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CLIMATE RESILIENTSustainable Safe RoadsSustainable Safe Roads
Zydex Nanotechnology
Light : Source of energy for life• However, prolonged exposure leads to degradation of most of
the construction materials used today.
Water : Is life• But it is also a major destroyer of materials, if in contact for
THE PARADOX OF LIFE ESSENTIALS
• But it is also a major destroyer of materials, if in contact for prolonged periods.
Oxygen : A life essential• But in presence of light and water, it can oxidize most of the
materials.
Sustainability Through Innovation
Understanding of the above is at the core of all our innovations
Challenges with increased Green House effects globally,
The Rain Intensity, rain frequency, and heat are becoming extreme and unpredictable.
This further intensifies the damages of PAVEMENTS, earlier, than anticipated.
95% of the damages are done by water ingress alone – a major cause of
Sustainability Through Innovation
Providing right solutions using Zydex’s Nanotechnologies
95% of the damages are done by water ingress alone – a major cause of deterioration and maintenance costs.
The PAVEMENT Engineers will have to overcome this challenge by new materials and construction methodology to build longer lasting and sustaining road
Zydex Solutions for Existing Roads (Soil-Gravel) –Roads (Soil-Gravel) –Surface Dressing
• Permeability Reduction :10-7 to 10-8cm/second (up to 10 mm depth)
Water will require minimum 100 days to travel through 10 mm barrier
The Technical Challenges – Water Permeability
Soil/Gravel Roads Water ingress Loss of strength
Surface waterproofing with Organosilane & Nano polymer
• Water will require minimum 100 days to travel through 10 mm barrier
• Breathable Layer : Prevents water entry, but allows vapor to escape.
• If some water enters the soil base, it will evaporate & escapes through the breathable waterproofed layer.
Road surfaces Restricting water entry Extended Pavement Life
Permeability reduced by 500 folds
Cm/s
ec
Organosilane & Water Permeability
CH (Black Cotton) Soil, India
Cm/s
ec
Soil surface leveling Compacted soil layer
Runway Extension Sub-grade, Enugu Airport, Nigeria
Spraying Terrasil Waterproofing confirmation
Zydex Solutions for New Roads (Complete scarification & top (Complete scarification & top dressing)
• Clay has a very large volumetric expansion when water is added. Moisture causes swelling and drying causes shrinkage and cracking, leading to loss of strength.
• Water addition to the level of OMC is necessary though, to achieve adequate compaction.
• The paradox is, water is WELCOME for compaction but MOST UNWELCOME after compaction and drying, because subsequent water ingress is detrimental to the strength of soil bases
WATER IN SOIL BASES – A PARADOX
Compacted Dry SoilCompacted Soil at OMC
The new water soluble nanotechnology additives make use of this paradox to the best advantage, as they can be dissolved in compaction water. Upon drying, the soil becomes hydrophobic and water entry is prevented .
OSi
OSi
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OO
Si
O
OHOH
O
Si
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Si
O
OH
O
Si
O
OO
O OO
O
Si
O
OH
O
Si
O
OH
O
Si
O
OHOH
-OH groups make surface very hydrophilic (water loving)
Particle surface
Organosilane Nanotechnology chemically converts water absorbing silanol groups to water resistant alkyl siloxane surfaces
at ambient temperature.
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Soil/clay particle surface silicate structure
Organosilane
molecule creates
molecular level
hydrophobic zone
(water repellent)Particle surface
Soil / Clay surface silicate structure after Terrasil reaction
Newly formedSiloxane bonds
InternalSiloxane bonds
Improved Compaction and Hydrophobicity
Nano layer of alkyl siloxane chains on the soil particles provides charge shielding to reduce the repelling effect between soil particles and gives
better lubrication for compaction
Charge shielding & oil (alkyl) lubrication
Enables optimum compaction
Field proctor density of 100 to 105 have been observed
With Nanotechnology application of Organosilane & Nano-polymer, field densities of Proctor 100 to 105
are consistently achieved
Dry density peaks at OMC
Soil grains densely packed
Dry D
ensi
ty (
d)
Water contentOptimum water content
Good strength and stiffness
Low permeabilityDry D
ensi
ty
d Max
OMC
ScarificationDuring first Evaluation
Length: 0.6 Km, Width: 6.2 m avg., Thickness: 15 cm avg.
