DEPARTMENT OF TECHNICAL EDUCATION,

BENGALURU.

Karnatak Lingayat Education Society's

CHIDANAND B KORE POLYTECHNIC,
CHIKODI.

Project Report On

“REPAIR OF POTHOLES USING COLD MIX

ASPHALT”
Submitted by,
AKASH S NAVI -339CE20005
AKASH L KALANNAVAR-339CE20004
RATAN B NAIK -339CE18032
OMKAR U PATIL - 339CE20019

Under the Guidance of

Prof. MANASA YADAGUDI

Department of Civil Engineering

(2022–23)
 Karnatak Lingayat Education Society's
CHIDANAND B KORE POLYTECHNIC,
CHIKODI.

Department of Civil Engineering

CERTIFICATE
This is to that certified that the Project work entitled “ REPAIR OF POTHOLES USING
COLD MIX ASPHALT”,PHASE-I being submitted by “OMKAR PATIL”
bearing REG:339CE20019to Department of Technical Education, Bengaluru, for award of
Diploma in CIVIL ENGINEERING, is a record of the bonafide work carried out by them. They
have worked under my guidance and supervision and have fulfilled the requirements for the
submission of this project.
The work contained in this project has not been submitted, in part or full, to any other university or
institution for award of any degree or diploma.

(Prof. Manasa Yadagudi) (Prof. M B Kurbet) (Prof. Darshankumar D Billur)

Guide HOD Principal
REPAIR OF POTHOLES USING COLD MIX ASPHALT

TABLE OF CONTENTS

CHAPTER 1.............................INTRODUCTION
CHAPTER 2.............................LITERATURE REVIEW
CHAPTER 3.............................OBJECTIVE
CHAPTER 4.............................METHODOLOGY
CHAPTER 5.............................OUTCOME
CHAPTER 6…………………..CONCLUSION
REFERENCE

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

ABSTRACT

Taking note of almost 3,600 deaths reported last year alone due to potholes on roads across
the country, the supreme court said it was "unfortunate" that some states were disputing the
data
.development of potholes on roads and streets of India after the onset of monsoons is a
common phenomenon quite often, potholes are repaired with antiquated techniques such as
placing soil or bare aggregate in the pothole because no hot mix asphalt is available during
monsoons. In this research, An economical, generic, readymade stockpile cold patching mix
has been proposed, which is manufactured in a batch type hot mix plant using local
aggregates also this mix does not require any preparation of the pothole such as squaring and
applying tack coat; the mix is simply taken out of the 50-kg bag, levelled with a rake, hit with
a hand rammer by ordinary laborer (no roller), some light sand or grass/leaves is sprinkled on
surface to prevent pick up by vehicle tyres, and opened to traffic right away. If there is water
in the pothole, simply sweep off the extra water. The patch will outlast the adjacent road area.
The mix has a storage life of at least 6 months, so it can be prepared in advance and used as
needed to repair potholes as soon as they develop throughout the year.
Roads play a major role in the overall infrastructure development of any country. India has a
vast road network spread throughout the nation. Any kind of deterioration in roadways needs
to be restricted, as it directly or indirectly affects the overall growth of our country. Road
material is composed of aggregates and bitumen. Aggregates form the structure that resists
vehicle loads and provide skid resistance, while bitumen binds the aggregates together. With
time, due to environmental exposure, bitumen degrades chemically and becomes brittle. In
addition, moisture may penetrate in the pavement/road structure, causing loss of adhesion
between aggregates and binder. And if the moisture penetrates up to the sub-grade then it will
cause structural defect to the road throughout all the layers. Furthermore, thermal effects,
freeze-thaw action, traffic movement, poor underlying support or some combination of these
factors may be the cause of crack propagation and aggregate losses that lead to formation of
different distresses. Any kind repair is necessary in those situations where distresses
compromise safety and pavement workability. As per the present scenario, temporary and
semi- permanent solutions are there, but rather than that we can improve our conventional
mix and overcome those future problems like potholes, Alligator cracking, Longitudinal
cracking etc. As urbanization takes place we need to improve old techniques of mix to
overcome new problems. In the study we are mainly focusing on the improvement of material
strength by adding admixtures like SBS(Styrene Butadiene Styrene), Nano clays and other
polymers. The main goal of our study is to understand the different properties of material
used in the mix and to improve the properties of conventional asphalt mix by adding some
admixtures.

