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H I G H W A Y

RESEARCH

NUMBER 38

General Report on

Road Research Work Done

In India during 2010-11

IRC HIGHWAY RESEARCH BOARD

Price ` 80.00 (Packing &

Postage Extra)

RECORD

Note:

This complete document is 184 pages long. Pages that are not relevant to the testing of SoilTech Mk. III Stabilizers have been purposely removed.

The complete document can be found at;

https://www.scribd.com/document/95128440/Highway-Research-Record-No-38-2010-11

(i)

CONTENTSPage No.

INTRODUCTION 1

EXECUTIVE SUMMARY 2

I. PAVEMENT ENGINEERING & MATERIALS 9

1. FLEXIBLE PAVEMENTS 9

SUMMARY 9

A. PROJECTS REPORTED FOR THE FIRST TIME 10

1. Development of Fly Ash –Waste Plastic Composite for Construction of 10

Bituminous Roads

2. Laboratory Study to Determine the Suitability of Fly Ash and Marble Dust as 10

Mineral Filler in Micro-Surfacing Mixture

3. Laboratory Evaluation of Warm Mix Additives 12

4. Feasibility Study on Use of RoadCem for Use in Situ Stabilization of Soil 12

5. Zyco Soil Nanotechnology Multilayer Waterproofing Treatment of Soil and 13

Asphalt Concrete in Road Construction

6. Zycosoil Nanotechnology Application in Leh Road, BRO 14

7. Evaluation of Bituminous Layers Bond Strength 14

8. Penetrative Preservation Installation Project NH8 Beawar to Gomti 15

9. Use of Fly Ash in Construction of Bituminous Road Surfacings 16

B. ON-GOING / COMPLETED PROJECTS 16

1. Use of Coir Geotextiles in Road Construction 16

2. Resource Mapping of Road Construction Materials in Kerala - Phase II 17

Pathanamthitta District

3. Study on the Use of Waste Plastic for Road Construction in Urban Areas 17

4. Development of Cold Mix Technology for Structural Layers of Flexible Pavement 18

in Different Climates

5. Performance Evaluation of Bituminous Concrete Surfacing Laid with SBS 19

Modified Bitumen (PMB-40) on NH-1, Near Delhi

6. Repair of Potholes and Patching using Jetpatcher and Infrared Recycling Patcher 20

7. Laboratory and Field Evaluation of Asphalt Mixes and Performance Evaluation of 20

Shell Thiopave Test Sections

8. Development of Methodology for Commissioning and ‘Site Acceptance Test (SAT)' 21

of ‘Heavy Vehicle Simulator (HVS)’ Type of APTF

ISSN 0970-2598

(ii)

9. Development & Design of Thin Stone Matrix Asphalt (TSMA) Mixes as Preventive 21

Maintenance Treatment

10. Development of Improved Quality Bituminous Binders through Polymer 22

Incorporation, Laying and Monitoring of Test Sections

C. R & D ACTIVITY REPORT BY CONSULTANCY FIRMS/CONTRACTORS/ 23

CONCESSIONAIRES

1. Design & Construction of Sub-Grade & Base Pavement Layers with Soil Stabilized 23

Base Course (SSB) for Lighter and Durable Highway Crust for Township Road at

M/s. Sasan Power Limited, Sasan, Madhya Pradesh (2nd Year)

2. Nano Polymer Base Stabilization of NH-1 Stretch on Panipat-Jhalandhar Section 29

from km 96.000 to km 387.000 in the State of Haryana & Punjab,

3. Village Road to Jhenjhari Joining State Highway Road of Durg to Dhamda under 31

PMGSY, Chhattisgarh

2. RIGID PAVEMENTS 36

SUMMARY 36

A. PROJECTS REPORTED FOR THE FIRST TIME 37

1. Technical Feasibility Studies on Geopolymer Based Building Blocks/Pavers 37

2. Study on Suitability of Synthetics Fiber Reinforced Concrete for the Construction 37

of Concrete Pavements

B. ON-GOING / COMPLETED PROJECTS 38

1. R & D Studies on Performance Evaluation of Rigid Pavements on High Density 38

Traffic Corridors Using Instrumentation Supported by Laboratory Tests

2. Effect of Bottom ash from Thermal Power Stations as an alternate to Fine Aggregate 38

in Cement Concrete

3. A Study on Dry Lean Concrete Containing Portland Pozzolana Cement 39

3. PAVEMENT EVALUATION AND PERFORMANCE 40

a. PAVEMENT EVALUATION 41

SUMMARY 41

A. PROJECT REPORTED FOR THE FIRST TIME 42

1. Evaluation of Master Plan Roads (60 m & 45 m ROWs) in Dwarka and Needed 42

Remedial and Improvement Measures

2. Design, Construction and Performance Evaluation of New Materials and Mixes 43

Towards Development and Upgradation of Standards / Specifications

3. Evaluation of Kosi- Nandgaon-Barsana-Govardhan Road and Needed Remedial 43

Measures

GENERAL REPORT ON

ROAD RESEARCH IN INDIA 2010-2011

INTRODUCTION

Highway Research Record No.38 describes the General Report on Road Research Work done in India during the year

