COLD MIX TECHNOLOGY FOR
CONSTRUCTION OF ICBRs
BIJAY KRISHNA DAS
JE (Civil)
HQ CE (P) Shivalik
e-mail:
[email protected]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
Cold Mix Technology for Construction of ICBRs 3
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
Cold Mix Technology for Construction of ICBRs 4
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
Cold Mix Technology for Construction of ICBRs 5
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
Cold Mix Technology for Construction of ICBRs 6
BACK GROUND
SOLUTION SUGGESTED BY CRRI
COLD MIX
(EMULSION BASED)
Cold Mix Technology for Construction of ICBRs 7
COLD MIX TECHNOLOGY – OVERVIEW
Cold Mix Technology for Construction of ICBRs 8
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.
Cold Mix Technology for Construction of ICBRs 9
COLD MIX TECHNOLOGY – OVERVIEW
COMPARATIVE ENERGY INPUTs IN COLD MIX
Cold Mix Technology for Construction of ICBRs 10
COLD MIX TECHNOLOGY – OVERVIEW
Comparison of Fuel and Material Consumption for Cold Mix
and Hot Mix Technology
(1 Km rural road construction)
Cold Mix Technology for Construction of ICBRs 11
COLD MIX TECHNOLOGY – OVERVIEW
Energy Consumption in Hot Mix and Cold Mix Technology
Cold Mix Technology for Construction of ICBRs 12
COLD MIX TECHNOLOGY – OVERVIEW
A Comparisons of Cold Mix Technology and Hot Mix Technology
Cold Mix Technology for Construction of ICBRs 13
COLD MIX TECHNOLOGY – OVERVIEW
A Comparisons of Cold Mix Technology and Hot Mix Technology
Cold Mix Technology for Construction of ICBRs 14
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
Cold Mix Technology for Construction of ICBRs 15
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
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BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
PROCUTION OF BITUMEN EMULSION
Cold Mix Technology for Construction of ICBRs 17
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
SPECIFICATION OF BITUMEN EMULSTION (IS : 8887:2004)
Cold Mix Technology for Construction of ICBRs 18
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
SPECIFICATION OF BITUMEN EMULSTION
Cold Mix Technology for Construction of ICBRs 19
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
RECOMMENDED USES OF BITUMEN EMULSION
Cold Mix Technology for Construction of ICBRs 20
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
BENEFITS OF BITUMEN EMULSION IN ROAD CONSTRUCTION
Cold Mix Technology for Construction of ICBRs 21
BITUMEN EMULSION FOR COLD MIX TECHNOLOGY
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
Cold Mix Technology for Construction of ICBRs 22
SPECIFICATIONS FOR COLD MIX TECHNOLOGY
Cold Mix Technology for Construction of ICBRs 23
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
Cold Mix Technology for Construction of ICBRs 24
SPECIFICATIONS FOR COLD MIX TECHNOLOGY
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 Technology for Construction of ICBRs 25
COLD MIX CONSTRUCTION TECHNIQUE
Cold Mix Technology for Construction of ICBRs 26
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
Cold Mix Technology for Construction of ICBRs 27
COLD MIX CONSTRUCTION TECHNIQUE
MODIFIED PENETRATION MACADAM (IRC:SP:20-2002)
Aggregate Requirement
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COLD MIX CONSTRUCTION TECHNIQUE
MODIFIED PENETRATION MACADAM (IRC:SP:20-2002)
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 Technology for Construction of ICBRs 29
COLD MIX CONSTRUCTION TECHNIQUE
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 Technology for Construction of ICBRs 30
COLD MIX CONSTRUCTION TECHNIQUE
COLD MIX OPEN GRADED PREMIX CARPET (CM OGPC) (IRC:SP:20-2002)
Aggregate requirement
Binder requirement
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COLD MIX CONSTRUCTION TECHNIQUE
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 Technology for Construction of ICBRs 32
COLD MIX CONSTRUCTION TECHNIQUE
COLD MIX BITUMINOUS MACADAM (CMBM) (IRC:SP:100-2014)
SPECIFICATIONS FOR 50 mm thick CMBM
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COLD MIX CONSTRUCTION TECHNIQUE
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
Cold Mix Technology for Construction of ICBRs 34
COLD MIX CONSTRUCTION TECHNIQUE
PREPARATION OF COLD MIX
Charging of Aggregates Wetting of Aggregates
Bitumen Emulsion for Mixing Discharging of Cold Mix
Cold Mix Technology for Construction of ICBRs 35
COLD MIX CONSTRUCTION TECHNIQUE
PRODUCTION OF COLD MIXES WITH HMP (SWITCHING OFF THE HEATING
ARRANGEMENT)
Cold Mix Technology for Construction of ICBRs 36
COLD MIX CONSTRUCTION TECHNIQUE
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
Cold Mix Technology for Construction of ICBRs 37
COLD MIX CONSTRUCTION TECHNIQUE
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
Cold Mix Technology for Construction of ICBRs 38
COLD MIX CONSTRUCTION TECHNIQUE
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
Cold Mix Technology for Construction of ICBRs 39
CONCLUSION
Cold Mix Technology for Construction of ICBRs 40
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
Cold Mix Technology for Construction of ICBRs 41
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
Cold Mix Technology for Construction of ICBRs 42
Let us Step towards Green and Sustainable infrastructure for our next generation
THANK YOU