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

CHAPTER 1

INTRODUCTION

Roads play a major role in the overall infrastructure development of any country. India has a
vast road network spread throughout the nation. Any kind of deterioration in roadways needs
to be restricted, as it directly or indirectly affects the overall growth of our country. Taking
note of almost 3,600 deaths reported last year alone due to potholes on roads across the
country, the supreme court said it was "unfortunate" that some states were disputing the
data
.development of potholes on roads and streets of India after the onset of monsoons is a
common phenomenon quite often, potholes are repaired with antiquated techniques such as
placing soil or bare aggregate in the pothole because no hot mix asphalt is available during
monsoons. Potholes create traffic congestion and lead to gross wastage of fuel. This
ultimately adds to the air pollution causing various, serious health problems to people.
Besides, a lot of accidents occur due to the presence of these potholes.
Among the various modes of transport, road transport plays the vital role in economic, social
and industrial development of the country. Just like arteries in human being, roads perform
the similar function in the transportation of people and goods from one place to another.
Before the advent of automobile carts and pedestrians were the main road users, pathways
and kachha (Earthen road) roads catered to their needs .but emergence of automobiles and all-
round developments the earthen road could not help for the smooth flow of goods and
passenger. Hence there was a need arose for all-weather and better surface road so as to
provide comfortable and efficient movement of vehicular traffic. If the pavement is not
suitably designed and properly constructed it would lead to uneven surface having poor riding
quality causing discomfort to passengers. In addition it will increase fuel consumption, wear
and tear of vehicle components resulting in overall increased vehicle operation cost. On the
other hand pavement design on scientific basis with proper material and adequate thickness
provide smooth riding surface and durability apart from providing comfort to the passengers
in order to understand the concept of flexible pavement design lets us have a look at the
components layers of the pavement structure the different component layers of the flexible
pavement comprise sub-grade, sub-base, base course, wearing course, surface seal coat,
constructed over a prepared soil layer. A pavement structure can be designed either as a
flexible pavement or a rigid pavement based on its structural behaviour. But flexible
pavements are widely preferred in India due to its advantages over rigid pavements and it is
comparatively economical. Flexible pavements have low or negligible flexural strength and
are rather flexible in their structural action under the loads. The layered pavement structure

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

transmits vertical or compressive stresses to the lower layers by grain to grain transfer
through the points of contact in the

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

granular structure with strong graded aggregates and should transfer the compressive stresses
to a wider area. In light of the above factors, it can be learnt that bituminous mix is one of the
best flexible pavement layer materials. Bituminous mix is generally used as a surface course
and wearing course in flexible pavements since it is necessary that the wearing course must
provide a smooth riding surface that is dense and at the same time take up wear and tear due
to traffic. Damage in pavements is a phenomenon that pavement design and maintenance
engineers are dealing with for years. There are two main reasons for damage i.e. fatigue
cracking and rutting in the pavement. Cracks are unavoidable and if neglected then leads to
accelerated cracking and formation of potholes which further reduces the pavement
serviceability. The problem of cracks is handled in many ways, ranging from pavement
maintenance activities, such as surface treatments and crack filling, to full-scale pavement
rehabilitation projects. Patching is becoming a difficult task as permanent solutions are not
available so potholes are needed to be repaired again in short time intervals after patching.
Road maintenance agencies are facing the challenge in dealing with these problems. There
are various methods that are presently being used to repair the potholes such as blow patch,
cold patch (throw and go method), concrete panel replacement, crack sealing, hot mix blow
and roll, hot mix wedge paving, infra-red recycling, mill and fill, microwave recycling, poly
patching, rapid set and slurry crack sealing are many of the methods. The traditional method
of using “throw and go” cold patch is increasingly perceived as ineffective, and therefore
costly method. On a small scale or at isolated locations patching is the most common
maintenance technique used to restore pavement functionality. While actual figures are
difficult to obtain, it was estimated that a huge amount of money is being spent on pothole
patching and maintenance of pavements. Here main focus is to find different additive
components to improve the mix rather than spending tons of money over maintenance work.
Pothole distress considerably degrades pavement performance and affects safety and driving
quality. However, pavement resurfacing is expensive and time consuming and requires
considerable human resources. Cold-mix asphalt (CMA) patching materials can be easily and
swiftly prepared for repairing potholes on a pavement surface. Moreover, the construction
and compaction of CMA patching material can be conducted at ambient temperatures, which
considerably reduces energy requirements. ,therefore, CMA patching materials are efficient,
time saving, and economical for pavement maintenance. CMA patching materials are
produced by mixing aggregate with liquid asphalt binders such as cutback asphalts and
emulsified asphalts. To ensure satisfactory workability of CMA patching materials at ambient
temperatures, cutback asphalts are manufactured by adding petroleum solvents to asphalt
binders; emulsified asphalts are produced by mixing an asphalt binder, water, and an
emulsifying agent. A low-viscosity-grade asphalt binder is generally selected for cold
weather, whereas a high viscosity-grade asphalt binder is considered for warm weather
conditions. In some cases, a modified asphalt binder is used to produce the liquid asphalt
binder for better durability.

