Crri Colas Project PDF

Field Performance Study of
STRUCTURAL LAYERS OF FLEXIBLE PAVEMENT IN

DIFFERENT CLIMATIC CONDITIONS
Laying of Bituminous Macadam with Emulsion

Based Cold Mix in Rajasthan
FLEXIBLE PAVEMENT DIVISION

CSIR- CENTRAL ROAD RESEARCH INSTITUTE,
(Council of Scientific & Industrial Research),
NEW DELHI-110025
October, 2010
1
Dr. S. Gangopadhyay : Director

Dr. Sunil Bose
: Head- Flexible Pavement & Coordinator,

COR-0013 Network Projects
PROJECT TEAM
Dr. N.K.S. Pundhir : Project Leader (Consultancy Project ) &

Task Leader - Network Activity 6 (A.1.2)
(E-mail: pundhir.crri@nic.in ,
pundhirnk@yahoo.com)
Sh. Jiwan Lal
: Technical Officer
ACKNOWLEDGEMENT
The report is a part of the Council of Scientific & Industrial Research (CSIR)
Network
Project
COR-0013.
During
implementation
of
the
project
M/s Hindustan Colas Pvt. Ltd. agreed to sponsor the field evaluation part of the
project for which we wish to extend our sincere thanks. We also extend our
sincere thanks to Hindustan Colas for providing bitumen emulsion for laying test
sections in Rajasthan, Mizoram and Jammu & Kashmir. We deeply acknowledge
with sincere thanks for the co-operation extended during the identification of test
sites in snow bound area (J&K) and desert area (Rajasthan) by Directorate
General Border Roads, Chief Engineers- Chetak and Beacon Projects,
Commanders of different BRTFs, Officer Commanding and other officials
especially from Beacon Project - 77 BRTF / 99 RCC and Chetak Project - 49
BRTF / 101 RCC. The assistance rendered by Border Roads Organisation is
gratefully acknowledged for providing manpower, materials & machineries during
the construction of test sections and their periodical performance evaluation. We
also extend our deep sense of gratitude to PWD Mizoram with special mention of
Sh. Vanlal Duhsaka, Chief Engineer, Sh. Dela, S.E and other officials for
providing test sites, man power and materials for laying test sections in Aizawl,
Mizoram. Thanks are also due to M/s OM Infrastructure for providing emulsion
for laying one test section in Mizoram. The assistance and cooperation rendered
by M/s Goyal Construction of Rajasthan and NBCC of Aizawl, Mizoram is
acknowledged for providing Bituminous Mix Plant and Paver for laying test
sections.
Thanks are also due to the staff of BRO, PWD Mizoram and Flexible Pavement
Division of Central Road Research Institute directly or indirectly connected.
DISCLAIMER
Central Road Research Institute (CRRI), New Delhi can accept no responsibility
for the inappropriate use of this report. Engineering judgment and experiences
must be used to properly utilize the principles and guidelines contained in the
report, taking into account available equipment, local materials and conditions.
All reasonable care has been taken in the preparation of this report; however, the
CRRI can accept no responsibility for the consequences of any inaccuracies,
which it may contain.
FOREWORD
The construction of bituminous roads by conventional methods is energy consuming
and pollutes the environment as a result of heating of bitumen and aggregates at
elevated temperatures. The findings of R & D programme for development of cold
mix technology for structural layers will address development of suitable emulsions
for open graded cold mixes including design methods and their validation by full
scale field trials, will enable highway profession for adoption of this technology.
There are no construction specifications for bituminous binder courses such as
bituminous macadam (BM) and wearing courses such as semi dense bituminous
concrete SDBC and mix seal surfacing (MSS) using cold mix technology. Therefore,
it is felt essential to develop the cold mix technology and to frame their specifications
and guidelines. To encourage environmentally friendly and energy efficient cold mix
technologies, Central Road Research Institute, with the help of Border Roads
Organisation and PWD Mizoram, conducted field trials for construction and
performance of BM as base course and wearing courses such as SDBC, MSS and
PMC using bitumen emulsion in desert climate (Rajasthan), heavy rainfall (Mizoram)
and in snow bound areas (J & K).
This report gives the details of selection of test sections, laboratory studies, and
construction of test sections with mechanized methods using mix plant, paver
and road roller;
and their
performance evaluation. It sets forth the
recommendations for cold mix technology using cationic bitumen emulsion in

road construction for bituminous macadam, semi dense bituminous concrete,
mix seal surfacing in different climatic condition in India.
Central Road Research Institute,
(Dr. S. Gangopadhyay)
New Delhi - 110 020

st
DIRECTOR
October, 2010
CONTENTS
S. No.
1.0
2.0
3.0
3.1
3.2
4.0
5.0
6.0
Content Description
Acknowledgements
Disclaimer
Foreword
List of Tables
List of Photographs
List of Figures
Executive Summary
INTRODUCTION
OBJECTIVES AND SCOPE
SPECIFICATIONS ADOPTED FOR TEST TRACK
Existing Construction Specifications with Emulsion
Specification Adopted For Test Sections
TEST LOCATIONS FOR TRIALS

4.1 Dantaur- Khajuwala Road in Desert Area in Rajasthan
4.2 Aizawl By-pass Road in High Rainfall Area in Mizoram
4.3 Jammu-Srinagar National Highway (NH-1A) in Snowbound and Cold Area ( J&K)
COLD MIX DESIGN OF SEMI-DENSE
BITUMINOUS
CONCRETE
(SDBC)
AND
BITUMINOUS MACADAM (BM)
5.1 Cold Mix Design
5.2 Development and Characterization of Emulsions
5.3 Characterization of Aggregate
5.4 Optimization of Premixing Water Content
5.5 Marshall Specimens for SDBC with emulsion
5.6 Optimisation of Emulsion Content
5.7 Cold Mix Design of BM
CO
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
CONSTRUCTION AND PERFORMANCE OF

BITUMINOUS MACADAM AND SEMI DENSE
BITUMINOUS CONCRETE/ MIX SEAL SURFACING
WITH BITUMEN EMULSION IN DESERT CLIMATES
(RAJASTHAN)
Construction of Bituminous Macadam with Emulsion
Preparation of Road Surface
Preparation of Cold Mix
Application of Tack Coat
Transportation of Mix
Spreading and Compaction of Cold Bituminous Mix
Traffic Control
Page
No.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
1
4
5
5
5
7
7
8
9
10
10
11
13
14
14
15
16
18
18
18
18
19
19
19
19
S. No.
Page
No.
Content Description
6.2 Construction of Semi dense Bituminous Concrete
(SDBC) with Bitumen Emulsion
6.2.1 Preparation of Road Surface Over
Macadam
6.2.2 Preparation of Cold mix
6.2.3 Transportation of Cold Mixes
6.2.4 Laying and Compaction of Cold Mixes
6.2.5 Traffic Control
Bituminous
6.3 Construction of Mix Seal Surfacing with Bitumen

Emulsion
6.3.1 General
6.3.2 Preparation of Cold Mix
6.3.3 Different Road Applications
6.4 Performance Evaluation of Test Sections
6.4.1 Visual Condition Survey
6.4.2 Results and Discussion
7.0
CONSTRUCTION
AND
PERFORMANCE
OF
WITH BITUMEN EMULSION IN HIGH RAINFALL
AREAS IN MIZORAM
7.1 Laying of Bituminous Macadam with emulsion
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6

Traffic Control
25
25
25
25
26
26
26
27
27
27
27
32
32
32
39
39
39
39
39
40
40
40
S. No.
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
Content Description
Construction of Semi dense Bituminous Concrete
(SDBC) and Mix Seal Surfacing with Bitumen
Emulsion
Preparation of Road Surface Over Bituminous
Macadam
Preparation of Cold mix
Transportation of Cold Mixes
Laying and Compaction of Cold Mixes
Traffic Control
Results and Discussion
7.3 Laying of Premix Carpet ( PMC) with Bitumen

Emulsion over Water Bound Macadam
7.3.1 Preparation of Road Surface
7.3.3 Laying of Premix Carpet
7.3.4 Performance Monitoring
8.0
Page
No.
44
44
44
44
45
45
45
46
52
52
52
52
52
CONSTRUCTION
AND
PERFORMANCE
OF
USING BITUMEN EMULSION IN COLD AND SNOW
BOUND AREA IN Jammu &Kashmir
Laying of Bituminous Macadam (BM) with Bitumen
emulsion
Traffic Control
56
8.2 Laying Semi Dense Bituminous Concrete with

Emulsion
8.2.3 Application of Tack Coat
8.2.4 Transportation of Mix
8.2.5 Spreading and Compaction of Cold Bituminous Mix
8.2.7 Performance of Semi Dense Bituminous Concrete /
MSS with Bitumen Emulsion
57
57
57
57
58
58
58
58
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
56
56
56
56
56
56
57
Sr. No.
9.0
Content Description
COST ANALYSIS OF CONSTRUCTION
EMULSION AND BITUMEN
Page
No
WITH
64
Economic Analysis
64
10.0
CONCLUSIONS
65
11.0
RECOMMENDATIONS
ANNEXURE-1
PROPOSED TENTATIVE SPECIFICATION FOR

BITUMINOUS MACADAM (BASE AND BINDER
COURSE) WITH CATIONIC BITUMEN EMULSION
66-67
68
ANNEXURE-2
PROPOSED TENTATIVE SPECIFICATION FOR

SEMI-DENSE BITUMINOUS CONCRETE (SDBC)
USING CATIONIC BITUMEN EMULSION
80
ANNEXURE-3
PROPOSED TENTATIVE SPECIFICATION FOR MIX

SEAL SURFACING (DENSE-GRADED PREMIX
CARPET) WITH CATIONIC BITUMEN EMULSION
92
LIST OF TABLES
Table
No.
1.
2.
3.
Description
Consumption of Bitumen Emulsion V/S Bitumen
Test Results Of Developed Cationic Bitumen Emulsion
Test Results of Cationic Bitumen Emulsion for Trials From
Hindustan Colas
Page
No.
2
11
12
Aggregate Gradation of Cold SDBC for Dantaur - Khajuwala

Road ( Rajasthan
13
Properties of Cold SDBC with Developed Emulsion
15
Performance Evaluation (Visual) of Test Tack in Rajasthan

(1st Inspection)
33
Performance Evaluation (Visual) of Test Tack in Rajasthan (

2nd Inspection)
34
Performance Evaluation (Visual) of Test Tack in Rajasthan (3rd

Inspection)
35
Performance Evaluation (Visual) of Test Tack in Mizoram
47
10
LIST OF PHOTOGRAPHS
Photo
No.
Description
Page
No.
Distress condition of road before laying test section on

Dantaur- Khajuwala Road ( Rajasthan)
20
Unevenness condition of road before laying test section on

Dantaur- Khajuwala Road ( Rajasthan)
20
Adding of Water Content in Aggregates before Mixing with

Bitumen Emulsion for Cold Mix
21
Distress condition in the form of ravelling on road before laying

test section on Dantaur-Khajuwala Road
(
Rajasthan)
21
Tack Coating with Bitumen Emulsion on Dantaur Khajuwala

Road
22
Site for Laying Test Sections on Dantaur- Khajuwala Road (

Rajasthan) with Border Roads Organisation and Hindustan
Colas
22
Transfer of Cold Mix into Paver for Laying
23
Laying of Cold Mixed Bituminous Macadam on DantaurKhajuwala Road ( Rajasthan)
23
Compaction of Cold Mixed Bituminous Macadam on DantaurKhajuwala Road ( Rajasthan)
24
10
View of Cold Mixed Bituminous Macadam on Dantaur Khajuwala Road ( Rajasthan)
24
11
Mixing Water in Aggregates before Mixing with Bitumen

Emulsion for Cold Mix
28
12
Modification of Hot Mix Plant for supply of bitumen emulsion for

laying test section on Dantaur- Khajuwala Road ( Rajasthan)
11
28
Photo
No.
Page
No.
Description
13
Laying of SDBC on Dantaur Khajuwala Road
29
14
Compaction of SDBC on Dantaur Khajuwala Road
29
15
Preparation of cold mix of MSS on Dantaur Khajuwala Road
30
16
Laying of MSS on Dantaur Khajuwala Road
30
17
Compaction of Cold Mixed MSS on Dantaur Khajuwala Road
31
18
View of Mix Seal Surfacing with Bitumen Emulsion on

Dantaur Khajuwala Road
31
19
SDBC with Emulsion After One Year Service Life
36
20
MSS with Emulsion After One Year Service Life
36
21
SDBC with Emulsion After One Year Service Life
37
22
MSS with Emulsion After One Year Service Life
37
23
SDBC with Emulsion After Two Year Service Life
38
24
MSS with Emulsion After Two Year Service Life
38
25
Examination of Bitumen Emulsion for Coagulation before its

Use
41
26
Preparation of Cold Mix for Bituminous Macadam
41
27
Tack Coating with Emulsion before Laying Bituminous

Macadam
42
28
Transfer of Cold Mix in Paver for laying Bituminous Macadam
42
29
Laying of Cold Mixed BM with Paver
43
12
Photo
No.
Description
Page
No.
30
View of Finished Bituminous Macadam Layer in Aizawl
43
31
Adding Optimum Water in Aggregates
48
32
Preparation of Cold Mix by HMP ( without heating facility)
48
33
Laying of Cold Mixed SDBC with Paver
49
34
Compaction of Cold Mixed SDBC
49
35
Finished SDBC with Emulsion on Aizawl By-pass
50
36
SDBC with Emulsion after a day on Aizawl By-pass
50
37
Satisfactory Performance of SDBC after 1 Year
51
38
Satisfactory Performance of MSS after 1 Year in March 08
52
39
View of Cold Mix for PMC
53
40
View of Tack Coating
53
41
View of Compaction of Cold PMC
54
42
Finished PMC after Construction in Aizawl, Mizoram
54
43
44
Satisfactory Performance of PMC after One Year in

Aizawl, Mizoram
Satisfactory Performance of PMC after One Year in Aizawl
55
55
45
View of Display Board for Field Trial on NH-1A near Srinagar
59
46
Preparation of Cold Mix by Cold Mix Plant ( HMP without

heating)
59
13
Photo
No.
Description
Page
No.
47
View of Tack Coating with Emulsion for Laying BM
60
48
Laying of Cold Mix by Paver on NH-1A (J&K)
60
49
View of Compaction of Cold Mixed Bituminous Macadam
61
50
View of Bituminous Macadam on NH 1A near Srinagar
61
51
View of Compaction of SDBC with Emulsion
62
52
Finished SDBC with emulsion after Compaction
62
53
View of SDBC with emulsion after 6 Months Under Snow
63
54
View of SDBC with emulsion after 6 Months Under Snow
64
14
LIST OF FIGURES
Photo
No.
Description
Page
No.
TEST TRACK WITH BITUMEN EMULSION DANTAURKHAJUWALA ROAD LAID IN APRIL 2007
TEST TRACK WITH BITUMEN EMULSION ON AIZAWL BYPASS AIZAWL ROAD LAID IN JUNE, 2007
TEST TRACK WITH BITUMEN EMULSION ON JAMMU SRINAGAR ROAD (NH - 1A) LAID IN SEPTEMBER, 2007
GRAPHICAL
GRADATION
13
PROPERTIES OF COLD MIX SDBC
PRESENTATION
15
OF
AGGREGATE
15-16
DEVELOPMENT OF EMULSION BASED COLD MIX TECHNOLOGY

