CGRRDA

Disadvantages of Hot Mix Technology

 Noise and air pollution

 High energy consumption
 Limited working season- No work
during rains and winters
 Sensitive to temperature control
during entire process.
 Unsafe to workers and their health
 Thermal oxidation of bitumen due
to need of heating.
 Hazardous for public in general
Hot Mix Technology: Hazardous to Labour
Hot Mix Technology: High Air Pollution
What is Juno Bitumix Cold Mix technology?

 Cold Mix technology is field application of mix design based MS/SS-2

Bitumen emulsion or tailor-made cold mix binders with the available
IRC SP 100:2014 recommended aggregates through modified HMP
plant or site mixing without need of any heating in an environment-
friendly manner.

 It is not simply supply of ordinary bitumen emulsions.

 It is the entire value chain of technology from laboratory mix designs,

supply of tailor made cold mix binder and overseeing the entire
mixing, laying & rolling activities through technical support and
supervision services.
Composition of Juno Cold Mix Binder

 Bitumen
 Water
 Emulsifier
 Acid or Caustic
 Polymers
 Solvents
 Additives
 Stabilizers
Tests on Juno Cold Mix Binder

 Residue on 600 micron IS sieve

 Viscosity by say bolt 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
 Water Content
How to do
Juno Cold Mix
on Road
Step 1:

S. No. Activation Schedules

Laying, Spreading & Compaction of Cold Mix

1 Inspection of site and other arrangement

2 Trial run of OGPC & Seal Coat at the concrete mixer/HMP

3 Demonstration / Regular Work

4 Application of Prime Coat/Tack Coat

5 Preparation of Cold OGPC at Concrete Mixer

6 Rolling & Compaction of Cold OGPC
7 Application of Seal Coat
Step 2:
S. No. Activation Schedules

Laying, Spreading & Compaction of Cold Mix

1 Curing & Setting

2 Observation of the pavement

3 Allow of Traffic

4
Observation of Pavement

5 Observation of the Demo Pavement

6 Construction continuously
7 Observation and Review of total work done
8 Submission of the report
Why Aggregates
play significant role in
Cold Mix Road Construction?
Before selecting Bitumen Emulsion,
Testing of Aggregates is important.

Who will do testing ?

Emulsion Provider
Tests of Aggregates

 Sand equivalent value test

 Methylene blue test
 Shape test
 Gradation test
 Soundness test
 Aggregate impact value test
 Water absorption test
 Stripping test
Precaution to be taken before and during
construction

Note: Consult with laboratory and find recommended binders for all such challenges
and site specific problems
Precaution to be taken before and during
construction

Do not use very wet

aggregate for seal coat

Do not use too dusty & soil

coated aggregate for seal coat

Mix produced for

carpeting should not
have lump formation
Precaution to be taken before and during
construction

Use standard & clean

aggregate for Carpeting,

Use standard & clean aggregate

for Seal Coat, if aggregate
is too dusty & soil coated,
get cleaned by screening and
wash if needed then dry it
Cold Mix Open Graded Premix Carpet

S. No. Premix Carpet

Coarse aggregate of nominal 13.2 mm size:

(a) passing IS 22.4 mm sieve and retained on IS 0.18 m3
11.2 mm sieve

Coarse aggregate of nominal 11.2 mm size;

(b) passing IS 13.2 mm sieve and retained on IS 5.6 0.09 m3
mm sieve
 Cold Mixed Seal Coat

S. No. Specification

Seal Coat A Stone chips shall be 6.7 mm 0.009 m³/m² 1.2kg -1.4 kg/m²
size, passing through 11.2
mm sieve & retain on 2.36
mm sieve
Seal Coat B Stone chips shall pass 0.006 m³/m² 1 kg – 1.2/m²
through 2.36 mm sieve &
retain on 180 micron sieve

Seal Coat C Stone chips shall be 6.7 mm 0.009 m³/m² 0.9 kg – 1.1
size, passing through 9.5 mm kg/m²
sieve & retain on 2.36 mm
sieve
Recommended Cold Mix
Design (RCMD) Report

Based on the aggregate

received from the
department/contractor and
was send to the laboratory
for testing.

