SoilTechMk. III de­signed roads re­duce con­struc­tion time and costs

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The world has changed dra­mat­i­cally dur­ing the last 100 years, with phe­nom­e­nal ad­vances in medicine, air­craft de­sign, mo­tor in­dus­try, cell phone tech­nol­ogy and the com­puter in­dus­try to name but a few. How­ever, the vin­tage McA­dam lay­ered road de­sign has ad­vanced very lit­tle over the last 190 years. Road en­gi­neers are known to be some­what con­ser­va­tive in their de­signs, re­ly­ing on good, faith­ful em­per­i­cal data per­tain­ing to ma­te­rial se­lec­tion and their re­spec­tive com­pres­sive strengths.

Smart Ma­te­ri­als for Road Con­struc­tion

Poly­roads, a South African com­pany, man­u­fac­tures a range of in­no­va­tive and en­vi­ron­men­tally-friendly and Smart Ma­te­ri­als for the road con­struc­tion in­dus­try. Poly­roads’ JV part­ner in In­dia for more than 10 years is Kaveri Ul­tra Poly­mers Pvt. Ltd, with of­fices in Ban­ga­lore, Mum­bai and Kolkata.

Nick Muller, CEO, Poly­roads, says, “Smart Ma­te­ri­als chal­lenge the core of con­ven­tional road de­sign and con­struc­tion by bring­ing in un­prece­dented re­silient mod­u­lus to the pave­ment layer ma­te­rial, which is re­quired for Mech­a­nis­tic-Em­pir­i­cal (ME) road de­signs. The im­proved E-mod­u­lus of Smart Ma­te­ri­als re­duces the num­ber of re­quired sup­port­ing ag­gre­gate lay­ers. Con­ven­tional road de­sign typ­i­cally com­prises four to five lay­ers of road ma­te­ri­als with vary­ing de­grees of com­pres­sive strengths. In com­par­i­son, SoilTechMk. III de­signed roads will re­quire one or two lay­ers to be sta­bi­lized, thereby, sub­stan­tially re­duc­ing con­struc­tion time and costs.”

Ce­ment sta­bi­lized ma­te­ri­als, by na­ture, dis­play lim­ited e-mod­u­lus char­ac­ter­is­tics, and hence, the need for strong sup­port­ing sub­strate lay­ers. Con­versely, SoilTech be­ing an elas­tomeric poly­mer, sig­nif­i­cantly in­creases the e-mod­u­lus of the road ma­te­ri­als. The e-mod­u­lus of the ma­te­rial is the mea­sure­ment stress over strain and de­ter­mines the ma­te­ri­als abil­ity to re­tain its for­mer shape after the load/stress has been re­moved, with­out show­ing per­ma­nent de­for­ma­tion of the road lay­ers.

Most road de­sign­ers sim­ply ig­nore the E-mod­u­lus fac­tors of ma­te­ri­als when do­ing a road de­sign based on ce­ment sta­bi­liz­ing, and sim­ply fo­cus on the com­pres­sive strengths of the ma­te­ri­als. The rea­son is quite sim­ple – con­crete does not have great e-mod­u­lus prop­er­ties, so en­gi­neers sim­ply fo­cus on CBR re­sults and do not fac­tor in e-mod­u­lus.

SoilTech Mk. III, a third-gen­er­a­tion poly­mer, has been pur­posely de­signed to in­crease the CBR and the e-mod­u­lus of ma­te­ri­als. SoilTech is used ex­ten­sively on mine haul roads where 300 ton trucks with two axles are com­mon. The rear axles carry 60% of the load, which equates to 195 tons on a sin­gle axle. This is 24 times more than the in­ter­na­tional equiv­a­lent sin­gle-axle load (ESAL) spec­i­fi­ca­tion of 80kN. Fur­ther­more,

nano-poly­mers in­her­ent in SoilTech will mi­grate from the sta­bi­lized layer into the sub-grade, fur­ther strength­en­ing the sup­port­ing layer. Smart Ma­te­ri­als – Mul­ti­ple Ben­e­fi­cia­ries Smart Ma­te­ri­als is a game changer for the road con­struc­tion in­dus­try with its numer­ous ben­e­fits:

Cus­tomers:

• Road projects are com­pleted faster

• Cost sav­ings is 25-35% cheaper than con­ven­tional roads

• Con­struct 25 – 35% more roads with the same bud­get

• Due to the higher e-mod­u­lus, roads have in­creased longevity

• Less main­te­nance

Con­sult­ing En­gi­neers:

• Projects are com­pleted faster

• Com­plete more projects in a cal­en­dar year

• Im­proved cash flow

• In­no­va­tion in road de­sign – be­come in­dus­try leader

• Re­peat busi­ness from sat­is­fied cus­tomers Con­struc­tion Com­pa­nies:

• Shorter con­struc­tion time

• Open sta­bi­lized, un­sealed roads to traf­fic 24 hours after con­struc­tion

• Place DBM or wear­ing-course seal four days after con­struc­tion

• Road con­struc­tion projects are less im­pacted by mon­soon

• Com­plete three times more projects per an­num

• Same plant is used to com­plete more projects per an­num – no ex­tra costs

• Less diesel costs per project

• Im­proved cash flow

• Re­duced ma­chin­ery main­te­nance per project

• Im­proved bot­tom-line on bal­ance sheet due to in­creased ef­fi­cien­cies and more project sign-offs En­vi­ron­men­tal­ists:

• Re­duce bor­row-pit ag­gre­gate by uti­liz­ing in situ ma­te­ri­als

• Re­duce car­bon emis­sions by 92%

• Wa­ter re­duc­tion due to fewer lay­ers and no need to keep the cur­ing road damp

• Zero tox­ins

At the IRC road con­fer­ence in Ban­ga­lore 2014, Late Dr. L.R. Kadiyali stated that In­dia con­sumes enough ag­gre­gate an­nu­ally to build a road around the world, 6-m wide x 600-mm deep. Cur­rent road de­sign based on the im­por­ta­tion of good bor­row ma­te­rial from an en­vi­ron­men­tal per­spec­tive, is sim­ply not sus­tain­able.

There is no doubt that Smart Ma­te­rial de­vel­op­ment and pro­duc­tion will ac­cel­er­ate in the com­ing years. For futher de­tails, please con­tact: E-mail: in­fra@kaveri.in

Web­site: www.poly­roads.in, www.kaveri.in

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