Ruiru Town Road, Kiambu County, Kenya
Construction In Year 2016
After treatmentCompaction
Thickness: 15 cm avg.
Dosage: Organosilane 0.6 kg/m3& NanoPolymer0.6kg/m3
Solution PreparationScarified ½ road width
Length: 0.2 Km, Width: 7 m avg., Thickness: 15 cm avg.
Iverland Mining, Kolwezi, D. R. Congo
Construction In Year 2016 – Dust Control
Grading and levellingSolution Spray
Thickness: 15 cm avg.
Dosage: Organosilane 0.6 kg/m3& NanoPolymer0.6kg/m3 with further top sprays
NEW TECHNOLOGYFOR CEMENT STABILIZATIONFOR CEMENT STABILIZATION
When soil gets wet, it swells and leads to undulation & cracking.
Organosilane Nanotechnology substantially reduces swelling (by 90% and more). This imparts dimensional stability to soil bases.
The Technical Challenges – Dimensional Stability
With Zydex nano chemicals addition with 1 to 3% cement a big break through in technological intervention achieved: Soil strength of CBR 100+ Waterproof soil layers Flexible Bonded soil layer
NEW TECHNOLOGY ENHANCES CEMENT STABILIZATION
Cement - Soil Stabilization Silane + Nano Polymer + Cement
• Proctor 95
• Cementitious bonds degrade with time and lose strength due to wet and dry cycles
• Proctor 100 to 105
• Unaffected by wet and dry cycles due to hydrophobicity
• Log term strength retention of cementitious bonds
Cement Particle ZycoBond Particle
Although water itself does not deteriorate cemetitious bonds, acids formeddue to absorbtion of CO2 and other gases in rain water can cause severedamage.
Some of these reactions are explained in subsequent slides.
Because of this, cement stabilizations begins to lose its effectiveness
DURABILITY OF CEMENT STABILIZATION
Because of this, cement stabilizations begins to lose its effectivenesstypically in 2-3 years time, and in 5-6 years the stabilizations becomespractically ineffective.
New technology prevents entry of water into soil bases and substantiallyretards degradation of cementitious bonds.
1. S + NO2 -----------------SOX (Sulfur Oxides)
SOX + H2O ------------- H2SO4 + H2SO3 + ….(Strong Acids)
2. N2 + O2 ------------------NOX (Nitrogen Oxides)
NOX + H2O ---------------HNO3 + HNO2 + ......(Strong Acids)
ACID RAIN
TYPICAL ACIDS FORMED
NOX + H2O ---------------HNO3 + HNO2 + ......(Strong Acids)
These reactions deteriorate cement bonds and soil keeps losing stability
• Ca(OH)2 + H2SO4 ------CaSO4 + 2H2O
• Ca(OH)2 + 2HNO3 -----Ca(NO3)2 + 2H2O
THE DETERIORATING REACTIONS
[OH-]
=Si-O-Si= + H2O --------------- =Si-OH…….OH-Si=
ALKALI-SILICA REACTION
Silicate Silica GelStrong Base
ASR & CARBONATION
CARBONATION REACTION
H2O + CO2 ------------- H2CO3 (Carbonic Acid)
Ca(OH)2 + H2CO3 ------CaCO3 + 2H2OCalcium Hydroxide Calcium Carbonate
These reactions deteriorate cement bonds and soil keeps losing stability
Spreading of 1% CementGrading
Length: 70m, Width: 65mThickness: 15 cm avg.
Transmara Sugar Company, Kilgoris, Kenya
Parking Yard Construction In Year 2016
After treatmentSolution Preparation
Thickness: 15 cm avg.
