The present invention relates to the field of civil engineering and road
construction. Specifically, the invention relates to a bitumen-based binder and
process for preparing the same. It further relates to the production of asphaltic
5 mixes comprising the said binder in combination with aggregates for application
in waterproofing, construction, repairing or maintenance of road surfacings, in
particular, sidewalks, roads, highways, parking lots or airport runways and service
roads, or any other rolling surfaces.
10 BACKGROUND OF THE INVENTION
[002] Road construction using flexible pavements consists of several layers. This
structure includes a sub-base or granular or stabilized material, a base and layers
of hot mixed asphalt. This pavement may have a thin surface on the top to provide
skid resistance, waterproofing and smoothness. These binders and surfacings must
15 have the mechanical properties to withstand traffic loading and maintain this
characteristic for a significant lifetime.
[003] Typically, the chemistry of these binders depends on the source bitumen
material, especially it's chemical composition and processing and conditions in
storage and handling. Under extreme conditions of traffic loading and sensitivity
20 to change in temperature, such conventional chemistry techniques are found to be
inefficient, in this case, modification may be carried out. These days, research into
the improvement of the binder through the addition of material, including a
polymer or compatibilizing agent, is being intensively and extensively conducted.
[004] For instance, WO1997044397A1 discloses an asphalt binder comprising a
25 bitumen component, a thermoplastic rubber in an amount of less than 8 wt.% and
an reactive terpolymer based on ethyl or glycidyl acrylate or combinations of
these monomers in an amount of less than 5 wt.%, both based on total bitumen
composition, wherein the ethylene vinyl acetate copolymer has a vinyl content in
the range of from 20 to 35 wt.%, based on copolymer. This application also
3
describes a process for preparing the binder and the use of the binder in asphalt
mixes for road applications.
[005] But the major problem with such existing processes is compatibility and
the chemistry of the bitumen base for modification must be adjusted to work with
5 a given polymer. To overcome these challenges, a high-performance bitumenbased binder and process of making the same having improved chemical and
physical properties is required which not only extends the durability of road
pavements but also overcomes the existing drawbacks of premature failure of
roads due to materials and design limitations.
10
OBJECT OF THE INVENTION
[006] An aspect of the present invention provides a novel, improved and
efficient process for making high-performance binder based on chemical
compatibility to optimize the range of performance both with respect to traffic
15 loading and overloading.
[007] Another aspect of the present invention provides a bitumen-based binder
as obtained using the said process.
[008] Another aspect of the present invention provides a system comprising the
combination of the said binder with aggregates to obtain asphalt mixes.
20 [009] Another aspect of the present invention provides at least one performancebased asphalt mix comprising the said binder in combination with aggregates.
[0010] Another aspect of the present invention provides a method of repairing the
damaged roads using the said asphaltic mix.
25 SUMMARY OF THE INVENTION
[0011] The present invention is described hereinafter by various embodiments.
This invention may, however, be embodied in many different forms and should
not be construed as limited to the embodiment set forth herein. Rather, the
embodiment is provided so that this disclosure will be thorough and complete and
30 will fully convey the scope of the invention to those skilled in the art.
4
[0012] Embodiments of the present invention relate to a bitumen-based binder
and the process of making thereof which may be further used in making highperformance asphalt mixes for application in pavement construction and
maintenance. The present invention uses components and a process to create a
5 binder that has the chemical and physical properties required for predictable high
performance in all conditions. The said binder in combination with aggregate
extends the durability of road pavements using asphalt. The present invention
overcomes the current drawbacks of premature failure of pavement construction
and maintenance due to materials and design limitations especially bituminous
10 binders and asphaltic mixes. The invention relies on the rheological optimization
of both binder and mix using binder chemistry and also performance-based
mixture design
[0013] Another embodiment of the present invention aims to provide a process of
making a bitumen-based binder, the process comprising
15 i. heating 56 wt % to 98 wt % of at least one bitumen base;
ii. optionally, adding 0.1 wt % to 18 wt % of a compatibilizing agent followed
by stirring for 15-45 minutes to obtain a homogenous mixture; and
iii. optionally, adding 0.1 wt% to 30 wt% of a bitumen modifier and
homogenizing the mixture for 3 to 24 hours to obtain a bitumen-based
20 binder
wherein, the bitumen-based binder is a Performance Grade (PG) binder tested
in accordance with AASHTO M332 standard and/or IS:15462-2019.