2010-2011. This document has been prepared by compiling the progress of research work reported by 16 Research

Organisations and Academic Institutions in the country. The names of reporting organizations have been listed at the

end of the report. As the General Report on Road Research is intended to provide information on research works

carried out under various research projects, works reported on routine investigations and laboratory/ field testing have

been omitted from the document.

As per the classification, the entire material has been divided into four sections, namely, Pavement Engineering

& Paving Materials; Geotechnical Engineering; Bridge Engineering and Traffic & Transportation Engineering. The

projects in each section are further classified in to two broad categories namely (i) Projects Reported First Time, i.e.,

New Projects and (ii) Ongoing Projects/ Completed Projects. The research works carried out as a part of Master and

Doctoral thesis in the Academic Institutions have also been reported separately in Section V of the report.

The research work in each section has been reported as per the standard Proforma for the three broad categories of

projects. The proformae alongwith other related information are given in Appendix.

Each sectional report begins with a brief overview in the form of summary followed by a few salient points towards

channelising the discussions during the presentation of the report in the IRC Annual session.

2 GENERAL REPORT ON

EXECUTIVE SUMMARY

In the General Report on Road Research Work done in India for the year 2010-2011, published as Highway Research

Record No. 38, the research work done by 16 organisations on various aspects has been reported. The report has

been compiled by CRRI. The R&D work reported under the following five major areas and the research work done

in Academic Institutions related to the thesis work is reported under Section V:

1. Pavement Engineering and Paving Materials

2. Geotechnical Engineering

3. Bridge Engineering

4. Traffic & Transportation Engineering

1. Pavement Engineering and Paving Materials

In this chapter projects related to “Flexible Pavements,

Rigid Pavements, Pavement Evaluation, Pavement

Performance and Instrumentation” have been

reported.

1.1 Flexible Pavements

This subsection deals with projects reported in the

Flexible Pavement area related to design, construction

and materials. CSIR-Central Road Research Institute

reported twelve projects. The significant projects

pertain to use of flyash in construction of bituminous

road surfacing, development of cold mix technology for

structural layers of flexible pavement, performance of

bituminous concrete surfacing laid with SBS modified

bitumen, repair of potholes and patching using different

techniques/machines, evaluation of asphalt mixes

containing thiopave. The developments and design of

thin stone matrix asphalt for maintenance of flexible

pavements, and warm mixes for bituminous road

construction. Guidelines have been developed for

bituminous Macadam, Semi dense bituminous concrete

and Mix seal surfacing using cationic bitumen emulsion.

Studies on use of chemical additives for improvement of

engineering properties of sub grade are also reported

by different organisations.

National Transport Planning and Research Center

reported findings of studies on coir jute geotextile

and plastic waste in road construction. The resource

mapping of available road construction materials in

Kerala is also reported as a ongoing project. Feasibility

study on use of Road Cem for insitu stabilization of

soil has been completed. From the durability test, it

is concluded that the resistance to effect of water on

strength is enhanced by use of 0.1 percent additive

in cement stabilization. Two projects related to water

proofing treatment of bituminous pavement are

reported. Studies indicated significant improvement in

properties of soil as well as bituminous mixes. Studies

have been carried out on performance of crumb rubber,

SBS and EBA modified bitumen. Laboratory studies

on warm mix additives indicates that the addition of

0.5 percent additive by weight bituminous mix can

lower the mix laying temperature by 40°C to 50°C.

Successful installation and field calibration of State-

of-Art Accelerated Pavement Testing Facility, Heavy

Vehicle Simulator is also reported by CSIR-CRRI.

1.2 Rigid Pavements

Research works reported in the area of Rigid Pavements

relate to technical feasibility studies on Geopolymer

based building blocks/ pavers, R&D studies on the

performance evaluation of rigid pavements on high

density traffic corridors using instrumentation supported

by laboratory tests ( in continuation of the earlier

work reported), study on the properties of concrete

incorporating bottom ash/pond ash as a replacement

of fine aggregate, study on suitability of synthetics fiber

reinforced concrete for the construction of concrete

pavements, study on dry lean concrete containing

portland pozzolana cement and suitability of oil well drill

cuttings (Assam assets) for road making.

