Cold Mix For Road Construction

COLD MIX TECHNOLOGY FOR
CONSTRUCTION OF ICBRs
BIJAY KRISHNA DAS

JE (Civil)
HQ CE (P) Shivalik
e-mail: bijay_er@rediffmail.com
Refresher Training for Junior Engineers, GREF Centre, Dighi Camp, PUNE-15
OUTLINE
 Back Ground
 Cold mix technology – Overview
 Bitumen Emulsion for Cold Mix
 Specifications for Cold Mix
 Construction Techniques
 Conclusion
Cold Mix Technology for Construction of ICBRs 2

BACKGROUND

BACK GROUND
STATUS OF ICBRs IN UTTARKHAND

Ser Name of Road Length Existing Upto date progress Orignal PDC
No (Linear) in class/Proposed
KM class FMN Blacktopping
(Km Linear) (Km Linear)
1 Nelong-Naga 8.10 Cl9/DL 7.60 0.00 2011
2 Naga-Sonam 11.65 Cl9/DL 8.45 0.00 2012
3 Naga-Jadhang 5.55 Tr/Cl9 5.30 0.00 2011
4 Naga-Nilapani 9.80 Cl9/Cl9E 7.80 0.00 2012
5 Musapani-Ghastoli 6.813 Cl9/DL 5.00 0.37 2012
6 Ghastoli-Rattakona 17.95 Tr/Cl9 17.20 0.00 2012
7 Joshimath-Malari 62.67 Cl9/DL 43.50 23.82 2012
8 Malari-Girthidobla 19.00 Cl9/DL 7.14 0.00 2012
9 Girthidobla-Sumna 6.55 Tr/Cl9 3.67 0.00 2015
10 Sumna -Rimkhim 14.00 Tr/Cl9 6.84 0.00 2012
Total 162.083 112.50 24.19

BACK GROUND
CONSTRAINTS FACED IN EXECUTION OF SURFACING WORKS ON

ICBRs
 Hot mix specification (DBM & BC) sanctioned in AEs

 Area falls in Gangotri National Park, Bhagrirathi Eco Senstive zone and Nandadevi
reserved biosphere
 No permission for HMP installation
 No permission for crusher installation
 Extreme cold climate and snow fall restricting working season.
 Non participation of contractors due to far flung area

BACK GROUND
LOOK OUT FOR ALTERNATE SPECIFICATION & TECHNIQUES

 Techniques which will not warrant installation of hot mix plant.
 Specification with less requirement of graded aggregate
 Technique for faster execution with in limited working season
 Less emission level and less impact to environment

BACK GROUND
SOLUTION SUGGESTED BY CRRI

COLD MIX
(EMULSION BASED)

COLD MIX TECHNOLOGY – OVERVIEW

WHAT IS COLD MIX ?

Cold mix is a bituminous mixture containing mineral aggregate,
water and binder (bitumen emulsion) prepared by a suitable
device like concrete mixer or cold mix plant or a modified hot
mix plant.

COMPARATIVE ENERGY INPUTs IN COLD MIX

Comparison of Fuel and Material Consumption for Cold Mix

and Hot Mix Technology
(1 Km rural road construction)

Energy Consumption in Hot Mix and Cold Mix Technology

A Comparisons of Cold Mix Technology and Hot Mix Technology

A Comparisons of Cold Mix Technology and Hot Mix Technology

BITUMEN EMULSION FOR COLD MIX TECHNOLOGY

BITUMEN EMULSION
A liquid product in which a substantial amount of bitumen is suspended in a
finely divided form of the size 4-10 microns in water
CONSTITUENTS :
 Bitumen
• penetration 100/200 (60-70 %)
• Softening point , max - 40 o C
• Solubility in TCE - 99 %
• Loss on heating , max - 1 %
 Water (Potable) - 30-40%
 Emulsifier (0.5 to 2 %)
 Kerosene (2 to 3 %)
 Hydochloric Acid HCl
 Calcium Chloride

PROCUTION OF BITUMEN EMULSION

SPECIFICATION OF BITUMEN EMULSTION (IS : 8887:2004)

SPECIFICATION OF BITUMEN EMULSTION

RECOMMENDED USES OF BITUMEN EMULSION

BENEFITS OF BITUMEN EMULSION IN ROAD CONSTRUCTION

WORLD WIDE CONSUMPTION OF BITUMEN EMULSION V/S

BITUMEN
Country Annual Tonnage Percentage
Emulsion Bitumen
USA 3166000 28000000 11
FRANCE 1200000 2800000 43
SPAIN 440000 1600000 27
BRAZIL 420000 1336000 31
SOUTH AFRICA 120000 300000 40
INDIA 60000 2250000 2.7
Source : CRRI
SPECIFICATIONS FOR COLD MIX TECHNOLOGY

THE PREVAILING SPECIFICATIONS FOR EMULSION BASED CONSTRUCTION

: IRC : 97-1987 Tentative specification for 20mm. thick
premix carpet using cationic bitumen
emulsion (now clubbed with IRC-14)
IRC:96-1987 Tentative specification for two coat
surface dressing using cationic
bitumen emulsion.

