Agenda

Indian Road Network

National Highways 58,112*
State Highways 1,37,119
Major District Roads 4,70,000
Village and Other Roads 26,50,000
Total Length 33,15,231
*National Highways are less than 2% of network but carry 40% of the total traffic

MODAL SHIFT
There has been a major shift in transportation mode from Railway s towards the Road
sector.
– Primary Network - Only 2 to 3 % 4 - laned , 15% single laned
– Primary/Secondary Network - Severe capacity constraint and lack of mobility
– Tertiary Network
- Connectivity an issue
- 40 % habitations not connected by all weather roads
CURRENT STATUS:
Road Railways
Passenger 85% 15%
Freight 70% 30%
 Types of Paved Roads
1996-97

845000
1000000
100000
9000
10000
1000
100
10
1
Bituminous Road Concrete Road

Bituminous Road
Concrete Road

Source: CMIE Data

 Flexible (Bituminous) Pavement Structure,
5% CBR and Traffic - 10-150 msa
Cumul Total Granul Granular
Bituminous Thickness & Composition, mm
ative Pavement ar sub-base,
Surfacing 800
traffic Thickness, base, mm
BC, DBM,
MSA mm mm 700
mm mm
600

500
10 660 40 70 250 300
400
20 690 40 100 250 300
300

30 710 40 120 250 300 200

100
50 730 40 140 250 300
0
10 20 30 50 100 150
100 750 50 150 250 300 Traffic, m sa

150 770 50 170 250 300

Source: IRC 37-2001

 Why bituminous Roads Fail?
• Prone to stripping by action of water
• Offer poor abrasion resistance
• Fuels and petroleum products dissolve
bitumen from the pavement
• UV rays make bitumen brittle
• Crack permeate water into the lower layers
of the pavement resulting in disintegration
of the pavement
This presented an opportunity to develop better
pavement materials system
 Grouted Macadam… Inception
• First project done on commercial basis in 2001.
• Patent has been applied
• CRRI has evaluated the technology.
• Till date we have done 4.80 lakh m2 or over
125 lane km.
• Orders in pipeline are for about Rs 40 crores /
9.7 lakh m2 /258 lane km.
• 75% of the above orders are under execution
(Rs. 30 crores).
 The Product
• Is a composite topping consisting of open-graded asphalt
completely filled up with the specially designed cement based
GROUTED MACADEM grout
• Is available as dry, ready-mix grout being used for execution of
road projects
• Is best suited for areas with:
- high Temperature fluctuations
- heavy mechanical loads
- requirement of high durability
- or where strengths of Asphalt do not suffice
 Grouted Macadam- Other Application Areas:

• Road Crossings
• Port Terminals
• Airports and Cargo terminals
• Storage Depots and Warehouses
• Bridge decks
• Container Depots
• Parking Areas
• Exhibition Areas
• Workshops etc.
 Grouted Macadam - Application Areas

• Bituminous Roads

• Pavements

• Damaged Concrete Roads and surfaces

• Resurfacing of worn out Asphalt surfaces

Grouted Macadam - The Benefits

• A Jointless Topping Material

• Stronger and more flexible surfaces
• Durable in aggressive environments
• Impervious and resistant to fuel oils, chemicals,
water etc.
• Ease of laying and Curing
 Grouted Macadam Roads - Extra Mileage On
Benefits

• Can have desired texture

• Provide anti-skid, high quality riding surface
• Significantly stronger than Bituminous materials and
more flexible than concrete
• Better Abrasion resistance than Concrete
• Lower curing time thus opening Grouted Macadam
roads to traffic within 1 day in comparison to
prolonged curing time required for Concrete Roads
 Grouted Macadam Roads
- Extra Mileage On Benefits (Contd.)

• Tolerates traffic from heavy lorries, forklifts,

cranes, tracked vehicles etc., without spalling and
crushing
• Cost effective as compared to Concrete Roads
• About double the life of Bituminous Roads or more
as per design parameters
• Endures strong static loads
• Proven in areas demanding high strength,
durability and chemical resistance
• Available in Black/Grey/Desired colours
 Application Guidelines
• Sub-base must be compacted and levelled according

to the standard practices of road construction

• Any unevenness, cracks, joints or holes should be
repaired and filled up
• A bonding agent is required to be applied to bind the
open-graded asphalt with the base
• Specific size aggregates selected for mixing with
bitumen should be dust and dirt free
 Application Guidelines (Contd.)
• Conventional asphalt batching plants are suitable
for producing the asphalt
• Asphalt laying can be carried out by either by using
a mechanical paver or manually
• Road rollers (not vibratory) are used for
compacting and finishing the asphalt surface
• On compaction of the asphalt laid by a smooth road
roller, after 24 hrs, Grouted Macadam mix is spread
on
the bituminous surface
• Surface ready for traffic within 24 Hours of laying
 Techno-economic Advantage of
Grouted Macadam
• The Grouted Macadam option was of
thickness from 30 mm to 75 mm. This
thickness was provided where the wear
course + the binder course needed re-laying.
• The cost of this thickness ranged between Rs
200-245 per m2
• This price is equivalent to the BC + DBM cost
 Development of Grouted Macadam
Property Bituminous Grouted Macadam
Concrete (BC)
(60/70)
Abrasion Resistance 1 40 times of BC