FOR STRUCTURAL LAYERS OF FLEXIBLE PAVEMENT
Executive Summary
The construction of bituminous roads by conventional methods is energy
consuming and pollutes the environment as a result of heating of bitumen and
aggregates at elevated temperatures. The use of bitumen emulsion based cold
mix technology for road construction can bring about both energy saving and
pollution control by eliminating the heating of binder and aggregates. Central
Road Research Institute (CRRI) with the help of Border Roads Organisation
(BRO), Hindustan Colas (emulsion producer) and PWD Mizoram conducted field
trials to develop environmentally friendly and energy efficient cold mix technology
for structural layers of flexible pavement. The test sections were laid with
Bituminous Macadam (BM) as base course and semi dense bituminous concrete
(SDBC), Mix seal surfacing (MSS) and Premix carpet (PMC) as wearing courses
at three locations viz. (i) Dantaur - Khajuwala in Rajasthan in desert area, (ii) Bypass Road Aizawl, Mizoram in heavy rainfall area and (iii) NH-1A in J&K under
cold and snow bound area. Laboratory cold mix design for BM, SDBC and MSS
was developed using Marshall method. First time in India, the hot mix Plant (with
out heating facility) was used for manufacturing cold mixes and paver for laying
cold mixes for speedy road construction.
Post construction performance
evaluation of test sections was carried out periodically. The marginal aggregates
were used for construction of test sections in Mizoram.
The report is a part of the Council of Scientific & Industrial Research (CSIR)
Network Project COR-0013 and provides with the details of selection of test
sites, laboratory studies, laying of test sections with emulsion based cold mixes
with mechanized methods using hot mix plant (without heating facility), paver and
road roller; and their periodical performance evaluation. It sets forth the
recommendations for cold mix technology using cationic bitumen emulsion in
16
road construction and maintenance in different climatic condition in India. From

laboratory and field studies the following conclusions are drawn:
Construction of structural layer of bituminous road such as bituminous

macadam (BM) as base course; and semi dense bituminous concrete
(SDBC) and mix seal surfacing (MSS) as wearing courses using bitumen
emulsion based cold mixes is feasible with utilization of presently available
road construction infrastructure such as paver, roller and hot mix plant
(used with out heating arrangement ).
The performance of road specification BM + SDBC and BM + MSS was

found satisfactory.
The performance of road specification PMC was satisfactory in High

rainfall area ( Mizoram).
The slow set (SS-2) bitumen emulsion shall be used for preparation of
cold mix for PMC when using marginal aggregates instead of medium set
(MS) grade as provided in IRC-14.
Construction with cold mix is economical by 20 % as against hot mix.
The construction of road with emulsion based cold mixes is environment

friendly as heating is eliminated contrary to the conventional method of
using bitumen which require heating which leads to emission of pollutants
and degrade the environment
Construction of roads with cold mix technology is feasible in all climates

including cold and wet climates.
Reduction of cracks propagation to overlay when emulsion is used as it

seals the cracks
Tentative Specifications of Bituminous Macadam, Semi Dense Bituminous

Concrete and Close-graded premix carpet (MSS) with cold mix technology
are drafted and are given in the report as Annexure 1 to 3.
17
1.
INTRODUCTION
Hot mix technologies involving use of bitumen serve the intended purpose but create
environment problems during production of mixes and laying. The other vital issues
associated with construction, maintenance and operation of road network are
materials and energy conservation, which is to be addressed by taking up research
and development activities. The road sector alone account for 71 % of total High
Speed Diesel (HSD) consumed which amount to about 32 million tones in a year,
the retail price of which is of the order of Rs. 60,000 crore. A mere 10 % saving
through better use of cost effective technologies mean a great deal to our economy.
Hot mixed bituminous macadam and bituminous concrete form various structural
layers of flexible pavements. The construction of these by conventional methods is
energy consuming and pollutes the environment. Cold mixes consume less energy
and does not create environmental pollution. The proposed R & D programme for
development of cold mix technology for structural layers address development of
suitable emulsions for open graded cold mixes, performance based mix design
methods and their validation by full scale field trials is of vital importance for our
country.
Bituminous road construction with conventional paving grades bitumen is
sometimes not feasible or even not desirable in high rainfall areas as intermittent
rain throughout the year affect production and laying of mixes. In cold climate of
snow-bound areas, the hot bitumen looses its temperature rapidly and its binding
property on contact with existing cold pavement surface. Cutback bitumen is,
therefore, specified to overcome such problems but requires a little heating and
is accompanied by emission of solvents used as cutter stock, which create
marginal environmental problems.
Slow but steady rise in consumption of bitumen emulsion has been registered
from 1930-1950s. With the enforcement of stringent environmental law in USA
and European countries the growth of emulsion consumption in road construction
noticed a rapid growth. Now bitumen emulsions are used world-wide for different
18
applications in road construction due to several advantages such as elimination

of heating of binder and aggregate while producing mixes, coating of damp
aggregate, protection of environment and energy conservation. Despite being a
versatile material with several advantages, use of bitumen emulsion in India is
about 2.7% as compared to much higher consumption of about 43% in
Switzerland, France and other European countries (Table 1). This may be due to
the inexperience in adopting this technology, non-availability of proper machinery
and lack of quality bitumen emulsion.
Table-1: Consumption of Bitumen Emulsion V/S Bitumen (2009)
Country
Annual Tonnage
Bitumen
Percentage
Bitumen
Emulsion
USA
3,166,000
28,000,000
11.31
FRANCE
1,200,000
2,800,000
43.0
SPAIN
440,000
1,600,000
27.5
GERMANY
168,000
2,780,000
6.0
JAPAN
334,996
4,418,000
7.6
SWEDEN
69,000
492,000
14.0
AUSTRALIA
80,000
807,000
9.91
AUSTRIA
21,000
386,000
5.4
BRAZIL
420,000
1,336,000
31.42
SOUTH AFRICA
120,000
300,000
40.0
MEXICO
45,000
266,360
16.9
SAUDI ARABIA
12,000
89,000
13.5
TURKEY
20,000
600,000
3.3
RUMANIA
30,000
200,000
15.0
INDIA
70,000
30,50,000
4.3
UK
140,000
3.0
19
The cold mix technology is not a new one in the field of highway engineering.
This technology is becoming more attractive due to awakening about
environmental protection. Significant research and development work in
developed countries and in our own country has brought out improved quality of
bitumen emulsion. Some considerations such as concern about environmental
pollution, increased cost of energy, limited time period available for road
construction and maintenance work with hot mixes, will make the cold mix
technology a viable option.
There are few technical reasons against cold mix technology namely quality of
bitumen emulsions, long setting time before allowing traffic on roads, nonavailability of appropriate specifications and construction machinery. In order to
find answer to these queries and thereby create confidence among the user
agencies to adopt this technology the present study has been undertaken.
In order to develop cold mix technology for structural layers of flexible pavement,
CRRI has undertaken the task activity as part of CSIR Core Network Project
0013. The test sections of structural layers with bitumen emulsion of Hindustan
Colas were laid in Rajasthan, Mizoram and J&K from 2007-2008. Hindustan
Colas requested CRRI for post construction performance evaluation of test
sections vide their letter No. HIN/NK/0016 dated 23.10.2009. The report has
been prepared based on laboratory and field studies for cold mix design ,
characterization of materials, construction of test sections with mechanized
methods using hot mix plant ( without heating facility), paver and road roller; and
their periodical performance evaluation.
.
20
2.
OBJECTIVES AND SCOPE

The objectives and scope of this study are given under:
To develop formulation for bitumen emulsions suitable for different type

of aggregates available in India for design of structural layers of
bituminous
macadam
(BM)
as
base
course
and
semi-dense
bituminous concrete (SDBC) and mix seal surfacing (MSS) with cold
mixes
To develop performance based mix design procedure for base course

and wearing courses such as BM and SDBC / MSS
Validation of design procedure by full scale field trials in different

climates.
Development of methodology for preparation of cold mixes using hot

mix plant (without heating arrangement), laying of cold mixes by
paver , compaction and quality control of structural layers- BM and
SDBC / MSS using cold mixes in different climatic conditions of India.
Development of guidelines for design, construction and quality control

of structural layers of base and wearing courses using emulsion based
cold mixes.
21
3. SPECIFICATIONS ADOPTED FOR TEST Sections

3.1 Existing Construction Specifications with Emulsion
A quality emulsion and application specifications are important

factors to adopt the emulsion based cold mix technology. The prevailing
construction specifications in India are limited and given below:
IRC: 14- 2004.
Specification for Premix Carpet using cationic bitumen

emulsion.
IRC: 110-2005
Standard Specification and code of practice for design

and construction of surface dressing.
MOST-2001
Specification of tack coat for Roads.
There are no construction specifications for wearing courses such as

semi-dense bituminous concrete (SDBC) and Mix Seal Surfacing (MSS) with
bitumen emulsion. The specification of structural layers in base course i.e.
Bituminous Macadam (BM) with emulsion is not available, Therefore, it is
imperative to frame guide lines and specification of cold mix technology for
structural layers (BM) and semi-dense bituminous concrete (SDBC) and Mix
seal surfacing (MSS) with bitumen emulsion through laboratory study and
field trials by laying test sections in different climatic conditions. The cold mix
technology has been developed for Open Graded Premix carpet with
marginal aggregates of Mizoram.
3.2 Specification Adopted For Test Sections
Border Roads Organisation and other road building agencies provide surface
courses such as Dense Bituminous Concrete (DBC), Semi Dense Bituminous
Concrete (SDBC), Mix seal surfacing (MSS) and open graded Premix Carpet
22
(PMC). In view of economic consideration the Semi-Dense Bituminous

Concrete (SDBC) has been most significant specification besides Mix seal
surfacing. Hence both SDBC and MSS specifications were adopted for laying
test-sections. Under this project, test sections were laid with specification of
50mm BM as base course and 25mm thick SDBC or 25mm MSS with
bitumen emulsion as wearing courses were laid while control sections with
normal bitumen of 80/100 grade were laid as per IRC specification. The laying
of 25mm SDBC with bitumen was carried out as per the specification IRC: 951987 and the gradation of aggregates of the MOSRTH specification was
followed for construction of test sections with bitumen emulsion due to nonavailability of construction specification of SDBC with bitumen emulsion.
23
4. TEST LOCATIONS FOR TRIALS

Three locations, viz. (i) Dantaur-Khajuwala in Rajasthan in desert area,
(ii) By-pass Road Aizawl, Mizoram in heavy rainfall area and (iii) near Jawahar
Tunnel on Jammu-Srinagar National Highway (NH-1A) in J&K under cold and
snow bound area. The details of road conditions and structural evaluation are
given in the following sections:
4.1 Dantaur- Khajuwala Road in Desert Area in Rajasthan
The Dantaur- Khajuwala Road in Rajasthan passes through the plain terrain. The
existing road surface had developed distress in the form of cracking and
potholes. The detailed field investigation of the road indicated that overall crust
thickness consisted of 20mm premix carpet, 75mm water bound macadam,
120mm brick soling and 100mm kankar. Hence total crust thickness worked out
to 320mm. An equivalency factor of unity was assigned for existing black top
surfacing as it was in cracked and in fatique state. Field investigation and
laboratory indicated unsoaked CBR value of subgrade as 8%, and 3% when
soaked for four days. The traffic was reported 400 CVPD. Mostly buses and
Military armoured vehicles are plying on the road. As per IRC: 37-1984 CBR
value of subgrade in area where climate is arid throughout the year i.e. annual
rainfall is of the order of 50mm or less, may be determined in field condition. The
location of test track was selected from Km. 57.200 to km. 57.450 on DantaurKhajuwala Road.
The plan of the test tracks on Dantaur- Khajuwala Road (Rajasthan) is given in
Fig 1
24
FIG 1:- TEST TRACK WITH BITUMEN EMULSION DANTAUR- KHAJUWALA

ROAD LAID IN APRIL 2007
DANTAUR
50mm BM
50mm BM
50mm BM
50mm BM
25mm SDBC
25mm MSS
25mm SDBC
25mm MSS
Bitumen
Bitumen
Emulsion
Emulsion
KM 57.200
4.2
0. 275
0.350
0.400
0.450
Aizawl By-pass Road in High Rainfall Area in Mizoram
Aizawl By-pass Aizawl Road was taken up for field trials. The road stretch from
km 2.100 to 2.300 on Aizawl By-pass was selected for laying test sections with
bitumen emulsion. The plan of laying of test tracks on Aizawl By-pass Aizawl
Road is given in Fig 2
FIG 2:- TEST TRACK WITH BITUMEN EMULSION ON AIZAWL BY-PASS
AIZAWL ROAD LAID IN JUNE, 2007
HILL
TOP
KM 2.100
50mm BM
50mm BM
25mm SDBC
25mm MSS
Emulsion
Emulsion
KM 2.200
25
KM 2.300
4.3
Jammu-Srinagar National Highway (NH-1A) in Snow-bound and Cold

Area ( J&K)
Jammu-Srinagar National Highway (NH-1A) is most vital hill road in the
country. Due to geographical situation and extreme climatic conditions, the

construction and maintenance of this road is very difficult as working with
bitumen at higher temperature is not feasible in most of the year. The situation is
aggravated due to the fact that the highway traverses through almost all types of
geological formations and hilly terrain. The area beyond Jawahar Tunnel and
onward to Srinagar is snow-bound. Major landslides occur during monsoons and
massive snowfall in the area of Benihal make construction and maintenance very
difficult. A stretch of road from km 213.200 to km 213.400 near tunnel was
selected for laying test sections. The heavy trucks and military armoured vehicles
are plying on the road. The traffic as reported was 2692 commercial vehicle per
day (CVPD). The pavement surface was found in a distressed condition with map
and alligator cracking).
The test-section were laid on the existing distressed road after minor repair in
the form of patch and pot hole repair. The plan of laying of test tracks on Jammu
- Srinagar Road (NH-1A) is given in Fig 3
FIG 3 : TEST TRACK WITH BITUMEN EMULSION ON JAMMU - SRINAGAR

ROAD (NH - 1A) LAID IN SEPTEMBER, 2007
BENIHAL
TUNNEL
KM 213.200
50mm BM
50mm BM
25mm SDBC
25mm SDBC
Emulsion
Emulsion
KM 213.300
26
KM 213.400
5. LABORATORY DESIGN OF SEMI-DENSE BITUMINOUS CONCRETE

(SDBC) AND BITUMINOUS MACADAM (BM)
5.1 Cold Mix Design
At present, each authority or organization uses its own methodology derived
from their own experience and laboratory investigations. The development of
a standardized procedure for the design of mixtures containing bitumen
emulsion and aggregate presents a significant challenge to the highway
profession. The design of emulsion mixes is considerably more complex
because of the difficulty of duplicating field curing. In emulsion mixes, ultimate
stability and related properties are not reached until virtually all water in the
mixture has evaporated. Under field conditions, this evaporation may require
several months, even as much as two years. To measure the test properties
of cold mixes, it is necessary to devise some type of laboratory curing
procedure. The degree and rate of curing should bear a known relationship to
the curing of the mixture in the field. Laboratory methods used to remove the
water and the rate of water removal can have a significant effect on the test
values obtained. Rapid evaporation of water by oven drying may be
unrealistic and diminish the values of test properties. Some of the test
procedures involve air drying, whereas others involve oven drying (curing). In
some cases, mixtures are left in the forming mould for curing so that the air
does not penetrate the interior of the specimen. Whether the mixture is open
graded or dense graded will also affect the specific approach used and the
type of data required. The percentage of water, percentage of total fluids, and
mixing time are critical considerations with respect to coating and compaction.
Laboratory study includes the determination of cold mix design for SDBC and
BM and optimization of premix water content for SDBC, BM and MSS. The
detailed experimental work is presented in following sub-sections.
27
5.2 Development and Characterization of Bitumen Emulsions

The bitumen emulsions were developed at CRRI using combined PMB-Emulsion
pilot plant. The one of formulation of emulsion is given in Table 2. The emulsions
developed were manufactured by M/s Hindustan Colas in consultation with CRRI
and these emulsions were supplied by Hindustan Colas for laying test sections in
Rajasthan, Mizoram and Jammu & Kashmir.
Table 2.
S. No.
1)
2)
Test Results of Developed Cationic Bitumen Emulsion

Properties of Bitumen Emulsion
Residue on 600 micron IS sieve

(% mass)
Viscosity by Saybolt Furol Viscometer,
seconds at 250C
3)
SS-2 grade emulsion

Specified
Values
0.05
( max.)
Results
Obtained
0.01
30 - 150
108
Coagulation of emulsion at low

