Cemento Vial

1.
Introduction
1. Introduction
1.1 Definition, market drivers
1.2 Applications
1.3 Road binder composition
1.4 Pros and Cons
1.5 Potential market volumes
2
Holcim Group Support 1. Introduction (optional) 08.04.2011/SN/SN
(optional) Filename.ppt
What are road binders?
Road binders are either used for
soil stabilization to create strength (composite cements)
soil improvement to make soil compactable and trafficable

by improving bearing capacity (combi binder with quick
lime CaO (QL))
Road binders are increasingly used in road construction
to create a stable platform for the road body
Soil improvement improves bearing capacity of the soil
to allow operation of heavy equipment during building of
the road embankment
Soil stabilization creates a solid platform to allow
construction of the overlying layers to provide support
for the pavement
Road binders are used mainly in Western Europe
(FBNL, D, CH), increasingly in parts of Eastern Europe,
AUS and US
3
What are road binders? Cont.
Cementitious road binders can either be standardized
composite cements with high MIC content or non-
standardized combi binders with OPC, MIC and QL
Strong competition by traditional binders like QL and
bitumen and construction methods including gravel or
lean concrete
Very conservative business, requires long breath for
changes in standards and practice
Co-operation with authorities and large road contractors
essential for successful start-up
Before entering business a detailed market analysis,
risk and opportunity evaluation required
Road binders can be used as a strategic tool to increase
market share, enter new markets, fighting brand to keep
cement margin, growing the pie by replacing quicklime
or gravel 4
What are road binder ? Cont.
Road binders
PCA 2005 5
Road binder definition
Hydraulic road binders are ready for use products, delivered on
time to the construction site
Road binders can be hydraulic/cementitious (OPC, MIC, Lime,
mixes) or bituminous materials (asphalt)
Their properties are specifically designed for its use in the
manufacture of pavement materials.
Road binders are used for:
Pavement base layers (sub-base and road-base)
Soil stabilization (capping layer)
Soil improvement (earthmoving)
They are mixed with a wide range of material :
Natural soils
Graded gravel or sands
Old pavement materials
Focus of this road binder manual is on cementitious road binders
using the in-situ or mixed-in-place technique
6
Use of road binders in roads
Part of road Usualy used binder (dosage)
Pavement – bitumen / cement (175 kg/m2)
Asphalt or concrete pavement
Surfacing
Road
foundation
Subbase stabilization – cement (60 kg/m2)
Improvement of strength and bearing capacity
In-situ asphalt recycling (cold recycling)
Subgrade
Soil stabilization – cement (50 kg/m2)
Improvement of bearing capacity
Frost and water resistance
Soil improvement – QL (and cement) (20 kg/m2)

Application for
Road Binders Reduce water content and improve
‘trafficability’ soils sensitive to water
Improve bearing capacity
QL: quick lime (CaO) 7
Road construction soil application definition
and requirements
Soil stabilization – use of hydraulic binder
Increase bearing capacity, frost and
water resistance
Slow setting
(2 to 4h) to enable
A1
A3 micro cracking
Distributed
A2 cracks
(use of CEM III)
A1 Soil improvement – use of QL, comb. QL / hydraulic binder
Legend: Improve traffic ability of soil material

A3 Capping layer sensitive to water
A2 Embankment
Bind water and improve
A1 Natural ground
compactability (proctor)
8
Road construction subbase application definition
and requirements (cont’d)
Subbase stabilization – use of hydraulic binder and aggregates
Strength improvement
Lean concrete, ~50% of thickness vs.
A1
B1 compacted aggregates
Slow setting (~2 to 10h)
Long job sites, working time
extension
Reduce risk of large cracks
Often ‘pre-cracking’ by vibration

Subbase recycling – use of hydraulic binder
Stabilization and
Legend:
strength improvement
B1 Subbase
Immobilization of recycled material
Setting time (~1h)
Short job sites, working time
extension less important
9
Use of Special Binder by soil type
Soil type Improvement / stabilization with
Gravel No binder required
Coarse
Sand Hydraulic binder (cement)
Gravel - silt
Mixed Gravel - clay QL in 1st step
grain Hydraulic binder (cement) in 2nd step
size Sand - silt
Sand - clay Combi-binder (QL+cement)
Silt
Fine
Clay QL
Hydraulic binder + admixtures
Partly organic
Organic Combi-binder (cement + admixtures)
Pure organic Exchange soil
Combi-binders (QL + cement) have significant

