1. Bitumen Overview India

2. CONTENTS OIL SECTOR OVERVIEW INDIAN ROAD SECTOR
BITUMEN AND ITS PROPERTIES
VALUE ADDED BITUMEN

3. OIL INDUSTRY OVERVIEW
1st year of deregulation

4. PETROLEUM PRODUCTS DEMAND
Historical
Going forward
Consumption grew at a CAGR of 3.4% p.a. over the last 5 years
Production registered a CAGR of 12.5% p.a. during the same period
Demand expected to grow at a CAGR of 3.7% p.a. during next 5 years
Demand registered over 5% growth during FY2003
Source: Company estimates FY03 MOP&NG Sub-group report for X Plan submitted to Planning Commission
Source: PPAC, FY03 company estimates

5. CRUDE SELF SUFFICIENCY
The gap being met through imports
Self sufficiency levels declined over the years
Source: Hydrocarbon Vision 2025

6. INDIAN ROAD SECTOR

7. Total – 3.3 MILLION Kms INDIAN ROAD NETWORK NATIONAL HIGHWAYS 58,112
Length ( km )
NATIONAL HIGHWAYS
58,112
STATE HIGHWAYS
1,37,119
DISTRICT ROADS
4,70,000
RURAL ROADS
26,50,000
Total – 3.3 MILLION Kms
INDIAN ROADS CARRY 85 % OF PASSENGER TRAFFIC & 70 % OF FREIGHT TRAFFIC

8. ROAD CONSTRUCTION SHIFTS TO HIGHER GEAR
HIGHWAYS BUILT Kms / Day
PROPOSED NHDP LENGTH Kms
DAILY PROGRESS Kms / Day
DAILY EXPENSES OF NHDP 10 ML. USD
FINAL PROGRESS OF NHDP 11 Kms/Day
ASSURED FUNDING MECHANISM IN PLACE

9. MAJOR PROJECTS
JAN 1999 – TARGET OF DEC 2004 FOR 4/6-LANING OF 5846 KMs HIGHWAY IN FIRST PHASE - GOLDEN QUADRILATERAL
SECOND PHASE ON 7300 KMs NE-SW CORRIDOR TO BEGIN ON JAN 2004 WITH TARGET OF DEC 07
SIMULTANEOUS DEVELOPMENT OF PORT ROADS, RURAL ROADS, STATE ROADS INTENSIFIED
B.R.O. PROJECTS

11. BITUMEN AND ITS PROPERTIES

12. BITUMEN DEMAND GROWTH
Bitumen demand is likely to grow at 12% per year for next five years
At this rate the demand in year would be 3900 TMT

13. BITUMEN SEASONALITY

14. Bitumen - An introduction
LAST RESIDUE OF CRUDE OIL TREATED TO PRODUCE BITUMEN.
USED IN BUILDING AND PAVING SINCE ANCIENT TIMES.
OLDEST ADHESIVE KNOWN TO MAN.
USED IN 3500 B.C. AS MORTAR FOR BUILDING STONES AND PAVING BLOCKS IN MESOPOTAMIA.
USED FOR WATER TIGHTENING OF RESERVOIRS, CANALS, BATHING POOLS & EMBANKMENTS OF RIVERS IN INDUS VALLEY.

15. Bitumen - An introduction (Contd.)
Streets of Babylon constructed in 2000 B.C. still in good shape.
Used for Mummification in 300 B.C.
Rock Asphalt used for flooring/sidewalks in France in 1800 A.D.
First road surfacing done in New Jersey in 1870 A.D.
From 1900 onwards Bitumen produced from Refineries being used extensively.

16. Types of Bitumen Conventional Bitumen Bitumen Emulsions
Paving Grade Bitumen
Industrial Grade Bitumen
Bitumen Emulsions
Modified Bitumen

17. Production Process Produced by fractional distillation of Crude oil.
Crude Oil heated to 300 – 350OC in distillation column. Lighter fractions separated at different column heights. Bottom product called long residue.
Long residue heated upto 450OC in Vacuum distillation column. Bottom residue (short residue) used for manufacturing Bitumen.
Hot air is blown through short residue OR blended with superior quality bottom products to achieve desired consistency / penetration.

