Laboratory Evaluation

of
optimum job mix design
using
various grades
of
Zuper Cote
produced
at

OMIPL

Zuper Cote is the trade name of

Dated 13 th April 2009 Cationic bitumen Emulsions
produced at OM Infracon Pvt Ltd

Factory Location: Rangia

 Sponsored
Sponsored by by :
This study has been carried out by : • • CRRI
CRRIDelhi
New Delhi
• • MNIT
MNITJaipur
Jaipur
Mr Sachin Gupta • • OMIPL
OMIPL Guwahati
Guwahati
Mr. Nitin Pathak
both are pursuing Post Graduate studies at MNIT Jaipur
….and this work is a part of their post graduate thesis
….. they have been assisted by Mr Prodip Borah (Laboratory in Charge at OMIPL)

their supervisors :
Mr Arun Gaur ( Sr Lecturer MNIT Jaipur)
Dr Sunil Bose (HOD Flexible Pavement Division CRRI)

………the work has been carried out under the direct supervision and guidance
of MR Preetam Rajkhowa (Technical Consultant to OMIPL ) at their research
and development facilities at OMIPL
Introduction
Introduction

This study was carried out as a research project by Mr Nitin Pathak and Mr Sachin Gupta
two P.G. students from Malviya National Institute Of Technology Jaipur at OMIPL
laboratory to establish the optimum mix design for dense and semi dense mixes using
various grades of emulsions produced at OMIPL:S plant at Rangia.

The aggregate gradations were as per MORTH and various molds were prepared
with different emulsion percentages to get optimum stability and flow values.

An attempt was also made to find the stability and flow behavior when cement is
incorporated in the mix design.

This study also laid focus on the Marshall Stability and flow behavior when certain
percentage of polymer is incorporated into the emulsions.

All these figures of different tests are plotted in a form of graphs for comparative studies.
This study however does not include the effect of emulsion percentage and
aggregate gradation on the density and void ratios in the job mix.

However, we intend to do further work on this aspect……..especially on the formulations which

are giving optimum flow and stability.

Basically three different product ranges were selected for the product study
namely SSZ, S-PME and S-PME+.

SSZ is an ordinary cationic emulsion without any modification.

S-PME and S-PME+ are cationic emulsions with modification with an in
house developed polymer.

SSZ and S-PME has a solid content of 61% and S-PME+ has a solid content
of 65%. The laboratory results of these grades of emulsions are also enclosed.
Procedure Followed
Procedure followed

Aggregates were graded as per MORTH specification both for SDBC and BC.

The cement content was incorporated in the mix prior to the addition of the requisite quantity of water.

The required emulsion was added and was mixed for about 30-50 seconds depending
upon the right consistency viscosity and coating obtained which is ascertained by visual assessment .

The mix was oven dried for 3 Hrs. at 60 C . Then the moulds were formed by
ramming 75 blows on both the faces.

The moulds were then kept in open air for 24 Hrs..

The formed blocks were taken out carefully and cured for 72 Hrs. at 40C.

The cubes were then subjected to tests in the Marshall Testing machine for stability and flow.
 Trial mixes
to
establish
coating properties
mixing properties
setting/ breaking times
water requirements
Trial Mixes
Several trial job mix have been tried just to ascertain
the coating properties, setting time and breaking time.
Trial job mix for SDBC and BC (with and without adding
Cement) were tried with several grades of Zuper Cote
manufactured by OMIPL, Rangia, Assam.

Following are the emulsions used-

Zupercote SSZ
Zupercote S-PME
Zupercote S-PME+
Zupercote MSC-PME
Zupercote MSC+
Zupercote MSZ

It was observed that with Zupercote MSZ & Zupercote MSC+

the coating is not proper and the mix starts setting during
mixing period itself. So these grades have been eliminated
from further studies.
It was observed from the trial mixes
that the quantum of water added plays
an important role in coating, setting and
breaking time. Also it was established that
the addition of approximately 1-2 % of
cement is a prerequisite to get optimum
results.

