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INGREDIENTS OF BITUMINOUS MIXES

AND
INTRODUCTION TO MODIFIERS



By

CHANDRA SEKHAR PASUPULETI
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S.N. Topic Time
1
Ingredients of bituminous
mixes and introduction to
modifiers
2 h
2
Bituminous mix design and
superpave mixes
2 h
3
Hot Mix Plant Calibration,
Laying, Compaction, and
Testing of Bituminous Mixes.--
CS
2 h
4
Distresses in flexible
pavements
2 h
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Objective
To discuss:
Ingredients of bituminous mixes.
Basics of bitumen and Tar
Introduction to modified bitumen
Economics of polymer modified bitumen
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Aggregate
Filler (R/filler or External filler)
Bitumen
Modifiers (Optional)

Ingredients
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Aggregate and Filler
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What is bitumen?
Hydraulic binders
Lime
Cement
Gypsum
Bitumen
Tar
Hydrocarbon binders
Tar
Bitumen
Binders
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Tar Bitumen
It is a by-product in the process of
destructive distillation of coal for
procuring coke
Maximum use was up to 1955
Relatively more adhesive with
aggregate
Relatively more susceptible to the
temp. variations
Get oxidized and become brittle
much quicker
Life of surface is very less
It is residue obtained in the
process of distillation of
petroleum crude at the
refineries
Availability is substantially
higher than tar
Less susceptible to the temp.
variations
Life of surface is better than tar
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Bitumen
Most of the bitumen used in road construction is
obtained from imported petroleum crude.
WHY?

Indigenous petroleum crude do not have sufficient
potential to produce bitumen due to high wax
content
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Digboi refinery in Assam, is producing some bitumen
from indigenous petroleum crude of Assam.
This bitumen is used in North-Eastern parts of the
country due to relatively favorable climatic and road
traffic conditions.
The specifications for Assam bitumen are also given
separately in IS:73
Bitumen
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As the petroleum crude is being imported, the refineries are
trying to extract oils to the maximum extent by improved
distillation techniques.Because of which the asphaltene
content in the bitumen is getting reduced.
Depending upon the crude source and procedure used for
distillation, the quality of the bitumen shall vary.

Bitumen
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Typical composition of different crudes
3
21
33
6
14
20
7
10
16
26
28
30
58
27
1
0
20
40
60
80
100
120
Boscan Arabian Nigeria
Asphalt residuum
Heavy gas oils
Light gas oils
Kerosine
Gasoline
Bitumen
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Manufacture of bitumen
Different crudes require different process conditions for
the separation and production of bitumen
Straight reduction from crude
Propane de-asphalting process
Air rectification of straight run bitumen
Preparation by blending
bit manf flow chart.doc
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Straight reduction from crude:
In this process, crude petroleum first enters a tube where it is
heated and then flushed into a fractionating column.
The lighter fraction are separated as over head products leaving
behind the long residue containing heavy oils and bitumen.
Long residue fed into the vacuum distillation unit where most of
the heavy oil fractions are removed.
The process conditions are so set that the paving bitumen of
desired grade is obtained as a short residue, this process is most
efficient means of obtaining bitumen
Manufacture of bitumen
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Propane de-asphalting process:
Bitumen is a by-product of the propane de-asphalting
and fraction process, which involves precipitation of
asphalts from a residuum stock by treatment with
propane under controlled conditions.
Its primary purpose is to recover lube.
In this process paving bitumen is obtained by blending
precipitated asphalt with aromatic extract or straight-
reduced residue.
Manufacture of bitumen
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Air rectification of straight run bitumen:

Bitumen produced by straight reduction from certain
crude oils may be deficient in certain desirable
properties like softening point, penetration, and
asphaltene etc.

These properties can be improved by oxidation of the
hot straight run bitumen by a current of air blown
through it.
Manufacture of bitumen
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Preparation by blending:

Straight run and air-rectified bitumen produced by
the process described above can be used to
produce intermediate grades of bitumen by suitable
blending process in hot conditions.
Manufacture of bitumen
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Bitumen Constitution :
Bitumen is a complex chemical mixture of molecules
that are predominantly hydrocarbons with a small
amount of structurally analogous heterocyclic species
and functional groups containing sulphur, nitrogen, and
Oxygen atoms.