18. Advantages of Bituminous Roads
Initial saving : fast construction + low cost.
Ageless – rehabilitation is inexpensive.
Stage Construction - in ribbons, not in slabs.
Safe: High skid resistance + Good Visibility
Better riding quality Less wear & tear of vehicle, Low noise while cruising
Can be fully recycled.

19. Engineering Properties of Bitumen
A visco-elastic material : Deformation under stress a function of temperature & loading time.
At high temperature & loading it behaves as viscous liquids, whereas at very low temperature or low loading it behaves as elastic solids.
In the intermediate range of temperatures / pressure, more typical of the conditions in road service, bitumen has visco-elastic behaviour.

20. Elemental Analysis Carbon 82 - 88 % Hydrogen 8 - 11 % Sulphur 0 - 6 %
Oxygen %
Nitrogen %

21. Composition of Bitumen
Chemical composition depends on origin of Crude Oil and refining process.
Chemical composition is extremely complex. Astronomically large number of Molecules with different chemical structures. Not feasible to attempt a complete analysis of Bitumen.
Elemental composition of Bitumen provides little information of the types of molecular structure present in Bitumen.

22. Properties of Bitumen IS 73 : 1992
Characteristics 80/ / /40
Specific gravity at 27OC
Softening Point OC to to to 65
Penetration at 25OC, 100gm, 80 to to to 40
5 secs., 1/10 mm
Ductility at 27OC, in cm min

23. BITUMEN TESTS AND THEIR SIGNIFICANCE
PENETRATION TEST / SOFTENING PT.
INDICATES CONSISTENCY
LOSS ON HEATING / THIN FILM OVEN TEST
RATE OF HARDENING ON ROAD
DUCTILITY TEST
AFFINITY FOR AGGREGATES

24. Tests….. TRICHOROETHYLENE SOLUBILITY VISCOSITY / SPECIFIC GRAVITY
INDICATES PURITY OF BITUMEN
VISCOSITY / SPECIFIC GRAVITY

25. Penetration
TRAVEL IN dmm OF A SPECIFIED NEEDLE UNDER 100 g Wt. FOR 5 SECONDS INTO BITUMEN AT 25 C.
DENOTES CONSISTENCY

26. Softening Point
3.5 GM STEEL BALL PLACED ON SAMPLE OF BITUMEN IN BRASS RING
BATH TEMP RAISED AT 5 DEGREES PER MINUTE

27. DUCTILITY
Gives an indication of the extent to which a sample of the material can be stretched before breaking.
Length in cm. at breaking point is ductility

28. FLASH POINT
Used to measure the temperature to which a sample of bitumen may be safely heated
The flash point is the temperature reached when the vapour causes an instantaneous flash.

29. Recommended Handling Temperatures
Characteristics / /70 30/40
Min. Pumping Temp.27OC
Mixing/Coating Temp. OC to to to 175
Laying Temp.OC to to to 160
Spraying Temp.OC
Max. Safe Hdlng. Temp. OC

30. Selection of Grade of Bitumen
Choice of Bitumen is based on
Climatic Conditions - Maximum & Minimum temperature & rainfall.
Intensity of Traffic - Number of vehicles per day & axle load of vehicles.

31. Applications of 80/100 Grade
Less viscous grade.
Used in all climatic conditions.
Suited for traffic load of less that commercial vehicles/day.
Better suited for high altitude/snow bound regions irrespective of traffic intensity.

32. Applications of 60/70 Grade
More viscous grade. Higher softening point.
Suited for traffic intensity of more than commercial vehicles/ day.
Can withstand heavier axle loads.
Suited for areas where difference between min. & max. temp. is more than 25 o C.
Reduced stripping of Bitumen from Aggregate in presence of water.
Better suited for highways, expressways & urban roads.

33. Applications of 30/40 Grade
Suited for traffic intensity of more than 1500 commercial vehicles/ day.
Suited for areas where difference between min. & max. temp. is less than 25 o C.
Used in metropolitan areas / airport runways.