IRC:100-1988 Tentative specification for single coat
surface dressing using cationic
bitumen Emulsion
IRC:SP:20-2002 Rural Road Manual

RECENT PUBLICATION BY IRC EXCLUSIVELY FOR COLD MIX
IRC :SP:100-2014 - USE OF COLD MIX TECHNOLOGY IN ROAD
CONSTRUCTION AND MAINTENANCE OF
ROADS USING BITUMEN EMULSION
EMULSION BASED COLD MIX TECHNOLOGIES (IRC:SP:100-2014)

Maintenance including periodic treatments
Surface treatment
including preventive
Other applications
and corrective
Cold Mixes Warm mixes
maintenance
Fog seal Patching Semi dense mixes Prime coat

Sand Seal Pothole repair Dense mixes Tack coat
Slurry seal Cold Recycling Crack sealing
Micro surfacing Bituminous macadam Soil stabilization
Cape seal Premix carpet
Chip seal Mix seal surfacing
Semi dense bituminous
concrete
Modified Penetration Macadam : IRC:SP:20-2002

COLD MIX CONSTRUCTION TECHNIQUE

MODIFIED PENETRATION MACADAM (IRC:SP:20-2002)
 Grouted/ Penetration type of construction

 Used for bituminous base course
 It can be laid in 50 mm or 75 mm thickness
 Hand broken metal used
 Less requirement of graded aggregate
 No need for installation of HMP
 No emissions & eco-friendly
 Faster execution


Aggregate Requirement


Binder Requirement
Rate of application for 10 m2 area
75 mm Requirement
Binder 50 mm
Grade of
Emulsion On
On WBM On bituminous On WBM
bituminous
surface surface surface
surface
Bitumen emulsion 31 kg 31 kg 27 kg 27 kg
for grouting
(Specified by CRRI)

COLD MIX OPEN GRADED PREMIX CARPET (CM OGPC) (IRC:SP:100-2014)

 Construction methodology is similar to BT using emulsion as per IRC:14:2004
(Recommended Practice for Open Graded Premix Carpets : Third revision)
 The cold mixed open graded premix carpet may also be prepared in a concrete mixer.
 Treys also can be used for mixing.
 Temperature independent process
 Eco-friendly
 Faster execution.

COLD MIX OPEN GRADED PREMIX CARPET (CM OGPC) (IRC:SP:20-2002)

Aggregate requirement
Binder requirement

COLD MIX BITUMINOUS MACADAM (CMBM) (IRC:SP:100-2014)

 Cold Mixed Bituminous Macadam (CMBM) involve construction of one or more
courses of compacted mixture prepared with bitumen emulsion and mineral.
 Hot mix plan can be used by switching off the heating arrangement.
 Concrete mixer can also be used.
 Faster execution
 Permits cold weather construction up to 8ºC.
 Eco-friendly

COLD MIX BITUMINOUS MACADAM (CMBM) (IRC:SP:100-2014)

SPECIFICATIONS FOR 50 mm thick CMBM

PREPARATION OF COLD MIX

FOR CM OGPC / CM BM
 Making emulsion homogeneous by rolling drum
5-10 m distance to- and fro for 5 times
 Charging of aggregates in concrete mixer
 Addition of optimum premix water content
 Addition of bitumen emulsion(SS-2)
 Mix for uniform coating of aggregate
 Mixing than 2 minutes results de-coating off aggregate

PREPARATION OF COLD MIX
Charging of Aggregates Wetting of Aggregates
Bitumen Emulsion for Mixing Discharging of Cold Mix

PRODUCTION OF COLD MIXES WITH HMP (SWITCHING OFF THE HEATING

ARRANGEMENT)

APPLICATION OF TACK COAT

 Bitumen emulsion of RS/MS grade is used Quantity
@ 3.5 kg / 10 m2 area
 Manually with perforated can with holes 3 mm apart
 Cleaned holes when tack coating discontinues
 Tack coat turned black from brown colour
 Wetting of road surface required, if dry
 MoRT&H Specification provides quantity @ 2.5-3.5

kg/10m2

TRANSPORTATION OF COLD MIX

 Cold mix transported to site
 Avoided newly laid surface or tacky road
surface while ferrying
SPREADING OF COLD MIX
 Spread cold mix in half the road-width
 Required thickness with spreader
 Cold mix turned black from brown
 Cold mix aerated for about 2 hours
COMPACTION
 Compacted with 8-10 ton road roller
 Wetting of wheels

PROBLEMS FACED AND EXPERIENCES GRAINED DURING CONSTRUCTION

 Ball Formation observed dusty aggregates
 Lump formation with aggregates having more fines and clay
 Concrete mixer was not found appropriate for graded cold mixes duet to sticking of finer
material inside.
 Long setting time and tenderness of dense cold mix
 Sand seal coat on PMC was observed problematic due ball formation during mixing of
emulsion and sand
 Rich mix formed with emulsion and fine aggregates stick to the bottom of concrete mixer
REMEDIAL MEASURES
 Regular cleaning of concrete mixer say after an hour work by tapping with
 wooden hammer
 Addition of fines after coating of coarse aggregates with emulsion