Typical elemental analysis:
Bitumen
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Bitumen
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Bitumen is broadly divided into two chemical groups
1. Asphaltenes
2. Maltenes
a. Saturates
b. Aromatics
c. Resins
Bitumen
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Elution with toluene
/ methonol
Resine Aromatics Saturates
Filiter
Silica gel /
Alumina,
Chromotography
Elution with
toluene
Precipitate of
Asphaltenes
Solubles In-solubles
Bitumen
n-heptane precipitation
Bitumen
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Asphaltenes :
Insoluble in n-heptanes and black or brown in colour
Contains mainly carbon and hydrozen, and some
nitrogen, sulphur and oxygen
Molecular weight is very high ranging from 600 to
3000000
It plays a major role in rheological properties of the
bitumen
Solid in state, Asphaltenes varies from 5 25 % in
the bitumen
Bitumen
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Resins :
Largely composed of hydrogen and carbon and
contain small amounts of oxygen, suphur and
nitrogen.
Dark brown in colour and solid / semisolid
These are dispersing agents or peptisers for the
asphaltenes.
Polar in nature and hence highly adhesive.
Bitumen
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Aromatics :
Contains lowest molecular weight naphthenic
aromatic compounds in the bitumen and represent
the major portion of the dispersion medium for the
peptized asphaltenes
Constitute 40 65% of total bitumen
Consists non-polar carbon chains and high
dissolving ability
Average molecular weight 300 to 2000
Bitumen
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Saturates :
Non-polar viscous oils
White in colour
Average molecular weight is similar to that of
aromatics.
This fraction forms 5-20 % of the bitumen.

Bitumen
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Impact of these on bitumen properties:
Increase the asphaltenes:
More harder bitumen
More viscous (Viscosity)
Lower penetration
Higher softening point
Asphaltenes varies from 5 25 % in the
bitumen
Bitumen
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Increasing aromatic: little effect on rheological properties
Increasing the saturates: softens the bitumen
Addition of resins: harden the bitumen, increasing the
viscosity, reduce the penetration index
Bitumen
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Basic properties required
Bitumen intend to use for road construction need to have
the following basic properties:

a. Adhesion with aggregate
b. Durability
c. Rheology (Viscosity temperature
relationship)
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Adhesion with aggregate:
Need to coat the aggregate in the form of film
Should have good adhesion with aggregate and
retain the film coating in all the weather conditions
especially when get contact with water
Basic properties required
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Factors affects the adhesion:
Most of the aggregate used in road construction, are
silicious in nature and have greater affinity to water
than bitumen.
Aggregate kept in stacks generally are dusty and
moist.
Remedy:
Pre-heating of aggregate before mixing with bitumen
will helps to certain extent.
Basic properties required
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Remedy:
To develop the mix further, especially in case of
wearing courses, commercially available anti-stripping
agents may need to incorporate into the bitumen.
The dose of the anti-stripping agent depends upon
the type of aggregate, grade of bitumen, type of
construction, and also type of anti-stripping agent.
Basic properties required
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Remedy:
Examples:
Dosage of the anti-stripping agent is in the following order:
Siliceous aggregate >calcareous aggregate
Softer paving > harder one
Open graded >Dense graded bitumen
Basic properties required
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Without anti-stripping
agent
0.5% by wt. Of binder
anti-stripping agent
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Durability:
Which is harder grade bitumen, 60/70 or 80/100?

Generally bituminous surface begins to show the
signs of distress when penetration value of bitumen
becomes less than 20.

Bitumen used in bituminous layers deteriorates by
atmospheric weathering (oxidization) resulting in
hardening of the bitumen.
Basic properties required
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Durability of bitumen can be enhance by addition of
suitable antioxidants.
Ex: hydrated lime etc.
It is quite appropriate to use harder grades of bitumen
if the ductility requirements are met.

