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By SAI Team IITB 1974 Chemical Engineering

ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS. INROADS IN NOVATIVE R OADS O PERATED A ND D ESIGNED S PECIFICALLY FOR ALL RURAL AREAS OF THE WORLD. DR. AROON SHENOY MR. AVINASH SANKHOLKAR DR. CARMO PEREIRA MR. DILIP VAIDYA MR. JAGDISH SHAH DR. JOSEPH GONSALVES

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By SAI Team IITB 1974 Chemical Engineering

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  1. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS INROADSINNOVATIVE ROADS OPERATED AND DESIGNED SPECIFICALLY FOR ALL RURAL AREAS OF THE WORLD DR. AROON SHENOY MR. AVINASH SANKHOLKAR DR. CARMO PEREIRA MR. DILIP VAIDYA MR. JAGDISH SHAH DR. JOSEPH GONSALVES MR. MILIND PRADHAN MR. PRASAD GHATE MR. RAJENDRA GADGIL MR. RATHIN BANERJEE MR. VIJU PARAMESHWAR By SAI Team IITB 1974 Chemical Engineering

  2. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Scientific & Technical Area • INROADS will involve inputs from • Chemical Engineering • Chemistry • Polymer Technology • Materials Science and Engineering • Electrical Engineering • Computer Engineering • Civil Engineering • Project Management INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  3. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Uniqueness & Novelty • Ingenuity of INROADS • Preparing road sections as slabs • Portable processing plant at paving sites • Simplified lay down operation • Speedier & inexpensive construction practices • Utilization of advanced techniques INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  4. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Impact on the World • Significant portion of human population lives in rural areas • Basic needs for a dignified life are deprived in highly inaccessible areas • Efficient road linkages are known to greatly improve quality of life • INROADS for rural areas will radically transform the quality of life INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  5. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Goal • To provide INROADS for rural areas of the world • That are easy to build and rehabilitate • That use the natural recyclable bio-friendly resources • That utilize environment-friendly energy sources, and • Which are designed using state-of-the-art technology INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  6. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Incentive • Most lower than middle-class/poor sections of society lives in rural areas • Need better connectivity through goodroads than uneven muddy pathways • Such arteries can equip Government bodies with inflation-fighting-tool • INROADS will have a great economic impact due to better transportation network INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  7. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Raw Materials • Major ones • Hard Solids – Naturally available mud from existing muddy pathways • Binders – Liquid rubber along with left-over fractions of bio-diesel or algae fuel • Other Additives – Chelating agents, catalysts, cross-linking agents, anti-degrading agents, oils, agro-waste, fiber waste, etc. INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  8. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • Building INROADS involves • Excavation at site to a depth of 12 inches • Excavated mud to be sieved to separate 100 microns or less particles • Particles > 100 microns to be mixed with 10% of recycled rubber particles and placed back at the excavated site to a compacted depth of 6 inches INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  9. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • Additionally • Recycled rubber particles will be from discarded rubber tires of cars and trucks • Cryogenically ground particles will not be stripped of reinforcing fibers • Compatibility of the rubber tires with the large particles is not an issue since the idea is to use them only as sub-base INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  10. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • Sub-base and Base • The compacted 6 inches of sub-base will be sprayedwith a dilute low-molecular weight epoxy asphalt solution containing small amount of slow-reacting cross-linking agent • Remainder of the mix would then be put and compacted using a road roller to fill an additional height of 4 inches as base and also sprayed with above solution INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  11. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • Epoxy Asphalt Solution • It would help in bonding of the sub-base with the base and the base with the slabs • The thinly formed two layers of epoxy asphalt will provide an elastic cushioning effect that will prevent reflective cracking as well as promote healing of minor deformation INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  12. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • Surface Layer • The remainder of the 2 inches would be filled by the INROADS slabs • The preparation of the slabs first involves mixing the fine size particles (<100 microns) with the binder along with all the additives in a continuous internal mixer like that shown schematically in Figure 1 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  13. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS • Figure 1 • Schematic diagram of the continuous internal mixer showing how the materials would be mixed and discharged Figure 1 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  14. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • INROADS Slab • Mixed material is extruded as INROADS slab that is 1½ feet x 1½ feet x 3½ inches • The next step is compression of the extruded slab to the correct size of 2 feet x 2 feet x 2 inches like that shown in Figure 2 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  15. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS • Figure 2 • Operation showing the extruded slab of 1½ feet x 1½ feet x 3½inches compression molded to give the final dimensions of 2 feet x 2 feet x 2 inches Figure 1 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  16. