Innovative Cold Mix Technology

(Construction and Maintenance of Roads)

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 Introduction of Dr P.K.Jain
Dr P.K.Jain worked at Central Road Research Institute for 38 years (1978-
2016). He performed duties of Head , Flexible Pavement, Secretary
,Research Council, Adviser, Pavement Engineering and Coordinator ,AcSIR
before superannuation on 31.1.2016.
He represented various committees of IRC and drafted IRC:SP:100, code of
practice for cold mix technology. He has handled over 300 research and
consultancy projects. He has also drafted several BIS codes and worked as
Chairman of PCD:6. He has published over 250 research papers and has 7
patents to his credit including CRRI patent of cold mix technology and pot
hole repair machine.
He has guided many M.Tech and PhD students. He has also delivered 50
invited lectures. He is conferred with National Award by President of India
for Innovation in Cold Mix Technology for Rural Road Construction.
He is core faculty at IAHE&Technical Advisor to Tinna

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 Cold Mix Technology
 Cold mix technology is defined as a road construction and
maintenance process dealing with bituminous mix
prepared by mixing unheated mineral aggregate with a
special tailor-made cold mix binder such as Tina bitumen
emulsion which is mixed, transported, paved and rolled at
ambient temperature.
 The energy input and GHG emission is minimum in this
innovative cold mix construction and maintenance
process .
 The innovative cold mix process can be accomplished by
spray application as well as mixing process
 NRRDA adopted this technology Under Technology
Initiative Programme
 Sustainable for BRO roads
Energy Consumption and GHG Emissions in
Road Construction Technologies

t u res
Mix
men
u
y Bit
g
E n er
Low
Hot Mix Technologies: Disadvantages
Heating of bitumen at 160-170°C
Heating of aggregates at 155-160°C
Production of hot mix at 150 °C
Laying of hot mix at 140°C
Compaction of hot mix at 100-130°C
 High noise and air pollution
Emission of green house gases
Hot Mix Technologies: Disadvantages
High energy consumption
Unsafe to workers and their health
Limited working season
Reduced durability due to oxidation of bitumen
Stripping in presence of water
Hazardous to public
Contribute to global warming
Huge machinery needs
 Suitability of Cold Mix Technology

 Cold application process

 Environment friendly
 Energy conservation
 Reduced global warming
 Reduction of carbon foot print
 Coat dry as well as damp aggregates
 Extended paving season
 Construction in all weathers
 Suitability of Cold Mix
Technology
 Suitable for high altitude
 Sustainable for all rural roads
 Suitable for spray applications
 Contains anti-stripping agents
 Need lesser manpower

 Least durability loss

 Minimum construction machinery
 Ideal for repairs and maintenance
 Cost effective if life cycle is considered
 Not harmful to health of workers
 Emulsion Based Cold Mix Technologies
IRC:SP:100

Surface Construction & Maintenance Interfacial

Treatments Cold Mixes Half Warm Treatments

 Fog Seal  Semi-Dense  Semi-Dense  Prime Coat

 Liquid Seal Bituminous Mixes  Tack Coat
 Sand Seal Concrete  Dense
 Slurry Seal  Patching Mixes
 Cape Seal  Pothole Repair  Recycled
 Chip Seal  Cold Recycling cold mixes
 Bituminous
Macadam
 Premix Carpet
 Mix Seal
Surfacing
 Tinna Innovative Cold Mix Binder
(Bitumen Emulsion)
 Bitumen emulsion is a heterogeneous two phase
colloidal systems consisting of two immiscible
liquids such as bitumen and water dispersed in each
other.
 Bitumen is dispersed in water throughout the
continuous water phase in the form of tiny discrete
globules , typically 0.1 micron to 25 micron in
diameter, which are held in suspension by
electrostatic charges.
 Bitumen emulsion is ideal binder for cold mix
technology used for road construction &
maintenance of roads.
Cold Mix Binder (Bitumen Emulsion)

 Bitumen
 Water
 Emulsifier
 Acid or
Caustic
 Solvents
 Additives
 Stabilizers
 Buffers
Structure of Cationic
Bitumen Emulsion
Cold Mix Binder ( Bitumen Emulsion)
 Types of Bitumen Emulsions

