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 : [email protected]
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