Nil
temperature
4)
Storage stability after 24 hrs., %, max.
1.0
5)
Particle charge
+ve
6)
Stability to mixing with coarse
NA
aggregate, % coagulation
7)
Coating ability and water resistance
NA
(a) Coating, dry aggregates
Coating after spraying water
(b) Coating, wet aggregates
8) Stability to mixing cement,
2.0
%coagulation
( max.)
9)
Miscibility with water (coagulation)
Nil
10)
Test on residue :
(a) Residue by evaporation, %
60 ( min..)
0
(b) Penetration, d mm at 25 C /100 gm 60-120
/ 5 sec.
(c) Ductility, 250C /cm.,
50(min.)
(d) Solubility in Trichloroethylene, % 98(min.)
28
Nil
0.4
+ve
NA
NA
1.6
Nil
65
89
90
99.5
Shelf Life Test : The shelf life test was conducted on emulsion by testing
emulsions after 6, 9 and 12 months and coagulation was not found which implies
that developed emulsions have shelf life of more than a year as required by BIS
standard. The particles of sizes in the range of 4-10 m were found after 6 month
which indicates stable emulsion (IS:8887-2004). The samples of bitumen
emulsion used in construction of test sections were evaluated for their properties
in accordance with IS: 8887- 2004. The coating test of aggregates suitability was
also carried out as per ASTM: D-2397. The test results of bitumen emulsion of
medium setting (MS) and slow setting (SS) grades are given in Table 3.
Table 3:Test Results of Bitumen Emulsion of Hindustan Colas for Trials
S.No
Results
Requirement of
.
obtained
IS:8887-1995
MS
SS-2
MS
SS-2
i)
Residue on 600 micron IS sieve
0.01
0.01
0.05
0.05
(% mass)
max.
max.
ii)
Viscosity by Saybolt Furol Viscometer,
seconds
At 250C
33.0
20-100
At 500C
98
50-400
iii)
Coagulation of emulsion at low
Nil
Nil
Nil
Nil
temperature
iv)
Storage stability after 24 hrs. , %, max.
0.6
0.2
1.0
1.0
v)
Particle charge
+ve
+ve
+ve
+ve
vi)
Stability to mixing with coarse
<40
<5
aggregate, % coagulation
vii)
Coating ability and water resistance
(a) Coating, dry aggregates
Good
Good
Fair
Fair
(b) Coating, wet aggregates
Fair
Fair
Fair
Fair
viii)
Stability
to
mixing
cement,
X
1.1
<2
%coagulation
ix)
Miscibility with water (coagulation)
Nil
Nil
Nil
Nil
x)
Test on residue :
(a) Residue by evaporation, %
66.1
61.7
65 min.
50 min.
0
(b) Penetration, 25 C/100 gm/5 sec.
96
205
60-210
60-210
(c) Ductility, 270C/cm.,
100+
87
75 min.
75 min.
(d) Solubility In Trichloroethylene, %
99.0
99.5
97.5
97.5
min.
min.
29
Characterization of Aggregate
The aggregates were tested for gradation and their properties as per IS :
2386 and the gradation and properties are given below in Table 4. The
gradation was found in specified gradation( Fig. 4)
Table 4. Aggregate Gradation of Cold SDBC for Dantaur- Khajuwala
Road ( Rajasthan)
Sieve
size(mm)
19
13.2
9.5
4.75
2.36
1.18
0.6
0.3
0.15
0.075
20mm
size
0
0
0
0
0
0
0
0
0
0
0
10mm
size
0.7
70
70
68
19
3
0
0
0
0
0
Stone
Dust
0.3
30
30
30
30
29
20
19
11
5
5
Combined Specified
Grading
Grading
1
100
100
100
100
98
90-100
49
35-51
32
24-39
20
15-30
19
0
11
9--19
5
0
5
3--8
120
100
% Passing by Weight
Coarse
Gradation
Fine Gradation
80
Blend
Gradation
60
40
20
22
.4
13
.2
11
.2
5.
6
2.
8
0.
71
0.
18
0.
35
5
0
0.
09
5.3
IS Sieve Size (mm.)
Fig.4: Graphical Presentation of Aggregate Gradation
30
5.4
Optimization of Premixing Water Content
For the determination of optimum water content for premixing, the quantity of
bitumen emulsion is first estimated using the following equation.
P = 0.05A+0.1B+0.5C
where ,
P = Quantity of bitumen emulsion, %
A = Percent aggregate retained on 2.8 mm sieve
B = Percent aggregate retained on 90 micron sieve
C = Percent aggregate passing on 90 micron sieve
Different batches of aggregates - emulsion mixes were prepared keeping
the above-predetermined quantity of bitumen emulsion constant and varying
the water content. The coated aggregates were visually observed for coated
area of aggregate with binder. The optimum water for SDBC was found 4.0 %
and BM 2.5% by weight of aggregates. However this quantity of optimum
water content may vary depending on site condition and quality of
aggregates. Similarly the premix water for MSS was found 3.0% by weight of
aggregate.
5.5 Marshall Specimens for SDBC with Emulsion
The Marshall test specimens were prepared with different bitumen emulsion.
1100gm graded aggregates were first moist with optimum water uniformly.
The 7 percent bitumen emulsion was then added to the wet aggregates and
mixed for 2 minutes for uniform binder coating. The cold mix was kept at 60oC
for three hours. The cured cold mix was then transferred into the Marshall
mould with a filter paper on base plate and compacted with 75 blows of
Marshall hammer on both faces. Similarly, the Marshall specimens were
prepared with optimum water content and other bitumen emulsion content of
8 and 9%. The Marshall specimens were extracted from the mould after 24
31
hours. Specimens were then cured in air oven at 400C for 72 hours. The
cured Marshall specimens were subjected to different tests such as bulk
density, stability and flow value in dry state at 250C. Different design
parameters like voids content, voids filled by binder will be calculated. The
properties of the cold mixes are given in Table 5.
Table 5 : Properties of Cold SDBC with Developed Emulsion
S. No.
5.6
Properties
Bitumen emulsion Content

7.0%
8.0%
9.0%
Bitumen residue, %
4.2
4. 8
5.4
Bulk density, gm/cc
2.33
2.37
2.34
Voids, %
11
Stability, kg. at 250C
470
600
535
Flow, mm
8.2
7.2
Optimisation of Emulsion Content : Optimisation of emulsion was
determined with the bulk density , air voids and stability of Marshall specimens.
1 2 .5
12
1 1 .5
11
1 0 .5
10
9 .5
9
2 .2 0 0
2 .1 8 0
2 .1 6 0
2 .1 4 0
4 .0 3
4 .5 8
5 .1 2
Air Voids, Percent
a ir vo id s
2 .2 2 0
gm/cc
Bulk Density,
b u lk d e n s it y
5 .6 6
B in d e r C o n te n t, M ix
Fig . 2 -a : P r o p e r ty o f C o ld S D B C M ix
32
stab
VFB
55
800
50
600
400
45
200
0
VFB, Percent
Stability, kg
1000
40
4.03
4.58
5.12
5.66
Binder Content, Mix
Fig. 5 : Properties of Cold Mix SDBC
The optimum emulsion content (SS-2) for Cold SDBC was 8% by weight
of aggregates for Rajasthan and J&K test section
The optimum emulsion content for Cold SDBC (SS-2) was 8% by weight
of aggregates for Marginal aggregate Mizoram test section
5.7
Cold Mix Design of BM with Bitumen Emulsion
The cold mix design for BM was carried out with emulsion (SS-2) in similar
manner as given in above paras.
The aggregates were tested for gradation and their properties as per IS :
2386 and the gradation and properties are given below in Table5.
33
Table 5: Aggregate Gradation of Cold BM for Dantaur- Khajuwala

Road ( Rajasthan)
Rajasthan
BM
50mm
Sieve
size
20
mm
0.4
10
mm
0.45
Stone
dust
0.15
Combined
1
mid
ll
ul
40
40
21
1
0
0
0
0
0
45
45
45
35
5
0
0
0
0
15
15
15
15
15
15
7
3
1
100
100
81
51
20
15
7
4
1
100
95
72
0
26
12
0
6
4
100
90
56
0
16
4
0
2
0
100
100
88
0
36
19
0
10
8
26.5
19
13.2
9.5
4.75
2.36
1.18
0.3
0.075
(MoSRTH)
The Marshall samples were tested at 25 oC and optimum emulsion was

determined for maximum density.
The optimum emulsion content (SS-2) for Cold BM was 6% by weight of
aggregates for Rajasthan and J&K test section
The optimum emulsion content for Cold SDBC was 7% by weight of

aggregates for Marginal aggregate Mizoram test section
34
6.0 CONSTRUCTION AND PERFORMANCE OF BITUMINOUS MACADAM

AND SEMI DENSE BITUMINOUS CONCRETE / MIX SEAL SURFACING
WITH BITUMEN EMULSION IN DESERT CLIMATE (RAJASTHAN)
6.1
Construction of Bituminous Macadam with Bitumen Emulsion

The existing pavement surface was in distressed condition with raveling,
cracks and pot holes (Photos 1 to 2). The pavement surface was thoroughly
cleaned of all dirt, dust and other loose materials by broom and brushes. Minor
irregularity and pavement distress such as pothole and patch were repaired by
cold mix. The cold mix in pothole was compacted after it turned black from brown
colour.
The bitumen emulsion was examined for coagulation of emulsion by
inserting the bamboo in the drums filled with bitumen emulsion. The bitumen
emulsion was usable when entire mass is of brown colour and no black sticky
material is found in the bottom of drum. The drums were rolled 4-5 times to and
fro for 4-5 m distance to mix the emulsion before using for preparation of cold
mix and other applications. The Hot Mix Plant (HMP) without heating facility was
used for preparation of cold mix. The hot mix plant was modified with erection of
bitumen emulsion tank to provide emulsion binder for aggregates. The
aggregates of different sizes 20mm, 10mm aggregate and stone dust were
charged from aggregate feeder on conveyor belt of Hot Mix Plant. The optimum
water content @ 3 per cent by weight of aggregate was added on conveyor belt
to damp the aggregate surface (Photo 3). The different sizes of aggregates were
then charged into the drum of HMP without heating facility. The 6 % quantity of
emulsion (SS-2) by weight of aggregates was added from emulsion tank by
pump and mixed uniformly. The prolonged mixing time was avoided as it causes
decoating of binder from aggregates. The cold mix from Mix Plant was
discharged to dumper to transport to site for laying (Photo 4).
35

The tack coat with bitumen emulsion of RS-1 or MS grade was applied
@ 3 kg for 10m2 area by means of pressure bar (Photo 5) on clean road surface.
The holes of nozzle were cleaned with water whenever tack coating was
discontinued to avoid choking of holes with residual bitumen. The tack coat
turned black from brown colour in 15-20 minutes. The road surface is made
damp by sprinkling of water before applying the tack coat with emulsion if road
surface is dry in summer months.
6.1.4 Transportation of Cold Mix
The cold mix was transported by dumper to site for construction of test
section (Photo 6). Due care was exercised to avoid early breaking of emulsion in
summer by putting wet gunny bags on cold mix.
6.1.5 Spreading and Compaction of Cold Mix
The cold mix was transferred from dumper into paver bin (Photo 7) for
spreading the cold mix on road surface. On half road width, the cold mixed BM
was spread over on tack coated area for thickness about 1/3 more than required
thickness by paver (Photo 8). The cold mix turns black from original brown colour
after 15-20 minutes when water of emulsion exudes after breaking of emulsion.
The cold mix was aerated for about one hour and then compacted with 8-10 ton
road roller (Photo 9). The rolling was done with the outside drive wheel covering
equal parts of the pavement and shoulder. The wheels of roller were kept wet
with water during compaction. The 8-9 passes shall be provided to achieve the
required compaction. The stiffness bituminous macadam was achieved with
passage of time (Photo 10).
The traffic was regulated at slow speed and test section was left open for
traffic after 3-4 hours. The traffic at some location could not be controlled at the
time of laying and traffic was allowed at slow speed as per IRC guidelines.
36
Photo 1: Distress condition of road before laying test section on DantaurKhajuwala Road (Rajasthan)
Photo 2: Unevenness condition of road before laying test section on DantaurKhajuwala Road (Rajasthan)
37
Photo 3: Adding of Water Content in Aggregates before Mixing with Bitumen

Emulsion for Cold Mix
Photo 4: Distress condition in the form of ravelling on road before laying test
section on Dantaur- Khajuwala Road ( Rajasthan)
38
Photo 5: Tack Coating with Bitumen Emulsion on Dantaur Khajuwala Road
Photo 6: Site for Laying Test Sections on Dantaur- Khajuwala Road ( Rajasthan)
with Border Roads Organisation and Hindustan Colas
39
Photo 7: Transfer of Cold Mix into Paver for Laying
Photo 8: Laying of Cold Mixed Bituminous Macadam on

Dantaur-Khajuwala Road (Rajasthan)
40
Photo 9: Compaction of Cold Mixed Bituminous Macadam

on Dantaur-Khajuwala Road ( Rajasthan)
Photo 10 : View of Cold Mixed Bituminous Macadam on

Dantaur - Khajuwala Road ( Rajasthan)
41
6.2
Construction of Semi dense Bituminous Concrete (SDBC) with

Bitumen Emulsion
6.2.1 Preparation of Road Surface over Bituminous Macadam

The Bituminous macadam surface was thoroughly cleaned of all dirt, dust
and other loose materials by broom and brushes. Minor irregularities were
rectified by repairing with cold mix before a day or two.
The bitumen emulsion was examined for coagulation in the drums of
bitumen emulsion as carried. The bitumen emulsion was only usable when entire
mass is of brown colour and no black sticky material is found at the bottom of
drum. Then the drums were gently rolled to and fro for distance of 4-5m for four
to five times to make the emulsion homogenous before preparation of cold mix
and other applications. The Hot Mix Plant without heating facility was used for
preparation of cold mix. The hot mix plant was rectified by erecting a bitumen
emulsion tank to supply emulsion for aggregates. The blended aggregates of
10mm and stone dust of specified gradation of were charged into HMP through
conveyor belt. The water content @ 4 per cent by weight of aggregate was
added into blended aggregates of SDBC grading over conveyor belt to wet the
aggregate surface (Photo 11). The required quantity of emulsion of SS-2 grade
@ 8% bitumen emulsion by weight of aggregates was added into wet aggregates
and mixed for about two minutes in drum. Prolong mixing was avoided as it tends
to decoat the binder from aggregate. The cold mix of brown colour was
discharged from Hooper into dumper (Photo 12) to transport to construction site
which is about 40km away.
The tack coat with bitumen emulsion of RS-1 grade was applied
@ 3 kg for 10m2 area by means of pressure bar as given in para 6.1.2 on clean
Bituminous Macadam (BM) surface. The holes of nozzle were cleaned with water
whenever tack coating was discontinued to avoid choking of holes with residual
42
bitumen. The tack coat turned from brown colour to black in 15-20 minutes
depending upon weather condition.
The cold mix was transported by dumper to site for construction for laying
cold mixed SDBC of test section. Due care was exercised to avoid early breaking
of emulsion in summer by putting wet gunny bags on cold mix.
6.2.5 Spreading and Compaction of Cold Mixes
The cold mix was transferred from dumper into paver bin for laying cold
mixed SDBC on Bituminous Macadam. For half road width, the cold mix was
spread over on tack coated area for thickness about 1/3 more than required
thickness by paver. The cold mix turns black from original brown colour after half
a hour when water of emulsion exudes after breaking of emulsion. The cold mix
was aerated for about one hour and then compacted with 8-10 ton road roller
(Photo 13). The rolling was done with the outside drive wheel covering equal
parts of the pavement and shoulder. The wheels of roller were kept wet with
water during compaction. The 8-9 passes shall be provided to achieve the
required compaction. The finished SDBC with emulsion was achieved
(Photo 14).
43
6.3
Construction of Mix Seal Surfacing with Bitumen Emulsion
6.3.1 General
Preparation of road surface was executed as mentioned in section 6.2.
The blended aggregates of 10mm and 10mm aggregates in 60: 40 ratio
were charged into HMP mixer. The water content @ 3 per cent by weight of
aggregate was added into aggregates over conveyor belt to wet the aggregate
surface. The required quantity of bitumen emulsion of slow set SS-2 grade @ 7
% by weight of aggregates was then mixed with aggregates for two minutes.
Prolong mixing was avoided as it tends to decoat the binder from aggregate. The
cold mix was discharged into trolley for transportation to the to construction site
( Photo 15).
6.3.3 Laying Test Section
Tack coating, spreading of cold mix and compaction of cold mixed MSS
with 8-10 Ton road roller( Photo 16 & 17) were carried as per para 6.2. The
photo 18 indicates the finished Mix seal surfacing (MSS) with emulsion..
The traffic was regulated and test section was left open for traffic after 4-5
hours. The traffic at some location could not be controlled after completion of
laying and traffic was allowed at slow speed as per IRC guidelines
44
Photo 11: Adding Water in Aggregates before Mixing with Bitumen Emulsion
for Cold Mix
Photo 12: Modification of Hot Mix Plant for supply of bitumen emulsion for
laying test section on Dantaur- Khajuwala Road ( Rajasthan)
45
Photo 13: Laying of SDBC on Dantaur Khajuwala Road
Photo 14: Compaction of SDBC on Dantaur Khajuwala Road
46
Photo 15: Preparation of cold mix of MSS on Dantaur Khajuwala Road
Photo 16: Laying of MSS on Dantaur Khajuwala Road
47
Photo 17: Compaction of Cold Mixed MSS on Dantaur Khajuwala Road
Photo 18: View of Mix Seal Surfacing with Bitumen Emulsion on

Dantaur Khajuwala Road
48
6.4
Performance Evaluation of Test Sections

6.4.1
Visual Condition Survey
All sections were usually observed for 8-point performance based

factors. These are General appearance of binder, Loss of aggregate,
Surface texture, Cracking, Pot holes, Surface evenness, Ravelling and
Stripping. The net result of this process of evaluation indicates a level of
performance and reduction in performance points indicates the
deterioration of service life of renewal treatment.
It is a pointer to
relative performance level in among different road test sections.