 Cationic Bitumen Emulsions

 Anionic Bitumen Emulsions
 Non Ionic Bitumen Emulsions
 Clay Stabilized Emulsions
Types of Emulsions
 Emulsifiers
 Emulsifiers are chemical additives reducing
interfacial tension between water and bitumen
phase in emulsion
 Decide whether emulsion formed is bitumen in
water or water in bitumen emulsion
 Stabilise bitumen droplet preventing coalescence
by providing identical charge on the droplets
 Control performance properties such as breaking
time, setting time , adhesion and cohesion in cold
mix
 Emulsifier are water soluble and create balance
between hydrophilic and lipophilic properties of
aggregates
 Role of Emulsifiers
 Correct choice of quality and quantity of emulsifier
control success of cold mix technology
 Emulsifier may be single chemical or a blend of two
or or more additive for control of compatibility
 Ionic part of emulsifier orient on surface of bitumen
while hydrocarbon molecular chain orient inside
bitumen
 In anionic emulsions, emulsifiers bear negative
charge
 In cationic emulsion , emulsifier bear positive charge
 In non ionic emulsifiers, hydrophilic head group is
covalent with polarity but dissolve without ionisation
 Preparation of Bitumen
Emulsion
 In case of cationic emulsions ,emulsifiers are fatty acid amines with long hydrocarbon
chain (16-22)
 In case of anionic emulsions, emulsifiers are fatty acids with long hydrocarbon chain
(16-22)
 High speed colloidal mill of minimum three stage is used for manufacture of
emulsion
 High speed rotor moves in stator at speed of 3000 to 6000 rpm
 The clearance gap is 0.25 to 0.50 mm and adjustable
 Preparation of Bitumen Emulsion
 Hot bitumen and emulsifiers are fed
simultaneously
 Viscosity of bitumen should be 1- 2 Poise
 Temperature of water must be less than bitumen
so that temperature of emulsion is 90 ˚C or less
 Pressurised mill are used for high viscosity
bitumen
 Plant may be batch type or continuous type
 Applications of Bitumen Emulsion

Type Recommended Applications and Grade

RS-1 Tack coat

RS-2 Surface Treatment, Surface Dressing
MS/Tailor Mixes with coarse aggregate such as premix
made carpet
SS-1 Prime coat
Tailor-made Mixes with graded fine aggregate in SDBC, MSS,
SS-2 BM, DBM and BC. This emulsion is also used for
slurry seal , mild warm mix and half warm mix
Specification of Bitumen Emulsion(IS:8887)
S.N Properties of Bitumen Grade of Emulsion (Softer Grade) Test
o Emulsion RS-1 RS-2 MS SS-1 SS-2 Method

i) Residue on 600 micron IS sieve 0.05 0.05 0.05 0.05 0.05 IS:8887
(% mass) Max
ii) Viscosity by Say bolt Furol IS:3117
Viscometer, Seconds
at 25°C - - - 20-100 30-150
at 50°C 20-100 100-300 30-300 - -

iii) Coagulation of emulsion at low Nil Nil Nil Nil Nil IS:8887
temperature
iv) Storage stability after 24 hr, % 2.0 1.0 1.0 2.0 2.0 IS:8887
max,
v) Particle charge +ve +ve +ve - +ve IS:8887
vi) Coating ability and water IS:8887
resistance
a)Coating, dry aggregates - - Good - -
b)Coating after spraying water - - Fair - -
c) Coating, wet aggregates - - Fair - -
d) Coating after spraying water - - Fair - -
vii) Stability to mixing with cement, - - - - 2 IS:8887
% coagulation
viii) Miscibility with water No No No Immiscibl No IS:8887
(coagulation) Coagulat Coagulati Coagulati e Coagul
ion on on ation
ix) Tests on Residue:
a) Residue by evaporation, % 60 67 65 - 60 IS:8887
min.
b) penetration, 25°C/100 gm/5 80-150 80-150 60-150 - 60-120 IS:1203
sec,
c)Ductility at 27°C, cm., min. 50 50 50 - 50 IS:1208
d) Solubility In 98 98 98 98 98 IS:1216
Trichloroethylene, %, min.
 Important Properties of
Bitumen Emulsion
 Stability
 Viscosity
 Adhesion
 Breaking
 Curing
 Cohesion
 Lower viscosity of bitumen emulsion make it
unstable , therefore not acceptable for roads
 Viscosity can be enhanced by increasing
viscosity of dispersion medium and reducing
particle size
 Factors Controlling Breaking
 Texture of aggregate
 Water absorption of aggregate
 Dust and PI of dust
 Humidity in weather
 Mechanical factors
 Surface area of aggregates
 Surface chemistry of aggregates
 Temperature
 Water quality
 Properties of emulsifier
 Properties of bitumen
Factors Controlling Emulsion Quality

