Building Water Resistant Durable Pavements Using Zydex … Presentation... · 2019-07-14 ·...
Transcript of Building Water Resistant Durable Pavements Using Zydex … Presentation... · 2019-07-14 ·...
Building Water Resistant Durable Pavements
Using Zydex Nanotechnology
By
Vishal Saluja – Vice President , Zydex Industries
Presentation to ASHGHAL, Qatar Public Works Authority
Oxidation
• Binder loss leading to raveling
• Loosening of the mix leading to surface cracking
• Increased Surface Roughness
Moisture
• Stripping of the aggregates and bitumen
• Inefficient compaction
Cracking
• Potholes and undulations
• High thermal cracking due to temp variations
• Premature pavement failures
• Increased maintenance costs
Bleed
• Tracking
• Pitting out/Pulling up chunks of pavements
• Slipperiness
Failures/Issues most common in roads and highways
Common Factor here is Water/Moisture Ingress
High performing mix to meet current needs
Technology that works under different climatic zones
User friendly technology
Permanent solution to the problem
Cost effective solution
Tested and approved
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
Chemical bonding is far superior to the physical bonding of bitumen
and aggregate
Bitumen bonded chemically to aggregate will ensure that stripping
and oxidation of bitumen is eliminated
Extended time & temperature of moisture conditioning parameter,
shows excellent retention of wet strength due to chemical bonding
Zycotherm mixes comply to AASHTO T 283 / ASTM tests (to
simulate ageing of actual production of mixes)
CHEMICAL BONDING
THE CHEMICAL ACTION
Aggregate / Soil / Clay / Sand surface silicate structure after ZycoTherm reaction
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Particle surface
-OH groups make surface very hydrophilic (water loving)
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 - Polar Interaction
5-15 % Asphalt participates in
Bonding
Non Polar – Non Polar Interaction
85-95 % Asphalt participates in
Bonding
ZYCOTHERM – AGGREGATE - BINDER INTERACTION
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)
0102030405060708090
100
Control 2%Hydrated
Lime
0.5% Amine 0.1%ZycoTherm
10 min
30 min
1 hr
6 hrs% C
oate
d A
ggre
gate
s
PG 64-22 / VG 30 / 60-70 Pen PG 76-22
SALT RESISTANT PAVEMENTS
0
10
20
30
40
50
60
70
80
90
100
PMB Control165 C
PMB + 0.1%ZycoTherm
135 C
10 Min
1 Hr
6 Hr
0
10
20
30
40
50
60
70
80
90
100
Control 135 C Control 120 C 1% HydratedLime 135 C
0.5% Amine135 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)
25
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
STATIC IMMERSION AASHTO T182 TEST :
EXTEND TO 360 HRS
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)
0
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
% C
oate
d A
ggre
gate
s
MARSHALL WET COMPRESSIVE STRENGTH
AASHTO T165 / ASTM D1075
0
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
M
ars
ha
ll S
tab
ility
(K
g)
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
Eliminates air interface at the aggregate surface due to faster
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
Reduces Oxidative effect at the aggregate – bitumen interface
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
Extends Pavement Fatigue Life because of improved stress
transfer due to complete mechanical impregnation of bitumen
into the finest pores of aggregate surface
ZycoTherm modified bitumen leads to faster coating and easier mixing with
less Torque to saturate the rough and porous aggregates.
Ensures improved mechanical interlocking of bitumen at the aggregate
interface for improved fatigue performance
Improves the heat transfer to RAP and mixing of virgin binder with oxidized
hardened RAP binder
Eliminates entrapped air between bitumen binder and aggregates and
gives the Jet Black look
Rate of Oxidation of bitumen binder is reduced due to elimination of air at
the aggregate surface
EFFICIENT WETTING
Faster wetting and 100 % dispersion of fines below 75 microns ensures
efficient distribution of bitumen binder in HMA mixes. This results in lesser
requirement of bitumen by 0.1 – 0.4%
Poor saturation of porous aggregates is a major cause of pre-mature
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
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
CONSISTENT COMPACTION
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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
operations.
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
on Temp 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
-55 A
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
shower. This leads
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
42
Higher Number of Cycles means Higher
Fatigue Life Reduction in
cracking in
surface layers –
field experience
Saturation of
micro pores and
complete coating
of fines leads to
higher bitumen-
aggregate
interface area
leading to better
load transfer
Reduced stress
for the mix
improves fatigue
resistance
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.