6.4.2

The performance evaluation was carried out periodically by a joint team
of CRRI, Border Roads Organisation / PWD and Hindustan Colas
Officials independently.
The marks obtained were also rated for
performance grading such as good (G) when marks were above 80%,
satisfactory (S) (60% - 80%), poor (P) (40% - 60%) and bad (B) (below
40%). These ratings have been denoted as G, S, P and B respectively.
The typical results for grade of marks allotted against the test sections
of BM+ semi-dense bituminous concrete or mix seal surfacing is given
in Tables 6, 7 and 8.
The construction of test sections BM + SDBC and BM + MSS using
emulsion based cold mixes and reference sections BM + SDBC using
hot bitumen mixes on Dantaur- Khajuwala Road in desert area was
found good as indicated by the marks obtained in the range above 91
to 93 percent for SDBC in first inspection carried out just after
construction. The marks obtained were above 80 percent so this was
placed in Good (G) rating. The 2nd Inspection indicated the good
performance of sections of SDBC / MSS with emulsion ( Photos 19 &
22) and with bitumen respectively. The evaluation of test sections in 3rd
inspection after two years showed negligible distress (Photo 23 & 24).
49
Table 6 :

Location
km 57.200
to
km 57.500
Inspection No.
1st
Date
16.04.2007
S.
No.
Factor
Bitumen
Performance
Marks
1
MSS
R
Aggregate
Surface
texture
Cracking
Pot. Holes
Surface
Evenness
Ravelling
Stripping
i) Normal
ii) Slightly dry/rich
iii) Dry/rich
iv) Very dry/rich
I) Normal
II) Less
III) Excessive
i) Good
ii) Satisfactory
iii) Smooth
iv) Coarse
i) No crack
ii) Fine hair cracks
iii) Localised cracks
iv) Scattered cracks
v) Extensive cracks
i) None
ii) Very few
iii) Scattered
iv) Extensive
i) Good
ii) Satisfactory
iii) Poor
iv) Very poor
i) None
ii) Very few
iii) Some
iv) Extensive
i) None
ii) Very few
iii) Medium
iv) High
Total Marks
10
7
5
3
10
5
3
10
7
5
3
10
7
5
3
1
10
7
5
3
10
7
5
3
10
7
5
3
10
7
5
3
Max. marks %
% Marks
Test sections
2
3
SDBC
MSS
R
T
9.2
9.2
10
10
10
10
9.5
9.0
10
10
73.5
73
74.4
74
80
80
80
80
92
91
93
93
Grading
Good
more than 80%
Satisfactory
60-80%
Poor
40-60%
Bad
less than 40%
T - Test Section with Emulsion.
R - Control (Reference) Section Dr. N.K.S. Pundhir, CRRI Naresh Prasad (AEE Civil) BRO
50
4
SDBC
T
Table 7:

Location
km 57.200
to
km 57.500
Inspection No.
2nd
Date
11.04.2008
S.
No.
Factor
Bitumen
Performance
Marks
1
MSS
R
Aggregate
Surface
texture
Cracking
Pot. Holes
Surface
Evenness
Ravelling
Stripping
v) Normal
vi) Slightly dry/rich
vii) Dry/rich
viii) Very dry/rich
IV) Normal
V) Less
VI) Excessive
v) Good
vi) Satisfactory
vii) Smooth
viii) Coarse
vi) No crack
vii) Fine hair cracks
viii) Localised cracks
ix) Scattered cracks
x) Extensive cracks
v) None
vi) Very few
vii) Scattered
viii) Extensive
v) Good
vi) Satisfactory
vii) Poor
viii) Very poor
v) None
vi) Very few
vii) Some
viii) Extensive
v) None
vi) Very few
vii) Medium
viii) High
Total Marks
10
7
5
3
10
5
3
10
7
5
3
10
7
5
3
1
10
7
5
3
10
7
5
3
10
7
5
3
10
7
5
3
Test sections
2
3
SDBC
MSS
R
T
4
SDBC
T
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
71
73
71
72
Max. marks %
80
80
80
80
% Marks
89
91.3
89
90
Grading
Good
more than 80%
Satisfactory
60-80%
Poor
40-60%
Bad
less than 40%
R - Control (Reference) Section Naresh Prasad (AEE Civil) BRO
51
Table 8 :
S.
No.

Location
km 57.200
to
km 57.500
Inspection No.
3rd
Date
29.11.2009
Factor
Performance
Marks
1
MSS
R
Bitumen
Aggregate
Surface
texture
Cracking
Pot. Holes
Surface
Evenness
Ravelling
Stripping
i) Normal
iii) Dry/rich
iv) Very dry/rich
i) Normal
ii) Less
iii) Excessive
i) Good
ii) Satisfactory
iii) Smooth
iv) Coarse
i) No crack
v) Extensive cracks
i) None
ii) Very few
iii) Scattered
iv) Extensive
i) Good
ii) Satisfactory
iii) Poor
iv) Very poor
i) None
ii) Very few
iii) Some
iv) Extensive
i) None
ii) Very few
iii) Medium
iv) High
Total Marks
10
7
5
3
10
5
3
10
7
5
3
10
7
5
3
1
10
7
5
3
10
7
5
3
10
7
5
3
10
7
5
3
Average Marks of Test sections

2
3
4
SDBC
MSS
SDBC
R
T
T
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
68
68
68
66
Max. marks %
80
80
80
80
% Marks
85
85
85
83
Grading
Good
more than 80%
Satisfactory
60-80%
Poor
40-60%
Bad
less than 40%
R - Control (Reference) Section
Neeraj Chaube
(Supdt B/R II-BRO)
52
Naveen Kumar, Sale Engineer

HINCOL
Photo 19: SDBC with Emulsion After One Year Service Life
Photo 20: MSS with Emulsion After One Year Service Life
53
Photo 21: SDBC with Emulsion After One Year Service Life
Photo 22: MSS with Emulsion After One Year Service Life
54
Photo 23: SDBC with Emulsion After Two Year Service Life
Photo 24: MSS with Emulsion After Two Year Service Life
55
7.0
CONSTRUCTION AND PERFORMANCE OF BITUMINOUS MACADAM

AND SEMI DENSE BITUMINOUS CONCRETE /
MIX SEAL
SURFACING WITH BITUMEN EMULSION IN HIGH RAINFALL AREAS
IN MIZORAM
7.1
Laying of Bituminous Macadam with Bitumen emulsion:

The emulsion was checked for its quality by inserting bamboo into emulsion drum
( Photo 25). The drums of emulsion were rolled for a distance of about 4-5 m. to
and fro for four to five times to make the emulsion homogeneous before its use.
The pavement surface was thoroughly cleaned of all dirt, dust and other loose
materials. All the cracks were cleaned and filled with bitumen emulsion of slow
setting (SS-2) grade by spraying the material @ 5 kg per 10m2 area. The
aggregate passing 2.8mm and retained on 180m were spread over the tacky
surface and compacted with 8-10 tones road roller for cracks of 3mm wide.
Proper cleaning was carried out in dry road condition before applying tack coat.
The graded aggregates of BM after blending different size of aggregates were
charged into HMP. Optimum water 3% by weight of aggregates was added on
conveyor belt. The required quantity of bitumen emulsion of SS-2 grade ( 6% by
wt. of aggregates) was then added into damp aggregate at ambient temperature
and mixed for two minutes to prepare cold mix . The additional time of mixing
was avoided as it causes decoating of binder from aggregates. The cold BM mix
was discharge into dumper ( Photo 26).
The tack coat with bitumen emulsion of RS-1/ MS grade was applied @ 3 kg for
10m2 area by mean of perforated cans as per IRC specification ( Photo 27). The
holes of cans were cleaned with water whenever tack coating was discontinued
to avoid choking of the holes with residual bitumen. The cold mix was spread
when tack coat turned black from brown colour after 15-20 minutes. At this point
all water of emulsion was dissociated from bitumen by coagulation and drained
56
off leaving behind the residual bitumen on the road surface. The road surface
was made wet or damp if found dry, before applying the tack coat with emulsion.
The cold mix was then discharged in wheel barrow and transported to
construction site for spreading cold mix on tacky road surface. Due care was
exercised to avoid taking wheel barrows on newly laid surface.
7.1.5 Spreading and Compaction of Cold Bituminous Mix
The cold mix was put into paver for spreading on half of road width (Photo 28).
The cold mix was laid over the tacky surface and spread uniformly by paver
(Photo 29) in required thickness of about 75 mm loose mix to get 50mm
compacted BM layer. The cold mix turns black from brown colour after some time
when water of emulsion exudes after breaking of emulsion. The cold mix was
aerated for about two hours and then rolled with 8-10 tones three-wheel roller to
compact the cold mix to achieve BM layer ( Photo 30). The rolling was done with
the outside drive wheel covering equal parts of the pavement and shoulder. The
wheels were kept wet with water during compaction. The rolling was also
repeated after 2 hours.
7.1.6
Traffic Control
The traffic was regulated and test section was left to open for traffic after 4 -5
hours. The traffic at some test sections could not be controlled after completion
of laying and hence, it was allowed at slow speed as per IRC guideline.
57
Photo 25: Examination of Bitumen Emulsion for Coagulation before its Use
Photo 26: Preparation of Cold Mix for Bituminous Macadam
58
Photo 27: Tack Coating with Emulsionbefore Laying Bituminous Macadam
Photo 28: Transfer of Cold Mix in Paver for laying Bituminous Macadam
59
Photo 29: Laying of Cold Mixed BM with Paver
Photo 30: View of Finished Bituminous Macadam Layer in Aizawl
60
7.2 Construction of Semi dense Bituminous Concrete (SDBC) and

Mix Seal Surfacing with Bitumen Emulsion
7.2.1 Preparation of Road Surface Over Bituminous Macadam
The Bituminous macadam surface was thoroughly cleaned of all dirt, dust
and other loose materials by broom and brushes. Minor irregularities were
rectified by repairing with cold mix before a day or two.
7.2.2 Preparation of cold mix
The bitumen emulsion was examined for coagulation of emulsion by
inserting the bamboo in the drums of bitumen emulsion. The bitumen emulsion
was only usable when entire mass is of brown colour and no black sticky material
is found at the bottom of drum. Then the drums were rolled to and fro for distance
of 4-5m for four to five times to make the emulsion homogenous before using for
preparation of cold mix and other applications. The Hot Mix Plant (HMP) without
heating facility was used for preparation of cold mix. The hot mix plant was
modified with erection of bitumen emulsion tank to provide emulsion for
aggregates. The blended aggregates of 13.2mm, 10mm and stone dust of
specified gradation of SDBC were charged into HMP through conveyor belt. The
water content @ 5 per cent by weight of aggregate was added into blended
aggregates over conveyor belt (Photo 31) to wet the aggregate surface. The
required quantity of emulsion of SS-2 grade @ 9% bitumen emulsion by weight
of aggregates for SDBC was added into wet aggregates and mixed for about two
minutes in drum. The cold mix of brown colour was discharged from Hooper into
dumper (Photo 32) to transport to construction site which is about 4 km away.
7.2.3 Application of tack coat
The tack coat with bitumen emulsion of RS-1 grade was applied
@ 3 kg for 10m2 area by means of pressure bar on clean Bituminous Macadam
(BM) surface. The holes of nozzle were cleaned with water whenever tack
coating was discontinued to avoid choking of holes with residual bitumen. The
tack coat turned from brown colour to black in 15-20 minutes depending upon
weather condition.
61

The cold mix was transported by dumper to site for construction for laying
cold mixed SDBC of test section. Due care was exercised to avoid early breaking
of emulsion in summer by putting wet gunny bags on cold mix.
7.2.5 Laying and Compaction of Cold Mixes
The cold mix was transferred from dumper into paver bin for laying cold
mixed SDBC on Bituminous Macadam. On half road width, the cold mix was
spread over on tack coated area for thickness loose 33mm for getting compacted
25mm SDBC layer by paver ( Photo 33). The cold mix turns black from original
brown colour after half a hour when water of emulsion exudes after breaking of
emulsion. The cold mix was aerated for about one hour and then compacted with
8-10 ton road roller (Photo 34). The rolling was done with the outside drive wheel
covering equal parts of the pavement and shoulder. The wheels of roller were
kept wet with water during compaction. The 8-9 passes shall be provided to
achieve the required compaction. The finished SDBC with emulsion was
achieved (Photos 35 & 36).
7.2.6 Traffic control
62
7.2.7

The performance of test sections and reference sections were monitored by
team of officials of CRRI and PWD Mizoram. All sections were usually
observed for 8-point performance based factors and were rated against
each factor using performance evaluation proforma by individual officers
independently. The marks obtained were also rated for performance grading
such as good (G), when marks were above 80%, satisfactory (S) (60% 80%), poor (P) (40% - 60%) and bad (B) (below 40%). The grade of marks
allotted against the test sections of BM+ semi-dense bituminous concrete or
mix seal surfacing just after construction were found to be above 91 % are
given in Table 9.
The construction of test section was found good with finished SDBC and
MSS Surface having more than 90 marks. The performance of cold mixed
SDBC and MSS over cold mixed BM was rated good after one year
Photos 37 & 38).
63
Table 9 :
S.
No.
Performance Evaluation (Visual) of Test Tack in Mizoram

Location
km 0.200
to
km 0.500
Inspection No.
1st
Date
16.06.2007
Factor
Bitumen
Aggregate
Surface
texture
Cracking
Pot. Holes
Surface
Evenness
Ravelling
Stripping
Performance
Marks
Marks of Test section

1
MSS
T
9
4
SDBC
T
9
10
10
10
10
74
Max. marks %
73
80
80
% Marks
91
93
i) Normal
iii) Dry/rich
iv) Very dry/rich
i) Normal
ii) Less
iii) Excessive
i) Good
ii) Satisfactory
iii) Smooth
iv) Coarse
i) No crack
v) Extensive cracks
i) None
ii) Very few
iii) Scattered
iv) Extensive
i) Good
ii) Satisfactory
iii) Poor
iv) Very poor
i) None
ii) Very few
iii) Some
iv) Extensive
i) None
ii) Very few
iii) Medium
iv) High
Total Marks
Grading
Good
Satisfactory
Poor
Bad
10
7
5
3
10
5
3
10
7
5
3
10
7
5
3
1
10
7
5
3
10
7
5
3
10
7
5
3
10
7
5
3
more than 80%

60-80%
40-60%
less than 40%
Dr. N.K.S. Pundhir, Scientist, CRRI
64
Photo 31: Adding Optimum Water in Aggregates
Photo 32: Preparation of Cold Mix by HMP ( without heating facility)
65
Photo 33 : Laying of Cold Mixed SDBC with Paver
Photo 34: Compaction of Cold Mixed SDBC
66
Photo 35: Finished SDBC with Emulsion on Aizawl By-pass
Photo 36 : SDBC with Emulsion after a day on Aizawl By-pass
67
Photo 37 : Satisfactory Performance of SDBC after 1 year
Photo 38: Satisfactory Performance of MSS after 1 year in March 2008
68
7.3 Laying of Premix Carpet (PMC) with Bitumen Emulsion over

