Innovation X -Modifier for Asphalt Base Course (60/70 Pen) using U... https://aecom.imaginatik.com/aecomidc1.nsf/0/2A89149CA50B6341...

Idea: Innovation X -Modifier for Asphalt Base Course (60/70

Pen) using UN-CONVENTIONAL material non polymers
Author Marius-Ovidiu Cherebetiu

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Description X-Modifier product provider of asphalt paving solutions using chemical in order to
improve specific properties of asphaltic concrete paving mixtures; namely, strength,
temperature susceptibility and aggregate adhesion. X-Modifier which so dramatically
increases the structural capacity of asphaltic materials that it is possible to reduce
the thickness of the base course and lower initial construction costs .X-Modifier is
composed by chemical components in solid states or liquid state as modifier which,
unlike polymers or additives for bitumen, reacts with bitumen and irreversible
changes the chemistry and the molecular structure of the bitumen under the
influence of temperature and oxygen. The X-Modifier product is designated for
Asphalt Base Course layers especially to improve the bitumen type (60/70
penetration) with the minimum one PG grade improvement from PG58 to minimum
PG 64 using non-conventional modifier. A very common Identified Problems of
others asphalt modifiers have been identified: Asphalt Additives: Trinidad Lake
Asphalt Natural occurring asphalt found in Venezuela. Used as a by-product in other
asphalts, mainly by the Germans. This asphalt doesn't have any air voids, which
results in a very brittle pavement. Gilsonite This is a natural occurring bitumen
(Rock solid mineral) which can be found in Sierra Nevada's, etc which can't be
pumped in traditional asphalt applications. It only hardens the asphalt which
reduces flexibility and fatigue. It replaces anywhere from 2-15% of binder and will
typically improve Marshall Stabilities 10-40%. Sasobit Sasobit is a bitumen additive
of Sasol Wax. It acts as a liquefier for neat and polymer modified bitumen and
enhances workability and reduces compaction resistance through a significant
viscosity decrease. Several new processes have been developed to reduce the
mixing and compaction temperatures of hot mix asphalt without sacrificing the
quality of the resulting pavement. One of these processes utilizes Sasobit, a
synthetic long chain Fischer-Tropsch wax. Sasobit can be blended with the binder at
a terminal or in the contractor’s tank, introduced in a molten form, added with the
aggregate, or pneumatically blown into a drum plant. The addition of Sasobit does
not affect the Resilient Modulus of an asphalt mix nor does it increase the rutting
potential of an asphalt mix. Polymers Polymers are manufactured in a chemical
process to combine particular molecules in a way that would not occur naturally.
Although various synthetic polymers have been capable of being produced since the
early part of this century it is the more recently developed polymers that are now
being used to modify bitumens and produce the new bituminous binders. The new
polymers being the result of Research and development by the large petro-chemical
industries. Polymer additives do not chemically combine or change the chemical
nature of the bitumen being Modified, apart from being present in and throughout
the bitumen. What polymers will do is change the physical nature of bitumen - they
are able to modify such physical properties as the softening point and the brittleness
of the bitumen. Elastic recovery/ductility can also be improved. This in turn will alter
the Properties of the aggregate / bitumen mixture in which the modified bitumen is
used. These criteria are important in a mix in relation to wheel track rutting at high
temperatures and fatigue cracking at low Temperatures due to the brittleness of the
mix. Types of Polymers: SBS (Styrene Butadiene Styrene) - This is a thermoplastic
rubber. SBS is a copolymer that you will come across in bitumen modification, it was
originally developed for use in the production of tires and shoe soles, but is suitable
for the modification of bitumen. SBR (Styrene Butadiene Rubber) - SBR Latex
Polymers contain emulsion polymerized Random co-polymers of styrene and
butadiene in a water-based system. In latex form, the SBR particles are extremely
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small (averaging .5 microns), exposing a very high surface area to the asphalt for
complete mixing. As a result, the physical dispersion of the polymer particles is
rapid and thorough. EVA (Ethylene Vinyl Acetate) - This is not regarded as part of
the thermoplastic rubber group but is still thermoplastic in its nature. One of the
uses for this type of polymer are the "hot melt" glues, the sticks of which you may
be familiar with in "D.I.Y" hot melt adhesive guns. The most common grade of EVA
for bitumen modification, for road pavement materials, is the classification "150/19".
This classification means it has a melt flow index of 150 and a vinyl acetate content
of 19%, how much you include in the bitumen to be modified for optimum benefit
can be debatable, but 5% by weight is a commonly quoted figure. Common Issues
with Polymers: The possible problems with modified bitumen’s are mainly in the
storage of the bitumen, mixing temperatures, and the length of time the material is
held at elevated temperatures before lying. The blending of bitumen and polymer is
not an easy process, so modified bitumen is usually Purchased by the suppliers in a
ready blended form from the bitumen supplier. This means small tonnages of most
modified bituminous materials are not financially feasible. It is usually necessary for
the modified bitumen to be held in a tank that is capable of being agitated in some
way, as the polymers being of a different density to the bitumen tend to separate if
kept in storage for prolonged periods. The polymer additive can be destroyed by too
high a temperature in mixing, or by being held at a high temperature for a long
period of time after mixing, even the binder storage times should be kept as short
as possible or deterioration of the polymer may take place.
Event Name AECOM Global Challenge

