Manufacturer of Crumb Rubber Modified Bitumen (CRMB) FROM Turkey and Dubai

 

What is Crumb Rubber Modified Bitumen?

Crumb Rubber Modified Bitumen is used the world wide for the improvement of binder characteristics for use in wearing courses of flexible pavements. CRMB modified bitumen prepared by the addition of reclaimed truck tires further improved by the additives.Research worldwide has shown that addition of crumb rubber to bitumen produces binders with improved resistance to combat pavement distresses such as rutting, fatigue cracking, thermal cracking etc. It has also been demonstrated that use of crumb rubber modified binder leads to reducing of overlay thickness as well as reduce reflective cracking potential. This adequately demonstrates that CRMB is a superior binder which has immense application in highly trafficked National and State Highways of India.
CRMB can be used to added to the bituminous mixtures as a filler i.e. Dry Process. Research has shown that bituminous mixtures produced in this way show limited engineering benefits as compared to the mixtures produced by addition of Crumb rubber to bitumen under appropriate processing conditions i.e. Wet Process, a method used to modify asphalt with crumb rubber modifier. This process requires cooking the liquid Bitumen and Crumb rubber Modifier at high temperatures (160℃ to 175℃) for almost two and half hours. The time and temperature of digestion of Crumb rubber modifier with Bitumen are known to have an important effect on the resulting Crumb Rubber Modified Bitumen. The major effect is due to absorption by the rubber particles of aromatic oil in the Bitumen. This causes softening and swelling of rubber particles so that a comparatively large proportion of binder (CRMB) consists of soft rubber.

Significance

The most remarkable aspect of CRMB is that it produces an environmentally friendly product. CRMB offers a solution to the waste disposal problem of the millions of tires produces world wide.
The addition of waste tires in place of costlier virgin polymers results in greater cost savings, lower energy consumption and lower environmental pollution. The highways made using CRMB have performed comparable with those produced using much costlier polymers.

Manufacturing Process

1. Crumb Rubber Preparation: Waste tires are shredded into small particles or granules, often between 0.5 mm and 2 mm in size.
2. Mixing: The crumb rubber is blended with hot bitumen at high temperatures to ensure proper dispersion and bonding.
3. Curing: The mixture is allowed to cure, ensuring the rubber particles swell and integrate fully with the bitumen.

Advantages of Crumb Rubber Modified Bitumen

Crumb Rubber Modified Bitumen (CRMB) offers several advantages, particularly in road construction and infrastructure projects. Here are the key benefits:

1. Enhanced Durability
   CRMB improves the longevity of pavements by increasing resistance to wear and tear, reducing maintenance costs.
   It is less prone to cracking, deformation, and rutting under heavy loads.
2. Superior Temperature Performance
   High Temperature: CRMB remains stable and resists softening in hot climates, reducing deformation (rutting).
   Low Temperature: It prevents thermal cracking in cold climates by maintaining flexibility.
3. Improved Elasticity and Flexibility
   The addition of crumb rubber enhances the elasticity of bitumen, allowing it to absorb stresses from traffic loads and environmental changes effectively.
4. Environmental Benefits
   Recycling Waste Tires: CRMB utilizes waste tires, reducing landfill waste and promoting eco-friendly practices.
   Lower Carbon Footprint: Its long-lasting nature reduces frequent repaving, cutting down emissions associated with road maintenance.
5. Better Skid Resistance
   The rubber particles increase the surface texture of roads, enhancing traction and reducing accidents, especially in wet conditions.
6. Noise Reduction
   Roads paved with CRMB can reduce noise levels due to the rubber’s ability to absorb sound.
7. Cost-Effective in the Long Term
   Although the initial cost may be higher, the reduced need for repairs and maintenance results in significant long-term savings.
8. Resistance to Aging and Oxidation
   CRMB offers better resistance to oxidation, ensuring it remains functional for longer periods under varying environmental conditions.
9. Reduced Road Maintenance
   Roads built with CRMB require fewer interventions, saving time and resources for infrastructure management.
10. Increased Load-Bearing Capacity
    Ideal for high-traffic roads, highways, and heavy vehicle zones, it can handle greater stress without compromising performance.