1.3 Pavement Evaluation

Research works reported in this area include projects

on structural and functional evaluation of pavements

and pre-mature distress / failure investigations for road

and airfield pavements. Completed projects include

Investigation to determine and ascertain the causes

of distress and suggest remedial measures for runway

pavement at Jaipur Airport.

On-going projects include Development of National

Document /Guideline on the Use of Weigh-In-Motion

System for Axle Load Monitoring. Development of

ROAD RESEARCH IN INDIA 2010-11 9

I. PAVEMENT ENGINEERING & MATERIALS

1. FLEXIBLE PAVEMENTS

SUMMARY

Research work reported under the area of Flexible Pavement includes studies to find out the possible utilization of fly

ash, marble dust and waste plastics as filler and fine aggregate in bituminous mixes. Laboratory and field performance

studies pertaining to the cold mixes, warm mixes additives for soil stabilization and use of nanotechnology based

materials in pavement layers have been also reported. Some of the reported studies includes performance of use of

coir and jute geotextile. Studies on use of plastic waste are also reported. Long term performance studies on use

of SBS modified bitumen on heavily trafficked roads have been completed. Laboratory studies on thin stone matrix

asphalt are also reported.

There are nine projects which have been reported first time. Twelve projects are reported under the ongoing and

completed project category.

SALIENT POINTS FOR DISCUSSION

1. Utilization of fly ash, waste plastic and marble dust in bituminous mixes

2. Use of warm mixes in bituminous road construction

3. Use of thin SMA for preventive maintenance of flexible pavement

4. Use of jute and coir based geotextile in pavements

5. Use of chemical additives include nanotechnology for stabilization of soil

6. Performance of polymer modified bitumen

7. Sustainable technologies for pothole repair & patching


Further Findings/Conclusions/Supporting Data

Based on the field observations, deflection data,

roughness data & subsequent laboratory analysis of

core samples, it was concluded that 25 mm SDBC

overlay constructed with Polymer and Crumb Rubber

modified binders sustained for three years more

than the conventional SDBC under the similar traffic

and and environmental conditions on SH-57.The

comparative performance was in the following order:

SBS>CRMB=EBA.

Recommendations for further Work

Thin PMB/CRMB overlays for State Highways catering

medium traffic.

Reports/Publications

● Development of Improved Quality Bituminous

Binders Through Polymer Incorporation , Laying

and Monitoring of Test Sections (SSP 4409)

Submitted in Jan, 2011

● Use of polymers/waste rubber in road network

in Uttarakhand, Kamal Kumar, and Singh (IIP),

Dr. Sangita, M.N. Nagabhushana, M.P. Singh

& Shivani (CRRI) 10th - 12th November, 2010

presented at Uttarakhand State Council for Scince

and Technology, Dehradun.

Further information/copy of report can be obtained from

Dr. P.K. Jain, Chief Scientist & Head, Flexible

Pavement Division, Central Road Research Institute,

New Delhi – 110 025.

Mobile 99101 13992 Phone 011-2631 1117,

2692 1833, 2692 1835 Fax +91 2684 5943,

e-mail ID: [email protected]

C. R & D ACTIVITY REPORT BY CONSULTANCY

FIRMS/CONTRACTORS/CONCESSIONARIES

1. Design and Construction of Sub-Grade and

Base Pavement Layers with Soil Stabilized

Base Course (SSB) for Lighter and Durable

Highway Crust for Township Road at

M/s. Sasan Power Limited, Sasan, Madhya

Pradesh (2nd Year)

Date of Starting and Duration: 02 Sep 2011

Date of Completion (Actual/Targeted) : 02 Sep 2011

i. Sasan Power Limited, Madhya Pradesh

(SPL)(I)

ii. Kaveri Unltra Polymers, Bangalore

Scope and Objectives

● To assess the suitability of SSB Layer with Nano

Polymer base “SoilTech MK-III” for Road, Runway,

Hard Strand Construction by comparing their

Physical, Engineering, Financial and Execution

time properties with those already implemented

vide IRC Codes, MORTH, MORD, NNRDA and

State PWD’s specifications by detailed Laboratory

investigations.

● To correlate design procedure with IRC:37;

as per the Pavement Crust Catalogue frizzed

in IRC:37, though; how the crust derived in

catalogue not detailed but formulas are given

for Layer Theory of Crust Design. Considering

the same formula but different E-module value

of higher strength Layer like SSB, design

establishment has been derived for failure of

Rutting and need to be endorsed.

● Design of Pavement Cross Section using

SoilTech MK-III, considering the actual traffic

to be stimulated over design life and site

condition.