application advantages in mixed granular soils 10
Decision factors for introduction of road binders
Advantages Disadvantages
High MIC absorption potential, CO2 Limited price premium or lower price
reduction, off-spec MIC use
Growing the pie (against QL and asphalt) Intense technical support, not comparable
to cement/concrete, hiring of external road
experts
Enter new markets/countries Only long-term volume increase, long
breath
Fighting brand vs. low cost competitors, Fight traditional solutions (binders and
multibranding (use of existing comp.cem.) construction)
Product differentiation, image Convincing road authorities, may be new
standards required
Technical support principle may be used High sophisticated equipment for in-situ
as master for grey cement method
Early involvement in large infrastructure Cannibalization of own composite
projects, pull effect for other cement sales cements
11
Reduction in material movement Higher administrative work load due to
(soil/gravel), disposal, new quarried wider range of project requirements,
material, reduced traffic disruption number of offers
Time savings vs. traditional methods Strong weather dependence
Economic option for stand-alone business Complex logistics, just-in-time, high

variability in job-site size
Low CAPEX for greenfield mixing plant Combi binders with risk of QL
(0.5 mio Euro) contamination in cement plant
Savings due to reduction of overlaying Restrictions due to standards
road structure
Specific market preconditions are required to overweigh

the disadvantages of road binders
12
Market drivers fo road binders
There are several factors which have promoted soil
stabilization during recent years :
Increasing number of heavy vehicles on the road network
Progress in pavement design procedures
Improved equipment and better mixing technology
Wider range with higher effectiveness of binders
New road binders from cement companies
Better understanding of the stabilized materials
performance
Stronger environmental awareness
Reduced availability of traditional materials (gravel) and
increasing disposal cost
13
Potential road materials
3 main types of materials :
« Assembling » of grains
Unbound Bound
Hydrocarbon Hydraulic
Water binder binder
(bitumen)
Compacted « vibrated » Compacted

materials materials materials
Untreated all-in Hydraulic

Cement
treated
Concrete materials
Focus of manual on hydraulically treated material 14
In-situ construction process
Treated soils - process
c BINDER d
Spreading binder ahead of Milling and mixing

the machine machine
e f
Profiling the treated Compacting the profiled

material mixture 15
In-situ construction process cont.
Treated soils - process (continued)
g Grave
l
Protection
The top of the treated layer is protected by a thin layer of bituminous

materials. So, the materials treated with Road Binder can harden in
optimal conditions.
16
In situ treatment procedure Wearing course
Animated, go in slide show mode Base
Subbase
Capping layer
Embankment
1 - Spreading of the hydraulic binder

2 - Mixing in place of the soil and the binder
3 - Levelling of the treated soil
4 - Compacting of the treated soil
17
Market analysis required before launch
Project methodology
Check fullfillment of key market drivers and prerequisites
Define Holcim objectives rate of relevance
Weigh rate of fullfillment of key drivers to Holcim objectives
for final decision on market entrance
Following project methodology should be used as

guideline
18
Project methodology (chronological)
1. Analysis / synthesis – current markets 4. Check fullfillment of Holcim objectives
Market and application segmentation Growing the pie
Manufacturing and logistics MIC integration
Comparison to current solutions Competitiveness
Standards, regulations New markets
2. Define product – application approach 5. Evaluation of all aspects and decision on

Positioning vs. own cement types
market launch
Multiple branding of existing cements 6. Define key initiatives:
New applications mainly for combi
Define new portfolio and
binders
manufacturing setup
3. Check key drivers for a successful road Evaluate market reach and technical
binder business service initiatives
Infrastructure investment Margin, product positioning and
High QL price function
Mixed granular soils
Environmental regulation
Cost of aggregates
Availability low cost MIC
Machines and know-how
19
Market drivers/prerequisites and
Holcim objectives for Road Binders
Market drivers/prerequisites Holcim objectives
Infrastructure investments Growing the pie for certain applications
(roads, railways, dams) (additional sales volume)
Mixed granular soils containing clay, MIC integration (FA, Gbfs), mitigate threat
silt and sand Increase competitiveness
High QL price (similar or higher CEM I) Differentiation, complete and application
Environmental regulations oriented product range
Disposal of soil Increase customer orientation (bonding
Access to aggregates to specialized international contractors)
High cost for aggregates and / or long Compete to lower price cements and
transport distances binders (e.g. imports)
Availability of low cost MIC Improve margin (integrate low cost /
Availability of equipment and contractor waste material, e.g. CKD, oil shale)
know-how Entering new geographical markets
Special Binder potential strongly depends on key drivers per market

Market specific implementation approach according to objectives
Pan European Georoc project 2004 20
Market drivers for Road Binder introduction
High investments in new infrastructure
Infrastructure investment
(roads, railways)
High QL price Price of bulk QL similar or higher vs. CEM I
Soils containing clay and sand / silt, possible