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Key Benefits We have found that X-Modifier product used as 2% by bitumen weight as modifier ,
and Features based on chemical formula not additives or polymers that is injected into the
bitumen , dossed in limestone filler or directly dosed in hot aggregates of asphalt
mixture and causes irreversible molecular change in the asphalt mixture. The
resulting asphalt can be used in the construction of almost any new highway, port,
bridges, airport, or railway where asphalt is required and reduces the cost of
construction while delivering a better road that will last longer and require less
maintenance. We find out that the common failure of asphalt base course mix
design in the harsh climate as Qatar named “ refusal density “ ( Marshall air voids at
400 blows per face, cannot be maintained as per minimum designed 3% air voids
after the simulated estimated traffic loads).We also observe that the TSR ( tensile
strength ratio) is very difficult to be achieved as 70 % due to the main reason of the
original bitumen used 60/70 penetration required improvement or modification. The
many benefits of X-Modifier product include: Increases modulus strength several
times, enabling our asphalt to withstand far heavier loads, Improves fatigue life
(something that is contrary to what normally happens when you increase
Strength/Stiffness), Flattens the temperature susceptibility curve and reduces
normal damage from thermal cycling (Improve performance with temperature
changes as well as very hot temperatures), Enables the use of marginal aggregates
(limestone crushed or river aggregates), Reduces water stripping, Reduces the time
needed to build. As opposed to polymers or additives, which add performance to a
road but also add to cost, the product is a cost-reducer. This is due to the fact that
the X-Modifier product is used in the Structural Layer or Base Course (the thick part
of the road between the sub-base and the top wear course layer) and enables a
significant reduction of the depth of the structural layer of asphalt, creating financial
savings. The Base course layer it is recommended to be covered by the next layer
within max 30 days in order to avoid exposure to oxidation . The following are some
of the components of costs savings: Asphalt savings: On a basic road or highway
which will have a asphalt layers greater than 190 mm, we can reduce this structural
layer by 20% to 40% and the X-Modifier treated structural layer would be stronger,
last longer, and require less maintenance than the thicker,untreated layer. The cost
savings from the asphalt reduction was significant. Aggregate savings: The cost of
crushing and transporting quarry rock, the ideal aggregate for roads can be
prohibitively expensive. The dosage in 2.5 %( solid state). in limestone filler
production of Cement Factory can be considered as (solid state). Sub-layer savings:
Because of the improved strength that X-Modifier delivers, it is often possible to
eliminate entire sub-layers depending on the road design calculation empirical
approach and can be apply direct on the subgrade layer ( with high CBR 70 % ).
Time and Labor: Because we reduce thickness, the amount of time and labor needed
to build a road can be reduced greatly. Environmental-Green Solution: Reactive
Organic Gasses (ROGs) are released into the air when asphalt is manufactured. By
reducing the amount of asphalt needed by 20% up to 40%, the amount of ROGs is
reduced by the same amount. Additionally, the same reduction in the amount of
bitumen (oil) and aggregate is achieved.

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Competing The competitors are Polymers Suppliers if used as bitumen modifier and no
Ideas/Solutions competitor if X-Modifier is used as pre-treated hot aggregates in the same scope of
or Competitors mix improvement .The X-Modifier product is already on the markets produced in
huge quantities used in others industries .The biggest producers of X-Modifier are in
Asia. The product is designed to capture the following customers: Large petro-
chemical industries. The Chemical factories can produce X-Modifier product liquid
state or solid state designated for end users as Asphalt Plants. Bitumen refineries.
The bitumen modified with X-Modifier 4 % (liquid state 50 % concentration )
product can be performed directly in the refineries avoids any other processing
before produce asphalt mixture in Asphalt Plants. The modified bitumen has no any
restriction for storage or transportation in regard of temperature range. Cement
factories .The limestone filler add with X-Modifier 2.5% (solid state as per filler
requirement JMF ) product can be performed directly in the cement factories avoids
any other processing before produce asphalt Mixture in Asphalt Plants. Asphalt
Plants as end users. The X-Modifier product can be dossed 2% (solid state dossed in
hot aggregates mixer) by bitumen weight directly in hot aggregates of asphalt
mixture in the Asphalt Plant of Contractors.
Potential No any potential barriers to the market have been identified except time of
Barriers to implementation for asphalt performance test during and in service life of the road,
Market or other potential Companies who use the same base chemical product but in
different industries.
Implementation AECOM has already mobilized resources in Qatar projects that can be used for
Resources implementation in the development Projects and new solution should be applicable
globally including new Projects like Projects as Build-Operate-Transfer Contracts (
BOT) or others types .
Development Ready for production
Status
Intellectual The new product should be developed under AECOM brand and name using the
Property know-how detailed chemical formula in the safety data sheet. Dosage : Optimum
dosage is 2% by bitumen weight lower than 5% comparative with competitors
polymers suppliers. Ease of integration: Any petro-chemical industries, bitumen
refineries, cement factories, end users Asphalt Plants can use X-Modifier reducing
cost of transportation and processing polymers modifiers according special technical
procedures required for storage. Quality/Design Benefits: Asphalt base course with
X-Modifier mixture perform: Resilient Modulus -Expect a doubling at 40 C at a lower
rate of loading Marshall Stability -Typically expect a 25-30% increase Indirect
Tensile Strength -Tensile strength at higher temps usually doubles Wheel
Tracking-40C, at least half of the rut depth of the control. The customers can design
their own pavement layers of the road structure according with clime, Traffic loads,
technical and economic aspects of aggregates data base.
Anticipated Greater than $500k
Costs to Market

