Prof. (Dr). P. K. Jain
Chief Scientist and Advisor
Pavement Engineering Area CSIR-Central Road Research Institute, New Delhi
Prof. (Dr). P. K. Jain
Chief Scientist and Advisor
Pavement Engineering Area CSIR-Central Road Research Institute, New Delhi
ICEMA Conference on Rural Roads 26thAugust, 2014
Introduction
�More than 800 million people of India live in rural
areas and having poor quality of life
�Villagers are also facing isolation and economic,
political and social sufferings
�Symptoms of deprivation due to lack of rural–
urban connectivity are high mortality rate of
pregnant women, children missing school
education, perishable agricultural produce cannot
reach market timely, non availability of quality
drinking water, unemployment and poverty
�PMGSY was lunched in December 2001 to improve
connectivity in rural areas
�Flexible pavement with bituminous surfacing
constitute major portion of rural roads under
centrally funded PMGSY scheme
�1 km long rural road consumes about 1800 liter of
fuel in construction of bituminous surface using
hot mix technologies presently in practice
�The estimated quantity of fuel for PMGSY
network is more than 1540 million liters, if only hot
mix technologies are used
�The estimated quantity of fuel for PMGSY
shall be about 132 million liters, if cold mix
technology is used for road construction
�Till date cold mix technology has saved 13,396
tonne emissions of CO2, 0.913 tonne Methane
and 183 tonne CO due to reduced consumption
of fuel
� Heating of bitumen binder at 160-170°C
� Heating of aggregates at 150-155oC
� Production of hot mix at 145-150oC
� Laying of hot mix at 125-135°C
� Compaction of hot mix at 115-130°C
� Reduced durability
� High energy consumption
� High GHG emissions
� Higher life cycle cost
� Limited working season
� Harmful to health of construction workers
� Hazardous for public in general
Hot Mix Technologies - Overview
Energy Input in Road Construction
Comparison of Fuel and Material Consumption for
Cold Mix and Hot Mix Technology
(1 Km rural road construction)
Specification Cold Mix (alternative) Hot Mix (Conventional)
Bitumen (MT) Fuel (L) Bitumen (MT) Fuel (L)
PMC 7.31 90 .00 8.03 1790
MSS 6.82 88 .00 7.13 1589
Specification Energy Kilo Cal x 108
Hot mix technology Cold mix technology
Mix Seal Surfacing 1.16 0.92
Premix with seal coat 1.02 0.90
Energy Consumption in Hot Mix and Cold
Mix Technology
Particulars Hot Mix Technology Cold Mix Technology
Equipment used Spot Mixer Concrete mixer
Cost Rs. 8 Lac 1 Lac
No of equipments with
same investment
1 8
Progress with same
investment
250 meter / day 1.5 km/day
A Comparisons of Cold Mix Technology and
Hot Mix Technology
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 Emulsion Binder
Surface Treatment
Including
Preventive and
Corrective
Maintenance
Maintenance Including Periodic
Treatments
Other
Applications
Cold Mixes Half Warm and
Mild Warm
Mixes
� Fog Seal
� Sand Seal
� Slurry Seal
� Microsurfacing
� Cape Seal
� Chip Seal
� Patching
� Pothole Repair
� Cold Recycling
� Bituminous
Macadam
� Premix Carpet
� Mix Seal
Surfacing
� Semi-Dense
Bituminous
Concrete
� Semi-Dense
Mixes
� Dense Mixes
� Prime Coat
� Tack Coat
� Crack
Sealing
Emulsion Based Cold Mix Technologies (IRC:SP:100-2014)
Bitumen Emulsion for Cold Mix Technology
� Bitumen
� Water
� Emulsifier
� Acid or Caustic
� Polymers
� Solvents
� Additives
� Stabilizers
� Buffers
Structure of Cationic Bitumen Emulsion
Emulsion Production
S.No Properties of Bitumen
Emulsion
Grade of Emulsion (Softer Grade) Test
MethodRS-1 RS-2 MS SS-1 SS-2
i) Residue on 600 micron IS sieve
(% mass) Max
0.05 0.05 0.05 0.05 0.05 IS:8887
ii) Viscosity by Say bolt Furol
Viscometer, Seconds
at 25°C
at 50°C
-
20-100
-
100-300
-
30-300
20-100
-
30-150
-
IS:3117
iii) Coagulation of emulsion at low
temperature
Nil Nil Nil Nil Nil IS:8887
iv) Storage stability after 24 hr, %
max,
2.0 1.0 1.0 2.0 2.0 IS:8887
v) Particle charge +ve +ve +ve - +ve IS:8887
Specification of Bitumen Emulsion
vi) Coating ability and water
resistance
a)Coating, dry aggregates
b)Coating after spraying water
c) Coating, wet aggregates
d) Coating after spraying water
-
-
-
-
-
-
-
-
Good
Fair
Fair
Fair
-
-
-
-
-
-
-
-
IS:8887
vii) Stability to mixing with cement,
% coagulation
- - - - 2 IS:8887
viii) Miscibility with water
(coagulation)
No
Coagula
tion
No
Coagulat
ion
No
Coagulat
ion
Immiscib
le
No
Coagu
lation
IS:8887
ix) Tests on Residue:
a) Residue by evaporation, %
min.