The table attached shows the summary of

our observations on the trial of coating and
breaking point carried out for the job mix.

A heap test was also carried out to ascertain

the applicability of mix after 1 hr.,
It was observed that the flow ability/ applicability is favorable
for all the mixes for at least 1 hr.
This is an important test as the mix has
to be carried from the mix plant to pavers which
may have the lead period of half an hour to
45 minutes and maybe at time up to 1 hours.
These trials had given us the base to carry
out rest of the work on the job mix design
using Zuper Cote
 Coating, Mixing Setting Time Tests
SDBC
Sl no Grade of Zuper Cote Aggregate in gms Wate ml Emulsion Gmns Cement Break/setting time hrs

1 SSZ 1000 40 80 0 1.4

2 1000 40 80 20 1.15
3 S- PME 1000 100 120 0 3:20

4
2 1000 90 100 20 2:00

5 S-PME+ 1000 90 120 0 5:00

6 1000 70 80 20 1:10

7 MSC-PME 1000 130 140 0 5:30

8 1000 100 100 20 1:00

9 MSZ NO COATING
10 MSC+ NO COATING 1-8 coating mix ability
was good
BC Coating, Mixing, Setting Time Tests

SL Grade of Emulsion Aggregate in gms Water ml Emulsion Gms Cement Gms Break/set time
hrs
1 SSZ 1000 50 80 0 1:45
2 1000 55 80 20 1:30

3 S- PME 1000 140 150 0 2:40

4 1000 120 120 20 1:30

5 S-PME+ 1000 120 120 0 6:00

6 1000 100 90 20 1:05

7 MSC-PME 1000 130 120 0 6:30

8 1000 110 100 20 1:10

9 MSZ NO COATING
1-8 coating mix ability
10 MSC+ NO COATING was good
 Readings
of
Marshal Stability
and
Flow
 SDBC Zuper Cote S-PME+
(AGGREGATE GRADATION AS PER MORTH
Zuper Cote S-PME+ WITHOUT CEMENT

Sl Mix Grade of Zuper Cote Agg gms Water ml Emulsion Gms Cement Zuper % Stability kgs Flow mm
1 SDBC S PME+ 1000 120 110 0 11 1124 2.9
2 1000 110 120 0 12 1311 3.5
3 1000 100 130 0 13 1218 3.35

SDBC+MSPME+ ( WITHOUT CEMENT ) SDBC+MSPME+ ( WITHOUT CEMENT )

4
1350
1311 3.5 3.5 3.35
1300
3 2.9
1250 2.5
1218
1200 2 FLOW VALUE
STABILITY
1150 1.5
1124 1
1100
0.5
1050
0
1000 11 12 13
11 12 13
FLOW VALUE 2.9 3.5 3.35
STABILITY 1124 1311 1218
 SDBC Zuper Cote S-PME+

AGGREGATE GRADATION AS PER MORTH

Zuper Cote S-PME+ WITH CEMENT

Sl Grade of Zuper Cote Agg gms Water ml Emulsion Gms Cement Zuper % Stability kgs Flow mm

1 S-PME+ 1000 100 90 20 9 1218 1.63

2 1000 100 100 20 10 1548 1.85
3 1000 100 110 20 11 1311 2.2
SDBC+MSPME+ ( WITH CEMENT ) SDBC+MSPME+ ( WITH CEMENT )

2000 2.5
2.2
1500 1548 2
1.85
1311 1.63
1218 1.5
1000 STABILITY FLOW VALUE
1

500 0.5

0 0
9 10 11 9 10 11

1218 1548 1311 FLOW VALUE 1.63 1.85 2.2

STABILITY
 Zuper Cote S-PME
SDBC
AGGREGATE GRADATION AS PER MORTH
Zuper Cote S-PME WITHOUT CEMENT
Sl Grade of Zuper Cote Agg gms Water ml Emulsion Gms Cement Zuper % Stability kgs Flow mm

