Building Water Resistant Durable Pavements Using Zydex Nanotechnology
By Vishal Saluja – Vice President , Zydex Industries
Presentation to ASHGHAL, Qatar Public Works Authority
Using Zydex Nanotechnology Presentation to ASHGHAL, Qatar Public - - PowerPoint PPT Presentation
Building Water Resistant Durable Pavements Using Zydex Nanotechnology Presentation to ASHGHAL, Qatar Public Works Authority By Vishal Saluja Vice President , Zydex Industries Failures/Issues most common in roads and highways Oxidation
Building Water Resistant Durable Pavements Using Zydex Nanotechnology
By Vishal Saluja – Vice President , Zydex Industries
Presentation to ASHGHAL, Qatar Public Works Authority
Oxidation
raveling
leading to surface cracking
Roughness
Moisture
aggregates and bitumen
Cracking
due to temp variations
failures
costs
Bleed
chunks of pavements
Failures/Issues most common in roads and highways
Common Factor here is Water/Moisture Ingress
3
Water Intrusion through Soil
Water Intrusion through Soil
Water Intrusion through Soil
Water Intrusion through Soil
Water Intrusion through Soil
Water Intrusion through Soil
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Damag age e due e to freeze ze thaw
Damag age e due e to freeze ze thaw
Damag age e due e to freeze ze thaw
Damag age e due e to freeze ze thaw
Damag age e due e to freeze ze thaw
ANSWER IS ZYDEX ROAD SOLUTION Currently being used in 65 + countries worldwide Tested, approved and accepted globally Received several awards globally under technology & Innovation
What is the solution to these issues
and aggregate
and oxidation of bitumen is eliminated
shows excellent retention of wet strength due to chemical bonding
simulate ageing of actual production of mixes)
CHEMICAL BONDING
THE THE CH CHEMICA EMICAL L ACTIO CTION
Aggregate / Soil / Clay / Sand surface silicate structure after ZycoTherm reaction
O S i O S i O S i O S i O S i O S i O S i O O S i O O O O S i O O O S i O O O S i O O O O O O O S i O O O S i O O O S i O O S i S i S i S i S i S i S i O O O O O O O O O O O O O O S i O S i O S i O S i O S i O S i O S i O O S i O O H O H O S i O O S i O O H O S i O O O O O O O S i O O H O S i O O H O S i O O H O H
Particle surface
Particle surface
Internal Siloxane bonds
Aggregate / Soil / Clay / Sand surface silicate structure Silanol Groups ZycoTherm creates molecular level hydrophobic zone (water repellent)
4 - 6 nm
Alkyl Siloxane surface
CHEMICAL BONDING
Basalt Granite Limestone
Aggregate Surface with ZycoTherm Nano Layer
Weak Physical Bonding Strong Chemical Bonding
Polar Asphaltenes (5- 15%)
BITUM BITUMEN BIND EN BINDER ER MIC MICROSTR OSTRUC UCTURE TURE
In Non-Polar Maltenes (85-95%)
dispersed
Polar - Polar Interaction 5-15 % Asphalt participates in Bonding Non Polar – Non Polar Interaction 85-95 % Asphalt participates in Bonding
ZY ZYCO COTHERM THERM – AGG GGREGA REGATE TE - BIN BINDER DER IN INTE TERA RACTIO CTION
ORANGE PEEL EFFECT APPLE SKIN EFFECT
Stripped Binder Clean Water
Aggregate
Faster Coating & Consistent Compaction Better workability, Pave at 0o Celsius, Higher RAP
BOIL TEST ASTM D3625 : EXTEND TO 6 HOURS
Basalt Aggregate (DBM) : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust Asphalt Grade: AC-20 (VG-30, 60-70 penetration grade)
10 20 30 40 50 60 70 80 90 100 Control 2% Hydrated Lime 0.5% Amine 0.1% ZycoTherm
10 min 30 min 1 hr 6 hrs
% Coated Aggregates
PG 64-22 / VG 30 / 60-70 Pen PG 76-22
SALT RESISTANT PAVEMENTS
10 20 30 40 50 60 70 80 90 100 PMB Control 165 C PMB + 0.1% ZycoTherm 135 C 10 Min 1 Hr 6 Hr 10 20 30 40 50 60 70 80 90 100 Control 135 C Control 120 C 1% Hydrated Lime 135 C 0.5% Amine 135 C 0.1% ZycoTherm 120 C 10 Min 1 Hr 6 Hr
BOIL TEST ASTM D3625 : EXTEND TO 6 HOURS
Basalt Aggregate (DBM) : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust Asphalt Grade: AC-20 (VG-30, 60-70 penetration grade)
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Boil Test Retained Coating 98 % of ZT mix v/s control 65 %
Test 30 minutes as per IS 14982 Mix made with VG 30 Bitumen Granite Aggregates Control Treated
EFFECT OF ZYCOTHERM ON BITUMEN BINDER