At site, aggregate for

carpeting are under graded
and seal coat were over
graded.
Type of Application in Rural Roads

 Surface Dressing
 Premix Carpet
 Mix Seal Surfacing
 Patch Work
 Pothole Repair
Cold Mix technology is now a mainstream technology and can
be utilized for following applications as per recently released
IRC SP: 100: 2014 Guidelines-

 Juno Bitumix COLD MIX (OGPC & Seal Coat)

 Juno Bitumix COLD MSS

 Juno Bitumix COLD SDBC

 Juno Bitumix COLD BM

Application Cold Mix Technology using
Hot Mix Plant
S. No. Particulars Qty.
Juno Bitumix Cold Mix Production
Smooth running HMP (40 ton/hr min) with conversion to
A 1
cold mix production
B Accessories for conversion of the plant

1 Sintax /MS tank (min 2000 L cap) 1

2 2” gate valve (Gun meal) 1 or 2

3 MS pipe, 2” 2m

4 MS Nipple, 2”x6” 3 pc

5 MS reducer (1.5”x2”) 1

6 MS Flange, 2 “ 3 pair

7 MS Flange, 3” 1 pair

8 Tank Connector, 2” (MS) 1

9 Socket, 2” (MS) 1
S. No. Particulars Qty.

10 JCB 1

11 Fork Lift 1

12 Operational team with operator 6

13 Plant supervisor 1

C Laying & Compaction of Juno Bitumix Cold Mix

1 Static Roller (8-10 ton) 1

2 Pneumatic Roller (15-30 ton) 1

3 Hydraulic Paver (4.5 m) 1

4 Compressor 1

5 Tack coat sprayer 1

6 Operational team with all arrangement 20

7 Site Supervisor 1

8 Site I/C 1
 S. No. Particulars Qty.
Key Elements (Aggregate & Juno Cold Mix Binder/Juno
D
Bitumix RS-1)
Bitumen Emulsion, Juno Bitumix RS-1 ( as per IS 8887 :
1 (0.250 kg/m²)
2004) for Tack Coat
E Cold Mix (OGPC)
1 Aggregate (13.2 mm & 11.2 mm) (0.027 m³/m²)
2 Juno Cold Mix Binder, (as per Exceed IS 8887 : 2004) (2.1 Kg/m²)
3 Stone chips (Seal Coat) 0.006 m³/m²
4 Juno Cold Mix Binder (Liquid Seat coat) (1.2 kg/m²)

F Cold Mix MSS (20 mm)

1 Aggregate (10 mm, 6 mm & fines) 0.027 m³/m²

2 Juno Cold Mix Binder ( 3.3 kg/m²)

Cold MPM Construction (50 mm)

1 Aggregate (Course aggregate of 40 mm size) 0.06 m³/m²

2 Juno Bitumix Cold Mix Binder 2.6 kg/m²

Cold SDBC (25 mm)

1 Aggregate (composite mixture of 10 mm, 6mm and fines) 0.03 m³/m²

2 Juno Bitumix Cold Mix Binder 7.5 % by wt of mix

Procedure for construction of
Open Graded Premix Carpet (using Hot Mix Plant)

 The blended aggregates of 13.2 mm and 11.2 mm nominal sizes

in 2:1 ratio, as per the specified requirement, shall be charged in
the hot mix plant which shall be used without heating
arrangement and with suitable modification for incorporation of
emulsion.
 The cold mix binder in required quantity approximately (6 percent
by wt. of aggregates) shall then be added into wet aggregate and
mixed for two minutes to get uniform coating.
 Prolonged mixing shall be avoided as it will uncoat the aggregates.
 The cold mixed open graded premix may also be prepared in a
concrete mixer.
 The required quantity of emulsion of tailor made cold mix binder
shall then be added and mixed with aggregates for two minutes.
Contd…

 The cold mix while indicating brown colour shall be discharged into
trolleys to transport to the construction site
 Compaction of cold mix with 8-10 tone roller shall be carried out to
get the finished premix carpet surface
 The required quantity of emulsion of tailor made cold mix binder
shall then be added and mixed with aggregates for two minutes
 The cold mix while indicating brown colour shall be discharged into
trolleys to transport to the construction site
 Compaction of cold mix with 8-10 tone roller shall be carried out to
get the finished premix carpet surface
Preparation of Cold mix

Laying of Cold Mix

Rolling of Cold Mix

Application Cold Mix Technology using
Concrete Mixer Machine

Juno Bitumix
S. No. Particulars Qty.
A Juno Bitumix Cold Mix Production (Cold OGPC)