[0014] Another embodiment of the present invention relates to an asphaltic mix
which may be a combination of the binder as obtained from the above-mentioned
25 process and aggregate. The mix may help in repairing or resurfacing of the
damaged roads, increasing or extending the service life of the roads and reducing
the expenses spent on maintenance and/or reconstruction of roads thus, the
invention provides a feasible and cost-effective solution to the existing problems.
30 BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
5
So that the manner in which the above-recited features of the present invention
can be understood in detail, a more particular description of the invention, briefly
summarized above, may have been referred by embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however, that the appended
5 drawings illustrate only typical embodiments of this invention and are therefore
not to be considered limiting of its scope, for the invention may admit to other
equally effective embodiments.
These and other features, benefits, and advantages of the present invention will
become apparent by reference to the following text figure, with like reference
10 numbers referring to like structures across the views, wherein:
Fig. 1 illustrates a graph plotting the grading types in accordance with the
embodiments of the present invention
DETAILED DESCRIPTION OF THE INVENTION
15 [0015] Various modifications to these embodiments are apparent to those skilled
in the art from the description and the accompanying drawings, if any. The
principles associated with the various embodiments described herein may be
applied to other embodiments. Therefore, the description is not intended to be
limited to the embodiments shown with the accompanying drawings but is to
20 provide broadest scope consistent with the principles and the novel and inventive
features disclosed or suggested herein. Accordingly, the invention is anticipated to
hold on to all other alternatives, modifications, and variations that fall within the
scope of the present invention.
[0016] Several embodiments of the present invention relate to an efficient,
25 sustainable and economically feasible process for the preparation of a bitumenbased binder. It further relates to the production of asphaltic mixes comprising the
said binder in combination with aggregates for application in waterproofing,
construction, or maintenance of road surfacings that includes, but not limited to,
6
sidewalks, roads, highways, parking lots or airport runways and service roads, or
any other rolling surfaces.
[0017] Generally, most of the existing binders and asphaltic mixes or their
variations used for construction and maintenance of roads are not adequate to
5 support heavy traffic and resist temperature or moisture damage thus, resulting in
deformation, rutting, fatigue or cracking of the pavements. Contrary to the
conventional solutions used to overcome these problems, the present invention
relies on optimization of chemistry by blending of different bitumens, especially
naturally occurring or chemically modified bitumen to form a high-performance
10 bituminous-based binder. This invention produces a predictable binder
composition that may be changed to suit the final use by use of the above process.
It can use existing inadequate bitumen to change its properties in a predictable
manner.
15 BITUMEN-BASED BINDER
[0018] In a preferred embodiment, the invention relates to a bitumen-based binder
and a process of making the same. The modified binders may be observed to see
the effects of a new additive or mix design in providing skid resistance,
waterproofing and smoothness to the pavements during construction. These
20 binders and surfacings must have the mechanical properties to withstand traffic
loading and maintain this characteristic for a significant lifetime. The chemistry of
these binders may depend on various factors such as the source bitumen material,
its chemical composition, processing and conditions in storage and handling.
Those skilled in the art recognize that these factors can be designed to obtain a
25 binder having the desired properties without departing from the concepts of the
invention described herein. For instance, under extreme conditions of traffic and
climate (moisture or temperature) and loading, the conventionally used chemistry
may be insufficient to obtain better results, in this case, modification of the binder
may be carried out. This may include the optimization of chemistry by blending
30 different bitumens, especially naturally occurring or chemically modified
7
bitumen. The addition of polymers, compatibilizing agents or bitumen modifiers
may also achieve it.
[0019] Some of the testing procedures that are common in USA involve
evaluations of the binder performance or evaluation of the actual asphalt mix
5 design. Some of the binder tests may include 1) Performance Grade grading
(AASHTO M 320 or ASTM D6373), 2) the Multiple Stress Creep Recovery
(MSCR) Test (ASTM D7405) and other similar tests may be performed.
