Road to progress

Paving the way for Nanotechnology

TM

The length and quality of roads are key indicators of

economic well being of any country. Political and

economic success of a country is a function of the

infrastructure development in that country. A World Bank

study indicates that a 10% investment in road

infrastructure leads to 100% growth in the economy i.e

multiplier effect of 10 times.

Budgetary constraints for new roads and maintenance

are the key limitations in making roads. The high cost of

labour and operations are the key factors for

maintenance and repairs of potholes, undulations, and

cracking of roads (as high as 40 - 60% of budgetary

provisions). Water is the natural destroyer of roads.

Highway pavements need to be protected from water

coming from underneath (capillary action), sides or top

surface.

The principle of sustainability in the 21st century dictates

the need of conserving resources such as aggregates by

extending the life of pavement. The focus has to shift

from replacement of aggregates to use of in-situ soils.

Zycosoil technology enables replacement of Granular

Subbase (GSB) layer with subgrade protected with

Zycosoil waterproof envelope.

INTRODUCTION

NANOTECHNOLOGY

Zycosoil nanotechnology allows waterproofing of

soils and aggregate surfaces permanently and acts

as a bonding agent to asphalt. This is the most

significant development in the last 50 years which

will improve the quality of road building with reduced

maintenance cost.

The technology addresses the critical subsurface

drainage problems in road making and repairs. It

also addresses the following issues:

• Loss in strength and expansion in wet

conditions for Soil Subgrade (CBR Values &

Plasticity Index)

• Utilization of in-situ soils and local stones

(Availability, Sustainability)

• Water absorption through potholes, cracks and

road shoulders / sides.

Zycosoil’s reactive bonding ability with the

aggregates and asphalt helps to almost eliminate

stripping of aggregates :

• Minimum loss of compressive strength and

flexibility of asphalt concrete under wet

conditions.

• Stripping and hydraulic scouring due to bond

failure of asphalt binder with aggregates under

wet conditions

TM

OParticleSurface

Silanol Groups

i

OO

i Newly formed siloxanebonds

O

ParticleSurface

Zycosoil is an water soluble compound, forms water clear solution. Zycosoil nano technology offers

• Permanent water repellent nano layer on all types of soils, aggregates and other inorganic road construction materials

• Reaction leads to permanent nano siliconization of the surfaces by converting the water loving silanol groups to water repellent siloxane bonds

• The Si-O-Si Siloxane bond is mother nature’s strongest bond

which survives for centuries

• Substantial reduction in soil water infiltration and erosion

• Has ultraviolet and thermal stability for 20 plus years

• Is non leachable as it chemically binds to surfaces permanently

organo-silicon

ZYCOSOIL FEATURES

O

Si

O

Si

O

Si

O

Si

O

Si

O

Si

O

Si

O

Si

O

OHOH

O

Si

O

O

Si

O

OH

O

Si

O

OO

O O

O

O

Si

O

OH

O

Si

O

OH

O

Si

O

OHOH

Silanol groups make surface very hydrophilic (Water Loving)

Typical Soil and Aggregates surface structure

ZYCOSOIL REACTION WITH SILICATE CONTAINING SURFACES

O

Si

O

Si

O

Si

O

Si

O

Si

O

Si

O

S

O

Si

O

OO

O

Si

O

O

Si

O

O

O

Si

O

OO

O O

O

O

Si

O

O

O

Si

O

O

Si

O

OO

O O O

O

O

O

O

O O

OSi Si Si Si Si Si S

Zyocosoil molecules create molecular level hydrophobic zone (water repellent)

Soil and Aggregates surface structure after Zycosoil reaction

O CO

O

TECHNICAL SPECIFICATIONS

Color : Clear to pale yellowSolid content : 41 + / - 2 %Solvent : Ethylene glycol

oFlash Point : 80 C

oViscosity (25C) : 200-800 cpsSolubility : Forms water clear solution and soluble in asphalt

TYPICAL ROAD CONSTRUCTION DESIGN

Crushed stone base course(WMM / WBM)

Asphalt layers (BC / DBM)

Granular Subbase (GSB)

Soil Layer (Subgrade)

SUB GRADE SOIL LAYER

Advantages of application of Zycosoil technology in subgrade :

Maintaining CBR value under wet condition

This is the most critical gain out of the Zycosoil technology which renders the soil subbase permanently waterproofed.