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process… • During compression molding • The slab is placed in the mold on top of a geo-synthetic or bamboo fabric 2 feet x 2 feet • Thin strips of materials that contain pressure-sensitive sensors of the same dimensions are placed on top of the slab as well INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  17. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Added Benefit… • Pressure sensitive sensors • Act as motion detectors • They would respond by generating an electrical output due to the pressure they experience every time a vehicle passes over them INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  18. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Added Benefit • Electrical Output • Will be stored in batteries alongside the roads • Will be used for providing automatic lighting of roads and road signs at no extra cost and no running expenses • Will be used to provide lighting alongside the roads (Solar cells may also be used for this purpose) INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  19. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Process • INROADS slabs placement • Compression-molded slabs have enough “Green Strength” • Though produced at ambient temperatures, the higher temperature for cross-linking is got “in-situ” after placement using the sun’s natural heating system INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  20. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Cross-linked product • What is being sought is a slab that is “hard and elastic” and not “hard and brittle” • Trick is to have as much mud fines as possible to get the hardness and have them coated with minimum binder in a thin layer to provide elasticity INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  21. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Final product property • The final compression-molded product containing high volume fraction of well-dispersed and distributed mud fines will have high compression strength and will be strong enough to bear the stresses of not only bullock-carts but also of heavy vehicles INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  22. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Lay down operation • The size of the slabs are kept to 1½ feet x 1½ feet x 3½ inches pre-compressed and 2 feet x 2 feet x 2 inches after compression molding to ensure that they can be lifted, carried, and laid by a single person without the need for help from any mechanical device like a crane INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  23. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Slab weight • The slab would have a manageable weight of about 20-25 kilos which would be in a range that would not pose much difficulty in carrying it a short distance for placement • The weight of each slab would be heavy enough to carry for long distances so as to discourage pilferage before placement INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  24. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Pilferage safeguard… • A trade mark of INROADS would be embossed or ingrained in the slab during the compression molding process to confirm & inform ownership • A slab found at a wrong place such as someone’s driveway or garden would surely be identified as a stolen one INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  25. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Pilferage safeguard • The top surface of the slabs will have a gradual slope and light horizontal grooves entrenched during compression molding that will also endorse ownership • The light grooves with a gradual slope will additionally serve the purpose of providing channels for rain-water drainage and creating an anti-skid surface to prevent accidents INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  26. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Pilferage safeguard… • One more option to prevent theft would be to rely on the integrity of the rural folks who upon realization and conviction that INROADS is an activity for their own good will act as their own security system INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  27. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Pilferage safeguard… • Another option would be to train and develop a vigilant community that has a sense of pride and ownership of INROADS • A vigilant community will report any suspicious activity to the police, making it difficult for thieves to operate • This sense of pride and ownership is further fostered if the community is provided with income-generating opportunities to improve their economic well-being INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  28. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Pilferage safeguard • In addition, there will be prompt repair and maintenance service because if INROADS falls into disrepair then thieves move in INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  29. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product… • Easy replacement… • There is a need to provide for easy replacement of defective or worn out slabs • Generally the area around the wheel-path would need repair due to overuse INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  30. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Product • Easy replacement • The idea is to build a modular system that would allow quick rehabilitation without having to close and rebuild the entire road section • Special tools will be provided to enable the unlocking of slabs and facilitating easy removal from their placement INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  31. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS • Figure 3 • The INROADS slab with light grooves, embossed logo and final dimensions of 2 feet x 2 feet x 2 inches (on one side) and 2.05 inches (on the other side) to provide the necessary gradual slope of ⅛° Figure 1 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  32. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Slab by Slab Figure 1 INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  33. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Heavy equipment like drum mixers and high energy for heating raw materials are used • INROADS: Small-scale units with low energy requirements will be utilized INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  34. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Mixing of aggregates (large as well as fine sized) with binders is done using drum mixers • INROADS: Mixing of the fine size particles with the binder along with all the additives will be done in a continuous internal mixer for greater efficiency of dispersion and distribution INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  35. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Mixing is done at high temperature and hence is an energy intensive process • INROADS: Mixing will be done at ambient temperature, thereby making it a highly energy efficient process INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  36. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Uses gas flames to generate the heat for binder liquefaction and mixing • INROADS: Will use solar energy to provide the increase in temperature for the cross-linking reaction to complete INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  37. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Pavements are built using road rollers and depend on in-situ compaction for the final properties • INROADS: Slabs will be prepared as separate entities through compression molding whose final properties can be controlled and tested before lay down INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  38. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Cost of 2 inches thick of asphalt pavement is $ 1.50 - $ 3.00 / square foot. Minimum of 4 inches is conventionally built. Hence, cost is $ 3.00 - $ 6.00 / square foot • INROADS: Estimated cost for the 2 inches thick slabs is $ 2.50 - $ 5.00 / square foot INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  39. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Entire operation of pre-construction preparation and the construction takes a long time • INROADS: Pre-construction preparation will be much less and slab laying operation would take much shorter time INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  40. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Pavements are built with certain level of air-voids (~3 to 7% with 4% being considered as an optimum) • INROADS: Pavements will be built with as minimum air-voids as possible even below 1% so that the surface of the built pavement is impervious to any infiltration of moisture or rainwater INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  41. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Life expectancy is 10-15 years and maintenance cost is high because of shorter life span and higher re-construction costs • INROADS: Life expectancy will be minimal of twice the above and much lower maintenance costs since only defective slabs need to be replaced INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  42. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology… • Differences… • Current: Repair and rehabilitation require entire lanes to be closed for traffic from the beginning to the end of the paving operation • INROADS: Modular system will allow for the repair and rehabilitation to be done by closing only the sections of the road that are defective or damaged INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  43. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS New Technology • Differences… • Current: Life cycle cost about $0.2 - $0.6 / square foot / year • INROADS: Life cycle cost about $0.1 - $0.25 / square foot / year INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  44. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • Initial focus • INROADS for rural areas will be restricted to India so that the feasibility and efficacy of the project can be well demonstrated before full-fledged roads’ revolution is undertaken throughout the entire world INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  45. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • Simplicity • INROADS will focus on keeping the entire production of the road slabs and final lay down of the pavement to be as simple a level as possible • Advantage of simplicity would be that each manufacturing unit could be given the status of a small-scale industry INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  46. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • Private & not Government • INROADS implementation will not be done through PWD or Government departments • INROADS would be amenable for implementation through private companies who could get a franchise INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  47. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • BOT model • INROADS would be built by private companies on a BOT (build operate transfer) model which will provide the necessary incentive for them to build longer-lasting roads that cost less to maintain INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  48. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • MoRD, PMGSY and NRRDA • We are aware that the Ministry of Rural Development (MoRD) is the nodal ministry for rural roads in India • Under the auspices of MoRD, there is the Pradhan Mantri Gram Sadak Yojana (PMGSY) from the National Rural Road Development Agency (NRRDA) INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  49. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • SRRDA • The state governments have State Rural Road Development Agencies (SRRDA) similar to the PMGSY which also operate under the auspices of the MoRD  • We certainly intend to work with all the relevant bodies to make INROADS a successful reality INROADS TO GO FROM ANYWHERE TO EVERYWHERE

  50. ONE GREAT IDEA TO CHANGE THE WORLD IN THE NEXT 50 YEARS Implementation… • Villagers’ inclusion • Villagers will not be just by-standers who are watching the construction done by an outside body and handed over to them • INROADS will utilize local labor • Villagers’ inclusion will bring in a sense of ownership and they would treat INROADS with a receptive attitude INROADS TO GO FROM ANYWHERE TO EVERYWHERE

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