● Geotechnical Laboratory and field investigation

to evaluate the suitability ofmaterial/design mix/

product application for real time construction.

● Quality execution and control assurance, guideline

and its implementation at site.

● Monitoring of performance of Constructed Road

over a period of time including monsoon which

includes DCP Test and APTF simulates.

Design, Drawing and Execution Methodology

Design of Road and Concept

As per IRC:37-2001, trail pavement design are to

be analyzed using linear elastic layered theory and

maximum vertical strain on sub-grade and maximum

tensile strain at the bottom of bituminous layer are

computed for a standard load. Design thickness

combination is so selected that the computed critical

strain values, which correspond to the initial condition

of the pavement, are less than the limiting strain

values given by the performance criteria adopted in

the guidelines. Limiting strain criteria have been given

in IRC:37 for two distresses: - rutting along wheel

paths and fatigue cracking in bituminous layers. No

separate criterion is available for rutting in bituminous

layers. The criteria for rutting and fatigue cracking

in bituminous layers are given in Equations 1 and 2

respectively.

24 GENERAL REPORT ON

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Thereafter the highway stretch had been constructed

with an over strength Nano Polymer Base Liquid called

SoilTech MK-III, as a composite SSB (Soil Stabilized

Base) Layer. While calculating the stress/strain failures

in Layer Theory formulated in IRC:37 for this crust, it was

found the reduced crust itself is more than enough to

take 5 CBR & 4 msa design over a period of 10 years.

Table B- Cross-Section Overview

CONVENTIONAL CRUST

PMC 20 mm

BM 50 mm

WMM 250 mm

GSB 250 mm

SUB GRADE 500mm

POLYMAR STABILIZED ROAD

SEAL COAT 10 mm

BM 40 mm

SOIL STABILIZED BASE 150 mm

GSB 125 mm

SUD GRADE 200 mm

Execution Methodology

● At first the selected borrow soil was spread over

the Sub-grade top layer.

● The additional blending of Aggregates for SSB

layer as per Design/requirement was spread over

the borrow soils for 150 mm thickness layer and

the aggregates mixed thoroughly with borrow soils.

● OMC of the material to be stabilized was

calculated as per lab. Thereafter SoilTech MK-III

@ 0.5 percent of the weight of Soil to be stabilized

was added to the water in the water tanker.

● This water mixed with Soil Tech was spread over

uniformly on the desired layer.

● Pulverization on the SSB layer after applying the

SoilTech MK-III.

● After proper mixing, the surface was graded to the

required camber and compacted to 98 percent of

MDD.

● On completion of stabilization , a diluted mix of

SoilTech + Water was sprinkled on treated road

surface in order to avoid dust during its usage by

the villagers and as the wearing course had be

done after 7 days.

Situations of Constructions

In this particular project the borrow/In-situ material

available in the entire stretch was plastic soil. Then,

additional 15 percent of 0 - 40 mm size aggregate

blended with this soil and then Soil Tech MK-III used. The

outcome is excellent with CBR more than 90 percent,

UCS 2918 KPa and Resilient Modulus 4578 MPa.

Performance of Such New Materials/Technology

The product had been invented long 13 years back

and being used extensively in South Africa, Australia,

Middle East, Europe and Far East Countries. Before

India Polyroads launched it commercially in India,

extensive trials were conducted in many places and

the outcomes are evaluated by Premier Authorities like

Central Road Research Institute, New Delhi, Indian

Institute of Technology, Kharagpur, West Bengal, Council

for Scientific Industrial Research, South Africa etc.

Annexed Tabular Reports are the fact finding results:

Table C

Sr. No.

Description Test Type

IIT, Kharagpur Test Results IPPL, GurgaonCSIR, South Africa

Test ResultsSasan Power Ltd Township Road

Natural Soil

With 0.5% SoilTech MK-III

by weight of Soil

Natural Soil

With 0.5% SoilTech MK-III by weight of

Soil

Natural Soil

With 0.5% SoilTech MK-III by weight

of Soil

Natural Soil

With 0.5% SoilTech MK-III by weight of

Soil

A. Physical Properties of Natural Soil

1 Gradation

Gravel (%) 17.00 12.00 24.00 4.3

Sand (%) 62.00 34.50 52.00 72.2

Silt & Clay (%) 21.00 53.50 24.00 23.5

2 Liquid Limit (%) 25.00 33.50 28.00 26.67

...Contd.