Application of Crumb Rubber Modified Bitumen

• Road Construction
  Highways and Expressways: CRMB is ideal for highways and expressways with heavy traffic loads, providing durability and resistance to rutting.
  Urban Roads: It improves the lifespan and performance of city roads subjected to frequent traffic and temperature fluctuations.
  Rural and Low-Traffic Roads: Offers cost-effective solutions by reducing maintenance needs in low-traffic areas.
• Airport Runways
  The elasticity and resistance to deformation make CRMB suitable for airport runways, where surfaces are subject to heavy loads and temperature variations.
• Bridge Decks
  CRMB is used in waterproofing layers on bridge decks to prevent water ingress and improve load-bearing performance.
• Industrial Flooring
  Its resilience and durability make it suitable for industrial flooring applications that require resistance to heavy equipment and thermal stresses.
• Waterproofing Applications
  CRMB is applied in roofs, basements, and other structures needing waterproofing due to its excellent water-resistant properties.
• Port and Container Yards
  Heavy-duty areas like ports and container yards benefit from CRMB’s ability to withstand heavy loads and frequent movements.
• Racing Tracks
  Used in race tracks for its ability to provide superior traction and resistance to wear, ensuring smooth performance over time.
• Noise-Reducing Pavements
  CRMB is used in urban areas and near residential zones for paving roads that reduce noise pollution.
• Heavy-Duty Pavements
  CRMB is ideal for industrial areas, logistic hubs, and loading zones where pavements are subjected to heavy and repetitive loads.
• Cold Regions
  In colder climates, CRMB prevents cracking due to its flexibility and ability to endure low temperatures.
• Sustainable Infrastructure Projects
  CRMB is utilized in eco-friendly construction projects to promote recycling and reduce the environmental impact of waste tires.

CRUMB RUBBER MODIFIED BITUMEN (CRMB) ADVANTAGES AND BENEFITS

CRMB has several advantages over conventional bitumen in road construction, such as:

Improved pavement performance: CRMB improves the pavement’s durability, stability, and resistance to deformation, fatigue, and cracking, which reduces maintenance costs and extends the pavement’s lifespan.
Environmental benefits: CRMB recycles waste tires and reduces their disposal in landfills, which reduces the environmental impact of waste and conserves natural resources.
Cost-effectiveness: CRMB is cost-effective compared to other pavement materials, such as concrete, and reduces the construction time and traffic disruptions.
Versatility: CRMB can be used in various pavement applications, such as high-traffic roads, low-traffic roads, thin pavements, and urban areas, which increases its versatility and adaptability to different design and climate conditions

CRUMB RUBBER MODIFIED BITUMEN (CRMB) INSTALLATION

The installation of Crumb Rubber Modified Bitumen (CRMB) largely follows the same procedure as traditional bitumen, with a few added steps to ensure the unique properties of the material are fully utilized. Below is a generalized process:

1. Material Preparation: First, the CRMB is prepared according to the specifications of the project. This involves creating a mixture of CRMB and aggregates, which include materials like stones and sand.
2. Heating: The CRMB mixture is heated to a certain temperature before application, usually around 160 to 170°C. It’s crucial to maintain this temperature range to prevent the premature cooling of the mixture, which can affect its workability and the quality of the finished surface.
3. Transportation: The heated CRMB mixture is then transported to the construction site. Again, it’s essential to maintain the mixture at the proper temperature during transport.
4. Placement: Upon arrival at the site, the mixture is placed on the prepared surface using a paving machine. The CRMB mixture is spread evenly across the area to be paved.
5. Compaction: After placement, the mixture is compacted using rollers to ensure a uniform, dense surface. Proper compaction is crucial to the performance and longevity of the road. This process must be completed before the mixture cools and hardens.
6. Curing: Finally, the paved surface is left to cure and harden. This can take a few hours to a few days depending on the specific mix and environmental conditions.