CONCLUSION

CONCLUSION
 Ready to use material – No heating, no preparation near road side.
 An environmentally responsible product with zero on-site fossil fuel burning and
absolutely zero pollution
 Simple to use and better workability – No expensive equipments required.
 Health friendly – No occupational hazards to workers
 Engages unskilled labours and creates income-earning green jobs to villagers
 Works even in wet and humid climatic conditions – extended paving season

CONCLUSION
 4-5 times faster progress compared with conventional hot mix system - Completes
1km in 3-4 days with proper manpower and support (by using Concrete Mixer)
 0%+ of fuel savings compared to the typical hot mix system, leading to the reduction
of over 4,000 kgs of CO2 emission per km
 The cold mix technology can be conveniently adopted for BM as binder course and
for SDBC as wearing course in cold, humid and wet climates.
 This technology can also be suitably used with marginal aggregates in N.E. Region

Let us Step towards Green and Sustainable infrastructure for our next generation
THANK YOU

Cold Mix For Road Construction

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Cold Mix For Road Construction

Încărcat de

Drepturi de autor:

Formate disponibile

COLD MIX TECHNOLOGY FOR

BIJAY KRISHNA DAS

 Cold mix technology – Overview

 Bitumen Emulsion for Cold Mix

 Specifications for Cold Mix

Cold Mix Technology for Construction of ICBRs 2

Cold Mix Technology for Construction of ICBRs 3

STATUS OF ICBRs IN UTTARKHAND

1 Nelong-Naga 8.10 Cl9/DL 7.60 0.00 2011

2 Naga-Sonam 11.65 Cl9/DL 8.45 0.00 2012

3 Naga-Jadhang 5.55 Tr/Cl9 5.30 0.00 2011

4 Naga-Nilapani 9.80 Cl9/Cl9E 7.80 0.00 2012

5 Musapani-Ghastoli 6.813 Cl9/DL 5.00 0.37 2012

6 Ghastoli-Rattakona 17.95 Tr/Cl9 17.20 0.00 2012

7 Joshimath-Malari 62.67 Cl9/DL 43.50 23.82 2012

8 Malari-Girthidobla 19.00 Cl9/DL 7.14 0.00 2012

9 Girthidobla-Sumna 6.55 Tr/Cl9 3.67 0.00 2015

10 Sumna -Rimkhim 14.00 Tr/Cl9 6.84 0.00 2012

Total 162.083 112.50 24.19

Cold Mix Technology for Construction of ICBRs 4

CONSTRAINTS FACED IN EXECUTION OF SURFACING WORKS ON

 Hot mix specification (DBM & BC) sanctioned in AEs

Cold Mix Technology for Construction of ICBRs 5

LOOK OUT FOR ALTERNATE SPECIFICATION & TECHNIQUES

Cold Mix Technology for Construction of ICBRs 6

SOLUTION SUGGESTED BY CRRI

Cold Mix Technology for Construction of ICBRs 7

Cold Mix Technology for Construction of ICBRs 8

WHAT IS COLD MIX ?

Cold Mix Technology for Construction of ICBRs 9

COMPARATIVE ENERGY INPUTs IN COLD MIX

Cold Mix Technology for Construction of ICBRs 10

Comparison of Fuel and Material Consumption for Cold Mix

Cold Mix Technology for Construction of ICBRs 11

Energy Consumption in Hot Mix and Cold Mix Technology

Cold Mix Technology for Construction of ICBRs 12

A Comparisons of Cold Mix Technology and Hot Mix Technology

Cold Mix Technology for Construction of ICBRs 13

A Comparisons of Cold Mix Technology and Hot Mix Technology

Cold Mix Technology for Construction of ICBRs 14

Cold Mix Technology for Construction of ICBRs 15

Cold Mix Technology for Construction of ICBRs 16

PROCUTION OF BITUMEN EMULSION

Cold Mix Technology for Construction of ICBRs 17

SPECIFICATION OF BITUMEN EMULSTION (IS : 8887:2004)

Cold Mix Technology for Construction of ICBRs 18

SPECIFICATION OF BITUMEN EMULSTION

Cold Mix Technology for Construction of ICBRs 19

RECOMMENDED USES OF BITUMEN EMULSION

Cold Mix Technology for Construction of ICBRs 20

BENEFITS OF BITUMEN EMULSION IN ROAD CONSTRUCTION

Cold Mix Technology for Construction of ICBRs 21

WORLD WIDE CONSUMPTION OF BITUMEN EMULSION V/S

FRANCE 1200000 2800000 43

SPAIN 440000 1600000 27

BRAZIL 420000 1336000 31

SOUTH AFRICA 120000 300000 40

INDIA 60000 2250000 2.7

Cold Mix Technology for Construction of ICBRs 23

THE PREVAILING SPECIFICATIONS FOR EMULSION BASED CONSTRUCTION

IRC:SP:20-2002 Rural Road Manual

EMULSION BASED COLD MIX TECHNOLOGIES (IRC:SP:100-2014)