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

CHAPTER 2

LITERATURE REVIEW
SL.N ARTICLE AUTHO DATE INFERENCE
O NAME RS

1 Cold mix Shobhit 6 Oct Cold mix asphalt is produced by

asphalt: An Jain & 2020 mixing emulsified bitumen, cutback
overview Bhupen or foamed bitumen with un-heated
dra aggregates.
Singh This process does not require any
aggregate heating which makes CMA
economical and relatively pollution
free
Manufacturing temperature of CMA
is in the range of 0–40 °C.
Production of cold mix also does not
require high investment in equipment
which also makes it easier to adopt.

2 Effect of Arshad 18 April Using Reclaimed Asphalt Pavement

Reclaimed Hussai 2013 (RAP) not only reduces the cost of
Asphalt n& new asphalt mixtures but also
Pavement Qiu conserve the natural resources.
on the Yanjun The stiffness of the binder is
Properties increasing with increasing RAP
of Asphalt binder.
Binders This research only address the binder
related study so to quantify RAP in
asphalt mix design the other factors
like aggregate and volumetric
properties need proper
considerations.

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

SL. ARTICLE AUTHOR DATE INFERENCE

NO NAME S

3 REPAIR OF Chandras June In colder region it is difficult to

POTHOLES hekar 2019 maintain the paving temperature of
USING COLD Gowda hot mix.
MIX K.N & To overcome these problems and
ASPHALT Manjuna conserve the energy bitumen
tha A.R emulsion is considered as good
option.
Producing And Placing Readymade
cold pothole Patching Mix In
Accordance With IRC-116

4 Creep Luis G & 5 May Cold Mix Asphalt (CMA) is

performance Diaz 2016. commonly used in lieu of typical Hot
evaluation of Mix Asphalt (HMA) for localized
Cold Mix pavement patching due to the
Asphalt quantities, intermittent locations and
patching mixes times when repairs need to be
executed.
The objective of this investigation
was to evaluate the resistance of
CMA to accumulate permanent
deformation under cyclic loading,
and to present an alternative to assess
stability potential from a portable
device.
Developed a performance rating
system involving visual inspection of
the patches for the presence of
bleeding, dishing, debonding,
raveling, and pushing/shoving, as
well as measurements of workability
and patch survival rate

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REPAIR OF POTHOLES USING COLD MIX ASPHALT

SL. ARTICLE AUTHOR DATE INFERENCE

NO NAME S

5 EVALUATIO Anna 2006 Cold mixed asphalt concretes consist

N OF COLD Abela of bituminous binder, either cutback
ASPHALT Munyagi or emulsion, and aggregates that have
PATCHING not been heated.
MIXES Cold mix asphalt is often used due to
unavailability of hot mix asphalt in
the vicinity of the project and also
used
for temporary patches.
Engineering properties of products
were investigated, including
volumetric properties, permeability
and Indirect Tensile Strength.

6 The Evaluation Chien- 23 The main objective of this study was

of Short- and Wei July to investigate and evaluate the
Long-Term Huang, 2020 indicators that correlate to Marshall
Performance Tsung- stability and resistance to moisture
of Cold-Mix Han damage, abrasion, and rutting for
Asphalt Yang, short- and long-term performance of
Patching and CMA patching materials.
Materials Guan-Bo Moreover, this study examined the
Lin effect of sample fabrication
conditions by comparing three
compaction methods summarized
from the literature.
Marshall stability, Cantabro abrasion,
and UK wheel tracking tests were
performed to evaluate the short- and
long-term performance of CMA
patching materials.

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CHAPTER 3

OBJECTIVE

1. Identification of issues concerned with the pothole.

2. Design of Cold mix Asphalt using Course aggregate , Fine aggregate, Cut back binder.
3. To assess the physical properties of aggregates, mc-800, cutback bitumen, cold mix
asphalt
4. To achieve sufficient workability of the mix with varying percentage of course
aggregate with RAP aggregate.
5. To promote cold mix asphalt technology as a Sustainable cost effective material and
better alternative & also to improve the standard of the transportation.