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Estimated Costs The total cost associated with delivering the product and service to the Clients
to Market Basis depends of the AECOM strategy to approach the Client or the Contractors as end
users using their storage or warehouses site facilities or the Client strategy. The
X-Modifier product cost is less than polymers .The asphalt base course/ binder
estimate to increasing price with aprox.10%, but ensuring saving from reduction of
asphalt thickness layers per project budget. Because X-Modifier product offer more
than bitumen modifier as design solution to reduce thickness of pavement asphalt
base layers is competitive with the other bitumen modifiers as polymers or
additives, the product is destined to the Employers/Designers who dealing pavement
design ,budgets ,cost and time. The estimated Cost basis also referred to as the tax
basis, is important especially if you reinvested dividends depends of the AECOM
strategy. If AECOM is authorized to commercialize chemical products or will use the
JV- chemical Supplier factories in the next future .As with other investment
mechanism, the spot price fluctuates depending on current local market conditions
as imposed by only polymers suppliers. The estimated product cost is around 2,5usd
/kg and the end product price can be 5 usd/kg for selling to be competitive with
polymer price .The asphalt base course estimate to increasing price with aprox. Max
10%, but ensuring saving from reduction of asphalt thickness layers per project
budget .
Commercial Implementation somewhat easy - 6 months or less
Implementation
Time
Commercial Implementation easy based on AECOM contract supply with Chemical Factories
Implementation imported or to set up new factory location Saudi Arabia for GCC area long term
Time Basis strategy or globally wise .Less than 6 months should be implemented on site by
import/trading the X-Modifier from ASIA.
Annual Greater than $50M
Revenue
Potential
Annual The potential annual revenue related at the minimum as example: If the SBS
Revenue polymer modifier cost is around 100 USD to 140 USD/ per ton of bitumen modified
Potential Basis with 5% dosage, the X-Modifier cost is less around is 50 to 100 USD per ton,
modified with 2% dosage. This is related only to the profit comes from the cost of
X-Modifier use for modify 1 tone of bitumen 60/70 penetration and not counting the
savings time and cost reducing impact of project required by Owner or base course
thickness reduction . If to extend the revenue potential to QATAR and GCC countries
or globally this should be multiplied according the quantities required for each
project separately.
Existing AECOM The Idea of using X-Modifier for asphalt base course has been developed by myself
Capability or in the last 9 years of research, testing , study in different countries and different
Offering resources of aggregates and bitumen and all test confirmed successfully .
Customer Base Both
Potential Clients Owners , Contractors of Asphalt Industries .
Date Submitted 08 Dec 2016
Idea Reference GC-WGIS4B
Area Global
Challenge Innovation X

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Comments
Author Sorin Popa
Date 08 Dec 2016
Submitted
Comment I think the innovative solution presented should be considered as a new challenge as
well as a significat help in changing the era of “Qatar Deserve the Best' into 'Qatar
Achieves the Best'. This would be also useful for all investors as well as the contractors
across the entire Middle-East as well as worldwide.

Author Leon J Walsh

Date 08 Dec 2016
Submitted
Comment Great description of how using unconventional materials to improve specific properties of
asphalt/concrete paving mixtures. Currently carbon, produced during the manufacturing
of concrete or asphalt, can be captured and injected back into the secondary processing
of either Ready Mix cement or asphalt where the Carbon is changed from a gaseous state
to a solid state and permanently stored. These processes reduce the volume of raw
materials required to achieve certain strength/ hardness requirements while removing
Carbon from the atmosphere. Partnering with this technology allows AECOM to add to our
reputation as stewards of the environment whilst constructing. Reducing Carbon
Footprints can be achieved in many ways and this is an innovative step. See relevant
links. http://www.cbc.ca/news/canada/calgary/calgary-startup-co2-storage-concrete-
1.3881801 CarbonCure.com

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