3 Plastic Limit (%) 13.00 19.60 18.00

4 Plasticity Index (%) 12.00 13.90 10.00 10.44

15%

Aggregate

Blending

materials

B. Laboratory Output results with Soil Tech MK-III

5 C.B.R. (%) 16.80 30.80 7.60 28.50 28.00 101.00 12.90 40.57

6 U.C.S. (KPa) 790 3871 378 1465 386 1100 (soaked) 2918

7 Resilient Modulus (MPa) 154 8016 268 6895 4578

C. Field Testing & Visual Observation

8 C.B.R. (%)

IIT & CRRI Laboratory Test Only

90

9 R.I.(mm/km) 1706

10 Rutting Not Found

11 Actual Traffic Stimulation 3,000 ESAL

Looking to Table C and Layer Theory of Highway

Design (IRC:37); it is now understood that once, we

are replacing Base /Sub-base Layer with SSB Layer,

the impact of wheel load or failure of Fatigue & Rutting

minimize substantially.

The most significant and impotent point in this road to be

noted that the Soil Stabilized Base (SSB) Layer which

is the top surface now has not been salted with the

designed Bituminous Layer. Already 2nd monsoon period

is going to get over and movement the earth moving

equipments such as dumpers, Tripper and 110 Transit

Mixture Machine on the bed of SSB layer is intact with

no Rutting, Porthole or any other failure.

Evaluation Report (Half Yearly) and Performance under

real traffic is regularly submitted to IRC and all other

premium Government Organisation.

Interim Conclusion

● The usage of Nano Polymer base SoilTech MK-

III has been optimized at 0.5 to 0.55 percent by

weight of Mix to be stabilized for cost effective

SSB Layer. In case, soil criteria don’t suit, then

additional blending of material recommended.

● The Geotechnical Characteristics, Laboratory

results and field in-situ results of many type of

soil stabilization are available. It is now time

to evaluate the standard of each based on

Strength, Durability and Ease of Application.

The outcome results of SoilTech MK-III is

substantially higher than any other stabilizer

and as it is used in OMC Ratio with water to be

pulverized, the ease of application and misuse

in this case is zero.

● Performance of real time traffic stimulation for

last twelve month shows that; this SSB Layer in

construction enhances the pavement life and also

minimizes the maintenance cost of pavement.

● Alternate composite design and pavement save

Time and enable first construction.

Connotation and Utilization Potential

● Substantially increases the Soil strength over

300 percent.

● Stabilized Base Layer has E- modulus of more

than 3000 MPa.

● Road can be designed with reduced Bituminous

and Base Layers.

● Thus; Reduction in Quarry/ Mining of Aggregate

is Substantial

● Reduction in Crust Layers Hence; reduction in

Construction time.

● Resulting in Lower Costs – Less equipment wear

and tear.

● Stabilization process simple- No Specialization

required.

● Exceeding AASHTO structural load bearing axle

capacity

● Environmental friendly and a green product, (Much

less CO2 emission than other stabilizers)

● Toxicity effect is Zero.

Contd. from prev. page...


Application of SoilTech MK-III on the SSB Stretch

SSB stretch after SoilTech used

Pulverization on the Compaction with 10 ton VibroProfile and Grading the top surface of SSB Layer Roller on the Stretch

Projects and Execution Photographs:

Before Soil Tech used

Additional R&D/works required in this Area

It may be excellent to stimulate the alternately designed

crust with HVS machine in CRRI campus or in any

project to know the life of road.

Further information/copy of report can be obtained

from

Kaveri Ultra Polymer P. Ltd, MultiTech Centre, 113B, Bommasandra Indl AreaHosur Road, BangaloreE: [email protected]: +91 80 4166 3444Cell: +91 988 602 8888


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2. Nano Polymer Base Stabilization of NH-1

Stretch on Panipat-Jhalandhar Section from

km 96.000 to km 387.000 in the State of

Haryana & Punjab

Date of Starting and Duration : 17 Dec 2010

Date of Completion (Targeted): 23 Dec 2011


● To assess the suitability of SSB Layer with Nano

Polymer base stabilizer “SoilTech MK-III” for

Road, Runway, Hard Strand Construction by

comparing their Physical, Engineering, Financial

and Execution time properties with those already

implemented vide current specifications by

detailed Laboratory investigations.

● To correlate design procedure with IRC:37; As per

the Pavement Crust Catalogue frizzed in IRC:37.

● Design of Pavement Cross Section using

Nano Polymer base stabilizer ‘SoilTech MK-III’

considering the actual traffic to be stimulated over

design life and site condition.

● Geotechnical Laboratory & field investigation to

evaluate the suitability of material/design mix/

product application for real time construction




Design, Drawing & Execution Methodology

a) Design of Road and Concept











in IRC: 37 for two distresses: - rutting along wheel



layers. The criteria for rutting and fatigue cracking

in bituminous layers are given as Equations 1 and 2

respectively.

Thereafter the highway stretch had been constructed

with an over strength Nano Polymer.