34. VALUE ADDED BITUMEN
Binder of the future

35. RELATIVE PRICING OF VALUE ADDED BINDERS
BITUMEN
EMULSION 11000
CRMB
NRMB
PMB

36. WHY MODIFIED BITUMEN? INCREASING DEMANDS ON ROAD INSISTENCE BY CLIENTS
INCREASING NUMBER OF VEHICLES
INCREASING AXLE LOAD
INSISTENCE BY CLIENTS
DESIRE TO MAINTAIN HIGHER SERVICEABILITY LEVEL
CHANGING PATTERN OF CONTRACTS
INCLUDES LONG TERM MAINTENANCE

37. Modifiers under use Polymers Rubbers Plastics Thermoplastic
Synthetic Elastomers
SBS, SBR etc.
Polymers
Rubbers
Plastics
Crumb Rubber
Natural Rubber
(Latex)
Plain
Chemically
Treated
Thermoplastic
EVA

38. EMERGING DEMAND AN ASSESSMENT

39. CURRENT MARKET FEATURES
DOMINATION BY CRMB
VALUE FOR MONEY BINDER
TEST TRACKS / RESEARCH WORK SHOW EXCELLENT RESULTS
HIGH COST OF PMB A DAMPENER
INSISTENCE BY CLIENTS ON REFINERY MODIFIED BINDERS
HIGH GROWTH RATE ASSURED
EMULSION MARKET STAGNATED
TACK COAT ORIENTED
HIGH VOLUME APPLICATIONS YET TO BEGIN

40. CRUMB RUBBER MODIFIED BITUMEN

41. Crumb Rubber Modified Bitumen+
Additives (Modifiers/Treated Crumb Rubber)

42. What is Crumb Rubber Modified Bitumen?
Crumb Rubber Modified Bitumen is Conventional Bitumen with treated Crumb Rubber Additive at high temperature which results in
Lower susceptibility to temp. variation
Higher resistance to deformation at high temperature
Better Age Resistance Properties
Higher Fatigue Life of Mixes
Better Adhesion Properties

43. Why Treat Crumb Rubber? Be compatible with Bitumen.
Blend with Bitumen properly & thoroughly.
Improve temperature resistance of Bitumen.
Resist degradation of Bituminous mix.
Be capable of being processed by conventional mixing plants and laying machinery.
Produce coating viscosity at application temp.
Maintain premium properties during storage,application and in service.
Be cost-effective considering life cycle cost.

44. Test and Trials with CRMB
Central Road Research Institute, New Delhi.
Highway Research Station, Chennai.
Gujarat Engineering Research Institute, Vadodara.
Indian Institute of Technology, Kharagpur.
Municipal Corporation of Delhi.
Research Station, P.W (R&B) Dept., Hyderabad., Andhra Pradesh.

45. Circular Test track study conducted by Highway Research Station, Chennai

46. Tests conducted in Circular Test Track Study
Surface Evaluation
Skid resistance
Texture depth
Depletion values

47. STUDY RESULT
CRMB mixes indicate better resistance to deformation at high temperature times higher values of stability, Marshall quotient and stiffness modulus.
Higher indirect tensile strength and stiffness modulus - better resistance to cracking in structural layers.
Modified mixes in structural layers take higher traffic stresses due to higher values of stiffness modulus.
Tensile strength ratio before and after conditioning in water is higher - superior resistance to moisture damage.

48. CIRCULAR TEST TRACK STUDY CONCLUSION
The Highways Research Station has opined that the performance of modified bitumen stretch improves by 1.7 times than the conventional bitumen stretch.

49. Guidelines on use of Modified Bitumen
MORTH letter No. RW/NH-34041/36/90-S&R(Vol. II) dated April 21, 1999 advised all States/UTs to use Modified Bitumen upto 10% for all works “as it has been proved by field trials that the life of the road increases by 1.5 times”.
IRC released new Specifications vide publication No. IRC-SP:53:2002 FOR USE OF MODIFIED BITUMEN in road development activities in India.
MORTH vide letter No. RW/NH-34041/36/90-S&R(Vol. II) dated 17, January 2000 requested all States to start using MODIFIED BITUMEN.
MORTH letter No. RW/NH-34041/36/90-S&R(Vol. II) dated April 14, 2000 requested MOP&NG to start Modified Bitumen production at Refinery level.

