Wearing Course
Bitugrip
Microsurfacing /
Slurry Seal
Surface
Dressing
Fog Seal
Roadbond
Jetpatcher
SAMI
TKSubhaash
Pavement Materials – Bitumen Emulsion
Viscosity is Critical
Application Conditions require bitumen to behave as a mobile liquid
• Environmental Pollution
Heat - Bitumen
• Risk to workmen
12
TKSubhaash
Pavement Materials – Bitumen Emulsion
Emulsions
The bitumen is dispersed
Bitumen
throughout the water phase in the
form of discrete globules, typically
0.1 to 50 micron dia
Water Emulsion
Emulsifier
Anionic
Cationic
TKSubhaash
Non ionic
1
3
TKSubhaash
Pavement Materials – Bitumen Emulsion
Emulsion Types
Material Cationic Anionic
emulsion emulsion
Electropositive Neutralizing Attraction
materials reacting
(limestone, Breaking
basalt) Breaking
+ + + + Forming of Forming of
+ + insoluble amine insoluble amine
++ + +++ carbonate carbonate
Adhesiveness
Adhesiveness
Electronegative Attraction
materials (silex, No
quartz, granite) Breaking neutralizing
- - - - Forming of reaction
TKSubhaash
Pavement Materials – Bitumen Emulsion
Bitumen Emulsion
Breaking
Heating Required Not Required Curing
Pollution High Nil Setting
Coating Good Excellent
TKSubhaash
Bitumen Emulsion
0.7 Kg/m2 0.25 kg/m2
Cold
Hot Application
Application
Uniform
Poor coverage
coverage
23 Rs/m2 7.6 Rs/m2
@ 30467 Rs/T @ 32996 Rs/T
TKSubhaash
Bitumen Emulsion – Tack Coat
RS1 (Tack)
RS1 (Tack)
Poor Full 69
Partial 64
Unbonded Fully bonded Poor Full 40
Poor 13
TKSubhaash
Bitumen Emulsion – Prime Coat
MoRTH Section 500, Clause 502: Prime Coat: The primer shall be cationic bitumen
emulsion SS1 grade conforming to IS:8887 or medium curing cutback bitumen conforming to
IS:217 or as specified in the Contract.
MoRTH Section 500, Clause 503: Tack Coat: The binder used for tack coat shall
be either Cationic bitumen emulsion (RS 1) complying with IS:8887
IRC SP 20: Rural Roads Manual: The primer shall be a slow setting bitumen emulsion
complying with IS:8887, or medium curing cut-back as per 1S:217-1983
Tack Coat : Rapid or medium or slow setting type emulsion (IS: 8887- 1 995
TKSubhaash
Bitumen Emulsion – Fog Seal
Fog Seal Arresting raveling and
(Hinmat) adding binder back to
aged surfaces
Improve Sealing or
waterproofing
Base 60 mm
Sub Base
TKSubhaash
TKSubhaash
Bitumen Emulsion – Fog Seal
Fog seal
Fog Seal surface preventing
after 4 years water intrusion
Fog seal
No fog seal
TKSubhaash
Bitumen Emulsion – Fog Seal
Airport References
TKSubhaash
Bitumen Emulsion – Fog Seal
Product offered & Key Specs
Key Specifications
Hinmat
Benefits
Emulsion is a Hinmat Residue by evaporation >60
specially Emulsion when Penetration @ 25 oC 40-100
formulated used for Fog
Modified Bitumen Seal: Softening Point (oC) >57
Emulsion for high • Seal very small Elastic Recovery, % >50
performing cracks and
applications. It Ductility at 27C >50
surface voids
allows for faster
paving • Renew old
applications and asphalt
improved overall surfaces those
pavement have become
strength dry and brittle
over age Hinmat
• It can help conforms to
delay the need IRC SP 81
for major
maintenance
TKSubhaash
when applied in
a timely
manner
TKSubhaash
Bitumen Emulsion – Cold Mix
Seal Coat
RS2 Emulsion
OGPC
Premix Emulsion
• 3 Kg/MT • 21
Reduction of emissions
Kg/MT with Cold Mix process
CO2
100
Hot Mix
Cold Mix 80
at 160C 60
Eq. CO2 Dust SO2
Eq. CO2 40
20
Hot Mix 0
Cold
at 160C
Mix
Energy
TKSubhaash
TKSubhaash
Bitumen Emulsion – Cold Mix
TKSubhaash
TKSubhaash
Bitumen Emulsion – Microsurfacing
Structurally Prior repair Prior repair Chemistry and selection of
sound of all cracks of Potholes emulsion components
pavement
Emulsion properties for good
and durable road performance
Microsurfacing Cost Effective
Understanding aggregate
quality,
Minimize Oxidation
Pavement Condition
Average Life : 5 – 7
HINMAT 4-10 here?