Base Liquid called SoilTech MK-III, as a composite

SSB (Soil Stabilized Base) Layer. While calculating

the stress/strain failures in Layer Theory formulated in

IRC: 37 for this crust, it was found the reduced crust itself

is more than enough to take 10 CBR & 10 msa design

over a period of 15 years.

Table B- Cross-Section Overview

CONVENTIONAL CRUST

BITUMINOUS CONCRETE

DENSE BITUMINOUS

WET MIX MACADAM 250 mm

GRANULAR SUB BASE 200 mm

SUB GRADE 500mm


BITUMINOUS CONCRETE


GRANULAR SUB BASE 150 mm

SUB GRADE 300 mm

b) Quantity & Resource’s Comparison

(Conventional Crust vs Alternate Crust)

Special Situations / Problems faced during

Investigations/ Constructions

In this particular project Panipat – Jhalandhar, NH-1,

Six Laning - the Borrow/ In-situ material available in

the entire stretch was less than 2µ particle size sandy

and non-plastic soil. The stabilization of the same was

not cost effective as coating area of SoilTech MK-III was

more and grading was not proper.

Then, additional 40 percent of 0 – 40 mm size aggregate

blended with this soil and then SoilTech MK-III used.

The outcome is excellent with CBR more than 218, UCS

1868 KPa and Resilient Modulus 1887 MPa.


The product Nano Polymer base stabilizer had been

invented long 13 years back and being used extensively

in South Africa, Australia, Middle East, Europe and Far

East Countries. Before India Polyroads launched it

commercially in India, extensive trials were conducted in


many places and the outcomes are evaluated by Premier

Authorities like Central Road Research Institute, New

Delhi, Indian Institute of Technology, Kharagpur, West

Bengal, Council for Scientific Industrial Research, South

Africa, Bhilai Institute of Technology, Durg, Chhattisgarh,

etc.


Table C Premium Organisation Investigation and Performance Report

Sr.

No.

Description Test

Type

IIT, Kharagpur Test

ResultsIPPL, Gurgaon

CSIR, South Africa

Test Results

IPPL-Panipat-Jh-

halandhar (NH-1)

Natural

Soil

With 0.5%

SoilTech

MK-III by

weight of

Soil

Natural

Soil

With

0.5%

SoilTech

MK-III by

weight of

Soil

Natural

Soil

With 0.5%

SoilTech

MK-III by

weight of

Soil

Natural

Soil

With 0.5%

SoilTech

MK-III by

weight of

Soil


1 Gradation

Gravel (%) 17.00 12.00 24.00 3.00

Sand (%) 62.00 34.50 52.00 62.00

Silt & Clay (%) 21.00 53.50 24.00 35.00

2 Liquid Limit (%) 25.00 33.50 28.00 20.00

3 Plastic Limit (%) 13.00 19.60 18.00 NA

4Plasticity Index

(%)12.00 13.90 10.00

NP 40% Ag-

g r e g a t e

B lend ing

materials

B. Laboratory Output results with SoilTech MK-III

5 C.B.R. (%) 16.80 30.80 7.60 28.50 28.00 101.00 12.00 46.00

6 U.C.S. (Kpa) 790 3871 378 1465 3861 1 0 0

(soaked)423 1868

7Resilient Modulus

(Mpa)154 8016 268 6895 154 3264

C. Field Testing and Visual Observation 7 Days 6 Months

8 C.B.R. (%)

IIT & CRRI

Laboratory Test Only

90 218

9Resilient Modulus

(Mpa)1448 1887

10 R.I. (mm/km) 1436 1232 1265

11 BBD Test (mm) 0.071 0.477

12 Rutting Not Found New Not Found

13 Fatigue Not Found New Not Found

14Actual Traffic

Stimulation1.80 MSA




the impact of wheel load or failure of Fatigue & Rutting

minimize substantially.

In Table C, it has been observed that after six months

report 1.80 MSA Real stimulation of traffic, there is no

major failure or deviation from the original construction

made.


Interim Conclusion


300 percent.


and Base Layers.


last six months shows that; this SSB Layer in

construction enhances the pavement life and also

minimizes the maintenance cost of pavement.


time and enable fast construction.

