The main difference between hot mix asphalt and warm mix asphalt is how they’re made.

Hot mix asphalt (HMA) is heated up to around 300 degrees Fahrenheit in a special oven to help reduce the curing time on the road. Warm mix asphalt (WMA) uses a process called “adhesive bonding” to create an even, strong bond between the aggregate and binder that allows it to be put down at about 180 degrees Fahrenheit without cooling.

HMA is produced and transported at a higher cost than WMA because of the higher temperatures needed to prevent it from solidifying.

Warm mix asphalt is more environmentally friendly than hot mix because it uses less fuel. The typical amount of fuel used to produce 1 ton of hot mix asphalt is 8 gallons, while with warm mix only 3.2 gallons is needed. Fuel consumption during WMA manufacturing is typically reduced by 20%.It also has a lower carbon footprint than hot mix, which means that not as much carbon dioxide is released into the air during production.

The reason warm mix asphalt can be placed at a lower temperature is because it is less viscous or thick than hot mix asphalt and therefore easier to apply at a lower temperature.

Construction crews can pave at lower temperatures, which allows to open the pavement for traffic sooner and lessens traffic gridlocks. The window for paving is widened and this results in the extension of the paving season, especially in colder climatic geographies.

On certain days when the air quality is bad, paving activities are halted, thereby delaying the process of paving. WMA also produces lesser emissions, making it a possibility to construct pavements on such non-attainment days. Also, working conditions are a lot better with WMA. Both at the production plant and on the building site, crews inhale lesser smoke and dust. This decrease is especially significant in tunnels where ventilation is lesser.

It has been utilized effectively in a wide scope of pavements with varying thicknesses. It is sufficiently strong to withstand high traffic demands. Warm Mix Asphalt has been utilized in a wide range of asphalt layers: dense-graded, stone matrix, porous, and mastic asphalt. Numerous WMA advances are available in the market, so the decision on the type of WMA can be adjusted according to the temperatures and materials required.

WMA has been utilized effectively in Europe for over 10 years. In the United States, WMA projects are presently in excess of 40 States.

Paved roads are preferred because of its numerous benefits such as smoother rides and longer life. However, converting an unpaved road to a paved road involves huge costs, due to which efforts are made to maintain the condition of the unpaved roads, especially in areas with low traffic.

The unpaved roads (or Gravel Roads) cause air pollution and significant dust generation which hampers the quality of plant and human life in the region. Dust settlement on plants refracts the sunlight and reduces the efficiency of photosynthesis, causing growth inhibition. It also causes breathing and related troubles in humans. Also, dusty roads can cause damage to vehicles and dusty driveways will cause vehicles to require more frequent car-washings at the very least. So it is essential to reduce the dust generation by bonding them in place with the road surface.

Traditionally, spraying water on the surface periodically was considered to be a good solution for dust mitigation. However, in areas with dry climate, it will only be a temporary solution. Applying a salt solution offers another way. It captures the water from the atmosphere, keeps the road top surface damp and prevents it from turning into dust.
One widely accepted practice is to use Gravel. However, it may not be a long term solution as it needs to be anchored to the road below, causing a rough ride.

Chemical technologies such as Zycobond offer a more permanent solution for dust suppression. It facilitates strong chemical bonding between the soil particles and prevents captures existing & new fines, thereby reducing the number of watering cycles.

Road Dust Control – A revolutionary solution by Zydex

Paved roads are a preferred choice when it comes to the development of roadways. However, paving pucca roads can be challenging economically and logistically. Zydex has come up with road dust control solution to treat muddy roads and provide effective and long-lasting road dust control. Understanding the need of the hour, Zydex presents road dust control techniques to reduce dust in the form of Zycobond.

Among the very few available road dust control chemicals, Zycobond from Zydex is a best-in-class dust-suppressing product that provides superior bonding strength on the roads and erosion control on agricultural lands. Zycobond dust control technology is an innovative solution that, when sprayed on any surface makes it hard and dust free. It also provides excellent water resistance, mitigating water damage. Zycobond is a highly stable, cationic nano acrylic binder with a strong bond strength that can mitigate up to 95-98% of the dust on roads, helipads, open grounds, etc.