The successful installation of CRMB requires careful planning and execution. From the accurate preparation of the CRMB mixture to maintaining the proper temperature during transportation and installation, every step of the process plays a role in achieving a high-quality, durable road surface. It’s also worth noting that different projects may require specific installation techniques or additional steps based on local conditions and regulations.

Specifications of crumb rubber modified bitumen

1. Physical Properties 

• Penetration (25°C): Indicates the consistency and hardness of CRMB, typically ranging from 25 to 75 dmm.
• Softening Point: Measures the temperature at which the bitumen softens; CRMB usually has a higher softening point, typically 60°C to 80°C.
• Elastic Recovery: Reflects the elasticity, generally specified as 50% to 75% at 25°C.
• Viscosity at 60°C: Ensures proper workability, with typical values ranging between 2000 to 5000 Poise.

2. Chemical Properties

• Rubber Content: Generally ranges from 10% to 15% of the bitumen weight.
• Loss on Heating: Limited to ≤1% to ensure resistance to aging.
• Flash Point: Specifies the temperature at which it becomes flammable, generally ≥220°C.

3. Performance Characteristics

• Rutting Resistance: High resistance to rutting under heavy traffic and high temperatures.
• Fatigue Resistance: Improved flexibility reduces cracking under repeated stress cycles.
• Resistance to Oxidation: Enhanced due to the presence of rubber, prolonging the material’s lifespan.

4. Specific Standards
Specifications may align with regional or international standards, such as:

• ASTM D6114: Standard specification for CRMB.
• BS EN 14023: European standard for polymer-modified bitumen, applicable to CRMB.
• Indian Standards (IS 15462): Specification for polymer- and rubber-modified bitumen in India.

5. Environmental Performance

• Temperature Susceptibility: Lower temperature susceptibility compared to conventional bitumen.
• Adhesion to Aggregates: Improved adhesion properties to ensure better bonding with aggregates.

6. Grades of CRMB
CRMB is typically categorized into various grades based on rubber content and application:

• CRMB 30: Suitable for moderate climates and general-purpose roads.
• CRMB 40: Used in heavy traffic areas or hotter climates.
• CRMB 50: High-performance grade for extreme weather conditions and heavy-duty applications.

The careful selection of additives greatly enhances binder performance, improves elasticity, reduces temperature susceptibility and improves adhesion. Our product range is particularly suited to heavy traffic locations such as highways, main roads, airfields, roundabouts and bus lanes.
Superior Elastic Modulus of Bernet CRMB helps control deformation under high pavement temperature and heavy loading conditions, Increases the fatigue life of pavement under repeated heavy loading conditions, Helps in reduction of maintenance cost and is more cost effective on a life cycle cost basis, Is used for use in thin surfacing and stone mastic asphalt (SMA) mixes; drainage (porous) asphalt applications and asphalt mixtures designed for high resistance to permanent deformation and high flexibility.
According to RPA (Rubber Pavement Association) Arizona, USA best bitumen choice for more than 80% of road construction projects are CRMB. RPA’s in depth research and analysis reports the cost of CRMB and conventional bitumen to be estimated at $10 PSY vs. $45 PSY respectively over four years. Using CRMB commits to a sustainable future, creates safer and less consumable smooth roads.

Advantages of using CRMB over Conventional Bitumen

 

Advantages of using CRMB over Conventional Bitumen

Specifications For All Grades of CRMB

 

Specifications For All Grades of CRMB

 

Bitumen Test Results Report PG-CRMB (82-28)-(82-10)-(82-16)

 

Bitumen Test Results Report PG CRMB 82-28

Bitumen Test Results Report PG CRMB 82-10

Bitumen Test Results Report PG CRMB 82-16