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CHAPTER 4

METHODOLOGY
MATERIALS

Readymade patching material packed in plastic-lined, 50-kg bags with a storage life of at
least 6 months. Sand to be sprinkled on compacted patch so that traffic tyres do not pick
the patching mix. Sand to be sprinkled on compacted patch so that traffic tyres do not pick
the patching mix.
In conventional cold mix processes, the liquid asphalt is in the form of an asphalt emulsion.
The asphalt emulsion is then blended with a sized aggregate to form a cold mixture useful
for asphalt pavement. The aggregate then cements into a hard pavement that is essentially
identical to the hot mix bituminous asphalt.
Cold mix asphalt is produced by mixing emulsified bitumen, cutback or foamed bitumen
with un-heated aggregates. This process does not require any aggregate heating which
makes CMA economical and relatively pollution free

BITUMEN

Viscosity grade 30 (VG-30) bitumen is used in our experimentation. It has been tested as
per Indian standard specification IS:1202-1978.

AGGREGATES

9.5mm down size aggregates are used for experimental program. It has been tested as per
Indian standard specification IS:2386.

FLY ASH

Fly ash can be used as mineral filler in CMA paving applications. Mineral fillers
increase the stiffness of the asphalt mortar matrix, improving the rutting resistance of
pavements, and the durability of the mix.

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MIXING METHODS

Aggregate and asphalt mixtures are generally either road mixes, plant mixes, or a
combination of both procedures. Because each method has its own unique problems, they
must be considered separately.

Road Mix

Nearly all cold-mix material in Kansas is mixed on the roadway by motor graders and rotary
tillers. The initial mixing is usually accomplished by the particular machine used to add the
asphalt to the windrowed material, but it may be added to a uniform lift (spread over the
roadway) by a conventional asphalt distributor in not less than three applications per inch of
base thickness. Initial mixing, if properly performed, can be the most effective period of all.
However, it is often felt that as long

Plant Mix

Although plant-mixed cold-laid materials are rapidly becoming common place throughout the
highway industry, Kansas has had relatively little long-term experience in this field.

BASIC TESTS ON AGGREGATE AND BITUMEN

TESTS FOR AGGREGATE

1. Aggregate impact test

2. Specific gravity test
3. Water absorption test
4. Crushing test

TESTS FOR BITUMEN

1. Penetration test
2. Ductility test
3. Softening point test
4. Specific gravity test
5. Viscosity test

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CHAPTER 5

OUTCOME
1. Main advantages of cold mix are cost effectiveness, environment friendly, lower
emissions, and easy availability. Some of the disadvantages of using cold mix are
lower early life strength, higher voids and higher moisture susceptibility
2. RAP recycling is classified as hot or cold recycling, depending on the use of heat. Cold
recycling uses cutback or emulsion as recycling [Link] recycling methods are also
determined by the removal depth of the old pavement

CHAPTER 6

CONCLUSION
The mix can be stockpiled and remains workable for at least 6 months and, therefore, it can be
used throughout the year including the rainy season. This cold patching mix is manufactured in a
batch type hot mix plant using local aggregates. This mix can be placed without preparing the pothole
such as drying, squaring the edges, cleaning, and tack coating Easy to carry and could be taken to any
remote places Urgent patches could be made which is usually considered to be impractical in the
[Link] patching allows less alteration to the traffic conditions. From the field evaluation also,
mix has been found to be suitable and good for repair of potholes. Fast patching the average pothole
can be patched in just a couple of minutes. It can be used in all weather condition..

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REFERENCE

I. Indian Roads Congress. IRC:116-2014 “Specifications for Readymade Bituminous

Pothole Patching Mix Using Cutback Bitumen”. New Delhi 2014.
II. Kandhal, P. S. and D. B. Mellott. Rational Approach to Design of Bituminous
Stockpile Patching Mixtures. TRB, Transportation Research Record 821, 1981.
III. Kandhal, P.S “A simple and effective method of repairing Potholes in India”,
Journal of the Indian Roads Congress, Volume 69-3, 2008.
IV. Wilson, T. P. Strategic Highway Research Program Pothole Repair Materials and
Procedures. TRB, Transportation Research Record 1392, 1993.
V. Berlin, M. and E. Hunt. Asphalt Concrete Patching Material Evaluation. Oregon
DOT Report No. OR-RD-01-19, June 2001.
VI. Thomas, H. R. and D. A. Anderson. Evaluation of Experimental Cold- Stockpiled
Patching Materials for Repairs in Cold and Wet Weather. TRB, Transportation
Research Record 1268, 1990.
VII. Estakhri, C. J. and J. Button. Test Methods for Evaluation of Cold-Applied Bituminous
Patching Mixtures, TRB, Transportation Research Record 1590, 1997.
VIII. Meng Guo, Yiqiu Tan & Shuiwen Zhou(2014), “Multiscale test research on interfacial
adhesion property of cold mix Asphalt”, Construction and Building Materials 68
(2014) 769–776
IX. N.F. Ghaly, I.M. Ibrahim & E.M. Noamy(2014), “Tack coats for asphalt paving”,
Egyptian Journal of Petroleum (2014) 23, 61–65

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