b) penetration, 25°C/100 gm/5
sec,
c)Ductility at 27°C, cm., min.
d) Solubility In
Trichloroethylene, %, min.
60
80-150
50
98
67
80-150
50
98
65
60-150
50
98
-
-
-
98
60
60-120
50
98
IS:8887
IS:1203
IS:1208
IS:1216
Tests of Aggregates
� Sand equivalent value test
� Methylene blue test
� Shape test
� Gradation test
� Soundness test
� Aggregate impact value test
� Water absorption test
� Stripping test
Type Recommended Uses
RS-1 A quick setting emulsion used for tack coat
RS-2 A quick setting emulsion used for Surface treatment, Surface
dressing, Penetration Macadam, Penetration Grouting
MS/
Tailor-
made
Amedium setting emulsion used for plant or road mixes with coarse
aggregate for premix carpet and surface dressing
SS-1 A slow setting emulsion used for priming
SS-2/
Tailor-
made
A slow setting emulsion used for plant mixes with graded fine
aggregate in SDBC, MSS, BM, DBM and BC. This emulsion is also
used for slurry seal treatment, tack coat, cold recycling, mild warm
mix and half warm mix
Modified Modified emulsion is used for microsurfacing
Recommended Uses of Bitumen Emulsion
Application of Cold Mix Technologies for
Rural Roads
�Prime Coat
�Tack Coat
�Surface Dressing
�Premix Carpet
�Mix Seal Surfacing
�Patch Work
�Pothole Repair
S. No. Premix Carpet
(a) Coarse aggregate of nominal 13.2 mm size: passing
IS 22.4 mm sieve and retained on IS 11.2 mm sieve0.18 m3
(b) Coarse aggregate of nominal 11.2 mm size; passing
IS 13.2 mm sieve and retained on IS 5.6 mm sieve0.09 m3
Cold Mixed Open Graded Premix Carpet for 10 m2 Area
(A) For Premix Carpet (MS) 20 to 23 kg
(B) For Seal Coat
(i) For Liquid seal coat (RS-2) 12 to 14 kg
(ii) For Premix seal coat (SS-2) 10 to 12 kg
Procedure for Construction of Open Graded
Premix Carpet (Using Hot Mix Plant)
� The blended aggregates of 13.2 mm and 11.2
mm nominal sizes in 2:1 ratio, as per the
specified requirement, shall be charged in the
hot mix plant which shall be used without
heating arrangement and with suitable
modification for incorporation of emulsion
� The optimum water content 1 percent by weight
of aggregates (if needed) shall then be added to
the aggregate for making it wet
� The emulsion of MS grade/SS grade/cold mix
binder in required quantity approximately
(7 percent by wt. of aggregates) shall then be
added into wet aggregate and mixed for two
minutes to get uniform coating
� Prolonged mixing shall be avoided as it will
uncoat the aggregates
Procedure for Construction of Open Graded
Premix Carpet (Using Concrete Mixer )
� The cold mixed open graded premix may also be
prepared in a concrete mixer
� For this purpose, the blended aggregates of 13.2
mm and 10 mm size in 2:1 ratio shall be charged
into concrete mixer
� The premixing water content @ 1 to 2 percent
by weight of aggregate shall be added into the
mixer and uniformly mixed with wet the
aggregate
� The required quantity of emulsion of MS grade
or tailor made (cold mix binder) shall then be
added and mixed with aggregates for two
minutes
� Prolong mixing (move then one minute) shall
be avoided as it tends to de-coat the binder
from aggregate
� The cold mix while indicating brown colour
shall be discharged into trolleys to transport to
the construction site
� Compaction of cold mix with 8-10 tone roller
shall be carried out to get the finished premix
carpet surface
Mix Seal Surfacing
Cold Mixed Mix Seal Surfacing (MSS), which is a continuous graded
mixture, may be used as surfacing/renewal coat on rural roads. Materials
and construction procedure for laying cold mixed mix seal surfacing using
cationic bitumen emulsion are as under.