Modulus of elasticity 1 10 times higher than BC

Marshall Stability 1 2.5 times more than BC

Percent air void content 4.2 Nil
Loss of material in diesel oil seven 4.2 Nil
day immersion, %
Effect of UV rays Affected No Effect
Resistance to water-stripping Poor Excellent

Expected durability is therefore 4 times higher

Grouted Macadam Technology

• Grouted Macadam consists of an open

graded coated aggregates with voids
completely filled up with a special cement
based grout. The grout is ready-mixed
which, when mixed with water, is a very
light fluid material with high properties of
penetration and internal cohesion.

• Grouted Macadam is laid Jointless. The

special coated aggregates provide the
flexibility and the grout, with its
characteristic dense micro structure, high
wear resistance and high durability in
aggressive environments.
Step 1 Laying operation
Step 2 Laying operation
Step 3 Laying operation
Step 4 Completed
 GROUTED
MACADEM
BEING LAID

GROUTED MACADEM
GROUT
SEEPING
INTO ASPHALT
 Comparison Of Erosion, Abrasion Resistance And
Flexural Properties Of Concrete Vis-a-vis
Grouted Macadim
Cement Particle Abradibility Abrasion Resistance
Composites Index As per DIN 52108
BS 1902 IA (cc/50cm2)

Concrete M-40 30 ~10

Grouted Macadam <15 5

Road with Grouted 20 7

Macadam
 Comparision Of Mechnical Properties Of
Concrete Vis-a-vis Grouted Macadam
Cement Particle Comp. Flexural Modulus of Poisson’s
Composites Strength. Strength Elasticity Ratio
(Mpa) (Mpa) (Gpa)

Concrete M-40 40 5 25 0.24

Asphalt 1-2 <1

GROUTED 100 15 50
MACADEM
ROAD 10 6 8
WITH GROUTED
MACADEM
 Flexible (Bituminous) Pavement Structure

Porosity
• In India, road designs are regulated. IRC
Wearing Course 3-4 % 37 2001 is currently prevalent
7-8% • The Indian Road Congress (IRC) is an
Binder Course (BM/DBM) entity under the Ministry of Road
Transport & Highways
20-25%
Granular Base

50%

Granular Sub-Base
 TYPICAL SECTION SECTION WITH GROUTED MACADEM
NO Asphaltic
Asphaltic Concrete
40 mm Required
Concrete/BC

Bituminous Bituminous
75 mm Macadam + Grouted 40 mm
Macadam

(Dense) Bituminous Base

Macadam(optional)

230 mm Water Bound

Macadam 230 mm

Gravel Sub-Base
230 mm or CBR >30 230 mm
Filling Hard MurrumCBR>8

Say CBR Say CBR

Sub-Grade <6
<6
Traditional MIX Per cum cost Thickness(mm) Cost sq.meter
(BM)

Asphalt 1313 40 mm 52.5

Concrete

BM 4768 75 mm 357.6
Cost of BM+ Asphalt Layer 410
GROUTED Per cum Cost Thickness(mm) Cost sq.meter
MACADEM

BM 4768 40 mm 190

SLURRY Poured into the BM mix 240

Cost of 40 mm Thickness 430

 Important Terminologies
Rural Roads Lightly Trafficked State Highways National Highways &
Roads Expressways
Traffic Spectrum
0 msa 1 msa 10 msa 50 msa 150 msa

Million Standard Axles (msa): The design traffic is expressed in terms of cumulative
number of standard axles to be carried during the designed life of the road and
standard axle load being 8.16 tonnes.