Bitumen Parameter Outcome Performance Grading It maintains the grading Viscosity AASHTO T316 at 135 0C Rotational Viscosity remains unchanged Rutting Improves Rut Resistance (higher G*/Sinδ) Aging Improves retention of elasticity reflected by higher phase angle (in PAV aged asphalt binder) Low Temperature Flexibility (BBR Test AASHTO T 313) Similar / Higher m value at -12 0C, even though the G* shows consistently higher values at 64 0C Stiffness Penetration number goes down showing increase stiffness of the binder
ST STATIC TIC IM IMMER MERSIO SION N AASHTO T182 TEST TEST : : EXTEND EXTEND T TO O 360 360 HR HRS S
Basalt Aggregate (DBM) : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust Asphalt Grade: AC-20 (VG-30, 60-70 pen. Grade)
10 20 30 40 50 60 70 80 90 100 Control 2% Lime 0.5% Amine 0.1% Zycosoil
24 Hours 48 Hours 120 Hours 360 Hours
0.1 % ZycoTherm
% Coated Aggregates
500 1000 1500 2000 2500 3000 Binder AC-10 Binder AC-20 CRMB-1 PMB-40
Control 2% Hydrated Lime 0.1% Zycosoil
2.85 2.70 3.02 2.71 3.14 3.09 2.95 2.78 3.18 3.10 3.00
Marshall Stability (Kg)
3.05 Flow Values (mm)
Basalt Aggregate (DBM) : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust Asphalt Grade: AC-20 (VG-30, 60-70 pen. Grade)
2% Hydrated Lime 0.1% ZycoTherm Control
COMPLETE COATING
coating, wetting and saturation of finest pores & crevices on aggregates / fines with bitumen
AGEING EFFECT ?
Bitumen Binder Control With ZycoTherm Air Interface Pinhole Free Surface, Jet black look
to ensure longer life Accelerated bitumen oxidation happens due to extra air interface created by poor saturation and de-bonding of bitumen film on account of wet & dry cycles during the pavement service life
RESISTANCE TO OXIDATION RESISTANCE TO FATIGUE
transfer due to complete mechanical impregnation of bitumen into the finest pores of aggregate surface
less Torque to saturate the rough and porous aggregates.
interface for improved fatigue performance
hardened RAP binder
gives the Jet Black look
the aggregate surface
EFFICIENT WETTING
efficient distribution of bitumen binder in HMA mixes. This results in lesser requirement of bitumen by 0.1 – 0.4%
failures due to moisture susceptibility and oxidation. ZycoTherm modified mixes show distinct improvement in performance, though the OBC may go up marginally
OPTIMUM BINDER CONTENT
Cumulative Effect Of The Above
Aggregate OBC
Low Absorption Lowers Medium Absorption Maintains High Absorption Increases
Colorado, USA
JE JET T BLA BLACK CK LOO OOK K
Comp Complete lete Sa Satu turation tion
Lowers Mixing Temperature by 10-15 0C Cooler Hot Mixes Lowers Compaction Temperature by 35-40 0C Warm Mix Benefit Eliminates Variability of Compaction Density Upto 90 – 100 0C Texas Experience ZycoTherm HMA mixes (unmodified bitumen) delivered to job sites at 145 0C (in front of the plant site) and 105 0C (hauling for 4 hours & paving on ranch), have been rolled successfully achieving specified compaction density
COMPACTION EFFICIENCY
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Consistent Compaction at Lower Temperature
Mexican Transportation Institute Greater compaction can be achieved for the same and lower temperatures than reference mix Mixes often cool down unexpectedly, due to drop in ambient temperature, high wind speeds or a sudden rain shower. This leads to inconsistent densities during paving
Compaction temperatures for unmodified PG 58-22 in the range of 131-136 0C in Nova Scotia, AMEC Americas Ltd
Compaction density is consistent from 135 - 950 C Eliminates Variability
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Bitumen Mixes Compaction Resistance at Lower Temperatures
Innovationsgesellschaf t Technische Universität Braunschweig mbH
Mix Type Binde r Type C / ZT Compacti
OC
50 % Coating Sec Compaction Resistance 21Nm Void Content Vol % AC 16 BS 50/70 C 135 25 41.6 7.0 ZT 135 15 43.5 7.1 115 19 42.8 7.2 95 19 41.3 6.9 AC 11 DS 25/55
C 145 37 37.3 4.3 ZT 145 22 34.2 4.6 125 30 36.5 5.0 105 30 36.5 5.3
Mixes often cool down unexpectedly, due to drop in ambient temperature, high wind speeds or a sudden rain
to inconsistent densities during paving operations. Often, this either attracts penalty or bonus is missed due to inconsistent densities.