This technology from Zydex is not just good for roads but also for the ecosystem. It reduces the hampering of plant and human life by dust formation on unpaved roads (also known as gravel roads). Plants’ capacity to absorb sunlight reduces due to dust accumulation and its development is affected. In humans, breathing and other bodily functions are tampered with due to dust particles in the air. Vehicles experience skidding and dirt accumulation hence more car washes. This is taken care of by Zycobond. Therefore, it becomes crucial to limit dust production by gluing them to the road surface.

Zycobond by Zydex is a long-lasting solution. It contributes greatly to society by binding soil and addressing multiple issues all at once.

Sustainable Road Construction made possible with Zydex Technology

Roads are one of the most used resources in any society. With development, we now see roads in the metropolitans and in the remotest of places. But the construction of roads incurs a heavy cost, both economically and environmentally. To tackle this mammoth environmental concern, Zydex has come up with sustainable road solutions. The concept of green road is manifested by not just planting trees along but also making durable roads that last long and are eco-friendly. This includes aiding moisture resistance, flexibility, strength, and maximal use of in-situ materials. Hence paving roads for a sustainable future through perpetual pavements and sustainable roads.

The road construction industry is an energy-intensive industry. Making asphalt ready for use requires heating and emits higher CO₂ emissions. Zydex contributes greatly to road sustainability by producing silane-based chemicals and bitumen additives. Zydex’s new generation nanotechnology-based bitumen additives address chemically bonded organosilane products.

The innovative Zycotherm range of products provides great bonding solutions and anti-strip properties that extend the life of roads by 5 to 7 years. Zydex focuses on road sustainability through innovative products. Terrasil provides hydrophobic properties in the soil/roads which do not allow water to seep in through cracks and ingress, eliminating damage considerably. Terrasil, when used with Zycobond, gives better results. Zycobond provides strong chemical bonding of soil particles, preventing erosion and resulting in sustainable road.

The Zydex sustainable road technology allows road asphalt mixtures to be used in extreme climatic conditions with an increased life span. This innovative technology strengthens pavements and successfully eliminates water-induced pavement damage. This offers stability and longer service life with consistent performance and reduced distress for sustainable road.

A pavement structure is designed and constructed to meet its service life, by taking into consideration the magnitude of the load and the environmental conditions under which it will have to sustain. However, along its service life, the pavement undergoes damage due to a multitude of factors. These factors can be classified as follows:

1. Climatic Conditions

The performance of road depends greatly on the temperature variations (wet and dry/freeze and thaw cycles), rainfall and moisture ingress. The materials used in road construction reacts differently with the presence of these factors. The variation of these factors beyond the tolerable limits will lead to premature failures of the roads. Common failures resulting from climatic variations are swelling and shrinkage of road layers, thermal cracks, potholes, stripping, debonding, bleeding and raveling. Generally, bitumen additives are used to help the pavement withstand these issues. Technologies such as adhesion promoters / antistripping agents prevent the moisture ingress into the asphalt mixes, keeping the pavement in a good condition.

2. Traffic Loading

The traffic load on any road is a very important criteria that determines the performance and ultimately the life of the road. All roads are designed for a given traffic/loading that it is likely to carry over its design life. Any significant overloading will affect the road performance and reduce the service life of the pavement. Few common failures resulting from excessive loading are shoving, rutting, fatigue cracking and depressions. These pavement distresses/failures can be avoided by designing the road adequately for future traffic and also with the use of high performance materials and technologies available. Chemical soil stabilization is one of the techniques that help the pavement withstand higher loads, by enabling to construct stronger soil bases. Other techniques also include, use of geogrids and geotextiles, fibres and modified bitumen binders, to provide higher strength and durability.

3. Operational Factors (Material Reliability and Construction Practices)

These factors includes everything from the usage of unusable/unsuitable materials to operational inefficiency in the field conditions. Inadequate practices lead to structural failures, roughness, cracks and moisture ingress in to roads and ultimately lead to pavement disintegration. Failure to obtain proper compaction, improper moisture conditions at the time of construction and inaccurate layer thicknesses after compaction all directly affect the pavement performance. The adoption of best and reliable construction practices will ensure the construction of durable and long lasting roads.

Consult Zydex and avoid premature failure of your road assets.