Dosage: Organosilane 0.6 kg/m3& NanoPolymer0.6kg/m3
ORGANO SILANE TREATED SOIL DISPLAYED THE FOLLOWING, Soil Swelling Reduced by 85 % Compaction Density Increased by 4%
Sr Parameters MeasureSoil w/oadditive
Soil + Cement 3%
Soil + Silane 0.75 kg/m3
+ nano polymer 0.75 kg / m3 + Cement 3%
CRRI Research : Executive Summary
/ m3 + Cement 3%
1 CBR% 7 67 125
% Improvement - 857% 1685%
2 UCSMPa 0.27 1.02 2.43
% Improvement 278% 800%
3Durability (Wet – Dry Cycles)
No. of cycles 0 4 12
IS : 4332 (Part 4)
Fails FailsPasses
(Simulates 20 years life)
BOND COATS AND EMULSIONS
Prime coat, Tack coat and Fog seal Prime coat, Tack coat and Fog seal
Slurry Seal, Microsurfacing and Chip Seal
Conventional Prime Coats Issues
Long setting time of 8 - 24 hours
Poor penetration, poor spreading and poor waterproofing effect
Tire pick up especially where vehicularmovement cannot be stopped i.e. rural roads
Cutback asphalts have high VOC’s but continue to be used in highways
Chemical Bonding
Higher Bond Strength
Waterproofing
Reduced Slippage
Quick Setting
Nozzle Clogging Eliminated
Benefits of Organosilane Priming Additive
Finer Spray leading to Improved Coverage
Uniform Load Transfer due to 100% Coverage
Reduce Tracking
Zero Volatile Emissions
Higher Performance with Lower Residual Bitumen
100% Surface Coverage with reduced bitumen consumption
NATIONAL HIGHWAY / RURAL ROAD
Organosilane additive with Cationic bitumen emulsion
Quick set in 15- 30 minutes
Water proofing effect of Organosilane Priming Additive
Put water drops on the treated surface
Retention of water drops on surface for 15- 20 minutes confirms priming & waterproofing
WATER DROP TEST
minutes confirms priming & waterproofing
ZYDEX NANOTECHNOLOGY
Organosilane applications for BITUMINOUS PAVEMENTS
For Improved Resistance to :
Oxidation, Moisture, Cracking & Bleed
East and Central Africa experiences on an average 100to 120 days of wet days
Being on the Equator, the intensity of the sun leads toaccelerated aging of the Bituminous roads
This leads to ravalling, potholes and cracking etc. on
CHALLENGES IN BITUMEN PAVEMENTS
This leads to ravalling, potholes and cracking etc. onthe highways
Aggregates love water and bitumen is oil. Bitumen don’t bind very well to water loving aggregates
specially in wet conditions
ORANGE PEEL EFFECT APPLE SKIN EFFECT
Aggregate
ORGANOSILANE – AGGREGATE - BINDER INTERACTION
Polar - Polar Interaction
5-15 % Asphalt participates in Bonding
Non Polar – Non Polar Interaction
85-95 % Asphalt participates in Bonding
Stripped Binder
Clean Water
Aggregate
Organosilane Additive provides 6 hours of boiling water resistivity
BOIL TEST ASTM D3625
50
60
70
80
90
100
10 min
30 min
% C
oate
d Ag
greg
ates
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)
* Specified Standards Less than 75% considered as failure
0
10
20
30
40
50
Control 2% HydratedLime
0.5% Amine 0.1%ZycoTherm
30 min
1 hr
6 hrs
% C
oate
d Ag
greg
ates
Control With ZycoTherm
With addition of Organosilane additive, due to lower surfacetension the bitumen wets the aggregate surface better. This resultsin improved wetting and saturation of micro pores on aggregatesurfaces.