● Reduction in Quarry/ Mining of Aggregate is

Substantial


Construction time.





from

3. Village Road to Jhenjhari joining State

Highway Road of Durg to Dhamda under

PMGSY, Chhattisgarh

Date of Starting and Duration : 09 June 2010

Date of Completion (Actual/Targeted) :

09 June 2010

i. Pradhan Mantri Gram Sadak Yojana,

Chhattisgarh (PMGSY) (I)

ii. Bhilai Institute of Technology, Durg (BIT) (I)

iii. BSBK Private Limited Contractor Bhilai,

Chhattisgarh (BSBK) (I)

iv. Kaveri Ultra Polymers P. Ltd, Bangalore


● To assess the suitability of SSB Layer with

Nano Polymer base “SoilTech MK-III” for

Road, Runway, Hard Strand Construction

by comparing their Physical, Engineering,

Financial and Execution t ime properties

with those already implemented vide IRC

Codes, MORTH, MORD, NRRDA and State

PWD’s specifications by detailed Laboratory

investigations.

● To correlate design procedure with IRC:37; as per

the Pavement Crust Catalogue frizzed in IRC:37,

though; how the crust derived in catalogue not

detailed but formulas are given for Layer Theory

of Crust Design. Considering the same formula

but different E-module value of higher strength

Layer like SSB, design establishment has been

derived for failure of Rutting and need to be

endorsed.

● Design of Pavement Cross Section using Soil

Tech MK-III, considering the actual traffic

to be stimulated over design life and site

condition.

● Geotechnical Laboratory & field investigation

to eva luate the su i tab i l i ty o f mater ia l /

design mix/product application for real time

construction.

● Quality execution and control assurance, guideline

and its implementation at site.




Design, Drawing & Execution Methodology

a) Design of Road and Concept











in IRC:37 for two distresses: - rutting along wheel



layers. The criteria for rutting and fatigue cracking in

bituminous layers are given as Equations 1 and 2,

respectively.

Kaveri Ultra Polymers P. Ltd, MultiTech Centre113B, Bommasandra Indl AreaHosur Road, BangaloreE: [email protected]: +91 80 4166 3444


Ta

ble

A A

lte

rna

te P

av

em

en

t D

es

ign

As

pe

r I

RC

:SP

-72


Alternate Pavement Design as per IRC: SP-72 (Layer

Theory of Crust)

Table B Cross-Section Overview

CONVENTIONAL CRUST

PMC 20 mm with Seal Coat

WBM 225 mm

GSB 100 mm

Sub Grade 150 mm


PMC 20 mm with Seal Coat


Sub Grade 100 mm

The reduced crust itself is more than enough to take

3 CBR & 400,000 ESAL design over a period of 10 years.

b) Execution Methodology

● At first the selected borrow soil was spread over

the Embankment top layer.

● The additional blending of Aggregates for SSB

layer as per Design/requirement was spread over

the borrow soils for 100 mm thickness layer and

the aggregates mixed thoroughly with borrow

soils.

● OMC of the material to be stabilized was

calculated as per lab. Thereafter SoilTech MK-III

@ 0.5 percent of the weight of Soil to be stabilized

was added to the water in the water tanker.

● This water mixed with SoilTech was spread over

uniformly on the desired layer.

● Pulverization on the SSB layer after applied the

SoilTech MK-III.

● After proper mixing, the surface was graded to the

required camber and compacted to 98 percent of

MDD.

● On completion of stabilization, a diluted mix of

SoilTech + Water was sprinkled on treated road

surface in order to avoid dust during its usage by

the villagers and as the wearing course had be

done after 7 days.

Situations of Constructions

In this particular project the borrow/ In-situ material

available in the entire stretch was plastic soil. Then

SoilTech MK-III used in the borrow soil. The outcome

is excellent with CBR more than 66, UCS 1866 KPa &

Resilient Modulus 1708 MPa.


The product had been invented long 13 years back

and being used extensively in South Africa, Australia,

Middle East, Europe and Far East Countries. Before

India Polyroads launched it commercially in India,

extensive trials were conducted in many places and

the outcomes are evaluated by Premier Authorities like

Central Road Research Institute, New Delhi, Indian

Institute of Technology, Kharagpur, West Bengal, Council

for Scientific Industrial Research, South Africa, Bhilai

Institute of Technology, Durg, Chhattisgarh etc.


Table C Premium Organisation Investigation & Performance Report

Sr.

No.

Description Test

Type

IIT, Kharagpur Test

Results

CRRI, New Delhi, Test

Results

CSIR, South Africa

Test Results

PMGS&Y Road

Durg to Dhamda

Natural

Soil

With 0.5%

SoilTech

MK-III by

weight of

Soil

Natural

Soil

With 0.5%

SoilTech

MK-III by

weight of

Soil

Natural

Soil

With

0.5%

Soil

Tech

MK-III by

weight

of Soil

Natural

Soil

With

0.5%

Soil

Tech

MK-IIIby

weight

of Soil


1 Gradation

Gravel (%) 17.00 6.00 24.00 27.40

Sand (%) 62.00 88.60 52.00 51.40

....Contd.