Water Bound Macadam
The procedures of laying of premix carpet with bitumen emulsion are innovative
and are different from IRC-14-2004 due to the use of marginal aggregates of
Mizoram. The water absorption of aggregates was 1.92 % and AIV was 34
resulting in crushing during transportation and compaction.
7.3.1 Preparation of Road Surface: The pavement surface was cleaned of dirt,
dust and loose materials. The tack coat with SS-2 grade emulsion over WBM
was provided with 5 kg per 10m2 area (Photo 39). The cold mix shall be laid
when tack coat turns black from brown.
7.3.2 Preparation of Cold Mix :The blended aggregates of 13.2 mm and 11.2
mm in 2:1 ratio as per requirement were charged in the mini hot mix plant used
with out heating arrangement. The optimum water i.e. 4% by weight of
aggregates was added to wet the aggregates. The emulsion of slow set (SS-2)
grade in required quantity ( 7% by wt. of aggregates) was then added into wet
aggregate gradually and mixed for two minutes to get uniform coating. Prolonged
mixing was avoided as it will decoat the aggregate.
7.3.3 Laying of Premix Carpet :The cold mix was transported to laying site.
The cold mix was spread manually for loose thickness of about 30mm over tack
coated area over WBM. The bitumen emulsion was sprayed over cold mix (
Photo 40) and compacted to get premix carpet with emulsion based ( Photo 41).
By this process, the laying of liquid seal was avoided as crushing of marginal
aggregates left very smooth surface. The surface was opened after 2-3 hours.
The good surface of SDBC was found (Photo 42)
7.3.4 Performance Monitoring : The performance of test sections was
monitored by team of officials of CRRI, PWD Officials. All sections were usually
observed for 8-point performance based factors and were rated against each
factor
using
performance
evaluation
proforma
by
individual
officers
independently. The performance of test section of PMC was monitored by PWD

Mizoram and reported that the performance of PMC was found satisfactory after
one year and two years (Photos 43 & 44).
69
Photo 39 : View of Cold Mix for PMC
Photo 40: View of Tack Coating
70
Photo 41: View of Compaction of Cold PMC
Photo 42 : View of Finished PMC after Construction in

Aizawl, Mizoram
71
Photo 43 : Satisfactory Performance of PMC after One Year in

Aizawl, Mizoram
Photo 44 : Satisfactory Performance of PMC after One Year in

Aizawl, Mizoram
72
8.0 CONSTRUCTION AND PERFORMANCE OF BITUMINOUS MACADAM

AND SEMI DENSE BITUMINOUS CONCRETE / MIX SEAL SURFACING
USING BITUMEN EMULSION IN COLD AND SNOW BOUND AREA IN
Jammu &Kashmir
8.1 Laying of Bituminous Macadam (BM) with Bitumen emulsion:
The trial was conducted on NH-1A near Benihal tunnel (Photo 45). The
pavement surface was cleaned of all dust and other loose materials. Proper
cleaning was carried out before applying tack coat.
The graded aggregates, after blending of different size of aggregates ( 13.2 mm,
10 mm, and stone dust) of Bituminous Macadam (BM) were charged into drum of
HMP (with out heating facility) by conveyor belt. The optimum water content as
determined in the laboratory was added into aggregates on conveyor belt to wet
the aggregate surface. The required quantity of bitumen emulsion of SS-2 grade
was then added into damp aggregate at ambient temperature and mixed for two
minutes to prepare cold mix. The cold mix was discharged into dumper
(Photo 46). The production of cold mix in using Hot Mix Plant without heating
arrangement is large enough as the entire process is carried out at ambient
temperature.
The tack coat with bitumen emulsion of RS-1 grade was applied @ 3 kg for
10m2 area by mean of perforated cans (Photo 47).
The cold mix was then discharged in wheel barrow and transported to
construction site for spreading cold mix on tacky road surface. Due care was
exercised to avoid taking wheel barrows on newly laid surface.
In half of road width, the cold mix was laid over the tacky surface and spread
uniformly in required thickness of about 75 mm loose mix by paver (Photo 48).
The cold mix was aerated for about 1-2 hours and then rolled with 8-10 tones
three-wheel roller to compact the mix (Photo 49). The rolling was done with the
73
outside drive wheel covering equal parts of the pavement and shoulder. The
wheels were kept wet during compaction. The rolling was also repeated after 2
hours. The finished BM layer was achieved (Photo 50)
The traffic was regulated and test section was left to open for traffic after 4 -5
8.2
Laying of Semi Dense Bituminous Concrete with Emulsion

The pavement surface was cleaned of dirt, dust and loose materials. The tack
coat with RS-1 grade emulsion was provided with 3 kg per 10m2 area. The cold
mix was spread when tack coat turned black from brown colour after 15-20
minutes. At this point all water of emulsion was dissociated from bitumen by
coagulation and drained off leaving behind the residual bitumen on the road
surface. The road surface was sprayed with water, before applying the tack coat
with emulsion.
The blended aggregates of 10mm and stone dust as per required grading of
SDBC were charged in the drum of hot mix plant and uniformly made aggregates
damp with optimum quantity of premixing water ( 3 % by weight of aggregates.
The 8 % emulsion of slow setting (SS-2) grade quantity was added gradually into
damp aggregates and mixed for two minutes to get uniform coating. Prolonged
mixing was avoided as it de-coats the aggregate.
The tack coat with bitumen emulsion of RS-1/MS grade was applied @ 3 kg for
10m2 area by mean pressure bar.
74

The cold mix was then discharged in a wheel barrow and transported to
construction site for spreading the cold mix on the road surface.
In half of road width, the cold mix was laid over the tacky surface and spread
uniformly in required thickness of about 33 mm loose mix by paver to get 25mm
compacted thickness. The cold mix turns black from brown colour after some
time when water of emulsion exudes after breaking of emulsion. The cold mix
was aerated for about two hours and then rolled with 8-10 tones three-wheel
roller to compact the mix. The rolling was done with the outside drive wheel
covering equal parts of the pavement and shoulder ( Photo 51). The wheels were
kept wet with water during compaction. The rolling was also repeated after 2
hours. The good surface of finished SDBC with emulsion was obtained (Photo
52)
8.2.6
Traffic Control
The traffic was regulated and test section was left to open for traffic after 2-3
8.2.7 Performance of Semi Dense Bituminous Concrete / MSS with
Bitumen Emulsion:
The first inspection of test section just after construction showed good
construction taking into account of performance factors. The test section was
completely covered with snow in the month of February and section was wet for
more than two months. The 2nd inspection after 6 month showed that
performance of test section SDBC / MSS with emulsion was satisfactory
(Photos 53 & 54).
75
Photo 45: View of Display Board for Field Trial on NH1A near
Srinagar
Photo 46: Preparation of Cold Mix by Hot Mix Plant (Without

Heating Facility)
76
Photo 47: View of Tack Coating with Emulsion for Laying BM
Photo 48: Laying of Cold Mixed BM by Paver on NH-1A (J&K)
77
Photo 49: View of Compaction of Cold Mixed Bituminous Macadam
Photo 50: View of Bituminous Macadam on NH 1A near Srinagar
78
Photo 51: View of Compaction of SDBC with Emulsion
Photo 52: Finished SDBC with Emulsion after Compaction
79
Photo 53 View of SDBC with emulsion after 6 Months under Snow
Photo 54 View of SDBC with emulsion after 6 Months under Snow
80
9.0
COST ANALYSIS OF CONSTRUCTION WITH EMULSION AND

BITUMEN
9.1 Economic Analysis for Cold and Hot Bituminous Macadam

The data for comparison of cost of construction with emulsion and neat bitumen
pertains to work carried out, which was associated with R&D and not susceptible
for measurement. A potential source of energy savings is to substitute hot mix by
cold mix using emulsion. The primary energy saving in using emulsion is
elimination of the fuel required to heat and dry the aggregate to provide good
coating and workability of bituminous mix. The higher cost of emulsion was offset by the elimination of heating of binder and aggregate for preparation of mix
and tack coating the existing area.
Cost economics of construction for bitumen 60/70 and bitumen emulsion for 7m.
width and 1000 m length with total area 7000 sq. m. 50mm BM and 25mm
SDBC has been calculated .
An economic analysis was carried out for a cold BM mix vis--vis a hot BM mix.
The cost is also determined for a BM with bitumen emulsion. The analysis was
done for a 1km. long and 7m. width road with a 50mm. thick BM layer.
The calculations made for the computation of volume of compacted mix and the
material required accordingly. The proportion of aggregates was kept same for
both the cold and the hot mix BM layer.
Calculations :
1) Volume of compacted mix required :
Length of road = 1000m.
Width of road = 7m.
Thickness of BM layer = 0.05m.
Volume of compacted mix = 1000*7*0.05 = 350m
81
2)
20mm:10mm:SD: water: emulsion :: 0.50 : 0.35: 0.15
by weight of mix
Also, hot mixes require LDO for the heating up of aggregates and bitumen.
The amount of LDO required is taken as 5% of the total mix produced, i.e. 5%
of 350m.
The total amount of these materials required and cost of layer for the 50mm thick
compacted BM mix is given in following Table 11.
Table 11: Cost Analysis of Cold Mix and Hot Mix Bituminous Macadam
Material for 50mm
Amount
Thick BM
required
Rate
Cost for cold
Cost for hot
mix layer
mix layer
(Rs.)
(Rs.)
20mm aggregate
207.5m
28/cft
205151
205151
10mm aggregate
180m
28/cft
177912
177912
Stone Dust
77.5m
30/cft
82096
82096
Water
18200 lit.
0.20/lit
3640
Bitumen emulsion
40974 kg.
24/kg
983376
Bitumen
25025 kg
28/kg
700700
250 kg
150 / kg
154000 lit.
30/lit
462600
514 MT
36/MT
18504
18504
1251
28/kg
Anti-stripping Agent
37500
( 1 % of bitumen)
Heating (LDO), 3%
Transportation,
Laying& compaction
Waste Bitumen (5%)
35035
Total
1470679
1719498
Cost per Sq. m.
210
246
Hence, the cold mix BM layer works out to be approximately 17% more cost
effective as compared to the hot mix layer.
82
9.2 Economic Analysis for Cold and Hot SDBC

The cost of construction of SDBC per sq.m. area has been calculated and given
in following Table 12.
Table 12: Cost Analysis of Cold Mix SDBC and Hot Mix SDBC
Material for 25 mm
Amount
Thick SDBC
required
Rate
Cost for cold
Cost for hot
mix layer
mix layer
(Rs.)
(Rs.)
10mm aggregate
178.5 m
28/cft
176479
173019
Stone Dust
76.5.m
30/cft
75634
75634
Water
10000 lit.
0.20/lit
2000
Bitumen emulsion
30590 kg.
24/kg
734160
Bitumen
20125
28/kg
563500
Anti-stripping Agent
200 kg
150/kg
30000
12500lit.
30/lit
375000
255 MT
36/MT
9180
9180
1006
28/kg
( 1 % of bitumen)
Heating (LDO), 3% of
mix
Transportation,
Laying& compaction
Waste Bitumen (5%)
28175
Total
993993
1254508
Cost per Sq. m.
142
179
Hence, the cold mix SDBC layer works out to be approximately 26% more cost
effective as compared to the hot mix layer.
83
Based on the study, the cost of construction of different specifications with cold
mix technology and hot mix technology was calculated and given below:
S. No.
Specification
Thickness,
Binder
mm
Cost / m2,
Rs.
SDBC
25
Bitumen
142
SDBC
25
Emulsion
179
BM
50
Bitumen
246
BM
50
Emulsion
210
84
10.
CONCLUSIONS
Construction of structural layer of bituminous road such as bituminous

macadam (BM) as base course; and semi dense bituminous concrete
(SDBC) and mix seal surfacing (MSS) as wearing courses using bitumen
emulsion based cold mixes is feasible with utilization of presently available
road construction infrastructure such as paver, roller and hot mix plant
(used with out heating arrangement ).
The performance of road specification BM+ SDBC and BM+ MSS is

satisfactory.
The performance of road specification PMC is satisfactory in High rainfall

area (Mizoram) after 3 years.
The slow set (SS-2) bitumen emulsion shall be used for preparation of
cold mix for PMC when using marginal aggregates instead of bitumen
emulsion of medium set (MS) grade as provided in IRC-14..
Construction with cold mix is economical by 20 % as against hot mix.
The construction of road with emulsion based cold mixes is environment

friendly as heating is eliminated contrary to the conventional method of
using bitumen which require heating which leads to emission of pollutants
and degrade the environment
Construction of roads with cold mix technology is feasible in all climates

including cold and wet climates.
Reduction of cracks propagation to overlay when emulsion is used as it

seals the cracks.
Tentative Specifications of Bituminous Macadam, Semi Dense Bituminous

Concrete and Close-graded premix carpet (MSS) with cold mix technology
are drafted and are given in Annexure 1 to 3.. The specifications are in
consideration of Indian Road Congress for implementation.
85
11.
RECOMMENDATIONS
For Desert Climate with Low Rainfall
(i)
Bituminous Macadam with bitumen emulsion (SS-2) grade should

be adopted for road construction.
(ii)
Bituminous Macadam with bitumen emulsion should be left for few

days before laying wearing course
(iii)
Semi Dense Bituminous Concrete (SDBC) with bitumen emulsion

(SS-2) grade should be adopted for road construction
(iv)
The course gradation of SDBC aggregate should be adopted for

SDBC with bitumen emulsion. The aggregate having dust and clay
should not be used with bitumen emulsion.
(v)
Mix seal surfacing (MSS) with bitumen emulsion (SS-2) grade

should be adopted for road construction
(vi)
The cold mix shall be covered with wet empty gunny bags to
prevent from early setting and hardening
(vii)
The road surface should be made damp before application of tack

coat.
For and High Rain Fall Area
(i)

(ii)

days before laying wearing course
(iii)

(iv)

(v)

(vi)
The optimum water may be varied after checking site condition of

aggregates.
(vii)
Bitumen emulsion (SS-2) grade shall be used for Premix Carpet

with marginal / soft aggregates
86
For Snow Bound or Cold Climate Area
(i)

(ii)

days for evaporation of water before laying wearing course
(iii)

(iv)

(v)

(vi)
The optimum water may be varied after checking site condition of

aggregates.
87
Annexure - 1
Proposed Tentative Specification for Bituminous Macadam (Base and
Binder Course) with Cationic Bitumen Emulsion
1.0 INTRODUCTION
Bituminous road construction with conventional paving grade bitumen is
sometimes not feasible or desirable in high rainfall areas as intermittent rains
throughout the year affect the production and laying of hot mixes. In snow-bound
areas and at high altitude, hot mixes get solidified quickly and loose binding
properties due to the existing pavement surface getting cold within short time.
Presently, there is no construction specification available in the country for
bituminous macadam (BM) with cationic bitumen emulsion as the binder, which is
expected to have great application in future. It is, therefore, imperative to develop
specification for BM with bitumen emulsion. the R & D studies had been
undertaken in the country to develop specification by conducting laboratory
studies and field trials in different climatic conditions of India.
Bituminous macadam shall consist of the construction of one or more courses of
compacted crushed aggregates, premixed with a bituminous binder, laid
immediately after mixing. It is an open graded mix suitable for base and binder
courses and should not be used as a wearing course as such. It may be used as
a temporary riding surface when covered with an appropriate seal coat.
The tentative specification has been prepared with inputs from
Dr. N.K.S.
Pundhir, Scientist, CRRI based on the results obtained from the laboratory study
and a number of field trials carried out by CRRI, BRO, PWD Mizoram and oil
companies (IOCL and Hindustan Colas Ltd.)
This tentative specification is intended to indicate what is considered to be a
good practice for construction of bituminous macadam (base and binder course)
under average operating conditions.
88
2.0
SCOPE
2.1
This draft specification deals with the basic outline for the design and
construction needed to lay Bituminous Macadam (BM) mix as base
course for highways using cationic bitumen emulsion. It only highlights
the essentials so as to be of use while preparing the contractual
documents for specific job and is not intended to be a detailed code of
practice.
2.2
Bituminous macadam shall consist of the construction of one or more

courses of compacted crushed aggregates, premixed with bitumen
emulsion, laid immediately after mixing. It is an open graded mix
suitable for base and binder courses and should not be used as a
wearing course as such. It may be used as a temporary riding surface
when covered with an appropriate seal coat.
3.0 MATERIALS
3.1
Aggregates
The aggregates shall consist of crushed stone, crushed slag, crushed gravel
(shingle) or other stones, as specified. The aggregates shall have clean, strong,
durable and fairly cubical fragments free from disintegrated pieces, organic and
other deleterious matter. The aggregates shall preferably be hydrophobic and of
low porosity.
3.1.1
Physical requirements: The aggregates shall satisfy the following

requirements:
Base course
Aggregate Impact Value, (Max.) ,%

Los Angeles Abrasion Value, (Max.),%
Loss with Sodium sulphate for
five cycles, (max.), %
Flakiness and Elongation Indices,Max., %
Stripping Value ,Max.,%
89
Binder course
35
50
30
40
12
30
25
12
30
25
Where all or some of these requirements can not be satisfied, it is left to the
Engineer-in-charge to allow reasonable tolerances.
The use of low grade aggregates by improving their qualities shall also be
considered.
3.1.2 Grading of Aggregates: The aggregates for the bituminous macadam
for different thicknesses shall conform to the grading, as given in Table 1.
Table 1 : Compacted Thickness of 50 mm
Sieve Size, mm
26.5
22.4
13.2
11.2
5.6
2.8
0.090
Bitumen Emulsion (SS-2) by
wt. of mix
Base or Binder course