Mixed granular soils
to be improved / stabilized
Regulations by government to use soil in-situ,

Environmental regulation
(red. disposal) and safe resources (aggregates)
High cost for aggregates and / or long

Cost of aggregates
transportation distances (cost)
Possibility to reduce product cost below

Availability low cost MIC
standard cement (e.g. integration OS, FA)
Availability of milling / injection equipment and

Machines and know-how
know-how of contractors
Priorities of Holcim objectives and criteria
1. Growing the pie Additional sales volume
Increase use of excess Gbfs

2. MIC integration Gbfs (stock, disposal)
Integrate FA and reduce concrete
FA
grade FA on market
3. Competitiveness Differentiation Complete cement product range
Customer orientation Bonding specialized int. contractors
Comp. low cost bind. Reduce price pressure on cement
Reduce production cost by integrating

Margin improvement
lower cost MIC (vs. standard cement)
4. New markets New geographical market

Priorities of Holcim objectives and criteria cont.
Variable cost reduction
5. Manufacturing
Capacity extension: avoid/defer CAPEX,
reduction of current assets (kiln)
6. CO2 Comply to CO2 target (Clinker Factor)
23
Objectives evaluation and priorization*
Holcim object. FR CZ DE HU BNL IT RO ES PL SK AT CH BG HR CS
Additional sales z z z z { z z z z { { { { { {
volume [‘000 t/y] - - -
Gbfs integration z z z { z { { { { z { { { { {
FA integration z z { { z { { { { { { { { { {
Differentiation z z z z z z z z { z z z { { {
Customer z z z z z z z z { z z z { { {
orientation
Compete to low z z z z { { { { { { { { { { {
price binder Imp.
Margin z z z z z z z { { { { { { { {
improvement
FA FA FA CKD FA Pozzo FA
Paper CKD Oil FA
ash shale
New markets z { { { { { { { z { { { { { {
Main Growing the pie Growing the pie Differen- No objective

objectives Use of MIC Differentiation tiation
Competition
Legend: z Fulfilled { Not fulfilled *Pan European Georoc project 2004 24

Internal requirements for success
Top management commitment to the segment
Sales team to be familiar with the road business, hiring
of road exports recommended
Appropriate training of sales team by road experts
Provide technical service, ensure availability of lab
testing facilities (in-house or outbound)
Consider partnership/alliance with road construction
companies
Strong logistics organization – essential to guarantee
delivery to the job on-time
25
1. Introduction
1.2 Applications
1.4 Pros and Cons
26
Use of road binders in roads
Part of road Usualy used binder (dosage)
Pavement – bitumen / cement (175 kg/m2)
Asphalt or concrete pavement
Surfacing
Road
foundation
Subbase stabilization – cement (60 kg/m2)
Improvement of strength and bearing capacity
In-situ asphalt recycling (cold recycling)
Subgrade
Soil stabilization – cement (50 kg/m2)
Improvement of bearing capacity
Frost and water resistance
Soil improvement – QL (and cement) (20 kg/m2)

Application for
Road Binders Reduce water content and improve
‘trafficability’ soils sensitive to water
QL: quick lime (CaO) 27
Road terms Europe
Main Detail Material

Surfacing Surface Extra asphalt
Wearing course Asphalt/concrete
Base course Cementitious
Asphalt
Road Road base (Road binders)
foundation
Platform
Subbase Road support
Subgrade Capping layer Road binders
Embankment Compacted/rock
Natural ground Untreated

Terminology may differ between countries 28
Focus for road binder: Capping layer
A capping layer can be added as a platform as part of
sub-grade to support road foundation.
Surface
CAPPING LAYER Road foundation
Sub-grade
Natural ground
Treated soils
+ Road binder
29
Hydraulic pavement materials and binders
Main Pavement material Binder
Surfacing Concrete OPC, composite cements
Concrete
Road Hydraulic materials
Materials
foundation
¾ Roller compacted concrete
¾ Lean concrete mix OPC, Composite cements,
¾ Treated gravel Road binders
¾ Treated sand Ggbfs, Fly ashes,
¾ Composite materials Pozzolans, Lime
Subgrade Treated soils
soils
Hydraulic pavement materials and treated soils: wide

utilization of cements, MIC, hydraulic binders, aggregates
30
Road binders in pavement structures
Rigid Composite Flexible

Surface Bituminous Materials
2 to 10 cm
Concrete
Road base
10 to 25 cm
Sub base Hydraulic
10 to 25 cm Materials
Sub grade
35 to 70 cm Untreated
Treated soils (road binders)
Materials
No use of road binders in flexible pavements 31