years
Poor
Base Base
TKSubhaash Time (Years)
Bitumen Emulsion – Microsurfacing
HINMAT
TKSubhaash
Bitumen Emulsion – Roadbond
Roadbond
TKSubhaash
Bitumen Emulsion – Stabilization
TKSubhaash
Bitumen Emulsion – Stabilization
Virgin RAP
WMM / Resilient
Chemical Stabilizer
Content
BSM Modulus
Composition
Moisture Degree of
Content Compaction
IS Sieve WMM Resilient Modulus
53.00 mm 100
45.00 mm 95-100
Reduction
Less Environ
Cost 600
Energy mental 26.50 mm -
Less Pace of 22.40 mm 60-80
Aggregate Noise
mix construction
11.20 mm 40-60 250
Less
Bitumen Dust Durable 4.75 mm 25-40
heating
2.36 mm 15-30 WMM EMULSION
STABILIZED WMM
0.600 8-22
Resilient Modulus
TKSubhaash 0.075 0-5
Bitumen Emulsion – Stabilization
Cold
Recycling
SS2 Stab
SS2 Stab
Conventional,
640 mm With Stabilized Cost, Cr/Km
Bituminous Layer, 540 mm
Design 130 mm BC 40 mm
Stabilized
• 19 MSA WMM, 150 3.11 2.56
• 6% CBR mm
• Width 5 - Granular CT Sub base
200 mm WMM EMULSION
10m 510 mm STABILIZED
WMM
Granular
150 mm Cost, INR - Cr/km
TKSubhaash
Bitumen Emulsion – Stabilization
IRC 37 : 2018
TKSubhaash
Bitumen Emulsion – Stabilization : Case Study
Fatigue & Rutting Life evaluated to be 102 Stabilization shall used at places when
and 178 MSA respectively against design life poor drainage, less crust pavement
of 19 MSA thickness is a concern
Stabilization with Emulsion us much easier The stretch should be allowed to cure
for at least 48 hours with light traffic
being allowed.
Normal to Medium Traffic can be allowed
after few hours over emulsion stabilized
layer
Minimum thickness shall be 75 mm
Execution and Quality Control is easier
TKSubhaash
Bitumen Emulsion – Recycling
- Hot-in-Place New
- Cold-in Place pavements
Aggregate and asphalt binders form a (emulsified)
previous pavement structure - Portable or centralized
Resurfacing
hotmix plants
Produced by milling, breaking and existing roads
grinding old pavements
RAP is then blended with new (virgin) Usually between 10 to 25 Subbase
pavements % used in mixes. materials
50 % is Max Shoulder
recommended paving and
widening
• Avoid contamination
IS Sieve BSM • Don’t over crush. Only crush
50 100 oversize RAP
37.5 87-100 • Fractionation helps for design of
26.5 77-100 high RAP mixes
19.5 66-99 • Watch the weather when
13.2 67-87 processing
• Cover stockpiles
9.6 49-74
• Free moisture in the RAP can
6.7 40-62
cause caking of RAP (blinding
4.75 35-56
of screens) Intermediate & base courses
2.36 25-42
• Building steep sided stockpiles < 15% R> 30%: AP: Must be screened but
1.18 18-33 will create segregation
0.6 12-27 not necessary to fractionate into different
sizes
0.425 10-24
>15%<30% : Must fractionate into different
0.3 8-21
sizes
0.15 3-16
Aged binder must be < 30% of new mix
0.075 2-9
TKSubhaash
Bitumen Emulsion – Stabilization
Case Study – KIIFB
Computed Strains
Tensile Subgrade
Strain Compressive Fatigue Rutting Allowable BC – PMB70V
Characteristics
(1) (BT) Strain Criteria Max Criteria Max Traffic in BC – VG40; -10;
Design
Traffic (3) (4) Allowable Allowable msa DBM – VG40 DBM – VG40
Traffic in msa Traffic in msa Minimum of Rs/sqm
9% CBR (msa) Rs/sqm
(2) (5) (6) (5) & (6)
Scenario 1
BC (40) + DBM (100) + WMM
(250) + GSB (200)
55 1.87E-04 3.15E-04 55 105 55 2600 2666
Scenario 2
BC (40) + DBM (50) +
WMMEmulsion (150) + GSB (300)
55 1.54E-04 3.56E-04 118 60 60 2144 2210
Scenario 3
BC (30) + DBM (50) +
55 1.39E-04 3.60E-04 180 57 57 2922 2972
WMMEmulsion (150) +
WMMEmulsion (225)
Scenario 4
BC (30) + DBM (50) +
55 1.38E-04 3.64E-04 181 55 55 2472 2522
WMMEmulsion (150) + CTSB (225)
TKSubhaash
Synthetic Emulsion – Bituclair
Bituclair – Coloured Bitumen
TKSubhaash
Bitumen Emulsion – Chip Seal
A Chip Seal
provides a little
heavier seal and
consists of a spray
applied bitumen
emulsion and then
aggregates added
to it.
TKSubhaash
Bitumen Emulsion – Chip Seal
Chip Seal
TKSubhaash
Services
Pavement
Mix Design Design Application
Competitors Customers
Offerings Needs
Marshall Resilient
Training
Modulus
Superpave Application
CBR
Hincol Support
Capabilities