Sieve size % Passing by weight
Type A Type B
13.2 mm - 100
11.2 mm 100 88-100
5.6 mm 52-88 31-52
2.8 mm 14-38 5-25
0.090 mm 0-5 0-5
Gradation of Aggregates for Cold Mixed Mix Seal Surfacing
The quantity of aggregate shall be 0.27m3 area. The quantity of bitumen emulsion
(SS-2) shall be 30 kg for Type A and 33 kg for Type B grading.
(a)Aggregate form site (b) Required grade of emulsion is added (c) Cold mix is prepared
(d) Cold mix is kept in tray (e) determination of breaking time, coating
and setting time
Design of cold mix
Charging of AggregatesMixing of Binder
Discharging of Cold Mix
Cold Mix Binder
Production of Cold Mix by Concrete Mixer
Laying of Cold Mix Rolling of Cold Mix
Seal-Coat Application Completed Road with Cold Mi x
Plant Mix Method – Uses HMP without Heating
Preparation of Cold mix
Laying of Cold Mix by Paver
Transfer of Cold Mix to Tipper
Rolling of Cold Mix
Comparison of Cold Mix and Hot mix Technology
Cold Mix Hot Mix
No heating – Saves Fuel and its Cost Requires 1,800 liters of fuel per Km
of PMGSY road
NO Pollution- Environment
Friendly
Polluting and energy intensive it
affects the health of public and
construction workers
Faster Progress and no
temperature control requirement
Slow Progress – Requires
temperature control and slow
progress
Local , unskilled and women
workers can execute the work.
Skilled and experienced workers
required
No chance of accident of labor Maximum chance of accident of
labor during work execution
Hot Mix is Harmful to Workers
Cold Mix: A Sustainable Technology Innovation for Road
Construction Labourers of North East, India, International
Review of Applied Engineering Research. ISSN 2248-9967
Volume 4, Number 4 (2014), pp.331-336 :
Sl. No. Name of Roads
1 GarAli to Medalujan Road Titabar, Jorhat (Assam)
2 Aanapurna Titabar Road, Titabar, Jorhat (Assam)
3 J.B.Road to Nij-Baligaon Road, Jorhat (Assam)
4 Naichuck to Lakhimikhat Road, Baligaon, Jorhat (Assam)
5 Sariamukh to thuramukh Road, Rangajan Golaghat (Assam)
6 Bokial To Purabangla Road, Bokial, Golaghat (Assam)
7 Lakhminath - Phukan Road near D.K.D. College, Dergaon, Golaghat
(Assam)
8 NH-37 to Khonikar Road, Dergaon, Golaghat (Assam)
9 Rajmai to Rajabari Road Rajmai, Sibsagar (Assam)
Performance of Cold Mix Technology
10 Rajuar to Balijan Road Sonari, Sibsagar (Assam)
11 P.G.J.H. to chapari Gaon Road, Majuli, Jorhat (Assam)
12 P.G.J.H to Ratanpur Miri Gaon Road, Majuli, Jorhat (Assam)
13 Borihat to Borpratima Phulguri Road, Mirza, Kamrup (Assam)
14 Urput to Kumaria Road, Mirza, Kamrup (Assam)
15 Bezera – Balikuchi – Rajkhuwa Suba Road, Bazera, Kamrup
16 NG Mandakata – Salmaraabz – Simalibari Road, Bezera, Kamrup
17 NH-31 Tinali to Matiapahar Road, North Guwahati, Kamrup
18 Barama to Bhalukdanga Road, Barama, Nalbari
19 Tihu to Mathurapur Road, Nalbari (Assam)
20 Borama to Kathailkuchi Road, Barama, Nalbari
21 Tihu Palister Road, Nathkuchi, Nalbari
Performance of Cold Mix Technology
22 Tukurakuchi to Batbari Road, Silbari, Baksa (BTAD) (Assam)
23 Hazua to Nalbari Road, Baksa (BTAD) (Assam)
24 Hazaua to Nalbari Road, Baksa (BTAD) (Assam)
25 Nalbari To Batbari Road, Doomni Jalahgaon, Baksa (BTAD)
(Assam)
26 Bhurbandha To Barwabhujia Road, Morigaon (Assam)
27 Mayangear to Kackadhara Road, Morigaon (Assam)
28 Bhurbandha to Sabukdhara Road, Morigaon (Assam)
29 Wabori to Hakudangbori Road, Morigaon (Assam)
30 North Salmara to Bakhalgaon, Abhayapuri, Bongaigaon (Assam)
31 Borghola to Tulungia RoadAbhayapuri, Bongaigaon (Assam)
Performance of Cold Mix Technology
32 Ekrabari to Barpukhuri Road, Abhayapuri, Bongaigaon (Assam)
33 Baghpara to Khagarpur Road, Ahayapuri, Bongaigaon (Assam)