50. Guidelines on use of Modified Bitumen
MORTH vide their letter No. RW/NH-35072/1/2001-S&R( R ) dated June 21, 2001 has requested all States to encourage use of Modified Bitumen in view of its various advantages and improved performance over conventional Bitumen.
MORTH vide their letter No. RW/NH-33041/3/2001-S&R dated June 13, 2002 has stated that “It has been decided that keeping in view its advantages, polymer/rubber modified bitumen may be adopted in surfacing for the whole length, subject to availability”.

51. CRMB Performance on Road

52. DEFORMATION OF SURFACE IN UNMODIFIED SECTION

53. PATCH WORK IN UNMODIFIED SECTION

54. POT HOLE IN KM-144 –UNMODIFIED

55. TRANSVERSE CRACKING –UNMODIFIED SECTION

56. A VIEW OF MODIFIED (CRMB) SECTION

57. CLOSE-UP OF MODIFIED SURFACE

58. GOOD SURFACE CONDITION OF MODIFIED SECTION

59. GOOD SURFACE OF MODIFIED BC

60. Grades of CRMB

61. Tests on Crumb Rubber Modified Bitumen
Penetration
Softening Point
Elastic Recovery
Thin Film Oven Test

62. Selection Criteria

63. Recommended Handling Temperatures
Stage of Work
Viscosity, Poise
Temp. Range, OC
Binder at Mixing
< 2
Mix at Mixing Plant
< 4
Mix at Laying Site
< 5
Rolling at Site
10 – 1,000

64. HANDLING OF CRMB CRMB should ideally be used in hot condition.
When supplied in drums, it shall be agitated properly in melted condition for minutes before use.
Mixing & rolling temperature should be approx. 10OC higher than conventional temperature.
Pneumatic tyre rollers should be avoided.

65. Field Trials Carried on CRMB
NH-1 NEAR AMBALA
SECUDERBAD-KUKATPALLI ROAD
BLR-KANAKAPURA HIGHWAY
NH-4,CHENNAI-BANGALORE ROAD
NH-5,CHENNAI-CALCUTTA
NH-8 at RAJIV CHOWK,NEAR GURGAON
NH0-1 A at UDHAMPUR, JAMMU
NH-25,LUCKNOW-JHANSI
INNER RING ROAD, HYD
INSIDE HRS CAMPUS,CHENNAI

66. Satisfied Clientele P W D - Maharashtra P W D - Madhya Pradesh
Major Private Contractors in Maharashtra
Ketan Constructions – Ahmedabad Vadodara Expressway
Contractors in Orissa, A.P. & Gujarat.

67. BITUMEN EMULSIONS

68. EMULSIONS IN DAILY LIFE
MILK
MEDICINES
PAINTS
ICE CREAM

69. BITUMEN EMULSIONS ??
BITUMEN EMULSION = BITUMEN+ EMULSIFIER/ADDITIVES + WATER
WATER = CONTINUOUS PHASE
BITUMEN = DISEPERSED PHASE
FREE FLOWING DARK BROWN LIQUID

70. EMULSIFICATION
BITUMEN MILLED INTO FINE PARTICLES & HELD IN MOLECULAR SPACES OF WATER
USE OF CORRECT EMULSIFIER / CHEMICALS FACILITATE PROPER EMULSIFICATION

71. COLAS S.A. OF FRANCE LARGEST CONSTRUCTION COMPANY IN THE WORLD
EXPERTS IN ROAD CONSTRUCTION
MANPOWER 40,000
TURNOVER
> 40, 000 CRORES

72. HINDUSTAN COLAS LIMITED
INCORPORATED IN JULY 1995 AS A JOINT VENTURE COMPANY.
HINCOL EMULSIONS VERY WELL RECEIVED ALL OVER INDIA:
FIRST PLANT AT MUMBAI IN 1996.
SECOND PLANT AT DELHI IN 1998.
THIRD PLANT AT CHENNAI IN 1999.
FOURTH PLANT BEING COMMISSIONED IN VIZAG.