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Deformation maintained with acceptable tolerance, for similar temperatures as reference mix, according to AMAAC specifications Lowering mixing & compaction temperature does not affect rutting behavior
Rutting Test
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Higher Number of Cycles means Higher Fatigue Life Reduction in cracking in surface layers – field experience Saturation of micro pores and complete coating
higher bitumen- aggregate interface area leading to better load transfer Reduced stress for the mix
Flexural Fatigue Test AASHTO T321-07
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Flexural Fatigue Test AASHTO T321-07
Beam µԑ Reference Beam Nf ZycoTherm Beam Nf Fatigue life Increment
1 300 3,995,009 5,480,003 37% 2 400 713,381 1,300,000 82% 3 500 224,321 380,010 69% 4 600 67,758 190,010 180%
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Flexural Fatigue Test AASHTO T321-07
Number of cycles in which the beam stiffness modulus decreases 50% compared to its initial value.
tolerance, for similar temperatures as the reference mix, according to AMAAC specifications
Moistur ure e sensitive ive Dolom
ite e Aggr gregat egate Ke Keystone ne Quarry under er wet cond ndit ition ion at 50 oC
Measure Control ZycoTherm modified SIP 4600 11000 Rut Depth 10 mm Utah DOT 9300 14300
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Deformation maintained with acceptable tolerance, for similar temperatures as reference mix, according to AMAAC specifications Lowering mixing & compaction temperature does not affect rutting behavior
Rutting Test
exhibit low odor, making paving crew comfortable
eliminates buildup as well tend to clean old build-up
the metal helps to maintain cleaner elevators and
gradation and eliminates periodic cleaning required
sub-zero (-50 C) temperature, or in cold windy conditions since it gives extended workability up to 90 0 C for unmodified bitumen & 1050 C for SBS binder
( for Amine 3)
machinery
– lesser emissions
KEY HEALTH AND ENVIRONMENTAL BENEFITS
Zycotherm is a safer product compared to typical products used for antistrip or warm mix purposes Approximate pH ZycoTherm- 7 Amines- 11 Lime- 12 NFPA Health Rating ZycoTherm- 1 Amines- 3 Lime- 3
Asphalt Binder ZycoTherm Dosage (% by weight of asphalt binder) Unmodified 0.1 PMB (SBS Polymer - below 3%) 0.125 PMB (SBS Polymer - above 3%) 0.15 CRMB (Rubber 12-15%) 0.15 RAP / RAS 0.15 – 0.20
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Dosing Zycotherm in Bitumen Binder
Co-inject / Pour ZycoTherm with bitumen binder before loading tanker in refinery or in storage tank under re-circulation, while unloading tanker at HMA plant storage tank Co-inject ZycoTherm EZ with bitumen binder prior to mixing with aggregates for a particular batch being made in batch or drum plant
ADVANTAGES OF CRMB WITH ZYCOTHERM
There are certain limitations of RAP addition. The challenge with use of RAP is melting and recovery of used asphalt in the limited time available for mixing. As a result, it is very difficult to achieve complete coating and to ensure that the final mix is homogeneous and workable. Usually, RAP is cold and moist which calls for mixing temperature to be raised, but the temperature cannot raised beyond a limit, as : It will cause blue smoke Higher temp expedites aging of binders – both virgin and RAP binder End re resul sult: : Incomplete melting and mixing of RAP binder with virgin binder Result is stiff, non-homogeneous mixes with poor workability
Limitations of RAP
SOLUTION
Zycotherm reduces the binder surface tension – enables better wetting, faster coating and easy mixing. This better wetting and faster coating ensures efficient heat transfer in the same available mixing time Easy mixing of Virgin binder and molten binder from RAP, leads to homogeneous mix Bott ttom
e: One can increase the RAP percentage in the mix till the OBC is maintained. In other words, it is a trade-off between increase in RAP percentage (cost saving) and quality of plant mix.