Frequently used mix performance assessment laboratory tests may include (1)
Hamburg Wheel Tracking Test (AASHTO M323 and AASHTO M332) and (2)
10 Mixture Fatigue Testing (AASHTO T321 and S-VECD testing), Dynamic
Modulus and Flow Number Testing using the AMPT (AASHTO TP79), Lowtemperature cracking resistance testing for asphalt binders using the Bending
Beam Rheometer (BBR) (AASHTO T313) and the Direct Tension Test
(AASHTO T316). In India, four types of modified bitumen are classified into the
15 below categories
(a) Type A – PMB (P): Plastomeric Thermoplastics based.
(b) Type B – PMB (E): Elastomeric Thermoplastics based.
(c) Type C – NRMB: Natural Rubber and SBR latex-based
(d) Type D – CRMB: Crumb Rubber / Treated Crumb Rubber based.
20 It is pertinent to note that the bitumen-based binder of the present invention is a
Performance Grade (PG) binder tested in accordance with AASHTO M332
standard and/or IS:15462-2019.
[0020] In one embodiment of the present invention, a process of making a
bitumen-based binder, wherein the process comprising
25 i. heating 56 wt % to 98 wt % of at least one bitumen base;
ii. optionally, adding 0.1 wt % to 18 wt % of a compatibilizing agent
followed by stirring for 15-45 minutes to obtain a homogenous mixture;
and
iii. optionally, adding 0.1 wt% to 30 wt% of a bitumen modifier and
30 homogenizing the mixture for 3 to 24 hours to obtain a bitumen-based
binder
8
wherein, the bitumen-based binder is a Performance Grade (PG) binder tested
in accordance with AASHTO M332 standard and/or IS:15462-2019.
[0021] In an embodiment, the process may include the selection of at least one
bitumen base. Among the bitumen base that may be used according to the
5 invention, bitumen base may comprise petroleum refined bitumen, naturally
occurring bitumen or chemically modified bitumen. One skilled in the relevant art
will advantageously choose from bitumen bases or bitumen base mixtures derived
from the refining of petroleum. Preferably, 56 wt % to 98 wt % of the bitumen
base may be used. According to the invention, the bitumen base may be heated to
10 a temperature in the range between 150°C to 230°C. A different or similar type of
bitumen base can be combined to obtain the best technical results. The
compatibility of the bitumen base is determined using the steps of the present
invention that either makes the bitumen compositionally controlled to optimize
performance or to create a base compatible bitumen that may be modified with
15 bitumen modifiers or compatibilizing agents or other additives to achieve the
required rheology and thus performance.
[0022] In another embodiment, the present invention may include 0.1 wt % to 18
wt % of a compatibilizing agent. The compatibilizing agent is preferably chosen
from the group comprising bio-oil, aromatic oil, naphthenic oil, bio maltenes,
20 deasphalted oil, bitumen maltenes fractions, or mixture thereof. The
compatibilizing agents may be mixed with the bitumen base followed by stirring
for 15-45 minutes at a temperature in the range of 150°C to 230°C to obtain a
homogenous mixture. The compatibilizing technology involves the use of
bituminous hydrocarbons combined and tested to ensure that the base material
25 may be modified to meet the binder performance requirements.
[0023] Some embodiments of the present invention may relate to the addition of
bitumen modifiers. Non-limiting examples of bitumen modifiers may include at
least one polymer, cross-linking agent, polyphosphoric acid and/or its derivatives,
rubber, waste plastic, stabilizer, or mixture thereof. More specifically, the polymer
30 may be selected from a group comprising styrene-butadiene-styrene,
polybutadiene, reactive terpolymer, styrene-butadiene rubber, waste polyolefins,
9
polyolefins or mixture thereof. Preferably, a bitumen modifier is present in the
range of 0.1 wt% to 30 wt% and the mixture is subsequently homogenized for 3 to
24 hours at a temperature in the range of 150°C to 230°C to obtain a bitumenbased binder.