1 S-PME 1000 100 110 0 11 1218 1.6

2 1000 70 120 0 12 1274 1.55
3 1000 100 130 0 13 1200 2.3

SDBC+SPME ( WITHOUT CEMENT ) SDBC+SPME ( WITHOUT CEMENT )

1280 2.5
1274 2.3
1260 2
1240 1.6 1.55
1.5
1220 1218 STABILITY FLOW VALUE
1
1200 1200
0.5
1180

1160 0
11 12 13
11 12 13
FLOW VALUE 1.6 1.55 2.3
STABILITY 1218 1274 1200
 SDBC Zuper Cote S-PME
AGGREGATE GRADATION AS PER MORTH
Zuper Cote S-PME With CEMENT
Sl Grade of Zuper Cote Agg gms Water ml Emulsion Gms Cement Zuper % Stability kgs Flow mm

1 SPME 1000 120 90 20 9 1218 1.9

2 1000 110 110 20 11 1350 2.1
3 1000 90 120 20 12 1274 2.03

SDBC+SPME ( WITH CEMENT ) SDBC+SPME ( WITH CEMENT )

1400 2.15
1350 1350 2.1 2.1
2.05
1300 2.03
1274 2
1250 STABILITY 1.95 FLOW VALUE
1218 1.9 1.9
1200
1.85
1150
1.8
1100 1.75
9 11 12 9 11 12
STABILITY 1218 1350 1274 FLOW VALUE 1.9 2.1 2.03
 SDBC SSZ
AGGREGATE GRADATION AS PER MORTH
Zuper Cote SSZ
WITHOUT CEMENT WITH CEMENT
Sl
Slno Grade Agg l Emulsion Cement Zuper % Stability Flow Grade Agg waterl Emulsion Cement Zuper % Stability Flow
Zuper cote gms gms kgs mm Zuper cote gms ml gms kgs mm

1 SSZ 1000 150 0 15 1367 3 SSZ 1000 110 140 20 14 806 1.32
2 1000 160 0 16 1348 5.6 1000 100 160 20 16 844 2.33
3 1000 170 0 17 1093 2.45 1000 100 170 20 17 806 2.03

SDBC+SSZ ( WITHOUT CEMENT ) SDBC+SSZ ( WITHOUT CEMENT ) SDBC+SSZ ( WITH CEMENT ) SDBC+SSZ( WITH CEMENT )

1600 6 850 2.5

5.6 844 2.3
1400 1367 1348 840
5
2 2.03
1200 830
1093 4
1000
820 1.5
800 STABILITY 3 3 FLOW VALUE STABILITY 1.3 FLOW VALUE
2.45 810
600 806 806 1
2
400 800
1 790 0.5
200
0 0 780 0
15 16 17 15 16 17 14 16 17 14 16 17
STABILITY 1367 1348 1093 FLOW VALUE 3 5.6 2.45 STABILITY 806 844 806
FLOW VALUE 1.3 2.3 2.03
 BC Zuper Cote S-PME+

AGGREGATE GRADATION AS PER MORTH

Zuper Cote S-PME+
With out cement With Cement
Slno Agg water l Emulsion Cement Zuper % Stability Flow Slno Agg water l Emulsion Cement Zuper % Stability Flow
gms ml gms kgs mm gms ml gms kgs mm
1 1000 120 130 0 13 1405 3.08 1 1000 110 80 20 8 1084 2.22
2 1000 110 140 0 14 1774 3.55 2 1000 100 90 20 9 1938 2.55
3 1000 100 150 0 15 943 4.3 3 1000 90 100 20 10 1790 2.55