Heat Transfer to RAP takes place as follows : Heated virgin aggregates[Conduction] RAP (Small part of total heat transfer) Heated aggregates[Convection] Molten Asphalt[Conduction] RAP (Major part)
ZT enables faster wetting of RAP and improves heat transfer efficiency to help melting and recovery of RAP in available mixing time, giving a homogeneous mix.
VIRGIN AGGREGATES @ ambient temp. RAP @ ambient temp. Heat Transfer through Radiation. Temp raises to 200-250 0C EXHAUST LIQUID ASPHALT @ 160 0C HOT MIX BURNER
Heat balance calculations show that increasing the proportion of RAP in the mix by 6.5 % (of the total mix by weight) and keeping the heat input the same causes the mix temperature to drop from 157 oC (315 oF) to 146
Since Zycotherm improves heat transfer and increases incorporation of the RAP binder it produces a homogeneous mix even at reduced temperatures. The Zycotherm mix will have excellent workability and will give equivalent
temperatures which are lower by 20-35 oC (40-70 oF )
Ass ssump umptions tions : Cost of Asphalt Mix ~ $50 / ton Cost of RAP (Including Milling, Crushing & Transportation ~ $8 / ton Total binder % in Mix (From RAP + Virgin) ~ 5.3% Comp
tions : Difference in Cost of Conventional Mix and RAP = $42 / ton 6.5 % increase1 in RAP will save ~ $2.73 / ton (6.5% of $42) Cost of ZycoTherm SP (@ 0.1 %) ~ $0.96 / Ton
Note : 1. Applicable only for original designs with RAP 25% or less. 2. No extra heat input will be necessary, for RAP increase by up to 6.5%.
Produc ucti tion
efits ts: Better density even at compaction temperature reduced by 20-35 oC (40-70 oF) Blacker and glossy mix and no segregation Cleaner flights, slats, silos and truck beds Substantial Low emission & low odor Pe Performan rmance ce ov
er long ng term rm : Excellent anti-strip performance Excellent rut-resistance mix
ZYCOTHERM + RAP – TYPICAL ECOMMENDATIONS
RAP
145 deg C.
then you can add up to 60% which is recommended mainly for Binder layer below wearing course.
enables better heat transfer to achieve quicker heating and melting of hardened asphalt
at higher RAP / RAS %, achieving 1 - 2% higher densities
Transportation using a 43% recycled asphalt pavement mix design. Owner: WSDOT Producer: Nationally Ranked Contractor Paver: Nationally Ranked Contractor Location: Burley Olalla to SR 303 Production Temp: 296 F Compaction Temp: 275 F RAP: 43% ZT Dose: 0.16% Size: 16,000 tons ZycoTherm passed the Hamburg Wheel Test with only 5.6 mm of rutting at 15,000 passes with no inflection point.