Zycosoil Modified Soil Dry soil mixed with 2% hydrated lime was treated with 20% diluted Zycosoil solution (1:100) on the weight of soil. The soil was conditioned at room temperature till it reached optimum moisture content and then compacted. The mould was completely dried for four days in the Sun. Complete drying allowed all the silanol groups of the soil to be converted into siloxane bonds to get waterproofed soil. The effect of waterproofing was checked by putting a drop of water on the dry surface.

Control Soil

Dry soil mixed with 2% hydrated lime was treated with water at optimum moisture content and then compacted. The mould was completely dried for four days in Sun.

Both the moulds were subjected to four day soak condition in water and followed by CBR test. Comparative CBR values are given below:

Zycosoil reacts with the soil particles and waterproofs the surfaces permanently. It improves the load bearing properties of different types of expansive and silty soils.

ConclusionThe CBR Value of 2 – 10 under four day soak condition increases to 10 - 70 with Zycosoil treatment.

Reduction of Soil PlasticityAll expansive soils absorb water, expand and lose strength. Zycosoil modified soils do not allow water to wet and absorb in the soil, resulting in substantially reduced plasticity.

Maintaining BreathabilityZycosoil being a nano modification keeps the pores open to allow vapour to escape while preventing water to come in.

CBR Value at Penetration Sandy Soil

ModifiedControl

Silty Clay

Control Modified

74.5023.90 2 10.32.5 mm

81.9914.35 1.8 11.25 mm

ANTISTRIPPING PERFORMANCE

The reactive chemistry of Zycosoil improves antistripping performance by an order of magnitude.

The Polar surface of aggregates gets converted to nonpolar surface by Zycosoil reactive modification. These nonpolar aggregates can bond with 95% of the nonpolar asphalt composition, contrary to 5% of the polar asphalt composition bonding to polar aggregates.This results into 15-20 fold improved antistripping performance and will lead to improved service life of the road.

Zycosoil is directly added to hot asphalt binder, mixed and then used.

STONE BASE COURSE (WMM / WBM) Zycosoil treatment waterproofs the crushed stone base course leading to improved dimensional stability and its load bearing capacity.

GRANULAR SUBBASE Since higher CBR values, reduced Soil Plasticity and breathability are achievable due to application of Zycosoil in Soil subgrade, the GSB layer can be eliminated with equivalent thickness of soil subbase.

ASPHALT LAYER (BC / DBM)

Technology at work

All control samples showed significant amount of stripped asphalt binder floating in water. Asphalt binder containing Zycosoil samples showed, if any, very little amount floating in water during boiling. Control samples were completely stripped in the boiling water test, while Zycosoil containing asphalt binder remained adhered to the aggregate surface even after six hours in boiling water.

Some aggregates such as Quartzite’s can give excellent antistripping performance by using 0.2 - 0.4 % Zycosoil in asphalt binder as an

oantistripping agent. Tests were carried as per AASHTO T182 at 60C.

AGGREGATES SUSCEPTIBLE TO STRIPPING

oASTM 1664 / AASHTO T182 at 60C

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)

Basalt Aggregate : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust (DBM)

ASTM 3625 Boiling Test

Asphalt Grade : AC-20 (VG-30, 60-70 penetration grade)

Test Sample 360 hr

4.5% asphalt binder containing 0.1% Zycosoil 9798

120 hr48 hr

98

24 hr

98

4.5% asphalt binder containing 0.5% amine 25*50*88*96

4.5% asphalt binder with 2% hydrated lime 30*55*90*98

4.5% asphalt binder 20*25*85*95

Test Sample

4.5% asphalt binder containing 0.1% Zycosoil

4.5% asphalt binder containing 0.5% amine

4.5% asphalt binder with 2% hydrated lime

4.5% asphalt binder TotalFailure

40

45*82

42*80

9898 96

TotalFailure

TotalFailure

TotalFailure

95

TotalFailure

TotalFailure

TotalFailure

30 min10 min 6 hours1 hour

by weight of mix % % % %

by weight of mix % % % %

Zycosoil containing asphalt concrete has a significant increase in stability strength of 35 - 45 % under wet condition alongwith flow properties. This is expected to improve the load bearing strength of the asphalt pavement in wet condition.