5 [0024] Adding modifiers, preferably one or more polymer has often been used as
a way to improve the application performance of binders. However, compatibility
with the bitumen base variable depends on chemistry. In the past, certain bitumens
were used as compatible bitumens and accordingly polymer manufacturers based
their determinations of both polymer percentage and its type. This rendered the
10 use of certain polymers for ensuring or improving the properties and performance
of bitumen, e.g. reactive terpolymers were not used in Qatar due to their
incompatibility with the local bitumen whereas in some areas of USA, crumb
rubber did not operate well due to the same reason. Styrene-butadiene-styrene
(SBS) modification is also based on its compatibility with the bitumen base.
15 Compatibility depends upon the chemistry of the bitumen base for modification
and it must be adjusted to work with a given polymer. The process of the present
invention and technology may produce a consistent base composition for
modification or optimization of a bitumen binder for optimum performance and
predictable properties of binder and asphaltic mix.
20 [0025] Another preferred embodiment provides an asphaltic mix comprising a
combination of the bitumen-based binder and aggregates. The amount of binder in
the asphaltic mix of the present invention will vary depending on the application
for which the asphalt is to be used. However, the asphaltic mix used in the present
invention preferably comprises 3 wt% to 12 wt% of the binder and 88 wt% to 97
25 wt% of the aggregate.
[0026] The asphaltic mixes may be heated at a temperature in the range of 25°C60°C, 125°C-180°C, and 90°C-125°C. A person skilled in the art can arrive at the
fact that the design of asphalts for paving application is largely a matter of
selecting and proportioning ingredients to obtain the desired properties in the
30 finished construction. The design of the asphaltic mixes typically based on the
grading of aggregates and these asphalt mixtures are usually classified into dense
10
graded, gap graded and open graded. The asphaltic mix of the present invention
may provide dense graded asphalt mix, gap graded asphalt mixes, porous mixes,
open graded mix, or stone matrix asphalt mix having nominal maximum
aggregate sizes (NMAS) in the range of 10 mm, 14 mm, 20 mm, 28 mm, or
5 37.5mm having nominal maximum aggregate sizes (NMAS) in the range of 10
mm, 14 mm, 20 mm, 28 mm, or 37.5mm.
[0027] It is pertinent to note that the binder and mix that is achieved in the present
invention is a function of the correct mix design regarding the required
performance and it is not obvious to a person skilled in the art. The invention
10 combines mixture design and development with the optimum binder. The binder
alone will not deliver the required performance and hence balanced mixture
design using fundamental engineering properties such as deformation resistance,
crack resistance, dynamic modulus master curves and simulative field compaction
is needed. This is a part of the invention use these methods are indicated with the
15 help of suitable examples.
[0028] In an embodiment, benefits of the present invention also include repairing
or resurfacing of roads having cracks or holes or any other failures particularly, in
concrete or bituminous roads. The repairing or resurfacing of the roads involves
filling the hole and overlaying the surrounding area of the road surface with
20 layer(s) or patches of one or more asphaltic mixes. Thus, the invention provides
an improved method of repairing holes or cracks roads that is durable,
inexpensive and lasts for an extended period of time.
[0029] The features, structures, or characteristics of the invention described
throughout this specification may be combined in any suitable manner in one or
25 more embodiments. For example, reference throughout this specification to
“certain embodiments,” “some embodiments,” or similar language means that a
particular feature, structure, or characteristic described in connection with the
embodiment is included in at least one embodiment of the present invention.
Thus, appearances of the phrases “in certain embodiments,” “in some
30 embodiment,” “in other embodiments,” or similar language throughout this
specification do not necessarily all refer to the same group of embodiments and
11
the described features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments.
[0030] It should be noted that reference throughout this specification to features,
advantages, or similar language does not imply that all of the features and
5 advantages that may be realized with the present invention should be or are in any
single embodiment of the invention. Rather, language referring to the features
and advantages is understood to mean that a specific feature, advantage, or
characteristic described in connection with an embodiment is included in at least
one embodiment of the present invention. Thus, discussion of the features and
10 advantages, and similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0031] Furthermore, the described features, advantages, and characteristics of the
invention may be combined in any suitable manner in one or more embodiments.