Quality and Price of Fuel will decide the Saving achieved: Our Field experience has shown that typical saving of $0.80 – $1.5 per ton of
Bitumen Optimization: $ 0.60 – $ 2.4 per ton HMA (80-90 % mixes have a lower OBC in base, binder & Wearing course. Field experience shows typical reduction of 0.1 – 0.4% per ton of HMA Anti-strip agent/ WMA additives : Costs $ 0.60 – 2 per ton HMA, ZycoTherm eliminates the use of these agent / additives Extra RAP Usage : With Zycotherm you can use nearly 7% extra RAP with no need to use rejuvenator Cleaner Equipment's, tanks, tipper & paver: No need for an additional chemical for cleaning equipment when working with Zycotherm
ECONOMICS
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UP RAJASTHAN BR O MP CHATTISGARH MAHARASHTRA AP KAR JAMMU & KASHMIR
PUN
WB PUNJAB BR O
Technology being used across length and width of India
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Poland Warmian-Mazurian Voivod Road 511, PRDiM Lidzbark
Production: 155o C Compaction Initial Temp: 135oC Mix Type: AC11 PMB 45/80-55 ZT EZ Dose: 0.1% Air Temp: 2o C Paving Time: Morning Wind Speed: Weak Haul Length: 25 Km Haul Time: ½ Hour Year: 2016
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Poland Zabrze, Skanska
Production: 150o C Compaction Initial Temp: 115-120oC Mix Type: AC 16 W 35/50 Aggregates: Limestone
RAP: 35%
ZT EZ Dose: 0.10% Air Temp: 15o C Paving Time: Night Wind Speed: Strong Haul Length: 90 Km Haul Time: 1 ½ Hours Year: 2015
Sample Height [cm] Bulk Density in-situ [Mg/m3] Bulk Density in-lab [Mg/m3] Maximum Density in-lab [Mg/m3] Compaction index [%] Air voids [% (v/v)] 7,2 2,401 2,460 2,570 98 6,6 7,2 2,418 2,460 2,570 98 5,9 7,7 2,443 2,460 2,570 99 4,9
71 71 50 100
ITSR [%]
ITSR
ZycoTherm 0,1% 5 10 produkcja badanie typu
PRD [%]
PRD [%]
ZycoTherm 0,10%
Poland Zabrze, Skanska
[WT-2 2010, ITSR min 80%]
method) below 6% in the plant mix [ PN-EN 13108-20: AC16 W PRD max 7%, traffic category 3-4]
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Poland Wisznica Voivod Road 812, Skanska Lublin
Production: 170o C Compaction Initial Temp: 140oC Mix Type: AC16 W 50/70 Aggregates: Dolomites + Sandstones
RAP: 25%
ZT EZ Dose: 0.05% Air Temp: 4o C Paving Time: Night Wind Speed: Strong Haul Length: 80 Km Haul Time: 1 ½ Hours Year: 2016
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Sweden Fridhemsgatan Sundsvall, Peab
Production: 150-155o C / *135o C Mix Type: SMA 11 Bitumen: 6.2 % (0.3% less)
RAP: 20%
ZT Dose: 0.1% added at Nynas depot Paving Time: Early / *Late morning Wind Speed: Strong Year: 2013
SMA 11 at 150⁰C - 155 ⁰C with lots of bitumen smoke around the paver SMA 11 at 135 ⁰C with no bitumen smoke around the paving crew
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USA WA State RAP Project
A large nationally‐ranked contractor in US, milled and paved 16,000 ton on SR 16 in August 2014 for the Washington State Department of Transportation using a 43% recycled asphalt pavement mix design. Owner: WSDOT Producer: Nationally Ranked Contractor Paver: Nationally Ranked Contractor Location: Burley Olalla to SR 303 Production Temp: 296 F Compaction Temp: 275 F RAP: 43% WMA Dose: 0.16% Size: 16,000 tons ZycoTherm passed the Hamburg Wheel Test with only 5.6 mm of rutting at 15,000 passes with no stripping inflection point
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USA Colorado Long Haul Project, Elam Construction
An independent survey of the roadway in 2015 found minor reflective cracking in
rutting, cracking, or raveling/weathering after numerous harsh Rocky Mountain freeze/thaw cycles
Production: Compaction Temp: Binder: PG 58 - 28 ZT Dose: 0.10% Haul Length: 100 Miles Year: May 2014
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Canada Trans Canada Highway, Lahrmann Construction
Owner: Alberta Trans, Suffield , Production: 250-285 oF Compaction Temp: 212- 250 oF Binder: PG 64 – 28
RAP: 20%
ZT Dose: i) 0.10% 30,000 tons ii) 0.12% 90,000 tons (10
Year: Summer 2015
to the shoes.
roller was not shoving material and that the roller-checking was gone
roll at cool temperatures, with no trouble keeping up with the roller train