Weak Soil Medium Strength Gravelly Soil

Soil
Quality of Soil
2% CBR 5% CBR 8% CBR 10% CBR
 Grouted Macadam Roads:advantages Over
Concrete Roads
•Durability
- Concrete Roads may be susceptible to sulphate and chloride attacks
- Grouted Macadam is 400 times more resistant than Concrete apart from

being impervious and resistant to chemicals, fuel oil and water

• Resistance to abrasion
- Concrete shows higher resistance to abrasion by two course laying viz.
using high quality aggregates (costlier), such as granite or basalt on the
wearing course
- Grouted Macadam is 30% more abrasion resistant than Concrete
•Surface Texture and Riding Quality
- Strict Supervision needed for Concrete laying and constructing of joints
for better surface
- Grouted Macadam being jointless is easy to lay and provides desired
texture and high quality riding surface
 Grouted Macadam Roads:advantages
Over Concrete Roads
•IRC 15-1981 - Specifies that design of roads should be based mainly on
flexural Strength of Concrete
Grouted Macadam has higher or similar (to M-40) Flexural Strengths

•IRC 15-1981 - Stipulates Curing techniques for Concrete Roads that are
cumbersome, costly, manpower intensive and spread over 28 days
Grouted Macadam has Curing time of 24 Hours from final laying

•IRC 15-1981 - Stipulates special methods of Sealing of Joints, both transverse

and Longitudinal
Grouted Macadam is jointless and simple to maintain
 Grouted Macadam Designed Roads- Sustenance
To Traffic

• Pavement designs normally consider standard Axle Load of 8.2

Tons or a wheel load of 4.1

• Further in India, overloading practice (10 T Lorry carries

15-20 T) with the chassis load takes standard Axle Load to
13 Tons or a wheel load of 6.5

• In India, no multiple axle vehicles are available as of now

and traffic growth is about 10-12% p.a., hence roads need to
be designed for higher wheel loads and increasing traffic density

Grouted Macadam designed roads can bear axle loads of 20-25 Tons in an
estimated life of about double the Bituminous roads or formulations can be
tailor-made according to design parameters
 Grouted Macadam Designed Roads-
some Salient Facts

•Grouted Macadam is more cost effective than

Concrete roads on initial investments specifically

• Cost of Grouted Macadam Road would be approx. 40

to 50% of Concrete Road

• GroutedMacadem Roads have negligible maintenance

costs as and is more or less similar to Concrete Roads
 CRRI Evaluation Summary
• “Overall pavement performance better than
bituminous sections”
• “Higher values of stiffness modulus indicate
improved resistance to deformation for ACCMarg as
compared to designed bituminous mix”
• “Stiffness modulus values at different temperatures
indicate better resistance to temperature variation in
case of ACCMarg as compared to BC mixes of 60/70
grade bitumen”
 CRRI Evaluation : Summary

Effect of Temperature on Stiffness Modulus, using

Notingham Asphalt Tester
200000
S tiffn e s s M o d u lu s , k2 g /c m

180000
BITUMEN
160000
ACCMARG
140000

120000

100000

80000

60000

40000

20000

0
0 15 30 45 60
0
Temperature, C
 CRRI Evaluation Summary (Cont’d)

• “Retained stability after immersion in water for ACCMarg

as compared to …..BC mix.. shows better resistance to
damage by water and moisture for ACCMarg.”

• “Negligible loss of material from core specimen of

ACCMarg in diesel oil against 4% loss in case of designed
and compacted BC mix indicates better resistance of
ACCMarg against damage due to spillage of petroleum
products.”
 Reference List
• Surat Municipal Corporation
• Bharat Petroleum Corporation
• Shapoorji Pallonji & Co Ltd, Mumbai
• Larsen & Toubro Ltd
• MMRDA
• Goa : City Roads
• Jharkhand : Ranchi, Dumka and Tisri
Sion Circle, Mumbai, (March 2001)
Mumbai-Pune
Expressway
(Feb 2002)
N.M. Joshi Marg (May
(May 2001)
2001)
Dadar Flyover Approach, Mumbai
(Dec 2002)
Kymore
Kymore Cement
Cement Works
Works
Bamangaon
Bamangaon to
to Plant
Plant (Dumper
(Dumper Road)
Road)
(2003)
(2003)
Dadar Flyover, Mumbai
Sion circle, Mumbai
 Cost
Materials for Pavement Work Cost per m2, Rs
Bituminous concrete (BC) wearing 120-150
course (40-50 mm thick)

Dense Bituminous Macadam (DBM) 210-510

(70-170 mm)
Granular Base (250 mm thick) 150-165

Granular Sub-base (300 mm thick) 150-210

 Reference List

MCGM CIDCO
• Resurfacing and strengthening • Resurfacing and strengthening
– Sion Circle – Panvel Creek Bridge
– N.M. Joshi Marg – Tolani fly over near Vashi
station
– Sion Station
MIDC
– Malad Sub-way – Thane Belapur Rd near
– L.B.S. Marg Mukand Steel
– Adishankaracharya Marg – Shirwane Block in New
– Side strip of Mumbai
Adishankaracharya Marg MSRDC
– Saki Vihar near L ward • Bridge decks
– Khandala Lonavla on the
Mumbai -Pune expressway
– Kon Kalamboli
Thank you