COMPLETE COATING
Bitumen Binder
Entrapped AirPinhole Free Surface, Complete Saturation
SLOWS AGEING PROCESS
Colorado, USAColorado, USA
JET BLACK LOOK
Complete Coating
Zydex’s soil and bitumen technologies
successfully demonstrated internationally
Tamatave, Madagascar
Before the work commenced
Tamatave, Madagascar (250 rainy days in a year)
Work in Progress
Spraying and Compaction
Grading Subgrade
Provincia Dal Azuary, Ecuador
Construction in Year 2015
Waterproofing Confirmed Top Surface Bitumen Layer
The stretch is in perfect condition.CBR of soil: 29.5 % and CBR of treated soil : 107%
PROVINCIA DAL AZUARY, ECUADOR
Post Rainy Season Performance In Year 2015
Length: 4.5 km Width: 6-8m Thickness: 0.20mDosage: Terrasil 0.5 Kg / m3 and cement 1% by soil weight
Solution PreparationScarification
Length: 42 Km, Width: 6.2 m avg., Thickness: 30 cm avg.
Region San Martin, Peru Construction In Year 2015
Bituminous Surface Spraying
Thickness: 30 cm avg.
Dosage: Terrasil 0.75 kg/m3, Bituminous treatment: Slurry Seal
Length: 32 Km, Width: 5.2 m average, Thickness: 13 cm average
Region Piura, Peru
Construction In Year 2013
Bituminous Surface Compacted Surface
Thickness: 13 cm average
Terrasil 0.5 kg/m3
Cement 1% by soil weight, Bituminous treatment: slurry seal
Length: 3500 m2, Thickness: 12-13 cm
Mixing Spraying
SpainParking Fuerte de San Cristobal Badajoz, Spain
Compacted Surface Lime Mixing
Terrasil 0.5 kg/m3 +Polymer + Lime 2%
Top Spray: Terrasil 0.01 kg/m2
Length: 3500 m2, Thickness: 10 cm
Spraying Mixing
Optimasoil, Madrid, Spain
Parking Carterpillar Malaga
Terrasil 0.4 kg/m3
Top Spray: (Terrasil + Polymer): 0.01 kg/m2
Compaction Grading
Construction in Year 2010Spraying Waterproofing
ConfirmationCompaction
Bharthali - Bharthna Road, Tal. Karjan, Dist. Vadodara, Gujarat
Tack CoatPrime Coat Carpet & Seal Coat
Clayey Soil CBR 1.3 – 2.1, treated with Multi Layer Waterproofed Envelope
CONTROL
2010 2011
Repaired in 2010
20132012
Post Monsoon Performance 2010 – 2013
Bharthali - Bharthna Road, Tal. Karjan, Dist. Vadodara, Gujarat
2010
TREATED
2010 2011 20132012
CONTROL
20152014 2016
Post Monsoon Performance 2014 - 2016
Bharthali - Bharthna Road, Tal. Karjan, Dist. Vadodara, Gujarat
TREATED
20152014 2016
Costs parameters (1km x 7m typical road):
Soil Surface dressing:$ 0.15/m2 which is apprx. $1050 per lane km
Complete Soil Scarification & surface dressing @ $ 6.5 per m3
+ 1% Cement cost of $ 1.8 per m3 = $ 8.3 per m3 = $ 8715 (for 150mm
SUMMARY
+ 1% Cement cost of $ 1.8 per m3 = $ 8.3 per m3 = $ 8715 (for 150mm thickness)
Priming: $ 700
Hotmix: for 40mm thickness, $ 1000 per lane km
Americas Europe Africa Asia
CanadaUnited States of AmericaMexicoColumbia
NorwaySwedenPolandSlovakiaSpain
NigeriaSouth Africa
IndiaIranMalaysiaIndonesia
Zydex Technology’s Commercial Adaptation
ColumbiaEcuadorPeruChileBoliviaArgentina
Spain
Americas Europe Africa Asia
Cuba United KingdomGermany
KenyaD R CongoZambia
VietnamSri LankaSingapore
Zydex Technology Currently Evaluated in
GermanySwitzerlandRussia
ZambiaZimbabweRwandaSwaziland
Singapore