73. PROJECTED DEMAND IN ‘000 MT
BITUMEN EMULSION
YEAR DEMAND DEMAND %
INTERNATIONAL NORM - 15% AVERAGE

74. WHY LOW CONSUMPTION IN INDIA ???
QUALITY
AWARENESS
INCLUSION OF SPECS IN DSR
GEOGRAPHICAL CONSTRAINTS
MYTH OF EXPENSIVENESS
NO MAJOR MANUFACTURER

75. TYPICAL USES OF EMULSIONS IN FRANCE
TACK COAT 12 %
SURFACE DRESSING 40 %
PATCH WORK 15 %
GROUTING 13 %
OTHER %

76. WHY USE EMULSIONS ?? ECONOMY
ALL WEATHER APPLICATION (IDEAL FOR MONSOON APPLN.)
WORKER FRIENDLY
ENVIRONMENT FRIENDLY
EFFICIENCY

77. TYPES OF EMULSIONS
RAPID SETTING
MEDIUM SETTING
SLOW SETTING

78. APPLICATIONS POT HOLE REPAIRS TACK COAT PRIME COAT SURFACE DRESSING
PREMIX / LIQUID SEAL COAT
20 MM PREMIX CARPET
FOG SPRAY/FOG SEAL/SLURY SEAL

79. PACKAGING
RECONDITIONED DRUMS
NEW DRUMS
BULK

80. THANK YOU

81. FUTURE ENERGY SCENARIO
Gas to replace the demand for oil and is expected to constitute 20% of the energy supply by 2025

82. INITIATIVES BY GOVERNMENT
GOVERNMENT’S VISION : TO CREATE ROAD NETWORK WHICH IS BEST IN THE WORLD.
INITIATIVES :
LEVY OF Rs. 1 PER LTR. CESS ON DIESEL AND PETROL EFFECTIVE 1999 FOR CENTRAL ROAD FUND ( $1.2 BILLION PER YEAR) PLUS FUNDING BY ADB / WB PLUS PRIVATE SECTOR
SPECIFIC FUND ALLOCATION FOR NATIONAL HIGHWAYS, STATE HIGHWAYS, RAIL OVER BRIDGES, RURAL ROADS ETC.
SPECIAL FINANCIAL INCENTIVES PACKAGE FOR TAXES AND DUTIES APPLICABLE FOR ROAD PROJECTS ANNOUNCED
HIGH TRANSPARENCY AND FAST DECISIONS

83. FUNDING OF NHDP

84. MAJOR CHANGES INDIAN ROAD SECTOR
TILL 15 YEARS AGO - ROADS MADE BY STATE AND CONTRACTORS ONLY PROVIDED LABOUR / MACHINERY ETC.
DURING 1990s GOVERNMENT INCLUDED MATERIAL PROCUREMENT IN CONTRACTOR’S SCOPE
CHANGES FURTHER ACCELERATED BY MASSIVE INVESTMENTS PROPOSED IN ROAD SECTOR – 1998 ONWARDS

85. COTRACTS AWARD METHODOLOGY MAJOR OVERHAUL
CHANGE FROM GOVT. SUPERVISED WORKS TO REWARD ORINETED EPC (ENGG, PLNG & CONSTRN) WITH PMC
INCENTIVE FOR EARLY COMPLETION - 1% - 6% : DISINCENTIVE FOR DELAY
SEPARATE O&M CONTRACTS FOR MAINTENANCE
ANNUITY BASED PROJECTS INCLUDING MAINTENANCE EXPERIMENTED

86. NORMAL BITUMEN DEMAND ? INDIA’S ANNUAL BITUMEN DEMAND : 2800 TMT
PERIODICAL RENEWALS / M&R NORMALLY NOT PER SCHEDULE
ADDITIONAL REQMT FOR NEW PROJECTS

87. Grades/Types of Bitumen
PAVING BITUMEN : 80/100, 60/70, 30/40
Used in Road Construction worldwide.
Conforms to IS:73 of 1992.
Industrial Bitumen
Conforms to IS:702 of 1988.
Harder grades.
Used in water proofing, cable insulation, gunny bags, rubber industries, etc.
Not marketed by Oil Companies.