Percent Passing by weight
100
75-100
50-85
20-40
5-20
0-5
5 - 6 percent
3.1.3 Coarse Aggregates: The coarse aggregates shall be crushed material

retained on 2.8 mm sieve and shall be crushed stone, crushed gravel
(shingle) consisting of angular, clean, tough and durable fragments free
from disintegrated pieces and organic or deleterious matter. The
aggregates shall satisfy the physical requirements, as given in Table 2.
Table 2: Physical Requirements of Coarse Aggregates
Aggregate Impact value (%)
30 (max.) IS : 2386 (Part IV)
Los Angeles Abrasion value (%)
40 (max.) IS : 2386 (Part IV)
Flakiness and Elongation Indices (%)
30 (max.) IS : 2386 (Part IV)
Coating value. (%)
75 (min.)
IS : 8887:2004 (Annexure F)
Water Absorption (%)
2 (max.)
IS : 2386 (Part III)
Soundness (Loss with Sodium
12 (max.) IS : 2386 (Part V)
sulphate),%
Soundness (Loss with Magnesium
18 (max.) IS : 2386 (Part V)
sulphate)
90
3.1.4 Fine Aggregates: The fine aggregates shall be the fraction passing 2..36
mm sieve and retained on 75 micron sieve. These shall consist of crushed
screenings, natural sand or a mixture of both and shall be clean, hard, durable,
uncoated and free from injurious, soft or flaky pieces and organic or deleterious
matter.
3.1.5
Filler: The requirement of filler in cold mix BM ( i.e. material passing
75 micron sieve) shall be stone dust, cement, hydrated lime or other approved
non-plastic mineral matter.
3.2
Cationic Bitumen Emulsion
The bitumen emulsion for preparation of cold mix BM shall be Slow setting grade
(SS-2), conforming to IS: 8887 2004. For tack coating, Rapid setting (RS-1) or
Slow setting (SS-2) grade of bitumen emulsion, conforming to IS: 8887- 2004,
shall be used. The bitumen emulsion should not be stored below 0oc and it shall
be thoroughly mixed by rolling the drum to and fro upto a distance of 10 metre for
five minutes before manufacturing cold mixes for road construction. The shelf life
of bitumen emulsion should be such that it meets the physical requirements, as
given in Table 2, at the time of its use. During prolonged storage of emulsion
(say about a year), the drum shall be kept in shade and rolled two or three times
to and fro upto 8-10m distance once in a month. The bitumen emulsion should
satisfy the various properties, as given in Table 3.
Table 3 : Properties of Cationic Bitumen Emulsion
S No.
i
ii
iii
iv
v
vi
vii

Residue on 600 micron IS sieve (% by mass)
Viscosity by Saybolt Furol viscometer, seconds
At 250C
At 500C
Coagulation of emulsion at low temperature
Storage stability after 24 hrs., %
Particle charge
Stability to mixing with cement ( percentage
coagulation)
Miscibility with water
Specified Values
RS-1
SS-2
0.05
0.05
20-100
Nil
2.0(max.)
+ve
No
91
30-150
Nil
2.0(max.)
+ve
2(max.)
No
viii
(d)
(e)
Tests on residue :
Residue by evaporation, (%)
Penetration, d mm at 250C/100 gm/5 sec.
Ductility, 270C/(cm)
Solubility in Trichloroethylene (%)
60(min.)
80-150
50 (min.)
98(min.)
4.0
QUANTITIES OF MATERIALS REQUIRED FOR 10 m2 OF ROAD

SURFACE
4.1
Aggregates
60(min.)
60-120
50(min.)
98(min.)
The approximate quantity of aggregates required for 50mm compacted thickness

of bituminous macadam shall be 0.60 to 0.75 m3 per 10m2 of area.
4.2
Binder
4.2.1
Premixing
The bitumen emulsion (SS-2) required for premixing of the bituminous macadam
shall be at the rate specified depending on the gradation of aggregates. The upper
limit may be raised when absorptive types of aggregates are used, and the exact
rate shall be specified by the Engineer-in-charge.
4.2.2
Tack coat
If and when required, the quantity of bitumen emulsion (RS-1 / SS-2), needed for
the tack coat, shall be between 3.0 to 3.5 kg. per 10 m2 on primed Water Bound
Macadam surface.
5.0
JOB MIX FORMULA FOR COLD MIX
5.1 While the laboratory cold mix design gives different proportions of the mineral
aggregates combination in terms of individual sieve sizes, blending of two or
more sizes of aggregates (each size having within it a range of individual sieve
sizes) would be necessary for actual operational purpose in the field. This
blending ratio is obtained on a weight basis, giving the percent weight of coarse
aggregate, fine aggregate and filler needed to give the ultimate basis based on
the unit weight or bulk density of the aggregate supplied. The mineral aggregate
92
combination together with the optimum premixing water content and bitumen
emulsion content, as determined in the laboratory, constitutes the job mix formula
for implementation during construction.
5.2
It is to be emphasized that in order to this formula be adhered to in
practice, the mix design shall be worked out based on a correct and truly
representative sample of the materials that will actually be used in the specific
construction project.
The detailed procedure for job mix formula for BM, using cationic bitumen
emulsion, is given in Annexure-I
6.0
CONSTRUCTION
6.1 Weather and Seasonal Limitations

Bituminous macadam with emulsion may be laid or placed during rainy season or
when the subgrade or base course is damp or wet or when the atmospheric
temperature in the shade is 8oC or below.
6.2 Equipment
All equipment necessary for the proper construction of work shall be available on
the work site in good working condition.
6.3 Arrangements for Traffic
Adequate provisions for safe movement of traffic shall be made as far as
possible, so as not to interfere with the construction operation on the road.
6.4
Preparation of Underlying Course
The underlying course on which bituminous macadam is to be laid shall be

prepared, shaped and conditioned to an uniform grade and levels as specified.
Any depressions or pot-holes should be properly made up of and thoroughly
compacted sufficiently in advance. The surface of the underlying course shall be
thoroughly swept and scraped clean and free from the dust and foreign materials.
93
6.5
Preparation of Base
The base over which the cold mix bituminous macadam is to be laid shall be
completely free from dust, caved mud etc, before its laying. Where the existing
base is having potholes or rutting, the irregularities shall be properly corrected. If
the existing base is extremely irregular and wavy, it may be considered worthwhile to lay a cold mix bituminous leveling course (Profile corrective course) of
adequate thickness.
6.6
Tack coat
For tack-coat, bitumen emulsion of Rapid setting (RS-1) grade may be used.
The bitumen emulsion is applied on an existing pavement, preferably on damp
surface, at the rate of 3.0 to 3.5 kg per 10 sq.m area if the surface is hungry and
dry and 3.5 to 4 kg. per 10 sq.m. area on a normal bituminous base. The tack
coat with emulsion shall be applied not earlier than 10 minutes before laying the
cold mix.
6.7
6.7.1 It is imperative to prepare the cold mix of proper and uniform quality for
bituminous macadam by using cold mix plant or hot mix plant without heating
arrangement. The plant may be either a batch mix type or a continuous type /
drum mix type having two-stage mixer.
6.7.2 The coarse aggregates shall be charged first into the operating mixer / pug
mill followed by the addition of optimum water content on conveyor belt leading to
mixer and then adding the required quantity of bitumen emulsion (SS-2). The
above ingredients shall be mixed for about one minute to achieve the uniform
coating. Thereafter, fine aggregates including filler shall be charged into the
coated coarse aggregates and allowed to mix for about one minute. The cold mix
shall be discharged for further loading on to the tipper / trolleys.
94
6.8
Spreading of Mix
6.8.1 The cold mix shall be transported from plant site by tipper trucks to the
laying site and the spreading will be done preferably by means of a self
propelled mechanical paver with suitable speed capable of spreading, tamping
and finishing the mix, true to the proper grade, line and cross-section. The mix
should be spread in such a manner that, after compaction, the required thickness
of surfacing layer is laid uniformly.
6.8.2 Longitudinal joints and edges shall be constructed true to the line,
marking parallel to the centre line of road. Longitudinal joints should be offset
atleast by 150 mm from those in binder course, if any, and transverse joints or
construction joints shall be placed in the original thickness of previously laid mix.
The vertical cut face shall be painted with bitumen emulsion prior to the laying of
fresh mix against it.
6.9
Compaction
The paver/manual laid cold mix, after becoming black from brown colour of
original mix due to breaking of emulsion on surface of coated aggregate, shall
be thoroughly and uniformly compacted through a set of rollers at a speed of
not more than 5 km per hour. The initial or break down rolling shall be done
with 8-12 tonne three wheel steel roller and the surface finished by final
rolling with 8-10 tonne tandem roller. Before finishing with tandem roller,
break down rolling shall preferably be followed by an intermediate smooth
wheel pneumatic roller of 15 to 30 tonne capacity having a tyre pressure of 7
kg. / sq.cm. The joints and edges shall be rolled with 8-12 tonne three wheel
roller. All the compaction operations i.e. breakdown rolling, intermediate
rolling and finish/final rolling can be accomplished by using a vibratory roller
of 8-10 tonne static weight. During finish rolling, the vibratory system shall be
switched off. The wheels of the roller shall be kept moist to prevent the mix
from sticking to them. Rolling shall commence longitudinally from edges and
progress towards the centre except on super elevated portions where it shall
progress from lower to the upper edge. Rolling shall be continued till the
95
desired density (of not less than 98 per cent of the laboratory design density)
is achieved and all roller marks are eliminated.
6.10
Opening to Traffic
Traffic may be allowed after 3-4 hours after the mix has set in the finished
surface and is not be picked up by the vehicles.
7.0
7.1
OUALITY CONTROL
Adequate quality control at every stage of the work is essential and as such
a field laboratory must be set up to ensure the following controls:
7.1.1 Periodic sieve analysis of each type of aggregate at feeder end should
be made to see that the gradation of aggregate follows reasonably the
original gradation of job mix designed. The number of samples per day would
depend upon the bulk supply of aggregates made in a day at the plant site.
The physical proportions of different constituent materials should be decided
to achieve the gradation, as given in Table 2. The characteristics of these
materials shall be determined at the rate of one test for every 50-100 m3 of
aggregates or as directed by the Engineer-In-Charge.
7.1.2
Periodic checks on emulsion covering binder contents, viscosity and
residue on 600 micron sieve should be done, in accordance with IS::8887-2004.

7.1.3 The emulsion should be thoroughly mixed by rolling the drum to and fro to
a distance of 10 metre for about 5 minutes before using emulsion for premixing
with graded aggregate.
7.1.4 At least one sample for every 100 tonnes of cold mix discharged at the
pugmil chute or a minimum of one sample per plant per day shall be collected
and the following tests shall be carried out.
(i) Three Marshall specimens shall be compacted, extracted from the mould after
overnight and then cured at 40c for 3 days. These specimens shall be tested for
average stability, flow, voids content and density. The value should be close to
the Laboratory design values.
(ii) Bitumen (from Bitumen emulsion) shall be extracted from about 1000 gm of
the mix after curing and bitumen content determined.
96
(iii) Sieve analysis of aggregates after the bitumen is extracted shall be done to
determine the gradation.
7.1.5 The permissible variation of the individual percentages of various
ingredients in the actual mix from the job mix formula shall be within the
limits indicated below in Table 4.
Table 4: Permissible Variations from Job Mix Formula
Permissible Variations by
S. No.
Description
Weight of Total Mix

(percent)
1.
Aggregate passing 13.2 mm or larger size
# 8
2.
# 7
5.
Aggregate passing 11.2 mm sieve and 5.6 mm

sieve
sieve
Aggregate passing 710 micron sieve and 355
micron sieve
Aggregate passing 180 micron sieve
# 4
6.
# 3
7.
Bitumen residue
3.
4.
# 6
# 5
# 0.3
7.1.6 For every 700 m2 or less of compacted surface, one field density test
should be conducted to determine the density of mix as laid, compacted and
finished. The density shall not be less than 98 percent of the maximum laboratory
density.
7.1.7 The longitudinal profile of the finished surface shall be tested with a 3m
straight
edge,
parallel to the centre line, and the transverse profile with a
camber template. Any irregularity greater than 6 mm shall be corrected.

8.0
Weather and Seasonal Limitations
The mix shall not be laid when the atmospheric temperature is less than 8c
and when it is raining heavily. The BM can, however, be laid on a damp
surface.
97
Enclosure- I
COLD MIX DESIGN OF BITUMINOUS MACADAM (BM)
I.
Evaluation of Materials
No universally accepted cold mix design procedure is presently available. The

mix design procedure, outlined here in this guideline, has been developed at
CRRI. The cold mix design involves optimisation of water and bitumen emulsion
for aggregates in the mix.. The aggregates are first moist with water to wet the
aggregate surface and then coated with bitumen emulsion. The different sizes of
aggregates are blended in different proportions to achieve the gradation of BM
specification. The following steps are taken to design cold mix BM with cationic
bitumen emulsion.
(i) Aggregate Characterisation : The aggregates supplied are subjected to sieve
analysis and tested as per IS: 2386 for determining the following properties.
Specific gravity
Aggregate Impact Value, (%)
Water Absorption Value, (%)
(ii) Testing of Bitumen Emulsion : The samples of slow setting bitumen emulsion
(SS-2) to be used for construction of BM shall be evaluated as per IS : 88872004. The coating test of aggregates suitability should also be carried out as per
ASTM: D-2397 or AASHTO: M208.
(iii) Optimization of Premixing Water Content : For determination of optimum
water content for premixing, the quantity of bitumen emulsion is first determined
using the following expression.
P = 0.05A+0.1B+0.5C
where ,
P = Quantity of bitumen emulsion ( %)
Different batches of aggregates - emulsion mixes are then prepared keeping the
quantity of bitumen emulsion constant (as determined from the above equation)
and varying the water content. The coated aggregates are visually observed for
coated area of aggregate with binder. The optimum water content is the water
content at which maximum coating of aggregate with water is attained. This
water content is taken as premix water content in designing the cold mix
Bituminous Macadam (BM). The optimum water content for BM is found to be 2
to 3% by wt. of aggregate. However, this quantity may vary depending on the
site conditions and quality of aggregates.
98
II.
Binder Optimisation using Marshall Equipment
a) Preparation of Marshall Specimens: The cold mix design procedure utilises

standard Marshall equipments for evaluation of mix properties. Marshall test
specimens in triplicate are prepared with different binder content (bitumen
emulsion). Different sizes of aggregates are blended to achieve the specified
aggregate gradation of BM. About 1100gm of graded aggregates are moistened
uniformly with optimum water content. The different percentage of bitumen
emulsion, say 5 % by weight of aggregate, are then added to the wet aggregates
and mixed for 2 minutes for achieving uniform binder coating. The cold mix is
kept in oven at 600C for 2-3 hours. The cold mix is then transferred into the
Marshall mould with filter paper on base plate and compacted with 75 blows of
Marshall hammer on both faces. Similarly, the Marshall specimens are prepared
with optimum water content and bitumen emulsion contents of 5,6, 7 and 8% by
weight of aggregates. The Marshall specimens are extracted from the mould
after 24 hours and cured in air oven at 400C for 72 hours before subjecting to
different Marshall tests.
b) Testing of Marshall Specimens : Marshall specimens are subjected to
different tests such as bulk density, stability and flow values. Marshall stability
and flow values are determined in dry state at 250C. Different properties of the
mixes are determined and other design parameters like voids content, voids filled
with binder etc. are calculated. Typical characteristics of cold mix BM with SS-2
at various bitumen emulsion contents are given as follows:
S.No
.
1.
2.
3.
4.
Properties
Bitumen Emulsion by aggregates

5.0%
6.0%
7.0%
3.0
3.6
4.2
2.20
2.21
2.19
720
850
750
6.0
5.0
7.5
Bitumen residue (%)