Zycosoil addition of 0.04 - 0.4 % on weight of asphalt binder is recommended. Higher dosage of 0.2 - 0.4 % for aggregates susceptible to stripping should be used.

MARSHALL STABILITY & FLOW VALUEO

ASTM D 1075 / AASHTO T165 at 60C, 24 hrs.

HIGHWAY ROADS 50 - 150 Million and RURAL ROADS 0.1 Million Equivalent Axle Load.

The existing road design should be kept intact. Utilizing the concept of nanotechnology waterproofed envelope, it is recommended to substitute the 300 mm granular subbase by in-situ soils, Silty & Sandy clays - ML, MI, CL, CI; and Clayey & Silty sands - SC& SM.

Typically 2 % hydrated lime for clayey soils and 2 % cement for silty soils are cost effective stabilization techniques to improve the engineering properties of Soil for subgrade.

FLEXIBLE PAVEMENTS ABOVE GROUND LEVEL

The performance of Zycosoil is equal or slightly better than the polymer modified asphalt binder

Basalt Aggregate : 45% 20 mm, 10% 10 mm, 45% less than 6 mm with stone dust (DBM)

4.5% asphalt binder byweight of mixAsphalt

Grade

AC-10 (VG-10, 80-100)

CRMB-60 *

PMB-40**

AC-20(VG-30, 60-70)

* CRMB-60 : Crumb Rubber Modified Bitumen ** PMB-40 : Polymer Modified Bitumen

1208

1350

1509

1846

Strength Kg

Flow Valuemm

2.71

3.18

3.05

2.78

4.5% asphalt binderwith hydrated lime

on weight of mix

2%

Strength Kg

Flow Valuemm

1465 2.85

1655 2.95

1794 3.14

2346 3.09

4.5% asphalt bindercontaining

Zycosoil by weight of mix0.1%

Flow Valuemm

2.7

3.0

3.1

3.02

Strength Kg

2080

2461

2988

2533

MARSHALL STABILITY STRENGTH OASTM D 1075 / AASHTO T165 at 60C, 24 hrs.

Basalt Aggregate : 45% 20 mm, 10% 10 mm, 45% less than 6 mm & with stone dust (DBM)

Stability StrengthTest SampleAsphalt grade

83.7

98.0

Ratio %

Hydrated Lime (2%)

PMB-40

Zycosoil (0.1%)

WetDry

1721

2346

2461

2056

2442

2512

AC-10 (VG-10, 80-100)

AC-20 (VG-30, 60-70)

PMB-40**

CRMB-60* 83.4CRMB 17942152

96.1

MULTI LAYER HYDROPHOBIC ENVELOPE - HIGHWAY ROAD

21. Spray diluted Zycosoil solution (1:100) @ 3-L/M on the bottom. Compact the bottom and Sun dry for 2-3 hours. Check for water repellency at 15-20 mm depth by drilling a hole. Lack of repellency indicates incomplete drying or penetration. Ensure complete drying before next layer is laid.

2. Put one layer of 150mm of soil with optimum moisture content (OMC) using roller compactor. The thickness can increase to 225 mm if vibratory compactor is used. Achieve the Proctor density of 95 -100 %.

3. Repeat step 1 & 2 and continue till the soil subgrade height of minimum 800 1000 mm above the highest flood water level.

4. Lay a 10 - 20 mm thick stone aggregate layer (4 - 8 mm size) on the finished soil base. Spray treat the above top layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/M. Compact with a roller compactor immediately, to allow stones to penetrate in sub soil base. Sun dry for 2-3 hours. Check for water repellency at 15-20 mm depth by drilling a hole. Lack of repellency indicates incomplete drying. Ensure complete drying before next layer is laid.