88. CLASSIFICATION OF BITUMEN EMULSION
ANIONIC - BITUMEN PARTICLE HAS NEGATIVE CHARGE
CATIONIC - BITUMEN PARTICLE HAS POSITIVE CHARGE
CATIONIC EMULSION HAS REPLACED ANIONIC EMULSION WORLDWIDE IN ROAD APPLNS.

89. BREAKING ELECTROSTATIC ATTRACTION CAUSES BREAKING OF EMULSION
BITUMEN +ve CHARGE
AGGREGATE -ve CHARGE
RESULT : EXCELLENT BONDING / ANTISTRIPPING BETWEEN BITUMEN & AGGREGATE

90. ECONOMY NO HEATING COSTS REDUCED MANPOWER COST FASTER EXECUTION
ECONOMICAL IN APPLICATIONS LIKE TACK COAT

91. ENVIRONMENT / SAFETY EMULSIONS RESPECT PEOPLE AND ENVIRONMENT
NO SMOKE/POLLUTION
CONSERVES WOOD/FUEL
IDEAL FOR CITY APPLICATIONS
WORKER FRIENDLY

92. MANUFACTURING IMPORTED PLANTS COLAS FORMULATIONS PROPRIETARY PROCESS
IMPORTED RAW MATERIALS

93. QUALITY CONTROL SOPHISTICATED LABORATORY
PARAMETERS CHECKED VISCOSITY BINDER CONTENT COATING PROPERTY SHELF LIFE PARTICLE CHARGE COAGULATION RESIDUE ON 600 MICRON IS SIEVE

94. BIS SPECS 8887-1995 OBSOLETE SPECS “ 8887-1978” REVISED IN 1995
MAJOR CHANGES MADE IN BINDER CONTENT, SHELF LIFE AND QUALITY CONTROL CHECKS.
ALL HINCOL GRADES MEET OR EXCEED BIS SPECS

95. MOST REV.SPEC -2000

96. WHERE TO USE EMULSION? FOLLOW THE THUMB RULE.
THUMB RULE IS BASED ON INTERNATIONAL PRACTICE AND ALSO AS PER MOST/ IRC SPECS.

97. APPLICATION OF HINCOL EMULSIONS
SESSION 2

98. ‘RS’ - RAPID SETTING APPLICATIONS
TACK COAT
LIQUID SEAL COAT
GROUTING
SURFACE DRESSING
PATCH WORK

99. ‘MS’ - MEDIUM SETTING APPLICATIONS
POTHOLE FILLING (PRE-MIX)
PATCH WORK
PRIME COAT
TACK COAT

100. ‘SS’ - SLOW SETTING APPLICATIONS
PRIME COAT
SLURRY SEAL
PREMIX SEAL COAT
FOG SPRAY/FOG SEAL

101. PRIME COAT
OBJECTIVES PLUG CAPILLARY HOLES HARDENS / TOUGHENS BASE COURSE BONDS LOOSE PARTICLES ASSISTS ADHESION WITH NEXT LAYER
QUANTITIES RECOMMENDED LOW POROSITY: SS TYPE KG / 10SQMT MED. POROSITY : MS TYPE KG / 10 SQMT HIGH POROSITY: MS TYPE KG / 10SQMT

102. SURFACE DRESSING
A THIN LAYER OF WEARING COURSE MADE OF SUPERIMPOSED LAYERS OF EMULSION AND METAL
FUNCTIONS:
1. PROVIDING WEARING SURFACE REHABILITATES WORN SURFACES 3. SHOULDERS ON A HIGHWAY LOW VOLUME / LOAD OR REMOTE AREA ROADS

103. 20 MM PREMIX CARPET WEARING COURSE FOR LOW VOLUME ROADS ECONOMICAL
FASTER EXECUTION
EMULSIONS OBVIOUS CHOICE PREPARING PRE-MIX ON THE SITE.

104. SEAL COAT PROVIDES A SEAL TO STOP WATER ENTRY INTO ROAD
LIQUID SEAL COAT RS TYPE KG / 10 SQMT ONLY EMULSIONS RECOMMENDED
PREMIX SEAL COAT SS TYPE KG / 10 SQMT