1 Concrete Mixer (0.5 ton or 1 ton capacity) 2 no

2 Concrete Mixer Operator 2 no

3 Skilled concrete mixer operation team 7 no

4 Fuel for one concrete mixture per day 10 – 15 L

5 Tagari 15 – 20 no

6 Hand Paver (Riana) 5 pc

7 Shovel (Belchaa) 10 pc
Empty half drum to receive Cold Mix Binder/Bitumen
8 4 pc
Emulsion
9 Hand gloves to concrete mixer operator and his assistant 2 pairs
Measuring Box or Mustard Oil tin to know the volume of the
10 4 no
aggregate
Measuring Cylinder, 2 L or 2 L mug to weigh Juno Bitumix
11 5 pc
Cold Mix Binder & Bitumen Emulsion
S. No. Particular Qty.
B Laying & Compaction of Juno Bitumix Cold Mix

1 Static Roller (8 – 10 ton) 1 no

2 Hand Cart (Thela)

Site construction team with site supervisor (skilled &
3 15 no
semi skilled)
4 Gunny bags/Jute bag to clean the roller 15 pc

5 Rope, 27 mm to maintain the thickness 10 kg

C Tack Coat Application

1 Iron Brush 7 pc

2 Broom 7 pc

3 Pressure Distributor or 1 pc

4 Manual sprayer using 15 kg tin Perforated tin 4 pc

S. No. Particular Qty.

D Key Elements

1. Aggregate

For OGPC, Composite mixer of 13.2 mm and 11.2 mm in 2:1

0.27 cm/10 m²
ratio

For Liquid Seal Coat (Seal Coat A)- stone chips, 6.7 mm

1. Juno Bitumix Cold Mix Binder (IS 8887 :2004)

For OGPC - MS 2.1 kg/10²

For Liquid Seal Coat – SS-2 1.2 kg/10²

E Tack Coat Material (IS 8887 : 2004)

Bitumen Emulsion RS-1 0.25 kg/sqm

Application of Tack Coat

Mixing in Concrete Mixer

Laying of Premix

Rolling of Premix
Rolled & Compacted Cold Mix Road
Performance of Rural Roads with
Cold Mix Technology
Precautions for Cold Mix Construction
Job After Reaching the Site:
Cleaning of WBM/WMM Surface
Check WBM/WMM surface. It
should be dry, clean from dirt,
soil and
debris. All the loose materials
from the surface should be
removed and refilled with
coarse aggregates & compacted.

Cleaning of WBM /WMM Surface

 Use cold mix binder
from air tight closed drum

Do not use cold mix binder from

the drums where lids are opened
Selecting required grade of
Juno Bitumix Cold Mix Binder
Drum Sticker

Grade
Manufacturing Date
Batch No.
Expiry Date
Rolling of cold mix binder drum

Roll the cold mix binder drum (in to and fro motion) to a distance of minimum 5
m for at least 4 to 5 times before use

Opening of mix binder drum

Open the lid of the drum by loosening it anti clockwise

Taking out cold mix binder from drum

Take Cold Mix Binder from the

drum in to the container as per
requirement

Checking PH of cold mix binder

Check the pH of the Cold Mix Binder.
PH shall be within 1 to 3
 Don’t

Do not mix water with Cold

Mix Binder

Do not heat Cold Mix Binder

drum when even found thicken
in uniformity
Emulsion Spraying Machine

Use Pressure Distributor for Prime Coat & Tack Coat Application

Manual Sprayer by means of 15 kg tin

container for Prime Coat & Tack Coat
Prime Coat Application

Grade Required Qty How to do

Juno 0.6-0.9 kg/m2 •WBM surface should be dry, clean from

Bitumix (for low porosity) dust, soil, debris or any loose materials.
CSS1 0.9 to 1.0 kg/m2 •Use pressure Distributor or sprayer to
(for medium porosity) supply primer at specified rates
1.2-1.5 kg/m2 •Ensure a uniformly unbroken spread of
(for high porosity) primer at normal temperature
•The surface should be allowed to core
preferably for 24 hrs.
Tack coat application

Grade Required Qty How to do

Juno 0.2-0.25 kg/m2 •Before applying Tack coat, WBM surface
Bitumix (for normal bituminous should be dry, clean from dust, soil, debris
RS1 surface) 0.25 to 0.3 or any loose materials.
kg/m2 (Dry & hungry •Use pressure Distributor or sprayer to
bituminous surface) supply primer at specified rates
0.25-0.3 kg/m2 •Ensure a uniformly unbroken spread of
(Granular surface primer at normal temperature
treated with primer) •Apply tack coat 30 minutes before laying
0.3-0.35 kg/m2 the carpet.
(Cement concrete •The tack coated surface should break
pavement) before laying the carpet.
Don’t

Do not spray emulsion on

loose surface

Do not mix different grades of

emulsion with cold mix binder
Completed Cold Mix Road

Rolling of Seal Coat application

Rolling operation is to be done
for 5 to 6 times. During rolling
operation, wheels of the roller
should be cleaned by wet cloth
or gunny bag to avoid falling of
dirt on the surface. Compacted
thickness of the finished road
should be 20 mm.