1. Introduction
1.2 Applications
1.4 Pros and Cons
32
Road binder component‘s effects
Constituents Effect
Cement Early strength
Lime Water sucking (Quick lime), clay binding
Ggbfs, Fly ash Slow reactivity, extending working time
Bitumen Improved elasticity
Chemicals - improved stiffness (e.g. lignosulfonates)
- hydrophobing agent (deny water access)
Road binders are tailor made products specific for each

application
33
Road binders for soil stabilization - Requirements
Soil treatment process Duration
1. Spreading of binder on soil surface 30 min -1h
2. Mixing binder into surface of soil 1h – 2h
3. Compacting the treated soil 1h30 – 3h
4. Levelling of the surface 30 min
5. Protection of the surface of the treated
layer by a thin bituminous layer for Long setting
optimum hardening. time (e.g.3h30
- 6 h) required
Key performance requirements:
Slow setting, long working time (~ 4 h)
Low mechanical strength
34
Road binders used in Europe by Holcim
Oil Paper Anhy- Geo-
Application Product CEM Clk Ggbfs FA shale ash LS QL drite CKD crete
Soil ROC TR z z z
improvement
DOROSOL z z z z z z z z
Soil ROC SOL HRB 30 z z z z
Stabilization DOROPORT HRB z z z z z
DOROPLAN z z
ROC AS HRB 30 z z z
Subbase ROC SC HRB 30 z z
stabilization
ROC SG HRB 20 z z z z z
ROC AF HRB 30 z z z z
Recycling DOROPORT HRB z z z z z
DORO products by Georoc
ROC products by Holcim FBNL
Legend: …% / z Key component (essential for performance) z Currently used z Potentially usable
Road binders mainly used in Western and partially E Europe (0.6 mio t/y)
In CemAust ca. 0.1 mio t/y 35
1. Introduction
1.2 Applications
1.4 Pros and Cons
36
High MIC absorption potential, CO2 Limited price premium or lower price
reduction, off-spec MIC use
Growing the pie (against QL and asphalt) Intense technical support, not comparable
to cement/concrete, hiring of external road
experts
Enter new markets/countries Only long-term volume increase, long
breath
Fighting brand vs. low cost competitors, Fight traditional solutions (binders and
multibranding (use of existing comp.cem.) construction)
Product differentiation, image Convincing road authorities, may be new
standards required
Technical support principle may be used High sophisticated equipment for in-situ
as master for grey cement method
Early involvement in large infrastructure Cannibalization of own composite
projects, pull effect for other cement sales cements
37
Reduction in material movement Higher administrative work load due to
(soil/gravel), disposal, new quarried wider range of project requirements,
material, reduced traffic disruption number of offers
Time savings vs. traditional methods Strong weather dependence
Economic option for stand-alone business Complex logistics, just-in-time, high

variability in job-site size
Low CAPEX for greenfield mixing plant Combi binders with risk of QL
(0.5 mio Euro) contamination in cement plant
Savings due to reduction of overlaying Restrictions due to standards
road structure
Specific market preconditions are required to overweigh

the disadvantages of road binders
38
1. Introduction
1.2 Applications
1.4 Pros and Cons
39
Market volumes
Volume potential for road binders estimated by future road
construction statistics may lead to wrong expectations as strong
competition by traditional materials and conservative authorities
and contractors to be convinced!
Real potential volumes determined by specific market situation
Competition to existing solution (QL or aggregates, other binders,
cement treated base)
Road binders partially replace higher margin composite cements in
road application
Real additional volumes mainly in soil improvement as competition
to quicklime!
Changes in market preconditions like MIC availability,
specifications, machinery can lead to an increasing market demand
for road binders
Before any decision on road binders a detailed market analysis
required 40
Example Georoc: Potential Holcim volumes
of Special Binder per market - 2008
100%
Niche
Others
products
80%
Injections
Holcim penetration potential based on:
Subbase
Cement 60% stabilization / Projects within 150 to 200 km radius of
recycling
substitution existing and potential new mixing plants
40%
Soil Current cement market penetration
stabilization
Additional 20% Competitive environment
Soil
volume improvement
0% FR BNL DE ATSKROHR ES IT PL
CHCZHUBGCS
[‘000 t/y] FR DE CH BNL RO CZ HU SK AT ES IT PL Σ

Additional 298
Substitution 804
Niche
For detailed data please contact authors 76
Total 1’178
Limited total additional volume