5. Construct a 250 mm WMM with aggregates size as per the current prescribed standard.

6. Spray treat the WMM layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/Mand sun dry. Check for water repellency.

7. Lay 150 mm DBM Zycosoil mixed asphalt concrete layer and compact to achieve 7-8% Voids.

8. Lay 50 mm BC Zycosoil mixed asphalt concrete layer and compact

9. After the slope is made by cutting / slicing the shoulder, spray on the sides and the slope with a mix of 1 part cationic asphalt emulsion with 10 parts Zycosoil solution (1:100 dilution) at 3 - L/M. Sun dry for 2-3 days. Check for water repellency 15 - 20 mm depth by drilling a hole. Now use soil to cover and build shoulder as per procedure.

2

2

to achieve 6-7% Voids.

2

250 mm WMM 150 mm DBM Layer

MULTI LAYER HYDROPHOBIC ENVELOPE – RURAL ROAD

21. Spray diluted Zycosoil solution (1:100) @ 3-L/M on the bottom. Compact

the bottom and Sun dry for 2-3 hours. Check for water repellency at 15-20 mm depth by drilling a hole. Lack of repellency indicates incomplete drying or penetration. Ensure complete drying before next layer is laid.

2. Put one layer of 150mm of soil with optimum moisture content (OMC) using roller compactor. The thickness can increase to 225 mm if vibratory compactor is used. Achieve the Proctor density of 95 - 100 %.

3. Repeat step 1 & 2 and continue till the soil subgrade height of minimum 200 -600 mm above the highest flood water level.

4. Lay a 10 - 20 mm thick stone aggregate layer (4 – 8 mm size) on the finished soil base. Spray treat the above top layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/M. Compact with a roller compactor immediately, to allow stones to penetrate in sub soil base. Sun dry for 2-3 hours. Check for water repellency at 15-20 mm depth by drilling a hole. Lack of repellency indicates incomplete drying. Ensure complete drying before next layer is laid.

5. Construct a 100 mm WBM with aggregates size as per the current prescribed standard.

6. Spray treat the above layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/Mand sun dry. Check for water repellency.

7. Lay 25 - 50 mm Wearing Course Zycosoil mixed asphalt concrete layer and compact to 7-8% Voids.

8. After the slope is made by cutting / slicing the shoulder, spray on the sides and the slope with a mix of 1 part cationic asphalt emulsion with 10 parts Zycosoil solution (1:100 dilution) at 3-L/M. Sun dry for 2-3 days. Check for water repellency 15 - 20 mm depth by drilling a hole.

2

2

2

Now use soil to cover and build shoulder as per procedure.

25-50 mmWearing Course

100 mm WBM Layer

Technology at work

FLEXIBLE PAVEMENTS BELOW GROUND LEVEL

MULTI LAYER HYDROPHOBIC ENVELOPE

1. Dig 60 cm trench & compact the bottom and the sides

22. Spray diluted Zycosoil solution (1:100), at 3-5 L/M on vertical side walls and bottom. Saturate at the top edge so that the run down of spray will be absorbed at the bottom.

3. Use good quality yellow soil. Put 30 cm on both sides of the trench, especially for expansive soil ( clayey soil).

4. Saturate the yellow soil 15-20 cm on both sides of the trench with Zycosoil solution (1: 100).

5. Compact soil layer with roller compactor / vibratory roller. Use water to achieve optimum moisture required for compaction.

6. Repeat steps 2-5 for all additional layers (every 15 -22 cms)

7. Lay a 10 - 20 mm thick stone aggregate layer (4 - 8 mm size) on the finished soil base. Spray treat the above top layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/M. Compact with a roller compactor. Sun dry for 2 - 3 days.

8. Construct a 100 mm WBM with aggregate size as per the current prescribed standard.

9. Spray treat the WBM layer with a mix of 1 part cationic asphalt emulsion and 10 parts Zycosoil solution (1:100 dilution) at 3-L/M and sun dry. Check for water repellency.