Ready cold mix road

Allow slow and light traffic

after 1 hour of completion
of seal coat application
What is Juno Bitumix Cold Mix Binder?

And what makes it different from other

emulsion in the market ?
 Regular Bitumen Emulsion in the market is mainly RS1, MS,
SS-1 or CSS-1, SS-2 Cationic Bitumen Emulsion as per IS
8887:2004. These are only for spraying purpose to be used in
Tack Coat and Prime Coat application and few of them may be
tried for cold mix applications. IRC mentions about tailor
made bitumen emulsions for appropriate cold mix design.

 It is manufactured with certain performance additives and

anti-stripping agents and possesses setting characteristics
required for the particular climatic zone and aggregate
conditions.
 Juno Bitumix Cold Mix Binder is a mix design based tailor
made bitumen binder. The main feature of this mix design
process is to identify and optimize the binder as per the
aggregates available from any source in India i.e. dusty
aggregates, soil coated aggregates, clean aggregates, damp
aggregates, pea gravel aggregates or the Calcarious (lime
mix) aggregates.

 This binder exceeds IS 8887 : 2004 specification of MS and

SS-2 regular emulsions and is proven as most ideally suited
for cold mix applications in our country’s conditions for
OGPC, MSS, SDBC and BM.
How quality is ensured
in Juno Bitumix Cold Mix Technology

 Cold Mix Design (RCMD) Report

 Raw Material tested before

final production.

 Master Batch produced

 Actual Product V/s Lab

RCMD comparative analysis.

 Packed in New HDPE Drums , mentioning date of manufacture, shelf

life, Other instructions.

 On-Site Technical Services execution till “Contractor Technology

Transfer Certificate” is jointly signed.
 DPR Technical Specification
on Juno Bitumix Cold Mix Technology
1. Prime Coat.
As per technical specification clause 502.
2. Tack Coat.
As per technical specification clause 503.

1. AS PER TECHNICAL SPECIFICATION MORD Book Clause 508.2. / MORT&H Book Clause 511.2./IRC:14-2004 Clause
4):
20mm Thick Open Grade Premix Carpet Using Juno Bitumix Cold Mix Technology (As Per Technical
Specification MORD Book Clause 508.2)
Providing laying and rolling of open- graded premix carpet of 20mm thickness composed of 13.2mm to 5.6mm aggregates
using Juno Bitumix Cold Mix binder to required line, grade and level to serve as wearing course on a previously prepared
base, including mixing in a suitable HMP plant / site concrete mixer without heating ,laying and rolling with a three wheel
80-100KN static roller capacity , under technical services training by Juno Bitumix engineer / applicator finished to
required level and grades to be followed by seal coat of either Type A or Type B or Type C as per technical specification
clause 508.2.
1. AS PER TECHNICAL SPECIFICATION MORD Book Clause 510 / MORT&H Book Clause 511.
Seal Coat Type A as per Juno Bitumix Cold Mix Technology (As Per Technical Specification MORD Book
Sec.510)
Sealing the voids in a Cold mix open graded carpeting surface and laid to the specified levels grade and cross fall using
Type A , B and Type C as per Technical specification clause 510 with Juno Bitumix Cold Mix binder (including carriage up
to initial lead of 5.0Km from quarry and carriage of mixed material up to 10.0Km initial lead from mixing plant) including
cost of testing of materials at site and laboratory as directed by the department.
List of work
done by
Juno Bitumix
Cold Mix
Technology
Rate Analysis
OGPC Rate Analysis
Seal Coat Rate Analysis
 Juno Bitumix Pvt. Ltd.
Corporate Office:
9-B, 2nd Floor, Tower-II, Plot No. C-25, Stellar IT Park, Sector-62, Noida-201301
(U.P.) Tel: +91.120.4574451/52 | Fax: +91.120.4574453
Regional Office:
A-3, 2nd Floor, Luv-Kush Tower, Exhibition Road Patna - 800001, Bihar
Production Unit:
E-106-107, UPSIDC Industrial Area, Kosi-Kalan, Mathura-281403 (U.P.)