BC+MSPME+ ( WITHOUT CEMENT ) BC+MSPME+ ( WITHOUT CEMENT ) BC+MSPME+ ( WITH CEMENT ) BC+MSPME+ ( WITH CEMENT )
2000 5
2500 2.6
1774 4.3 2.55 2.55
4 2000 2.5
1500 3.55 1938
1405 1790
3 3.08 2.4
1500
1000 943 STABILITY FLOW VALUE STABILITY 2.3 FLOW VALUE
2 1000 1084
2.2 2.22
500
1 500
2.1
0 0 0 2
13 14 15 13 14 15 8 9 10 8 9 10
STABILITY 1405 1774 943 FLOW VALUE 3.08 3.55 4.3 STABILITY 1084 1938 1790 FLOW VALUE 2.22 2.55 2.55
 SSZ
BC
AGGREGATE GRADATION AS PER MORTH
Zuper Cote SSZ

Without Cement With Cement

Slno Agg water l Emulsion Cement Zuper % Stability Flow

Slno Agg water l Emulsion Cement Zuper % Stability Flow
gms ml gms kgs mm
gms ml gms kgs mm

1 1000 120 150 0 15 594 3 1 1000 120 180 20 18 460 1.85

2 1000 110 160 0 16 620 3.4 2 1000 110 200 20 20 480 3.83
3 1000 100 170 0 17 537 3.8 3 1000 120 210 20 21 384 3.6

BC+SSZ ( WITHOUT CEMENT ) BC+SSZ ( WITHOUT CEMENT )

BC+SSZ ( WITH CEMENT ) BC+SSZ ( WITH CEMENT )
640 4
3.8
620 620 3.4 600 4
3.8
3 3 3.5 3.6
600 500 480
594 460 3
580 400
2 FLOW VALUE 384 2.5
560 STABILITY
300 STABILITY 2 1.85 FLOW VALUE
540 537 1 1.5
520 200
1
500 0 100
0.5
480 15 16 17
0 0
15 16 17 3 3.4 3.8 18 20 21 18 20 21
FLOW VALUE
STABILITY 594 620 537 STABILITY 460 480 384 FLOW VALUE 1.85 3.8 3.6
Conclusions
Conclusions

……………from the above study it has been observed that Zuper cote S-PME
and S-PME+ can be recommended for actual road work for SDBC
as well as BC
……………incorporation of approximately 2% cement improves
mix ability and coating with a reduction in the emulsion requirements
In the job mix
………….. a detailed study on the plots show the S-PME+ gives
optimum results on both Marshall Stability and flow values which
are comparable with that obtained with similar job mix designs done
by various organizations and parties using various grades of bitumen.

……………the above study clearly shows that the cationic emulsion can
provide alternate solutions to dense and semi dense carpeting to the presently
used hot mix technology.
 Cold mix technology
• A Green Technology
• Eco friendly
• Energy efficient
• Cost Effective
• Vesatile

The additional advantages of using Cold Mix Technology Envisaged are :

• …………all weather road work.
• ………..higher capacity of mix production hence larger road lengths.
• ……….. with slight modification in an existing hot mix plant it can be
converted to the production of cold mix plant doubling the capacity
of the plant. also the paver used for hot mix lane can be used for cold mix
• ………. a concrete mixer can also be used for all types of mixes including
micro surfacing mix…….. the mix can be laid by mini pavers developed
at OMIPL
• ……….significant advantage in going in for cold mix technology is a drastic reduction
in the energy and being pollution free becomes eco friendly and thus
a green technology.
• ……….based on the market price of the emulsion produced by OMIPL
a detailed cost analysis for execution of an actual road work is under preparation.
Visits to Sites
where
Zuper Cote
is
being used
 Zuper Cote

Site Visits
Mangaldoi 20 mm carpeting
ASSAM with seal coat
Nitin Pathak
in progress
Sachin Gupta
Simanta Kalita
Preetam Rajkhowa
Zuper Cote