One skilled in the relevant art will recognize that the invention can be practiced
15 without one or more of the specific features or advantages of a particular
embodiment. In other instances, additional features and advantages may be
recognized in certain embodiments that may not be present in all embodiments of
the invention.
[0032] One having ordinary skill in the art will readily understand that the
20 invention as discussed above may be practiced with steps in a different order,
and/or with hardware elements in configurations which are different than those
which are disclosed. Therefore, although the invention has been described based
upon these preferred embodiments, it would be apparent to those of skill in the art
that certain modifications, variations, and alternative constructions would be
25 apparent, while remaining within the spirit and scope of the invention. In order to
determine the metes and bounds of the invention, therefore, reference should be
made to the appended claims.
ADVANTAGES OF THE PRESENT INVENTION
12
 The invention provides a binder and a process of making the same which
when used with aggregates minimizes the requirement of frequent maintenance
of the surface after being applied as it effectively protects and restores the
conditions of the pavements thus cost-effective in nature.
5  The process of the invention can change the properties of inadequate
binders in a predictable and useful manner.
 The binder of the invention allows traffic and climate and overloading to
be accommodated to extend the life by up to double for surfaces and allow
pavement design for perpetual pavements.
10  The binder, when combined with aggregates, provides a resultant asphalt
mix having improved properties such as deformation resistance, crack
resistance, dynamic modulus master curves and simulative field compaction.
EXAMPLES
15 Compatibilization method
 The base bitumen is analyzed based on crude source, refinery and fractionated
by thin-layer chromatography-flame ionization detection (TLC-FID) and
categorized for chemistry balance. If possible Heithaus parameters are
mentioned to determine internal compatibility. (numbers).
20  The composition may be adjusted with other bitumen.
 Compatibilising oils of the aromatic, naphthenic, bio maltenes or deasphalted
oil are added to adjust composition is required.
 If needed, the polymer type to be used is referenced to the chemical
composition requirements for compatibility.
25  Reactive terpolymers (RET) require a high level of asphaltenes, anhydrides or
phenols.
 Styrene-Butadiene-Styrene (SBS) or Styrene-Butadiene Rubber (SBR) requires
an excess of aromatic or naphthenic oils.
13
 Waste plastics require a steric stabilizer such as reactive terpolymer, gilsonite
or crosslinking agent for bitumen.
Making binder
 The bitumen is heated to 180°C and blended with oils or other bitumen as
5 needed.
 Blending is on high shear for 15 minutes.
 If a polymer is to be used the polymer is added slowly and mixed on high shear
for 45 minutes.
 Ultraviolet (UV) fluorescence microscope is used to monitor reaction or
10 dispersion.
 If Reactive terpolymers (RET) is used 0.2% Polyphosphoric Acid (PPA) is
added and mixed further for 10 minutes, Reactive terpolymers (RET) % is 1.5-
1.9%.
 If Styrene-Butadiene-Styrene (SBS) is used the polymer is Kraton 4203 at 5-
15 9%.
 If gilsonite is used, it is added at 10-15%.
 If waste plastics are used, they are added at 5-15%.
 Ultraviolet (UV) Fluorescence microscopy with a magnification of >100.
Characterizing
20  The binder produced is characterized by AASHTO M332 and/or IS:15462-
2019.
 Its Performance Grade grading is determined and referenced to the required
condition.
 Steps 1 and 2 are repeated, if improvements are needed.
25  The Performance Grade span can be up to 88°C –34°C and any requirement in
between.