What happens when it further hardens due to
atmospheric weather?
Basic properties required
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Hardening of bitumen does not alone responsible for
Pavement distress.
A very high degree of weathering resistance is not
considered essential.
Slight weathering of the surfaces laid with such bitumen
results non-skid surface, which is good especially in
surface courses.
Basic properties required
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Viscosity temperature relationship:
This relation gives a good insight into its thermo-viscous
characteristics.
Values of viscosity of bitumen corresponding to various
road construction operations are considered
significant.
Basic properties required
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80/100 grade
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BITUMEN MODIFIERS

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Necessity of modifiers?
Reason = Need + Waste

What happens when excavated materials from canal
excavation is used in canal embankment filling
simultaneously?

What is need and waste in this context?

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Need:
To avoid 4 Res
Remedy Rectify
Redo Remove
Asphaltene content in to-days bitumen?
Temperature variation
Over loaded commercial vehicles (affecting stability)

Necessity of modifiers?
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Because of above reasons the following distresses are encountered at site:
Ravelling bleeding
Undulation Shoving
Rutting Potholes
Cracking

Necessity of modifiers?
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Waste:
There is a great deal of plasticwaste being generated
from household and agricultural waste.
It is quite feasible for some of these material to be
incorporated into bituminous mixtures, both as an
aggregate bulking material, and as modifier of existing
bituminous mixtures.
This recycling of waste helps in environmental safety
as well as to improve the bituminous mix quality.

Necessity of modifiers?
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What is modifier?
Modifier is an additive, when added to the bitumen,
improves the properties of bitumen as well as bituminous
mixes by 50 to 100 % (Life-cycle-cost basis)

Plain Vs Polymer.zip


Most commonly used modifiers are Polymers
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What is polymer & co-polymer ?
Polymer is not at all a synthetic material, but it is a
combination of small similar molecules or monomers into
large molecules or polymers
Copolymer is the polymer that has more than one type of
molecules/monomers incorporated in the polymer.
These are generally two types
Natural (Polymer or Copolymer)
Synthetic (Polymer or Copolymer)
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Major categories of Polymer
Natural polymer: These are the polymers occurring in the
natural-form or in the form of raw material.
For example Hair, Diamonds, Rubber, Sulphur.
Synthetic polymer: These are polymers manufactured in a
chemical process to combine particular molecules in a way
that would otherwise not occur naturally.
For example Ethylene Vinyl Acetate (EVA)
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Polymer names need to know
The following are the commonly used polymers / additives
for modification of bitumen
Reclaimed Rubbers
Ex:Tyre crumb rubber powder
Elastomers
Ex: Styrene Butadiene Styrene (SBS)
Plastics
Ex: Ethylene Vinyl Acetate (EVA)
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Polymer indicative doses
Reclaimed Rubber:
Bitumen modified by this polymer called Crumb
Rubber Modified Bitumen (CRMB)
Ex:Tyre crumb rubber powder
Indicative dosage is 10 12 % by wt. Of bitumen.

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Elastomers:
Bitumen modified by this polymer called Elastomeric
Polymer Modified Bitumen (Elasotmeric PMB)
Ex: Styrene Butadiene Styrene (SBS)
Indicative dosage is 3 5 % by wt. Of bitumen


Polymer indicative doses
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Polymer indicative doses contd
Plastics:
Bitumen modified by this polymer is called
Plastomeric Polymer Modified Bitumen (Plastomeric
PMB)
Ex: Ethylene Vinyl Acetate (EVA)
Indicative dosage is 3 6 % by wt. Of bitumen

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Does polymer react with bitumen?
The polymer additives do not chemically combine or
change the chemical nature of the bitumen.
Polymers only will change the physical nature of the
bitumen.
The additive / polymer usually influences the bitumen
characteristics by dissolving certain component fractions of
the bitumen itself.
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Does polymer reacts with bitumen?
Polymer spreads out its long chain polymer molecules to
create an inter-connecting matrix of the polymer through
the bitumen.
Because of the thermoplastic nature of the polymers, some
polymers will break up into their constituent molecular
blocks at high temperatures during mixing and laying, and
recombine into their polymer chains at lower temperatures
(ambient temp.)
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Advantages of Modifier
Lower susceptibility to daily and seasonal temperature
variations.
Higher resistance to deformation at elevated pavement
temperatures.
Better age (aging) resistance properties
Higher fatigue life of mixes
Better surface texture