Bulk density (gm/cc)
Stability at 250C(kg.)
Flow (mm)
Optimum bitumen emulsion of 6% by wt. of aggregate or 5.76% by wt. of mix was

found in the above case.
99
Annexure - 2
PROPOSED TENTATIVE SPECIFICATION FOR SEMI-DENSE BITUMINOUS
CONCRETE (SDBC) USING CATIONIC BITUMEN EMULSION
1.0
INTRODUCTION
Use of cold mixes in road construction eliminate emissions and reduce fuel
requirement leading to conservation of energy at the mixing plant. Construction
of .bituminous road with conventional paving grade bitumen is sometimes not
feasible or desirable in difficult areas such as high rainfall areas as intermittent
rains throughout the year affect the production and laying of hot mixes. In snowbound areas and at high attitude, hot mixes get solidified quickly and loose
binding property due to the existing pavement surface getting cold within short
time. presently, there are no construction specifications available in the country
for semi-dense bituminous concrete (SDBC), mix seal surfacing (mss) and
bituminous macadam (BM) with bitumen emulsion, which are expected to have
great applications in the near
future due to environmental concerns and
pressure on energy conservation. It is, therefore, imperative to develop

specifications for SDBC, mss and BM with bitumen emulsion. in this regard, a
number of r & d studies were undertaken in the country to develop specifications
for cold mixes by conducting laboratory studies and field trials.
The tentative specification on SDBC has been
prepared with
inputs from
Dr. N.K.S. Pundhir, Scientist, CRRI, based on the results obtained from the
laboratory study and a number of field trials carried out by CRRI, BRO and Oil
Companies such as Indian Oil Corporation and Hindustan Colas Ltd.
100
2.0
2.1
SCOPE
construction needed to lay Semi-dense bituminous concrete (SDBC)
mixes as wearing course on highways using bitumen emulsion. It only
highlights the essentials so as to be of use while preparing the
contractual documents for specific job and is not intended to be a
detailed code of practice.
2.2
Semi-dense bituminous concrete shall be used as wearing course and

shall not be laid directly over WBM or any granular base course. The
item shall consist of mineral aggregate and cationic bitumen emulsion of
Slow setting grade (SS-2) mixed in a cold mix plant or any other suitable
mixer and laid with paver or manually on a previously prepared base, in
accordance with the specifications and conforming to the lines, grades
and cross-sections.
3.0
3.1
DESIGN CRITERIA
Being high cost specification, cold mix semi-dense bituminous concrete

should be properly designed so as to satisfy certain criterion needed to
ensure satisfactory performance and durability. The cold mix SDBC, as
designed and laid, should satisfy the requirements given in Table-1 based on
Marshall method which is suggested due to its simplicity and uniformity.
Table: 1 Requirement of the Cold Mix
(i)
(ii)
(iii)
(iv)
(v)
Notes:
Number of compaction blows on each side of Marshall specimen

Marshall stability at 25c in kg (minimum), after curing the
Marshall specimen at 40c for 3 days
Marshall flow (mm)
Per cent Voids in mix
Binder content by weight of total mix (%)
75
400
8 (max.)
5 10
6.0 8.0
1. It is suggested that higher stability values, consistent with other

requirements, should be achieved as far as possible.
2. The attempt should be to have well graded aggregate and percent
voids in the mix closer to the lower limit.
101
4.0
4.1
MATERIALS
In order to satisfy the requirements envisaged in para 3, the cold mix

semi-dense bituminous concrete shall consist of coarse aggregate, fine
aggregate and filler in suitable proportions mixed with sufficient quantity of
bitumen emulsion. True and representative samples of the aggregates
proposed to be used on the specific job shall be tested in the design
laboratory and proper blend of the aggregate shall be worked out so that
the gradation of final composition will satisfy either of the two specified
aggregate gradations, set forth in Table 2.
Table 2: Gradation of Aggregate in the Cold Mix
Sieve Size
Percent Passing by Weight

Grade 1
Grade 2
22.4 mm
--
100
13.2 mm
100
79-100
11.2 mm
88-100
68-90
5.6 mm
42-64
33-55
2.8 mm
22-38
22-38
0. 710 mm
11-24
6-22
0. 355 mm
7-18
4-14
0. 180mm
5.13
2-9
0.090 mm
3-9
0-5
Note : Grade 1 is suggested for compacted thickness upto 25 mm while grade 2

is suggested for compacted thickness of 25mm. and above. It is preferable to
use grade 2 for 25mm thick SDBC.
The exact bitumen emulsion content required shall be arrived at as per Marshall
procedure of mix design worked out in the laboratory and by using the same
bitumen emulsion (SS grade) and aggregate to be used in the field.
102
4.2
Physical requirements of Constituent materials
4.2.1 Cationic Bitumen Emulsion: The bitumen emulsions shall be of Slow

Setting grade (SS-2), conforming to IS: 8887 2004 for preparation of SDBC
cold mix.
Rapid Setting ( RS-1 ) / Slow Setting ( SS-2 ) grade of bitumen
emulsion conforming to IS: 8887- 2004 shall be used for tack coat. Bitumen
emulsion should not be stored below 0oc and it shall be thoroughly mixed by
rolling the drum to and fro upto a distance of 10 meter for five minutes before
manufacturing cold mixes for road construction. The shelf life of bitumen
emulsion should be such that it meets the physical requirements, as given in
Table 3, at the time of its use. During prolonged storage of emulsion (about a
year), the drum shall be kept in shade and rolled two or three times to and fro
upto 8-10m distance once in a month. The bitumen emulsion should satisfy
various properties, as given in Table 3.

S No.
i
ii
iii
iv
v
vi
vii
viii

Residue on 600 micron IS sieve (% mass)
At 250C
At 500C
Storage stability after 24 hrs., %, max.
Particle charge
coagulation)

Tests on residue :
(g)
Residue by evaporation, %
(h)
Ductility, 270C/cm.,
Solubility in Trichloroethylene, %
103
Specified Values
RS-1
SS-2
0.05
0.05
20-100
Nil
2.0
+ve
30-150
Nil
2.0
+ve
NA
2 (max.)
No
No
60(min.)
80-150
50 (min.)
98(min.)
60(min.)
60-120
50(min.)
98(min.)
4.2.2 Coarse Aggregate: The coarse aggregate shall be crushed material

retained on 2.8 mm sieve and shall be crushed stone, crushed gravel (shingle)
and shall consist of angular, clean, tough and durable fragment free from
disintegrated pieces and organic or deleterious matter and adherent coatings.
The aggregate shall satisfy the physical requirements as given in Table 4.
Table 4: Physical Requirements of Coarse Aggregate
Requirement
Tests
(Percent
Test Method
Maximum)
Aggregate Impact value
30
IS : 2386 (Part IV)
Los Angles Abrasion value
40
IS : 2386 (Part IV)
Flakiness and Elongation Indices
30
IS : 2386 (Part IV)
Coating value
75
IS : 8887 : 2004 Annexure F
Water Absorption,
12
IS : 2386 (Part V)
18
IS : 2386 (Part V)
sulphate)
Soundness, (Loss with Magnesium
sulphate)
4.2.3 Fine aggregate: The fine aggregate shall be the fraction passing 2..8 mm
sieve and retained on 90 micron sieve, and shall consist of crushed screenings,
natural sand or a mixture of both. It shall be clean, hard, durable, uncoated and
free from injurious, soft or flaky pieces and organic or deleterious matter.
4.2.4 Filler :
The requirement of filler in cold mix semi-dense bituminous
concrete shall normally be met by the material passing 90 m sieve in fine

aggregate. In case the fine aggregate is deficient in material passing 90 m
sieve, extra filler shall be added. The filler shall be inert material, the whole of
which passing 710 m sieve, atleast 90 per cent passing 180 m sieve and not
less than 70 per cent passing
90 m sieve. The filler shall be stone dust,
cement, hydrated lime or other approved non-plastic mineral matter.
104
5.0
5.1
JOB MIX FORMULA FOR COLD MIX
While the laboratory mix design gives different proportion of the mineral
aggregate combination in terms of individual sieve size, for actual operational

purpose in the field, blending of two or more sizes of aggregates (each size
having within it a range of individual sieve sizes.) would be necessary. This
blending ratio is obtained on a weight basis, giving the percent weight of coarse
aggregate, fine aggregate and filler needed to give the ultimate basis based on
unit weight or bulk density of the aggregate supplied. The mineral aggregate
combination together with the optimum premixing water content and bitumen
emulsion content, as determined in the laboratory, constitutes the job mix formula
for cold mix for implementation during construction.
5.2
It is to be emphasized that in order that this formula be adhered to in
practice, the cold mix design shall be worked out based on a correct and truly
representative sample of the materials that will actually be used in the specific
construction project.
The detailed procedure evolved for job mix formula for Semi Dense Bituminous
Concrete using cationic bitumen emulsion, is given in Annexure-I
6.0
6.1
CONSTRUCTION
Preparation of the Base
The base over which the cold mix semi-dense bituminous concrete is to be laid
shall be completely free from dust, caved mud etc, before laying the surface
course. Where the existing base is having potholes or ruttings, the irregularly
shall be corrected. If the existing base is extremely irregular and wavy, it may be
considered worthwhile to lay a cold mix bituminous levelling course (Profile
corrective course) of adequate thickness to avoid an excessive use of costly
surface course.
105
6.2
Tack coat : For tack-coat, bitumen emulsion of rapid setting (RS-1) grade
may be used. The bitumen emulsion is applied on existing pavement preferably

on damp surface at the rate of 3 to 3.5 kg for 10 sq.m area if the surface is
hungry and dry and 3.5 to 4 kg. per 10 sq.m. on a normal bituminous base. The
tack coat with emulsion shall be applied not earlier than 10 minute before laying
the cold mix.
6.3
Preparation of the Cold Mix

It is imperative to prepare the cold mix for semi-dense bituminous
concrete by using cold mix plant or any other suitable mixer of adequate capacity
to yield a cold mix of proper and uniform quality. The plant may be either a batch
type or a continuous one having a two-stage mixer.
The coarse aggregate shall be charged first into the operating mixer / pug mill
followed by addition of optimum water content on conveyor belt leading to mixer
and then required quantity of bitumen emulsion (SS-2). The above ingredients
shall be mixed for about one minute for uniform coating. Then fine aggregate
including fillers shall be charged into the coated coarse aggregate and allowed to
mix for about one minute. The cold mix shall be discharged for further loading on
tipper / trolleys.
6.4
Spreading of the Mix

The cold mix shall be transported from plant site by tipper trucks to the
laying site and the spreading will be done preferably by means of a self propelled
mechanical paver with suitable speed capable of spreading tamping and finishing
the mix true to proper grade, line and cross-sect ion. The mix should be spread in
such a manner that after compaction, the required thickness of surfacing layer is
uniformly laid.
106
Longitudinal joints and edges shall be constructed true to line marking

parallel to the centre line of road. Longitudinal joints should be offset atleast by
150 mm from those in binder course, if any, and transverse joints or construction
joints shall be placed in the original thickness of the previously laid mix. The
vertical cut face shall be painted with bitumen emulsion prior to the laying of fresh
mix against it.
6.5
Compaction
The paver/manual laid cold mix, after becoming black from brown
colour of original mix due to breaking of emulsion on surface of coated

aggregate, shall be thoroughly and uniformly compacted by rolling through a
set of rollers at a speed of not more than 5 km per hour. The initial or break
down rolling shall be with 8-12 tonne three wheel steel
roller
and
the
surface finished by final rolling with 8-10 tonne tandem roller. Before
finishing with tandem roller, break down rolling shall preferably be followed by
an intermediate smooth wheel pneumatic roller of 15 to 30 tonne having a
tyre pressure of 7 kg. /sq.cm. The joints and edges shall be rolled with 8-12
tonne three wheel roller. All the compaction operations i.e. breakdown rolling,
intermediate rolling and finish rolling can be accomplished by using a
vibratory roller of 8-10 tonne static weight. During finish rolling, the vibratory
system shall be switched off. The wheels of the roller shall be kept well moist
to prevent the mix from sticking to them. Rolling shall commence
longitudinally from edges and progress towards the centre except on super
elevated portions where it shall progress from lower to the upper edge, to the
centre line of pavement. Rolling shall be continued till the desired density of
not less than 98 per cent of the laboratory design density is achieved and all
roller marks are eliminated.
6.6
Opening to Traffic
Traffic may be allowed after 3-4 hrs after ensuring the setting of mix in the
finished surface and the mix should not be picked up by vehicles.
107
7.0 OUALITY CONTROL
7.1
Adequate quality control at every stage of work is essential and as such a

field laboratory must be set up to ensure the following controls.
be made to see that the gradation of aggregate reasonably follows the
original gradation of job mix designed. The number of samples per day would
depend upon the number of bulk supply of aggregates made in
a day at
the plant site. The physical proportion of different constituent materials should
be decided to achieve the gradation, as given in Table 2. the characteristics
of these materials shall be determined at the rate of one test for every 50-100
m3 of aggregates or as directed by the Engineer-In-Charge.
7.1.2
Periodic check on binder content, viscosity and residue on 600 micron
sieve on emulsion should be done in accordance with IS:8887-2004.

a distance of 10 meter for about 5 minutes before using
for premixing with
graded aggregate.
7.1.4 At least one sample for every 100 tonnes of cold mix discharged at the
(i) Three Marshall specimens shall be compacted, extracted from the mould after
overnight and then cured at 40c for 3 days. These specimens shall be tested for
average stability, flow, voids content and density. The values should be close to
the laboratory design values.
(ii) Bitumen shall be extracted from about 1000 gm of the mix and bitumen
content determined.
(iii) Sieve analysis of aggregates after the bitumen is extracted shall be done and
gradation determined.
108
ingredients in the actual mix from the job mix formula shall be within the
limits indicated below in Table 5
Table 5: Permissible Variations from Job Mix Formula
S. No.
Description of Ingredient
Weight of total mix

(percent)
1.
# 8
2.
# 7
5.

sieve
sieve
micron sieve
# 4
6.
# 3
7.
Bitumen residue
3.
4.
# 6
# 5
# 0.3
finished. The density shall not be less than 98 percent of the maximum laboratory
density.
7.1.7 The longitudinal profile of the finished surface shall be tested with a 3-m
straight edge, parallel to the centre line and the transverse profile with a camber
template. Any irregularity greater than 6 mm shall be corrected. The longitudinal
profile of the finished surface shall also be tested with a roughometer /
profilometer and it should be ensured that the roughness shall not exceed 2500
mm per kilometer.
8.0
Weather and seasonal limitations

The surfacing shall not be laid when the atmospheric temperature is
below 8c and when it is raining heavily. The Semi-dense bituminous concrete

can however, be laid on damp surface.
109
Enclosure-2
COLD MIX DESIGN OF SEMI DENSE BITUMINOUS CONCRETE (SDBC)
I.
Evaluation of Materials
No universally accepted cold mix design procedure is presently available. The

mix design procedure, outlined here in this guideline, has been developed at
CRRI. The cold mix design involves optimisation of water and bitumen emulsion
for aggregates in the mix.. The aggregates are first moist with water to wet the
aggregate surface and then coated with bitumen emulsion. The different sizes of
aggregates are blended in different proportions to achieve the gradation of SDBC
specification. The following steps are taken to design cold mix semi dense
bituminous concrete with cationic bitumen emulsion.
(j) Aggregate Characterisation : The aggregates supplied are subjected to sieve
analysis and tested as per IS: 2386 for determining the following properties.
Specific gravity
Aggregate Impact Value
Water Absorption
(ii) Testing of Bitumen Emulsion : The samples of slow setting bitumen emulsion
(SS-2) to be used for construction of SDBC shall be evaluated as per IS : 88872004. The coating test of aggregates suitability should also be carried out as per
ASTM: D-2397 or AASHTO: M208.
(iii) Optimization of Premixing Water Content : For determination of optimum
water content for premixing, the quantity of bitumen emulsion is first determined
using the following expression.
P = 0.05A+0.1B+0.5C
where ,
P = Quantity of bitumen emulsion, %
Different batches of aggregates - emulsion mixes are then prepared keeping the
quantity of bitumen emulsion constant (as determined from the above equation)
and varying the water content. The coated aggregates are visually observed for
coated area of aggregate with binder. The optimum water content is the water
content at which maximum coating of aggregate with water is observed. This
water content is taken as premix water content in designing the cold mix semi
110
dense bituminous concrete. The optimum water content for SDBC is found to be
3- 4% by wt. of aggregate. However, this quantity of optimum water content may
vary depending on site conditions and quality of aggregates.
III.
Binder Optimisation using Marshall Equipment
a) Preparation of Marshall Specimens: The cold mix design procedure utilises

standard Marshall equipments for evaluation of mix properties. Marshall test
specimens in triplicate are prepared with different binder content (bitumen
emulsion). Different sizes of aggregates are blended to achieve the specified
aggregate gradation of SDBC. About 1100gm of graded aggregates are
moistened uniformly with optimum water content. The different percentage of
bitumen emulsion, say 6 % by weight of aggregate, are then added to the wet
aggregates and mixed for 2 minutes for uniform binder coating. The cold mix is
kept in oven at 600C for 2-3 hours. The cold mix is then transferred into the
Marshall mould with filter paper on base plate and compacted with 75 blows of
Marshall hammer on both faces. Similarly, the Marshall specimens are prepared
with optimum water content and other bitumen emulsion content of 7, 8 and 9%.
The Marshall specimens are extracted from the mould after 24 hours. Specimens
are then cured in air oven at 400C for 72 hours before subjecting to different
Marshall tests.
b) Testing of Marshall Specimens: Marshall specimens are subjected to
different tests such as bulk density, stability and flow values. Marshall Stability
and flow values are determined in dry state at 250C. Different properties of the
mixes are determined and other design parameters like voids content, voids filled
with binder etc. are calculated. Typical characteristics of cold mix SDBC with SS2 at various bitumen emulsion contents are given as follows:
S.No
.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Properties
Bitumen residue, %
Bulk density, gm/cc
Volume of Agg., %
Volume of binder, %
Voids, %
Voids in Mineral Aggregate (VMA), %
Voids Filled with Binder (VFB), %
Stability, kg. at 250C
Flow, mm
Bitumen Emulsion Content