Carpeting work in progress

Zuper Cote

Seal Coat with 004

A modified Zuper Cote
 e
ot
rC
pe
Zu

Grouting

Carpeting work in progress

Zuper Cote

… a mini paver
…mix being made
in a concrete mixer

Cold Mix Technology

A Green Technology
Eco Friendly
Energy Efficient
Cost Effective
,,,,laid surface Versatile
Laboratory Test Results
of
the grades
of
Zuper Cote
used
for
the
Study
 OM INFRACON Pvt. Ltd.
PRAGLAND BHAWAN, 2ND FLOOR, FLAT NO. 2 C & D
(OPP. BORA SERVICE STATION, G.S. ROAD,
PRODUCT : Cationic Bitumen Emulsion ULUBARI, GUWAHATI- 781 007
STANDARD: BIS 8887:2004
GRADE : S-PME
S-PME PHONE: 0361- 2450230, FAX: 0361-2451189

PLACE: Lab, OMIPL.

RUN NO : 197
mnf date 27.2.2009 Sl. No. Characteristics Results

1 Residue on 600 micron 0.024

IS sieve, Percentage, Max

2 Viscosity by Saybolt Furol Viscometer, Seconds 34

at 25OC
3 Coagulation of emulsion at law temperature Nil

4 Storage stability after 24h,Percent, Max 0.33

5 Particle Charge Positive

6 Stability to mixture with cement 0.356

(Percentage Coagulation), Max
7 Miscibility with water No Coagulation

8 Tests on residue: 63.3

(i) Residue by evaporation
percent, Min
(ii) penetration 76
25oC/100g/5sec More than 50
(iii) Ductility27oC/cm, Min
More than 98
(iv)Elastic Recovery
50%
 OM INFRACON Pvt. Ltd.
PRAGLAND BHAWAN, 2ND FLOOR, FLAT NO. 2 C & D
(OPP. BORA SERVICE STATION, G.S. ROAD,
ULUBARI, GUWAHATI- 781 007
PRODUCT : Cationic Bitumen Emulsion PHONE: 0361- 2450230, FAX: 0361-2451189
GRADE : S-PME+
PLACE: Lab, OMIPL.
RUN NO : 197
S-PME+
mnf date 27.2.2009
Sl. No. Characteristics Results

1 Residue on 600 micron 0.020

IS sieve, Percentage, Max
2 Viscosity by Saybolt Furol Viscometer, Seconds at 46
25OC
3 Coagulation of emulsion at law temperature Nil

4 Storage stability after 24h,Percent, Max 0.32

5 Particle Charge Positive
6 Stability to mixture with cement -
(Percentage Coagulation), Max
7 Miscibility with water No Coagulation
8 Tests on residue: 64.20
(i) Residue by evaporation
percent, Min
(ii) penetration 81
25oC/100g/5sec More than 50
(iii) Ductility27oC/cm, Min
(iv) Solubility:
In trichloroethylene More than 98
Percent by mass, Min
9 Elastic Recovery in Ductility Apparatus 50%
(done at BCT, Guwahati)
 OM INFRACON Pvt. Ltd.
PRAGLAND BHAWAN, 2ND FLOOR, FLAT NO. 2 C & D
(OPP. BORA SERVICE STATION, G.S. ROAD,
ULUBARI, GUWAHATI- 781 007
PHONE: 0361- 2450230, FAX: 0361-2451189

SSZ
PRODUCT : Cationic Bitumen Emulsion
GRADE : SSZ
PLACE: Lab, OMIPL.
RUN NO : 197
mnf date 27.2.2009
Sl. No. Characteristics Results

1 Residue on 600 micron 0.022

IS sieve, Percentage, Max
2 Viscosity by Saybolt Furol Viscometer, Seconds at 25OC 25
3 Coagulation of emulsion at law temperature Nil

4 Storage stability after 24h,Percent, Max 0.30

5 Particle Charge Positive
6 Stability to mixture with cement -
(Percentage Coagulation), Max
7 Miscibility with water No Coagulation
8 Tests on residue: 61.2
(i) Residue by evaporation
percent, Min
(ii) penetration 74
25oC/100g/5sec More than 50
(iii) Ductility27oC/cm, Min
More than 98
(iv) Solubility:
In trichloroethylene
Percent by mass, Min