Bitumen Emulsions

Revolutionizing Road Construction: Introducing Zydex’s Silane-Based Additive for Bitumen Emulsions! Say goodbye to nozzle clogging and tire pickup with enhanced bonding and water resistance

Revolutionizing Road Construction: Introducing Zydex’s Silane-Based Additive for Bitumen Emulsions! Say goodbye to nozzle clogging and tire pickup with enhanced bonding and water resistance. Discover the future of prime and tack coats today!

Globally bitumen emulsions have been used for prime coat or we can call it tack coat. They are also used for prime coats which are used above the GSB or the WMM surface. One of the problems is wetting, spreading, penetration & good emulsion stability, which means resistance to nozzle clogging and the ability to bond with the aggregate soil surface, and clay surface.

Zydex has innovated silane based additive for bitumen emulsions which are water soluble but at the same time are reactive with silanol groups which are present on aggregates, soil particles or clay particles. This bonding and reaction happens at room temperature upon drying. And also it reduces the surface tension to make it very easily spreadable. It also forms a layer on the bitumen emulsion and reduces the tackiness so that tyre pickup is reduced in all the bitumen emulsion applications. These silane modifiers are used at 0.1 percent on the weight of bitumen emulsions and gives excellent non clogging performance to the bitumen emulsion used. The ease of spraying and the spray pattern of the bitumen emulsion is very good and the bonding of bitumen emulsion also comes out excellent when you cut the core after three weeks or six weeks. The quality of bonding has actually improved and its water resistance has also improved because of the chemical bonding of the silane additive which then helps bonding of the bitumen emulsion and the aggregate surface.

Hot Mix Asphalt

Addressing Weaknesses in Hot Mix Asphalt and Keeping Our Roads Strong

Addressing Weaknesses in Hot Mix Asphalt and Keeping Our Roads Strong

Hot mix asphalt (HMA) reigns supreme in road construction for its versatility, affordability, and smooth ride. However, it’s not without its flaws. This blog post will delve into these drawbacks and explore a promising solution from Zydex.

The Achilles’ Heel of HMA

While HMA boasts numerous advantages, achieving consistent density after compaction and ensuring long-lasting water resistance can be tricky. The culprit? The bond between bitumen (asphalt binder) and the aggregate (stones), especially the finer particles and dust. Under wet conditions, high-speed traffic can cause water to scour away this crucial binding material, a phenomenon known as ravelling. This dislodges small and large stones, compromising the road’s integrity.

Cracking Under Pressure

Another weak spot is cracking due to fatigue and oxidation. Sun exposure and constant traffic flexing take their toll, leading to cracks over time. Sudden temperature swings can further exacerbate this distress, ultimately causing pavement failure.

ZycoTherm: A Revolutionary Approach

Zydex steps in with its innovative ZycoTherm technology, a reactive bonding solution for the aggregate surface. Imagine transforming the surface of these aggregates from “orange” (hydrophilic with silanol groups) to “apple” (hydrophobic with protective oily chains). This transformation happens during the hot mixing and paving process, creating a more robust and water-resistant bond.

The Importance of Complete Coverage

Efficiently coating the fine particles within the HMA mix with bitumen is paramount during those critical 40 to 60 seconds of intense mixing. Incomplete coverage creates microscopic pathways for water to infiltrate the aggregates. These wet-dry cycles, over time, can strip away the bitumen film, significantly weakening the bond between the aggregate and fines within the asphalt mix.

Conquering Segregation: The Enemy of Uniformity

Segregation, the uneven distribution of large and fine aggregates within the HMA mix, is another hurdle the industry faces. A uniform void distribution in the compacted pavement is crucial to achieve optimal performance.

ZycoTherm Range: A Winning Formula

Innovation of ZycoTherm range tackles these problematic areas head-on. Users have reported excellent results on the field, appreciating the technology’s positive impact on performance without breaking the bank. The cost, when viewed through the lens of the value it delivers, makes ZycoTherm a compelling solution for those seeking long-lasting, high-performing roads.

Warm Mix Asphalt

Warm Mix Asphalt: Paving the Way for a Sustainable Future

Warm Mix Asphalt: Paving the Way for a Sustainable Future

Warm Mix Asphalt (WMA) is a revolutionary paving technology offering a cooler, greener, and healthier alternative to traditional Hot Mix Asphalt (HMA). Let’s delve into the key benefits of WMA:

Lower Production Temperatures

WMA boasts lower production temperatures compared to HMA. This translates to significant advantages:

  • Environmental Benefits: Reduced production temperatures mean less fuel consumption (up to 15% savings!) and lower greenhouse gas emissions.
  • Extended RAP Use: WMA excels at efficiently melting Recycled Asphalt Pavement (RAP) content exceeding 30-35%. This promotes sustainable practices by reusing old asphalt materials.
  • Improved Workability: WMA additives, like ZycoTherm SP2, act as anti-stripping agents, preventing moisture-related asphalt weakening. This translates to a less sticky mix with minimal segregation, leading to consistently higher densities on the paved surface.