7.0%
8.0%
9.0%
4.2
4.8
5.4
2.20
2.21
2.19
79.67
79.64
78.40
8.87
9.95
11.23
11.46
10.36
10.37
20.33
20.36
21.6
43.63
48.87
21.6
790
900
600
7.5
7.0
6.5
Optimum bitumen emulsion of 8% by weight of aggregate or 7.4% by wt. of mix

was found in the above case.
111
Annexure- 3
PROPOSED TENTATIVE SPECIFICATION FOR MIX SEAL SURFACING
(DENSE-GRADED PREMIX CARPET) WITH CATIONIC BITUMEN
EMULSION
1.0
INTRODUCTION
A number of specifications viz. IRC : 97-1987 ( Tentative specification for

20mm thick premix carpet using cationic bitumen emulsion); IRC:96-1987
(Tentative specification for two- coat surface dressing using cationic bitumen
emulsion) and IRC:100-1988 ( Tentative specification for single coat surface
dressing using cationic bitumen Emulsion) have been recently revised in the
years 2004 and 2006 based on the results obtained through the studies
carried out by CRRI in collaboration with Border Roads Organisation and Oil
Companies. Mix seal surfacing, which is a dense graded premix carpet, is an
important type of surfacing being widely used in the country as a renewal
coat.
Presently, there is no construction specification available in the country for
Mix seal surfacing (MSS) with cationic bitumen emulsion, which is expected
to have great application in future. It is, therefore, imperative to develop
specification for MSS with bitumen emulsion. In this connection, R & D
studies had been undertaken in the country to develop specifications for
MSS with bitumen emulsion by conducting both laboratory studies and field
trials. Laboratory and field studies carried out for the
first time in India
indicate that Mix seal surfacing (MSS) with cationic bitumen emulsion can be
laid successfully using the same machineries and plants as used for hot mix
type construction
such as hot mix plant ( without heating arrangement),
paver, sprayer, road roller etc.

The
tentative
specification
has
been
prepared
with
inputs
from
Dr. N.K.S. Pundhir, Scientist, CRRI based on the results obtained through the
laboratory studies and field trials.
112
2.0
2.1
SCOPE
construction needed to lay 25mm thick Mix seal surfacing (MSS) using
bitumen emulsion as wearing course for highways. It only highlights the
essentials so as to be of use while preparing the contractual documents
for specific job and is not intended to be a detailed code of practice.
2.2
Mix seal surfacing (MSS) shall be used as wearing course and shall not
be laid directly over WBM or any granular base course. The item shall
consist of mineral aggregates and cationic bitumen emulsion of Slow
setting grade (SS-2) mixed in a cold mix plant/any other suitable mixer
and laid with paver / manually on a previously prepared base, in
accordance with the specifications and conforming to the lines, grades
and cross-sections.
3.0
3.1
MATERIALS
Binder: For premixing, the binder shall be cationic bitumen emulsion of
Slow setting (SS-2) grade complying with IS 8887-2004. For tack coat , Rapid
setting (RS-1) grade of cationic bitumen emulsion, complying with IS 8887-2004,
shall be used or as directed by the Engineer.
The bitumen emulsion shall satisfy the various properties, as given in Table 1.
113

Specified Values
S
RS-1
SS-2
Residue on 600 micron IS sieve (% by mass)
0.05
0.05
ii
iii

At 250C
At 500C
20-100
Nil
30-150
Nil
iv
Storage stability after 24 hrs., (%)
2.0
2.0
(max.)
(max.)
+ve
+ve
No.
Particle charge
vi

coagulation)
vii
viii
3.2

Tests on residue :
Residue by evaporation (%)
(k)
Ductility, 270C(cm)
Solubility in Trichloroethylene (%)
2 (max.)
No
No
60(min.)
80-150
50 (min.)
98(min.)
60(min.)
60-120
50(min.)
98(min.)
Coarse Aggregate : The coarse aggregate shall be crushed material

retained on 2.8 mm sieve and shall be crushed stone or crushed gravel
(shingle) consisting of angular, clean, tough and durable fragments
free from disintegrated pieces and organic or deleterious matter. The
aggregates shall satisfy the physical requirements as given in Table 2.
114
Table 2: Physical Requirements of Coarse Aggregate

Aggregate Impact value (%)
30 (max.) IS : 2386 (Part IV)
Los Angeles Abrasion value (%)
40 (max.) IS : 2386 (Part IV)
Flakiness and Elongation Indices (%)
30 (max.) IS : 2386 (Part IV)
Coating value (mm )
75 (min..) IS : 8887 : 2004 (Annexure F)
Water Absorption (per cent)
2 (max.)
12 (max.) IS : 2386 (Part V)
sulphate)
Soundness, (Loss with Magnesium
sulphate)
3.3
18 (max.) IS : 2386 (Part V)
Fine Aggregate: The fine aggregate shall be the fraction passing 2..8 mm
sieve and retained on 90 micron sieve, and shall consist of crushed screenings,
natural sand or a mixture of both. It shall be clean, hard, durable, uncoated and
free from injurious, soft or flaky pieces and organic or deleterious matter.
3.4
Grading of Aggregates :
The gradation of aggregates for mix seal surfacing is given in Table 3.
Table 3 : Gradation of Aggregates for Mix seal surfacing
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
Note : The coarser side of the grading is desirable.
115
3.5
Quantities of Materials Required to Lay 25mm thick MSS per 10m2 of

surface Area
The quantity of aggregate shall be 0.27 m3 for 10 m2 area. The quantity of

bitumen emulsion (SS-2) shall be 30 kg for type A and 33 kg for type B.
4.0
CONSTRUCTION
4.1
Preparation of Base
The base over which the cold mix seal surfacing is to be laid shall be completely
free from dust, caved mud etc, before its laying. Where the existing base is
having potholes or ruttings, the irregularly shall be corrected. If the existing base
is extremely irregular and wavy, it may be considered worthwhile to lay a cold
mix bituminous levelling course (Profile corrective course) of adequate thickness.
4.2
Tack coat : For tack-coat, bitumen emulsion of Rapid setting (RS-1) grade
may be used. The tack coat can also be carried out with bitumen emulsion of
Slow setting grade,(SS-2). The bitumen emulsion is applied on an existing
pavement, preferably on damp surface, at the rate of 3 to 3.5 kg for 10 sq.m area
if the surface is hungry and dry and 3.5 to 4 kg. per 10 sq.m. on a normal
bituminous base. The tack coat with emulsion shall be applied not earlier than 10
minutes before laying the cold mix.
4.3
6.3.1 It is imperative to prepare the cold mix for MSS by using conventional hot
mix plant without switching heating arrangement or cold mix plant or any other
suitable mixer of adequate capacity to yield a cold mix of proper and uniform
quality. The plant may be either a batch type or a continuous type having twostage mixer. The bitumen emulsion can be added into the mixer by having a
separate outlet of emulsion tank.
116
The aggregate shall be charged first into the operating mixer / pug mill followed
by the addition of optimum water content on conveyor belt leading to mixer and
then adding the required quantity of bitumen emulsion (SS-2). The above
ingredients shall be mixed for about one minute to achieve the uniform coating.
The cold mix shall be discharged for further loading on to the tipper for its
transportation to laying site.
4.4
Spreading of Mix
4.4.1 The cold mix shall be transported from plant site by tipper trucks to the
laying site and the spreading will be done preferably by means of a self propelled
mechanical paver with suitable speed capable of spreading, tamping and
finishing the mix, true to the proper grade, line and cross-section. The mix should
be spread in such a manner that, after compaction, the required thickness of
surfacing layer is laid uniformly.
4.4.2 Longitudinal joints and edges shall be constructed true to the
line,
marking parallel to the centre line of road. Longitudinal joints should be offset
atleast by 150 mm from those in binder course, if any, and transverse joints or
construction joints shall be placed in the original thickness of the previously laid
mix. The vertical cut face shall be painted with bitumen emulsion prior to the
laying of fresh mix against it.
4.5
Compaction
4.5.1 The cold mix laid with the paver, after being changed to black from
brown colour of due to breaking of emulsion on surface of coated aggregate,
shall be thoroughly and uniformly compacted through a set of rollers at a
speed of not more than 5 km per hour. The initial or break down rolling shall
be with 8-12 tonne three wheel steel roller and the surface finished by final
rolling with the 8-10 tonne tandem roller. Before finishing with tandem roller,
break down rolling shall preferably be followed by an intermediate smooth
wheel pneumatic roller of 15 to 30 tonne having a tyre pressure of 7 kg.
/sq.cm. The joints and edges shall be rolled with 8-12 tonne three wheel
roller. All the compaction operations i.e. breakdown rolling, intermediate
117
rolling and finish/final rolling can be accomplished by using a vibratory roller

of 8-10 tonne static weight. During finish rolling, the vibratory system shall be
switched off. The wheels of the roller shall be kept moist to prevent the mix
from sticking to them. Rolling shall commence longitudinally from edges and
progress towards the centre except on super elevated portions where it shall
progress from lower to the upper edge. Rolling shall be continued till the
desired density is achieved and all roller marks are eliminated.
4.6
Opening to Traffic
Traffic may be allowed after 3-4 hours after the mix has set in the finished
surface and the mix should not be picked up by the vehicles.
5.0
5.1
OUALITY CONTROL
Adequate quality control at every stage of the work is essential and as such
a field laboratory must be set up to ensure the following controls.
be made to see that the gradation of aggregate reasonably follows the
specified designed gradation. The number of samples per day would depend
upon the bulk supply of aggregates made in a day
at the plant site. The
physical proportions of different constituent materials should be decided to

achieve the gradation, as given in Table 3.
The characteristics of these
materials shall be determined at the rate of one test for every 50-100 m3 of
aggregates or as directed by the Engineer-In-Charge.
5.1.2
Periodic checks on emulsion covering binder content, viscosity and
residue on 600 micron sieve should be done, in accordance with IS : 88872004.

a distance of 10 metre for about 5 minutes before using emulsion for premixing
with graded aggregate.
5.1.4 At least one sample for every 100 tonne of cold mix discharged at the
118
(i) Bitumen shall be extracted from about 1000 gm of the mix and bitumen
content determined.
(ii) Sieve analysis of aggregates after the bitumen is extracted shall be done to
determine gradation.
ingredients in the actual mix from the job mix formula shall be within the limits
indicated below in Table 4.
Table 4: Permissible variations from Designed Mix
S. No.
Description
Weight of total mix (percent)
1.
# 8
2.
# 7
5.

sieve
sieve
micron sieve
# 4
6.
# 3
7.
Bitumen residue
3.
4.
# 6
# 5
# 0.3
finished.
5.1.7 The longitudinal profile of the finished surface shall be tested with a 3m
straight edge, parallel to the centre line, and the transverse profile with a camber
template. Any irregularity greater than 6 mm shall be corrected. The longitudinal
profile of the finished surface shall also be tested with a roughometer /
profilometer and it should be ensured that the roughness shall not exceed 2500
119
mm per kilometre.
6.0
Weather and Seasonal Limitations
The surfacing shall not be laid when the atmospheric temperature is below 8c
and or when it is raining. The Mix seal surfacing with cold mix can, however, be
laid on a damp surface.
120

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Field Performance Study of

STRUCTURAL LAYERS OF FLEXIBLE PAVEMENT IN

Laying of Bituminous Macadam with Emulsion

FLEXIBLE PAVEMENT DIVISION

Dr. S. Gangopadhyay : Director

: Head- Flexible Pavement & Coordinator,

Dr. N.K.S. Pundhir : Project Leader (Consultancy Project ) &

Sh. Jiwan Lal

performance evaluation. It sets forth the

recommendations for cold mix technology using cationic bitumen emulsion in

Central Road Research Institute,

New Delhi - 110 020

TEST LOCATIONS FOR TRIALS

CONSTRUCTION AND PERFORMANCE OF

6.3 Construction of Mix Seal Surfacing with Bitumen

Preparation of Road Surface

7.3 Laying of Premix Carpet ( PMC) with Bitumen

8.2 Laying Semi Dense Bituminous Concrete with

PROPOSED TENTATIVE SPECIFICATION FOR

PROPOSED TENTATIVE SPECIFICATION FOR

PROPOSED TENTATIVE SPECIFICATION FOR MIX

Aggregate Gradation of Cold SDBC for Dantaur - Khajuwala

Properties of Cold SDBC with Developed Emulsion

Performance Evaluation (Visual) of Test Tack in Rajasthan

Performance Evaluation (Visual) of Test Tack in Rajasthan (

Performance Evaluation (Visual) of Test Tack in Rajasthan (3rd

Performance Evaluation (Visual) of Test Tack in Mizoram

Distress condition of road before laying test section on

Unevenness condition of road before laying test section on

Adding of Water Content in Aggregates before Mixing with

Distress condition in the form of ravelling on road before laying

Tack Coating with Bitumen Emulsion on Dantaur Khajuwala

Site for Laying Test Sections on Dantaur- Khajuwala Road (

Transfer of Cold Mix into Paver for Laying

Laying of Cold Mixed Bituminous Macadam on DantaurKhajuwala Road ( Rajasthan)

Compaction of Cold Mixed Bituminous Macadam on DantaurKhajuwala Road ( Rajasthan)

View of Cold Mixed Bituminous Macadam on Dantaur Khajuwala Road ( Rajasthan)

Mixing Water in Aggregates before Mixing with Bitumen

Modification of Hot Mix Plant for supply of bitumen emulsion for

Laying of SDBC on Dantaur Khajuwala Road

Compaction of SDBC on Dantaur Khajuwala Road

Preparation of cold mix of MSS on Dantaur Khajuwala Road

Laying of MSS on Dantaur Khajuwala Road

Compaction of Cold Mixed MSS on Dantaur Khajuwala Road

View of Mix Seal Surfacing with Bitumen Emulsion on

SDBC with Emulsion After One Year Service Life

MSS with Emulsion After One Year Service Life

SDBC with Emulsion After One Year Service Life

MSS with Emulsion After One Year Service Life

SDBC with Emulsion After Two Year Service Life

MSS with Emulsion After Two Year Service Life

Examination of Bitumen Emulsion for Coagulation before its

Preparation of Cold Mix for Bituminous Macadam

Tack Coating with Emulsion before Laying Bituminous

Transfer of Cold Mix in Paver for laying Bituminous Macadam

Laying of Cold Mixed BM with Paver

View of Finished Bituminous Macadam Layer in Aizawl

Adding Optimum Water in Aggregates

Preparation of Cold Mix by HMP ( without heating facility)

Laying of Cold Mixed SDBC with Paver

Compaction of Cold Mixed SDBC

Finished SDBC with Emulsion on Aizawl By-pass