Silt & Clay (%) 21.00 17.40 24.00 21.20

2 Liquid Limit (%) 25.00 34.00 28.00 31.85

3 Plastic Limit (%) 13.00 21.30 18.00 21.13

4Plasticity Index

(%)12.00 12.70 10.00

10.72

B. Laboratory Output results with SoilTech MK-III

5 C.B.R. (%) 16.80 30.80 4.80 34.00 28.00 101.00 10.40 43.69

6 U.C.S. (Kpa) 790 3871 3684 4 4

(soaked)386

1 1 0 0

(soaked)468 1866

7Resilient Modulus

(Mpa)154 8016 172 6254 268 6895 282 7568

C. Field Testing & Visual Observation 7 Days 1 Year

8 R.I. (mm/km)

IIT & CRRI

Laboratory Test Only

1638 1708

9 C.B.R. (%) 57 66

10 Rutting NewNot

Found

11Actual Traffic

Stimulation

1 0 , 0 0 0

ESAL




the impact of wheel load or failure of Rutting minimize

substantially.

The most significant and important point in this road is

to be noted that the Soil Stabilized Base (SSB) Later

which is the top surface now has not been sealted with

the designed Bituminous Layer. Already 2nd monsoon

period is going to get over and the bed of SSB layer

is intack with no Rutting, Porthole or any other failure

(Average Rainfall 1136 mm).

Evaluation Report (Half Yearly) and Performance under

real traffic is regularly submitted to IRC and all other

premium Government Organisation.

Interim Conclusion

● The usage of Nano Polymer base SoilTech MK-

III has been optimized at 0.5 to 0.55 percent by

weight of Mix to be stabilized for cost effective

SSB Layer. In case, soil criteria don’t suit, then

additional blending of material recommended.

● The Geotechnical Characteristics, Laboratory

results and field in-situ results of many type of

soil stabilization are available. It is now time

to evaluate the standard of each based on

Strength, Durability and Ease of Application.

The outcome results of SoilTech MK-III is

substantially higher than any other stabilizer

and as it is used in OMC Ratio with water to be

pulverized, the ease of application and misuse

in this case is zero.


last twelve month shows that; this SSB Layer

in construction enhances the pavement life

and also minimizes the maintenance cost of

pavement.


Time and enable first construction.

Connotation and Utilisation Potential


300 percent.

● Stabilized Base Layer has E- modulus of more

than 3000 MPa.


and Base Layers.

● Thus; Reduction in Quarry/ Mining of Aggregate

is Substantial


Construction time.

● Resulting in Lower Costs – Less equipment wear

and tear.

● Stabilization process simple- No Specialization

required.

Contd. from Previous page ....


Pulverization on the SSB stretch after Soil Tech used surface of SSB Layer Profiling and grading the top

Compaction with 10 ton Vibro. Roller on the Stretch Surface of SSB Layer Finished

● Exceeding AASHTO structural load bearing axle

capacity

Projects & Execution Photographs




Spreading the Borrow Soil at Site SoilTech MK-III on the SSB Stretch

Additional R&D / works required in this area

It may be excellent to stimulate the alternately designed

crust with HVS machine in CRRI campus or in any

project to know the life of road.


from

Kaveri Ultra Polymers P. Ltd, MultiTech Centre, 113B, Bommasandra Indl AreaHosur Road, BangaloreE: [email protected]: +91 80 4166 3444


ACKNOWLEDGEMENTS

The Highway Research Board (HRB) of the Indian Roads Congress (IRC) expresses thanks to

Dr. S. Gangopadhyay, Director, Central Road Research Institute (CRRI), New Delhi for preparation

of the General Report on Road Research Work Done in India during 2010-2011. The report

was prepared, compiled and edited by Shri T.K. Amla (Head, Information, Liaison & Training),

S/Shri R.C. Agarwal (Sr. Technical Officer (3)) and M.K. Meena (Scientist), Information, Liaison &

Training Division, CRRI with inputs from the scientists of the various R&D Divisions of CRRI viz.

Dr. P.K. Jain, Chief Scientist & Head (FPD), Dr. Renu Mathur, Senior Principal Scientist & Head

(RPD), Shri S.P. Pokhriyal, Senior Principal Scientist (PED), Dr. P. Lakshmy, Senior Principal Scientist

& Head (BAS), Shri R.K. Swami, Principal Scientist (GTE), Dr. S. Velmurugan, Principal Scientist

(TES) and Dr. K. Ravinder, Senior Scientist (TPE).

The useful suggestions received from the scientists of R&D Divisions in compilation and editing of the

report are gratefully acknowledged. The Board also expresses its gratitude to the various research

organizations and Institutes for providing research progress reports.

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