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Advantages of Modifier
Better adhesion between aggregate and binder
Prevention of cracking and reflective cracking
Overall improved performance in extreme climatic conditions and under
heavy traffic conditions.
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Selection criteria
Based on the atmospheric temperatures, purpose, and
availability the type of modifier shall be selected.
Guide lines for selection of grade of modified bitumen is
given in the following table:

selection criteria of modified bitumen.xls
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Different types of modifiers and their impact on
performance of the mix

modifiers and theri impact.doc

Selection criteria
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Agencies dealing with polymers
CRMB - Tinna overseas Ltd.
PMB Novaphalt
- Osnar Chemicals Pvt.Ltd.
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General requirements of modifier
Should be compatible with bitumen
Resist degradation of bitumen at mixing temperatures
Should be capable of being processed by conventional mixing and
laying machinery

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General requirements of modifier
Produce coating viscosity at mixing temperature
Maintain rheological properties during storage, application
and in service
Should be cost effective on life-cycle-cost basis
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Application
Quite suitable for overlays are required to be laid over
badly cracked surfaces. (elastic modulus, tensile strength)


SAM (sealing of cracks)
SAMI (reflection of cracks)
Renewal layers for maintenance

Crack
Preventive
Courses
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Application Contd..
Pavements subjected to heavy traffic loads (increased
stability)
High rain fall areas (Adhesion)
Gives better life of surfaces at intersections, roundabouts
(creep resistance)
Note : It is not advisable to use Plastomeric thermoplastic
modifiers for SAM and SAMI
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Specification require-ments of PMB /CRMB
As per IRC:SP 53 1999 / 2002 Table 2, 3 and 4

Ex : selection criteria of modified bitumen.zip

Also see how to determine the optimum dose

Deter optim dosage.zip

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Precautions and controls
Thorough blending by capable agitators
Blending techniques based on modifier used
Advisable to be mixed at plant sites (storage stability)
If supply is in drums those must be thoroughly mixed
before use with proper devices for at least 15 minutes
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Precautions and controls
Tests for penetration, softening point , and elastic
recovery shall be conducted at site for every lot of 5
tonne modified bitumen.
Temperatures at the time of mixing and rolling shall be
slightly higher than that of conventional mixes.
Exact temp. depends on type of additive and suppliers
advice.
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The temperatures required at different stages of activities
can be determined based on the viscosity requirements of
the mixes
A typical requirements of viscosity at various stages is
given in the following table for reference
Note : pl. see Viscosity vs. temp. table in excel

viscosity vs temp for bitumen.zip

viscosity vs temp. table.zip
Precautions and controls
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Common problems
The possible problems with the modified bitumen are
mainly:
storage of the bitumen without agitator in the tank
Densities of polymer and bitumen are different.
Modified bitumen may tend to separate if kept in store
for prolonged period.
The polymer additives can be destroyed at too high
temperature during mixing, or being held at a high
temp. for long period of time after mixing.
Maintaining temperature during mixing, laying and
rolling is very important.
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Example:
Total binder at 5%, density say 2400 kg/ cu.m. = 2400
X 5/100 = 120 kg.
If modifier used (CRMB) at 12%
Total conventional bitu = 120 X 88 /100 = 106 kg
Total modifier = 120 106 = 14 kg
Economics
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Economics
Cost of modifier @ Rs. 30 per kg = 14 X 30 = 420
Less cost of bitumen @ 12 per kg = 14 X 12 = 168
There will be some additional cost (approximately Rs
50/Kg per Cum) due to additional energy requirement for
heating.
Extra cost incurred = 420 168 +50 = 302 per cu.m
But the life span increases 2.0 to 2.5 times than the
conventional bituminous mixes
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References
BS:594
BS : 4987
TRRL(Thermoplastic Road Research Laboratory),
Road Note 36
IRC: SP-53
Web site : www.highwaysmaintenance.com

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Any Questions?

***

THANK YOU