 Chemistry of bitumen
 Chemistry of emulsifiers
 Particle size of bitumen in emulsion
 Dose of emulsifier
 Type of colloidal mill
 Quality of water
 Bitumen content
 Viscosity of bitumen
 Viscosity of emulsion
 Temperature of water and emulsion phase
Properties Affecting Emulsion Quality
 Chemical properties of bitumen
 Chemical Properties of Emulsion
 Dose of emulsifiers
 Quality of colloidal mill
 Sequence of adding ingredients
 Quality of water
 Viscosity of dispersed phase
 Viscosity of dispersion medium
 Temperature of different phases
 Handling of Emulsion
 Storage temperature shall be 10 to 50˚ C
 Shall not be heated above 70˚ C
 Do not freeze below 4˚ C
 Temperature of aggregate shall not exceed 80˚ C
 Do not use air jet for circulation
 Warm pump to maximum 65 ˚C
 No dilution in general
 Use of Good quality water ,if needed
 Handling of Emulsion
 Check quality of water if dilution is recommended
 Roll to and fro before use
 Inlet pipe below return line
 Pumping from bottom of tank
 Certificate of testing , MSDS from supplier
 Date of expiry and manufacturing must be
mentioned
 Test report by suppliers
 Laboratory Level Tests (IS : 8887)