Mixes made examples
14
 A dense-graded asphaltic Mix formulation that has using wheel tracking
Austroads T231, a deformation of less than 4mm at 60C at 20,000 Cycles and
Tex 242F cycles of 10,000 at 12mm rut depth at 64C. This mix may have a
Nominal Maximum Aggregate Size (NMAS) of 10, 14 20 or 28mmm. It has a
5 fatigue resistance of 200 million cycles of a standard load and minimum
fracture energy by SCB of 750J/m2 at -24C test: A dense-graded asphaltic Mix
formulation that has fatigue, SCB and DCT crack resistance 20% higher than
specification requirements. This mix may have a Nominal Maximum
Aggregate Size (NMAS) of 10, 14 20 or 28mmm. This will have a binder in
10 the range of 4-7%, and air voids level of 4-6% and a Voids in Mineral
Aggregate (VMA) that complies with standard requirements for dense-graded
mixes, e.g. NZTA M10.
 A gap graded (SMA) asphaltic Mix formulation that has using wheel tracking
T231, a deformation of less than 2mm at 60C at 40,000 Cycles and Tex 242F
15 cycles of 15,000 at 12mm rut depth at 64C. This mix may have a Nominal
Maximum Aggregate Size (NMAS) of, 6,8 10, or 14 mm. It has a fatigue
resistance of 200 million cycles of a standard load and minimum fracture
energy by SCB of 750J/m2 at -34C test. This will have a binder % of 4-7%,
and air voids level of 4-7% and a Voids in Mineral Aggregate (VMA) that
20 complies with standard requirements for SMA mix, e.g. NZTA M10.
 An open-graded (PA) asphaltic Mix formulation that has using wheel tracking
Austroads T231, a deformation of less than 10mm at 60°C at 1000. This mix
may have a Nominal Maximum Aggregate Size (NMAS) of, 6,8 10, or 14 mm.
This will have a binder % of 5-8%, and air voids level of 12-28 % and voids in
25 Mineral Aggregate (VMA) that is in compliance with standard requirements
for Open-graded mixes, e.g. NZTA M10.
 The compatibilising technology involves the use of bituminous hydrocarbons
combined and tested to ensure that the base material may be modified to meet
the binder performance requirements. The compatibilizing agents are but not
30 limited to naphthenic oils, aromatic oils, bio-oils, bitumen maltenes fractions,
deasphalted oils, penetration, viscosity or PG graded bitumen. Levels would be
15
0-30% based on compositional control and testing. This may include SARA
analysis, Automated Flocculation Titrimetry, Rheology, Atomic Force
Microscopy and nanoindentation.
 The binder is optimized by the use of Ultraviolet Violet Fluorescence to a
5 stable structure and is stable to less than 2% separation in Austroads test T254-
13 or equivalent test.
 SCB ASTM D 8044, DCT ASTMD 7313
Formulations
a) 7.5% Kraton D0243
10 5% aromatic oil
VG30 base binder that has at least 20% asphaltenes and 50% aromatics
and 28% Resins to 100%
Ration of (resins + asphaltenes)/ oils + aromatics <0.6
Heithaus fractions (Automated Flocculation Titrimeter (AFT):VG30.
15 Peptising power of maltenes P o> 0.87, Peptiseability of asphaltenes Pa
>0.8. State of Peptisation P > 3.0.
Alternatively, a base bitumen can be blended to produce this. After
blending UV fluorescence testing is performed before crosslinking with
2% Sulphur.
20
b) Reactive Terpolymer Elvaloy 5610 1.7%
Bitumen with at least 22% asphaltenes
0.2% PPA
After reaction in method UV Fluorescence, if testing shows no features
25 then it is complete. If not mix for another 60 minutes and rest. If still spots
measure if rheological properties required are met.
c) Crumb Rubber 12%
Compatibilising oil 8%
16
VG30 base binder that has at least 20% asphaltenes and 50% aromatics
and 28% Resins. To 100%
Ration of (resins + asphaltenes)/ oils + aromatics <0.6
Heithaus fractions (Automated Flocculation Titrimeter (AFT): V30.
5 Peptising power of maltenes P o> 0.87, Peptiseability of asphaltenes Pa
>0.8. State of Peptisation P > 3.0.
Alternatively, a base bitumen can be blended to produce this.
After blending Ultraviolet (UV) fluorescence testing is performed.
d) Gilsonite is used to modify the base bitumen binder to a known balanced
10 structure using Saturate, Aromatic, Resin and Asphaltene (SARA) thinlayer chromatography-flame ionization detection (TLC-FID) and
Automated Flocculation Titrimeter (AFT).