34 Koreya – I to Koreya – II, Abhayapuri, Bongaigaon (Assam)
Performance of Cold Mix Technology
Harun Vanahally to Rangnehally
Road, Baragelahally Village, Terekare,
Chikmagalore, Karnataka
Exiting WBM Surface:
Trial near Bhubaneswar,
Orissa
� Potholes are bowl shaped formation
� Grow wider and deeper, if not attended
� Potholes on the road is a matter of
critics
� Cause of accidents on road
� People dies falling in deep potholes
� Cost of repair high with passage of time
� Repair by hot mix emit fumes
� Repairs do not last long
Sustainable repair techniques
� Cold mixes jet patcher
� Stock piled cold mix using cut back
� Ready to use patching mixes
� Emulsion based cold mixes
� Freshly prepared cold mixes
A view of Pothole
Sustainable Repair of Potholes and Patching
Surface repaired by JetpatcherA view of Jetpatcher
Potholes repaired by ready mix Cold mix in rectangular raveled surface
�Cold mix technology is environment friendly
�Cold mix technology helps in saving of fuel but
about 5 % costlier
�The use of cold mix technology is worker friendly
�The health of construction workers do not
deteriorate if road construction is done by cold
mix technology
�An assessment of CSIR-CRRI cold mix technology
was carried out by a social scientist
Conclusions
�It was concluded that cold mix technology is good
for health of construction workers as it prevents
burns, occurrence of diseases like asthma, cancer
and frequent vomiting
�Female construction workers prefer jobs of cold
mix technology
Partnership between CRRI and Bitchem
� CRRI developed technology and conducted field studies.
�Bitchem-CRRI commenced field performance
evaluation, 2009 onwards in Assam
�In 2010, World Emulsion Congress held in Lyon,
France invited CRRI and Bitchem for a
presentation of cold mix technology
�In 2013, CRRI granted Pan-India license to
Bitchem for scaling up cold mix technology in
roads sector
Policy Desired for Rural Roads
�To adopt Green Roads Mission for PMGSY promote
energy-efficient construction using cold mix
technology and other green technology
�Technology management agreement between CRRI,
Bitchem and NRRDA
�Policy decision to adopt 100 percent cold mix
technology in hilly regions, disturbed areas, wild life
and forest areas for faster progress
Technology Level
� The technology falls under existing technology that is
required for larger implementation, i.e. it can be used 100%
in DPRs
� It can be used both in new as well as ongoing works, even in
world bank funded projects
� It can be used in all applications like BM/SDBC, OGPC and
MSS
� IRC specifications IRC:SP:100 published in 2014
� 2500 km in different States viz. Assam, Tripura, Meghalaya,
Maharashtra, Karnataka, West Bengal, Himachal Pradesh
in last 5 years
Technology Management Agreement (TMA)
�A model for larger implementation to benefit from
the technological advantages of new technology like
cold mix technology
�TMA is a tool proposed to partner CRRI, Bitchem
and State Agency to achieve faster progress of works
under execution and to build green roads
TMA Framework
Benefit of TMA to State
�Outsource technical supervision of field implementation
to technology developer and technology provider, in this
case CRRI.
�Unlike hot mix carpeting, we have a strong agency to
back-up the department engineers for avoiding media or
public pressure in case of any issue.
�Plan execution of quality work by providing mandate to
an agency without spending any extra money on the
PMC services.
Like time, Science is not constant…it keeps changing and
evolving !
Build Roads Smarter Way …..the Greener Way..!