10. Lay 25-50 mm Wearing Course Zycosoil mixed asphalt concrete layer as per specifications and compact to 7-8% Voids.

(Rural / Internal / City Roads)

2

2

15 - 20 cm Hydrophobic Yellow and base soil

25-50 mmWearing Course

10-20 mmStone aggregate

layer

EarthenShoulder

100 mm WBM Layer

COMPLETE HYDROPHOBIC SUB SOIL BASE

Use complete hydrophobic subbase for areas which are completely submerged in water during the rainy season.

1. Dig 60 cm trench for below ground . In case of above ground start with point no. 2.

2. Pulverize 15 cm soil layer. Spray Zycosoil solution (1: 100). Use 15-20 parts Zycosoil solution on 100 parts of soil by weight. Allow it to semi-dry and at optimum moisture content , compact it with a vibratory compactor roller. Sun dry for 2 -3 days. Check for water repellency by drilling a 100 - 125 mm hole. Lack of repellency indicates incomplete drying. Ensure it is completely dry before the next layer is laid.

3. Repeat step 2 for all additional layers.

4. Construct a 250 mm WMM / 100 mm WBM with aggregate size as per prescribed standards.

5. Spray treat the WMM (Highway) / WBM (Rural) layer with a mix of 1 part cationic asphalt emulsion and 10 parts

2 Zycosoil solution (1:100 dilution) at 3-L/M and sun dry. Check for water repellency.

6. Lay DBM (Highway) / BC Layer or Wearing Course Zycosoil mixed asphalt concrete layer as per specifications and compact.

25-50 mmWearing Course 100 mm WBM Layer

MAINTENANCE

Road damage is primarily due to the water seepage from the top of the road, the shoulders and the sides. The damage inflicted by water seepage for unpaved and paved roads can be minimised by creating an umbrella - waterproof cover on the entire road from the top.

UNPAVED AGGREGATE ROADS

Saturate the aggregate-soil surface including 2 meters each on both sides 2of the road with diluted Zycosoil solution (1:100) @ 3-L/M.

BLACK TOP PAVED ROADS

2Spray diluted Zycosoil solution (1:100) @ 1.5- L/M on black top area and 3 2L/M on 2 meters each on both sides of the road shoulder and slope.

Sun dry for 2-3 hours and check for water repellency 15 – 20 mm depth by drilling a hole in the soil area.

APPLICATION CONCEPT OF ZYCOSOIL

Always ensure complete saturation of soil and full drying at least once. This is critical for successful implementation of this technology.

Every application of Zycosoil (1: 100) spray and dry cycle must be followed and recorded with a water repellency test alongwith depth of penetration achieved.

For very expansive soils, 100 parts of soil is mixed with 20 -25 parts of diluted Zycosoil solution and additional 40-50 parts of water. The additional water of dilution is needed to saturate the clayey soils, to ensure complete wetting and achieving acceptable hydrophobation.

Technology at work

50 mmBC Layer

250 mm WMM150 mm DBM Layer

Remove the loose asphalt binder, aggregates and soil.

• Spray diluted Zycosoil solution (1:50) to completely wet the road base including 10-15 cm top surface around the pothole. Ensure a complete saturation of the pothole surface by spraying the solution from the top of the vertical surface, till almost a puddle of solution is formed at the bottom. Saturation is the key to ensure complete success.

• Allow the surface to completely dry and check water repellency.

• Fill the pothole with asphalt concrete containing Zycosoil in asphalt binder.

• Use extra fines, 50 - 55 % composition should be less than 6 mm

• Follow normal procedure for compaction.

REPAIRS - POTHOLES

Spray diluted Zycosoil solution10-15 cm area around the pothole

Spraying on potholes Laying of Aggregate with Asphalt

Final top compacted layer Final top compacted layer

Black soil excavation

Spraying continued

Spraying on sides

Waterproofing of Black soil

Final top compacted layer

Asphalt to be put on the asphalt layer

Treated Compacted first layer

Zydex Industries25 - A, Gandhi Oil Mill Compound, Gorwa, Vadodara - 390 016 (Gujarat) India

Ph.: +91 265 228 0865 / 0120 / 3386 Fax: +91 265 228 0872

www.zydexindustries.com email : zycosoil@zydexonline.com

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