15% Gilsonite plus VG30 bitumen is taken.

We Claim:
1. A process of making a bitumen-based binder comprising
i heating 56 wt % to 98 wt % of at least one bitumen base;
ii optionally, adding 0.1 wt % to 18 wt % of a compatibilizing agent followed
5 by stirring for 15-45 minutes to obtain a homogenous mixture; and
iii optionally, adding 0.1 wt% to 30 wt% of a bitumen modifier and
homogenizing the mixture for 3 to 24 hours to obtain a bitumen-based binder
wherein, the bitumen-based binder is a Performance Grade (PG)
binder tested in accordance with AASHTO M332 standard and/or
10 IS:15462-2019.
2. The process claimed in claim 1, wherein the bitumen base is a petroleum
refined bitumen, naturally occurring bitumen or chemically modified bitumen.
15 3. The process claimed in claim 1, wherein the bitumen modifier is selected
from a group comprising one or more polymer, cross-linking agent,
polyphosphoric acid and/or its derivatives, rubber, waste plastic, stabilizer or
mixture thereof.
20 4. The process claimed in claim 3, wherein the polymer is selected from a
group comprising styrene-butadiene-styrene, polybutadiene, reactive terpolymer,
styrene-butadiene rubber, waste polyolefins, polyolefins or mixture thereof.
5. The process claimed in claim 1, wherein the compatibilizing agent is
25 selected from a group comprising bio-oil, aromatic oil, naphthenic oil, bio
maltenes, deasphalted oil, bitumen maltenes fractions, or mixture thereof.
6. The process claimed in claim 1, wherein the temperature in step (i), step
(ii) and step (iii) is maintained in the range between 150°C to 230°C.
18
7. A bitumen-based binder as obtained from the process as claimed in claim
1.
5 8. An asphalt mix comprising a combination of the bitumen-based binder as
claimed in claim 1 and aggregate mixed at a temperature in the range of 25°C60°C, 125°C-180°C, and 90°C-125°C.
9. The mix as claimed in claim 8 wherein, the binder is present in the range
10 of 3 wt% to 12 wt% and the aggregate is present in the range of 88 wt% to 97
wt%.
10. The mix as claimed in claim 8 wherein, the mix is dense graded asphalt
mix, gap graded asphalt mixes, porous mixes, open-graded mix, or stone matrix
15 asphalt mix having nominal maximum aggregate sizes (NMAS) in the range of 10
mm, 14 mm, 20 mm, 28 mm, or 37.5mm.
11. The mix as claimed in claim 8 wherein, the use of aforesaid binder is for
extending the shelf life of the surface or pavement layers by at least 25% and
20 improving the resistance to deformation, crack or fatigue.
12. The mix as claimed in claim 8 wherein, dense-graded asphalt mix with
wheel tracking Austroads T231, a deformation of less than 4mm at 60°C at 20,000
25 Cycles, and Tex 242F cycles of 10,000 at 12mm rut depth at 64°C, Nominal
Maximum Aggregate Sizes (NMAS) of 10, 14, 20, or 28 mm, fatigue resistance of
200 million cycles of a standard load and minimum fracture energy by SCB of
750J/m2 at -24°C test.
30
19
13. The mix as claimed in claim 8 wherein, gap-graded asphalt mix with
wheel tracking T231, a deformation of less than 2mm at 60°C at 40,000 Cycles,
and Tex 242F cycles of 15,000 at 12mm rut depth at 64°C, Nominal Maximum
Aggregate Sizes (NMAS) of 6,8 10, or 14 mm, fatigue resistance of 200 million
5 cycles of a standard load and minimum fracture energy by SCB of 750J/m2 at -
24°C test.
14. The mix as claimed in claim 8 wherein, open-graded asphalt mix with
10 wheel tracking Austroads T231, a deformation of less than 10mm at 60°C at 1000
and Nominal Maximum Aggregate Sizes (NMAS) of 6, 8 10, or 14 mm.