ZYCOTHERM & RUT RESISTANCE
• At 0,075% ZT, deformation maintained with acceptable
tolerance, for similar temperatures as the reference mix,
according to AMAAC specifications
• Lowering mixing temp. and compaction temp. does not
affect rutting behavior.
ZYCOTHERM & RUT RESISTANCE
MOISTURE SUSCEPTIBILITY – WET WHEEL TEST AASHTO T 324
Moisture sensitive Dolomite Aggregate
Keystone Quarry under wet condition 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
Odor Free: Zycotherm modified bitumen mixes
exhibit low odor, making paving crew comfortable
Cleaner Tanks: Zycotherm added in bitumen binder
eliminates buildup as well tend to clean old build-up
Lesser heating: Results in reduction of heating time
to half due to cleaner coils
Cleaner Equipment's & flights: Reduced stickiness to
the metal helps to maintain cleaner elevators and
buckets. It helps to maintain consistency in
gradation and eliminates periodic cleaning required
Paving season extended: Zycotherm allows paving in
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
Health Rating ZycoTherm 1
( for Amine 3)
REACH Registered
TSCA Registered
Odor reduction due to less volatiles
Non corrosive to equipment &
machinery
Low temp at production and paving
– lesser emissions
Low carbon footprint
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
DOSAGE
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
Much better resistance to thermal cracking
Better resistance to permanent deformation (rutting)
Reduced Odor of the mix compared to CRMB mix
Fuel saving due to lower mixing temperature (10 - 150 C)
Much Improved Compaction
Enables increase of crumbs % in the bitumen binder
Higher moisture resistance at par with PMB ( ~ 10 – 15%)
Increased resistance to crack propagation
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 result:
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
Bottom Line:
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.
ZYCOTHERM AND HEAT-TRANSFER TO RAP
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
Increase RAP with Same Heat Input
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 oC (295 oF)
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
or better compaction than the original mix even at compaction
temperatures which are lower by 20-35 oC (40-70 oF )
Zycotherm RAP Cost Calculation (Indicative only)
Assumptions :
Cost of Asphalt Mix ~ $50 / ton
Cost of RAP (Including Milling, Crushing & Transportation ~ $8 / ton
Total binder % in Mix (From RAP + Virgin) ~ 5.3%
Computations :
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
Net saving ~ $1.77 / ton ($2.73 – $0.96) 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%.
Benefits Other Than Cost Savings
Production Benefits:
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
Performance over long term :
Excellent anti-strip performance
Excellent rut-resistance mix
ZYCOTHERM + RAP – TYPICAL ECOMMENDATIONS
Over heat aggregate to 250 deg C . add 35% Cold RAP in
collar section. Mix for min 25-30 sec.
Use 70-100 Pen binder if using 60-70 Pen grade binder with
RAP
The final production temperature should be maintained at
145 deg C.
If you preheat RAP to 120 deg C by installing preheaters
then you can add up to 60% which is recommended mainly
for Binder layer below wearing course.
Increase the RAP by 6.5% without any extra heat input
Zycotherm modified asphalt binder coats RAP faster,
enables better heat transfer to achieve quicker heating and
melting of hardened asphalt
Improves ease of mixing of aggregates
Better mixing & melting helps virgin binder to mix
homogenously with aged asphalt binder from RAP, to
ensure binder mix uniformity
Zycotherm mixes are greasier and compact easier even
at higher RAP / RAS %, achieving 1 - 2% higher densities
HIGHER RAP - HIGHER SAVINGS
RAP EXPERIENCE IN WASHINGTON STATE 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% 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
HMA. This varies from plant to plant and region to region
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
68
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
69
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
70
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
0
50
100
ITSR
[%
]
ITSR
ZycoTherm0,1% 0
5
10
produkcja badanietypu
PR
D [
%]
PRD [%]
ZycoTherm0,10%
Poland Zabrze, Skanska
ITSR above 90 % in the plant mix
[WT-2 2010, ITSR min 80%]
Rutting (wheel tracking test, dry
method) below 6% in the plant mix
[ PN-EN 13108-20: AC16 W PRD
max 7%, traffic category 3-4]
72
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
73
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
74
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
75
USA Colorado Long Haul Project, Elam Construction
An independent
survey of the roadway
in 2015 found minor
reflective cracking in
one section, but
otherwise no
observations of
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
76
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 oC drop)
Year: Summer 2015
Mix not sticking
to the shoes.
Break-down
roller was not
shoving material
and that the
roller-checking
was gone
Able to finish
roll at cool
temperatures,
with no trouble
keeping up with
the roller train