High potential for cement substitution by low cost Special Binder
Niches products only feasible in highly developed markets
41
QL used for soil improvement
[‘000 t/y] European market overview 2003 (~1.3 Mio t)
500
Facts on European lime industry 60 70
~30 Mio t/y from 250-350 sites 350
(-5%)
Main players are Carmeuse and 93
Lhoist (-7%) 65 63 50
Main applications: Steel, agro, (+5%) (-5%) 60
chemicals, construction 25 (-8%)
Total EBIT ~11% (< cement ind)
80 10
Only 3-7% for soil improvement - 20 62
but strong activities in Eastern 90 10 (+15%) 50 55
Europe (additional sales to (-10%) 67 10 (-17%) (-15%)
compensate missing hydrated 110
75 (+8%)
lime sales for masonry) 0
(-5%)
[‘000 t/y] 0
€/t 60 100
(Δ to (-15%)
CEM I)
High volumes are strong indicator for additional SB volume potential

European price level represent good basis for high SB margins
Opportunities for road binders due to cost advantage 42
Consumption of aggregates in selected countries (1997)
400 Building
300 Road
Mio tons
200
100
0 y
Ve tina
ce
ria
K
ly
en
al
a
um
Sw n
an
el
nd
an
ai
U
I ta
ug
an
ed
st
zu
Sp
gi
en
rla
nl
rt
Au
Fr
el
ne
er
Fi
Po
rg
he
B
A
et
N
Strong competition by aggregates in several countries

43
Consumption of aggregates in USA and West Europe (1997)
Building
Road
1000
750
Mio tons
500
250
0
USA West Europe
44

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1.

 soil improvement to make soil compactable and trafficable

Soil improvement – QL (and cement) (20 kg/m2)

Legend:  Improve traffic ability of soil material

 Often ‘pre-cracking’ by vibration

Combi-binders (QL + cement) have significant

Economic option for stand-alone business Complex logistics, just-in-time, high

Specific market preconditions are required to overweigh

Compacted « vibrated » Compacted

Untreated all-in Hydraulic

Spreading binder ahead of Milling and mixing

Profiling the treated Compacting the profiled

The top of the treated layer is protected by a thin layer of bituminous

Animated, go in slide show mode Base

1 - Spreading of the hydraulic binder

 Following project methodology should be used as

2. Define product – application approach 5. Evaluation of all aspects and decision on

 Special Binder potential strongly depends on key drivers per market

High QL price  Price of bulk QL similar or higher vs. CEM I

 Soils containing clay and sand / silt, possible

 Regulations by government to use soil in-situ,

 High cost for aggregates and / or long

 Possibility to reduce product cost below

 Availability of milling / injection equipment and

1. Growing the pie  Additional sales volume

 Increase use of excess Gbfs

3. Competitiveness Differentiation  Complete cement product range

Customer orientation  Bonding specialized int. contractors

Comp. low cost bind.  Reduce price pressure on cement

 Reduce production cost by integrating

4. New markets  New geographical market

Pan European Georoc project 2004 22

Main  Growing the pie  Growing the pie  Differen-  No objective

Legend: z Fulfilled { Not fulfilled *Pan European Georoc project 2004 24

Soil improvement – QL (and cement) (20 kg/m2)

Main Detail Material

Natural ground Untreated

Hydraulic pavement materials and treated soils: wide

Rigid Composite Flexible

No use of road binders in flexible pavements 31

Road binders are tailor made products specific for each

Economic option for stand-alone business Complex logistics, just-in-time, high

Specific market preconditions are required to overweigh

[‘000 t/y] FR DE CH BNL RO CZ HU SK AT ES IT PL Σ

 Limited total additional volume

 High volumes are strong indicator for additional SB volume potential

Strong competition by aggregates in several countries

S-ar putea să vă placă și

soil improvement to make soil compactable and trafficable

Legend: Improve traffic ability of soil material

Often ‘pre-cracking’ by vibration

Following project methodology should be used as

Special Binder potential strongly depends on key drivers per market

High QL price Price of bulk QL similar or higher vs. CEM I

Soils containing clay and sand / silt, possible

Regulations by government to use soil in-situ,

High cost for aggregates and / or long

Possibility to reduce product cost below

Availability of milling / injection equipment and

1. Growing the pie Additional sales volume

Increase use of excess Gbfs

3. Competitiveness Differentiation Complete cement product range

Customer orientation Bonding specialized int. contractors

Comp. low cost bind. Reduce price pressure on cement

Reduce production cost by integrating

4. New markets New geographical market

Main Growing the pie Growing the pie Differen- No objective

Limited total additional volume

High volumes are strong indicator for additional SB volume potential