Enhanced Performance and Durability

The cooler production process of WMA offers these advantages:

  • Bitumen Benefits: Lower temperatures minimize bitumen oxidation, extending its lifespan and enhancing the paved layer’s flexibility. WMA additives like ZycoTherm SP2 excel at handling and processing even highly modified polymer-rich bitumen.
  • Proven Performance: Millions of kilometers of WMA pavements worldwide demonstrate their exceptional performance and durability.

Human Health Matters

One of the most significant advantages of WMA is its positive impact on human health, particularly for paving crews. WMA production generates nearly 92-93% less vapor phase emissions compared to HMA. While hot bitumen is classified as “probably carcinogenic,” Adopting WMA significantly reduces exposure to these harmful fumes, and makes world a safer place.

The Global Shift Towards WMA

Leading countries like China, the USA, and Europe are actively transitioning towards WMA technologies. This shift reflects the cost negative and environment positive advantages WMA offers for sustainability, worker health, and overall road quality.

Asphalt Anti Strip Solution from Zydex for Better and Durable Roads

Asphalt Anti Strip Solution from Zydex for Better and Durable Roads

Asphalt Anti Strip Solution from Zydex for Better and Durable Roads

Roads are integral assets for any country around the world. Laying roads constitutes a major part of the state’s budget. While countries incur huge costs developing new roads, a significant amount is spent on repairs because of their earlier-than-expected damage. While we commonly attribute this damage to water, change in climate and heavy traffic, the actual root cause is the weakening of bonds between asphalt and aggregate.

Zydex, with its intensive study in the field of over 25 years has introduced solutions that help the roads by addressing this root cause. Zydex’s Zycotherm has been adopted around the world as a next-generation Anti Strip and warm mix asphalt additive technology and has been used to produce upwards of 50 million tons of asphalt mix.

Using organosilane chemistry, this additive achieves what no other additive has been able to achieve; chemical bonding with the aggregate thereby making it waterproof with improved bonding to the asphalt. As demonstrated through extensive field and laboratory testing, this permanent chemical bond provides enhanced resistance to moisture damage and extended life to asphalt pavements.

Benefits of Zydex Asphalt Anti Strip solutions include combined Anti Strip, reduced mixing temperatures, higher incorporation of RAP, excellent compaction in cold climates, longer hauls and excellent salt tolerances. ZycoTherm is compatible with PPA, SBS and CRMB and is used at extremely low dosages. Zydex also produces effective soil and dust additives that provide excellent bonding for next generation soil bases for heavy traffic roads.

Asphalt for Paving

Asphalt for Paving: Building Sustainable, Durable and Long-Lasting Roads

Asphalt for Paving: Building Sustainable, Durable and Long-Lasting Roads

The construction and maintenance of roads, parking lots, ports, and airport runways, among other constructions within the category, all require the usage of asphalt, a mixture of aggregates, bitumen, and filler. Zydex technology provides products that enhance paving with asphalt and provide best results by binding. The range of leading products is Zycotherm, Terraprime and Nanotac. The technology provides moisture-resistant, durable and long-lasting roads.

Most contractors today, use asphalt for paving. It is one of the widely accepted materials in the road construction sector. Asphalt is a thick viscous liquid used in the construction of roads, and pavements, Asphalt paving has multiple benefits including durability and safety. Zydex Industries offers a range of products to enhance asphalt paving thus resulting to long-lasting and durable asphalt pavements.

There’s a growing demand for sustainable roads, which are designed to minimize the environmental impact of road construction and maintenance while delivering superior performance. Zydex, through its products, vouches for asphalt pavements to be an excellent choice to build sustainable roads. The key advantages of Asphalt pavements are durability, safety, easy maintenance and importantly sustainability.

Hot Mix Asphalt Vs Warm Mix Asphalt

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.

4 ways for Road Dust Control

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

Road Dust Control – A revolutionary solution by Zydex

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

Sustainable Road Construction made possible with Zydex Technology

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.

Why do roads get damaged frequently? Know the important factors

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.