A bitumen calculator is an essential tool for accurately determining the quantity of bitumen needed for road construction and other paving projects. It helps in estimating material requirements, ensuring efficient resource allocation, and maintaining project budgets.

How to Calculate Bitumen Quantity

The basic principle behind a bitumen calculator involves two main steps:

1. Calculate Total Area

The total area to be covered is determined by multiplying the length and breadth of the surface.

Total Area=Length×Breadth

Example: If Length = 10 m and Breadth = 7 m Total Area=10 m×7 m=70.00 m2

2. Calculate Quantity of Bitumen

Once the total area is known, the quantity of bitumen required is calculated by multiplying the total area by the specified rate of spray.

Quantity of Bitumen=Total Area×Rate of Spray

Example: If Total Area = 70.00 m2 and Rate of Spray = 0.7 kg/m2 Quantity of Bitumen=70.00 m2×0.7 kg/m2=49.00 Kgs

Note:

• m2 refers to square meters.
• Length and breadth should be in meters or centimeters.
• 1 m2=10.7639 ft2

What is Bitumen Calculation?

Bitumen calculation, often facilitated by a bitumen calculator, involves determining the precise amount of liquid bituminous material (primer) required for application on a porous granular surface. This preparatory layer is crucial before applying a full bituminous treatment or mix.

Scope of Work

The process consists of applying a single coat of low-viscosity liquid bituminous material to a prepared granular or stabilized surface. This work adheres to specific clauses and standards outlined in contract specifications.

Material Specifications

The primer used can be either

• Cationic bitumen emulsion SS1 grade: Conforming to IS:8887.
• Medium curing cutback bitumen: Conforming to IS:217.

It’s important to note that primer should not be prepared on-site. The type and quantity of cutback bitumen for various granular surfaces are specified in the contract and determined by the Engineer.

Emulsion Bitumen Types of Surface	Rate of Spray (kg/sq.m)	Cutback Bitumen Types of Surface	Cutback	Rate of Spray (kg/sq.m)
WMM / WBM	0.7 – 1.0	WMM / WBM	MC 30	0.6 – 0.9
Stabilized soil bases/Crusher Run Macadam	0.9 – 1.2	Stabilized soil bases/Crusher Run Macadam	MC 70	0.9 – 1.2

The Engineer ultimately decides the correct quantity of primer, ensuring it’s absorbed by the surface without excessive run-off and achieves a penetration of about 8-10 mm.

Weather and Seasonal Limitations

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Understanding the Bitumen Calculator

A bitumen calculator is an essential tool for accurately determining the quantity of bitumen needed for road construction and other paving projects. It helps in estimating material requirements, ensuring efficient resource allocation, and maintaining project budgets.

How to Calculate Bitumen Quantity

The basic principle behind a bitumen calculator involves two main steps:

1. Calculate Total Area

The total area to be covered is determined by multiplying the length and breadth of the surface.

Total Area=Length×Breadth

Example: If Length = 10 m and Breadth = 7 m Total Area=10 m×7 m=70.00 m2

2. Calculate Quantity of Bitumen

Once the total area is known, the quantity of bitumen required is calculated by multiplying the total area by the specified rate of spray.

Quantity of Bitumen=Total Area×Rate of Spray

Example: If Total Area = 70.00 m2 and Rate of Spray = 0.7 kg/m2 Quantity of Bitumen=70.00 m2×0.7 kg/m2=49.00 Kgs

Note:

• m2 refers to square meters.
• Length and breadth should be in meters or centimeters.
• 1 m2=10.7639 ft2

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Weather and Seasonal Limitations

For effective application of bitumen, environmental conditions are critical:

• Prohibited Conditions: Primer should not be applied during dust storms, fog, rain, or windy conditions. The shade temperature must not be less than 100C.
• Surface Condition for Cutback Bitumen: Cutback bitumen must not be applied to a wet surface.
• Surface Condition for Emulsion Primer: Surfaces receiving emulsion primer should be damp, but free from standing water. A very light sprinkling of water can be used to achieve this dampness

Construction Equipment

The application of primer requires specialized equipment:

• Primary Equipment: A self-propelled or towed bitumen pressure sprayer, equipped for uniform material spraying at specified rates and temperatures, is preferred.
• Hand Spraying: Hand spraying is generally not permitted, except for small, inaccessible areas or narrow strips, where a pressure hand sprayer can be used.

Preparation of Road Surface

Before applying the primer, the granular surface must be meticulously prepared:

• Cleaning: The surface must be swept clean using power brooms or mechanical sweepers to remove all dust, loose material, and foreign matter.
• WBM Surface: If soil/moorum binder was used in the WBM surface, a portion should be brushed away to a depth of approximately 2 mm to ensure good primer penetration.

Application of Bituminous Primer

After proper surface preparation, the primer is sprayed uniformly at the specified rate. The application method depends on factors such as equipment type, nozzle size, spray bar pressure, and forward movement speed. Contractors must demonstrate, through a spraying trial, that their equipment and method achieve uniform spray within specified tolerances.

• SS1 Bitumen Emulsion: No heating or dilution of SS1 bitumen emulsion is permitted on-site.
• Cutback Bitumen: Cutback bitumen must be heated sufficiently to allow effective spraying through jets and uniform surface coverage.

Curing of Primer and Opening to Traffic

Proper curing is vital for the longevity of the primer coat:

• Curing Period: A primed surface needs to cure for at least 24 hours, or longer if necessary, to allow all moisture/volatiles to evaporate before any subsequent surface treatment or mix is applied.
• Unabsorbed Primer: Any unabsorbed primer should be blotted with a light, minimum application of sand.
• Traffic Restriction: A primed surface should only be opened to traffic necessary for laying the next course.

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Quality Control and Traffic Arrangements

• Quality Control: Quality control of materials and work adheres to relevant provisions outlined in Section 900 of the specifications.
• Traffic Management: Traffic arrangements during construction operations must comply with Clause 112.

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Measurement for Payment and Rate

• Measurement: Prime coat is measured by the surface area of application in square meters.
• Payment Rate: The contract unit rate for the prime coat fully compensates for all required operations and components. Payment is based on an application rate of 0.6 kg/m2 or the specified contract rate, with adjustments for variations between this quantity and the Engineer-approved actual quantity.

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Importance of Bitumen Calculation

Accurate bitumen calculation and the use of a bitumen calculator offer numerous benefits for pavement projects:

Smooth Ride Surface

Bitumen pavements provide a smooth riding surface due to the absence of joints, resulting in less sound emission compared to concrete pavements. Reduced wear and tear also contribute to maintaining this smoothness.

Gradual Failure

Unlike the brittle failures seen in concrete pavements, bitumen roads exhibit gradual deformation and failure, allowing for more time to address issues.

Quick Repair

Repairing bitumen roads is a swift process. They set quickly, minimizing traffic disruption and allowing for faster reopening of paths.

Staged Construction

Bitumen pavements facilitate staged construction, which is beneficial when facing funding constraints or uncertainties in traffic estimation.

Lower Life Cycle Cost

Compared to concrete pavements, bituminous pavements generally have lower initial costs and overall maintenance expenses throughout their lifespan.

Temperature Resistant

Bitumen pavements are resistant to de-icing materials and can withstand high temperatures without melting, ensuring durability in varying climates.

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