 Residue on 600 micron IS sieve

 Viscosity by Saybolt Furol viscometer
 Coagulation at low temperature
 Storage stability
 Particle charge
 Coating ability and water resistance
 Stability to mixing with cement
 Miscibility with water
 Residue by evaporation
 Tests on residue
 Distillation test ( SS-1)
 Field Level Tests on Emulsion
(IRC : SP : 100)
 Residue on 600 micron IS Sieve
 Viscosity by Saybolt Furol Viscometer
 Residue content by evaporation
 Storage stability ( 24 Hours )
 Testing of Aggregates
 Sand equivalent value test
 Methylene blue test
 Shape test ( Flakiness Index )
 Gradation test
 Soundness test
 Aggregate impact value test
 Water absorption test
 Stripping test
 Sand Equivalent Value Test
 This test is used to determine the amount of fine clay
particles in fine aggregate
 Aggregates with high clay content are not suitable in
cold mix applications
 When this is the case, a substitute aggregate is often
used for the job.
 This test can be done as per ASTM D 2419 (AASHTO T
176) or IS: 2720 ( Part 37)
 The value of sand equivalent shall be minimum 50 for
cold mix construction
 Lower value of sand equivalent require tailor made
products
 Sand Equivalent Test Procedure
( IS: 2720:Part 37)
 Take 1500 gram of material passing 4.75 mm sieve
 Divide sample in 4 parts and dry at 105 ˚C for 4
hours
 Damp material to prevent segregation or loss of fines
during quartering operation
 Fit siphon assembly to 4 liter capacity bottle
containing calcium chloride solution
 Place bottle 915 mm above the working Table
 Siphon 100 mm working calcium chloride solution to
graduated cylinder and shake after lid is closed
 Sand Equivalent Test
(IS: 2720, Part 37)
 Pour test specimen to graduated cylinder
 Bottom of cylinder shall be taped to remove air
bubble if any
 Allow sample to stand for 10 minutes
 Stopper cylinder and shake cylinder with contents
for 45 seconds left to right by hand or by shaker
 Place cylinder upright on working Table
 Wait for 1 hour
 Calculate sand equivalent value
Sand Equivalent Value
 Stripping Test
 Stripping is displacement of bitumen film from aggregate
surface in presence of water
 Basic test procedure is given in IS:6241
 Compatibility of aggregate with emulsion depend upon
stripping and surface characteristics of mineral
aggregates
 Aggregate of 12.5 to 20.0 mm size shall be coated with
7% bitumen emulsion at room temperature and allowed
to curing for 4 hours in a oven at 40˚C or in sunlight
 Place mix in beakers and submerge in distilled water
before conditioning at 40 ˚for 24 hours in a water bath
 Percent coating is visually observed after 24 hrs.
 Methylene Blue Value Test
 Test indicate presence of clay in fine aggregates, its
content and type
 Differentiate between good and bad clay fines
 Measure Methylene blue absorbed per gram of fine
aggregates
 Test is give in ASTM C 1777 or AASHTO T 330
 Test is done on fraction passing 75 micron
 May be done by titration or using colorimeter method
 Value shall be less then 4 for cold mix applications
 Compatibility Between Aggregate
and Emulsion
 Key success of cold mix technology depend on
compatibility of emulsion with mineral aggregates
 Properties of aggregate and binder are important for needed
compatibility between them
 Sand Equivalent Value must be greater then 50 for good
compatibility with emulsion
 Conventional emulsion of MS grade is suitable for all types
of aggregate with sand equivalent value more than 50
 For aggregate of lower Sand Equivalent value,
compatibility needs detailed investigations
 Compatibility Between Aggregate
and Emulsion
 Lower value of Sand Equivalent of aggregate requires special
emulsifiers during formulation of emulsion
 Test is important for BM, SDBC,MSS, & OGPC type cold
mixes
 Methylene blue test is significant for fine aggregates used for
SDBC, Slurry Seal , and Seal Coat
 Compatibility test shall be done for emulsion as well as
aggregate to decide source of these materials prior to
construction
 Test may be done by supplier or in a central laboratory
 Compatibility Test for Cold Mix

 Sieve the aggregate available at site and collect fractions

passing 19 mm and retained on 13.2 mm and passing
11.2 mm and retained on 4.75 mm sieve separately
 Wash and dry both samples of aggregates (one Kg
each)
 Take 600 gm. of coarse aggregate in a round bottom
metal pan of 200 mm diameter and add 6.5% emulsion
by weight of aggregate followed by mixing for one
minute
 Take 600 gm. of fine aggregate in pan of 150 mm
diameter and add 7% emulsion by weight of aggregate
followed by mixing for one minute
 Compatibility Test for Cold Mix

 Cure both cold mixes in sunlight or in oven at 40˚ C for 4 hours

and observe coated area (90% coating is acceptable)
 Take 3 samples of 200 gm. of both mixes in beakers of 400 ml
and then add distilled water in each beaker
 Place 1st set of beaker in water bath at 40 degree centigrade for
24 hours and observe coating and place second set for boiling for
3 minutes observe coating
 75% coating is acceptable for clearance of compatibility test
between aggregate and emulsion
Comparison Rigid and Flexible Pavement
Pavement Layout

PQC : Pavement Quality Concrete DBM : Dense Bituminous Concrete

DLC : Dry Lean Concrete WMM : Wet Mix Macadam
BC : Bituminous Concrete
Comparison Between Rigid and Flexible
Pavement

CO2 Emitted (in Tonne CO2 Eq)

 Methods
 
Rigid Pavement Flexible Pavement

Embodied Energy 1246.0 95.0

During
6.6 84.0
construction
Material Transport
46.7 40.7

Total 1299.3 219.7

Comparison of GHG Emission for Cold Mix and
Hot Mix Technology
(1 Km Rural Road Construction)
CO2 Emitted (Tonne of CO2 Equivalent )
Material & Premix Seal Coat
Process 
Hot Mix Cold mix Hot mix Cold Mix

Bitumen or
40.2 21.4 43.5 18.2
Emulsion
Crushed
8.2 2.7
Aggregate
During
141.5 7.5 141.5 7.5
Construction
Total 189.9 37.1 187.7 28.4
 Comparison of Fuel and Material Consumption
for Typical Cold Mix and Hot Mix Construction
Process
(1 Km Rural Road Construction)
Specification Cold Mix (Present Innovation) Hot Mix (Conventional)

Emulsion Aggregate Fuel Bitumen Aggregate Fuel

(MT) (cum) (L) (MT) (cum) (L)

OGPC 13.8 135 90 9.1 135 1698

MSS 12.4 101 85 8.2 101 1600

Energy Consumption in Hot Mix and
Cold Mix Technology

Specification Energy Kilo Cal x 108

Hot mix Cold mix
technology technology
Mix Seal Surfacing
1.02 0.88
(20 mm)
Premix with Seal
1.16 0.92
Coat
(20 mm )
Economic Benefits of Cold Mix Technology
 Cost of emulsion and bitumen is comparable
 Cost of fuel in cold mix is saved as heating is
eliminated
 Life of hot mix and cold mix surfacing is same
 Cold mix consumes 35% higher binder
 Cost of mixing and laying must be less in case of
cold mix
 Construction cost of hot mix and cold mix is
comparable
 Cost of cold mix may be 5 to 10 % higher in
certain situations ,
 Maintenance by cold mix is cheaper
Social Benefits of Cold Mix Technology
 Hot mix technology is harmful to health of construction
workers ,
 Causes burns during application
 Inhaling of fumes causes many diseases like asthma and
stomach disorder
 Prolonged exposure may cause cancer also
 Construction by hot mix causes irritation to nearby habitat
 Repair using cold mix is easy and construction is possible
in rainy season
 Studies by social scientists reported merits of cold mix and
its health merits
 Cold Mix Technologies for
Construction
 Prime Coat
 Tack Coat
 Chip Sealing
 Open Graded Premix
 Mix Seal Surfacing
 Bituminous Macadam
 SDBC
 Recycling
 Slurry Sealing
 Microsurfacing
 Cap Seal
 Cold Mix Technologies for
Construction
 Surface Dressing
 Premix Carpet
 Mix Seal Surfacing
 Bituminous Macadam
 SDBC
 Slurry Seal
 Cold Mix Technologies for
Maintenance
 Patch Work
 Pothole Repair
 Crack Sealing
 Fog Seal
 Sand Seal
 Slurry Seal
 Microsurfacing
 Tinna Innovative Cold Mix Binders
Product Compliance Applications
RS-1 ( Tack Coat Grade ) IS:8887 Tack Coat
RS-2 (Chip Seal Grade ) IS :8887 Chip Sealing ( Surface Dressing , Cap Seal )
RS-2 ( Seal Coat Grade ) IS:8887 Seal Coat ,Type A
SS-1 ( Priming Grade ) IS:8887 Prime Coat
SS-2 & MS IS: 8887 Premix and Seal Coat Type B and Type C
( Premix :All –in One) (Hot, Moderate and Cold climate Climate )
SS-2 (Special Grades ) IS : 8887 Premix ( SDBC,BM,OGPC , Recycling )
MS/SS-2 ( Patching Grade ) IS: 8887 Pothole repair and Patch work

Special grade MS emulsion are also available for pothole and patch mix
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Technical expertise for site work is also available as technical support service
 Selection of Cold Mix Treatments
Title of Treatment Traffic (CVPD) Climate Choice of
Temperature Rainfall Emulsion

Prime Coat No Limit No Limit No Limit SS-1

Tack Coat No Limit No Limit No Limit RS-1
Seal Coat <1500 No Limit No Limit SS-2
Sand Seal <1500 No Limit No Limit SS-2
Cap Seal <3000 No Limit No Limit RS-2 , SS-2
and Modified
Chip Seal <1500 Avoid in Cold No Limit RS-2,
Climate Modified
Slurry Seal <1500 No Limit No Limit SS-2
Microsurfacing No Limit No Limit No Limit Modified
OGPC <1500 Moderate & Medium Tailor- made
cold climate MS/SS-2
MSS <1500 Moderate & Low Tailor- made
cold climate MS/SS-2
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Questions
Tinna Caring for Environment

Thanks

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