Bitumen Emulsion is a stable dispersion of fine bitumen droplets in water, produced using emulsifying agents and high-shear mechanical mixing. This technology allows normally immiscible bitumen and water to coexist temporarily, reducing viscosity and enabling safe cold application.
After application, the emulsion breaks, water evaporates, and bitumen droplets coalesce into a continuous, durable binding film. Bitumen emulsion is an energy-efficient, environmentally preferable alternative to hot bitumen and cutback bitumen.
Emulsification & Manufacturing Process
Base Bitumen Preparation
Penetration or VG bitumen is heated to 120–140°C.
Emulsifier Solution Preparation
Water, emulsifier, stabilizers, and pH modifiers are prepared separately.
High-Shear Mixing
Bitumen and solution pass through a colloid mill, forming 1–10 micron droplets.
Cooling & Storage
Finished emulsion is cooled and stored at ambient temperature.
Quality Testing
Tested for stability, viscosity, residue, and breaking behavior.
Breaking Mechanism (How It Works)
Application Phase: Emulsion is sprayed or mixed at ambient temperature.
Breaking Phase: Water separates due to evaporation, absorption, or chemical reaction.
Setting Phase: Bitumen droplets merge to form a cohesive waterproof film.
Types of Bitumen Emulsion by Ionic Charge
Cationic Emulsion (Positive Charge)
Excellent adhesion, works with damp and siliceous aggregates.
Anionic Emulsion (Negative Charge)
Used with calcareous aggregates under dry conditions.
Key Technical Characteristics
✔ Cold application and energy savings
✔ Excellent adhesion and bonding
✔ Strong water resistance
✔ Easy workability
✔ Low emissions and eco-friendly
✔ Wide grade availability
Typical Mechanical & Performance Properties
| Property | Typical Value |
|---|---|
| Viscosity (Saybolt Furol) | 20 – 100 sec |
| Residue on Evaporation | 55 – 65% |
| Penetration of Residue | 60 – 200 dmm |
| Softening Point of Residue | 45 – 60°C |
| Breaking / Setting Time | RS / MS / SS |
| Ductility @27°C | ≥ 50 cm |
| Storage Stability | Excellent |
Grades & Engineering Applications
| Grade | Typical Applications |
|---|---|
| RS-1 / RS-2 | Surface dressing, tack coat, chip seals |
| MS-1 / MS-2 | Premix carpets, cold mixes, patch repairs |
| SS-1 / SS-2 | Prime coat, slurry seal, soil stabilization |
Special & Modified Emulsions
Polymer Modified Emulsion (PME) improves elasticity and durability. High-performance cationic emulsions are used for micro-surfacing and heavy traffic roads.
Packaging & Supply Formats
Bulk tankers, HDPE barrels (200 kg), IBC containers, and customized packaging.
Storage & Handling Guidelines
Store between 5°C and 50°C. Avoid freezing and overheating. Typical shelf life is 3–6 months with gentle circulation.
Applications of Bitumen Emulsion
Road construction and maintenance, waterproofing, soil stabilization, anti-corrosion coatings, and industrial protective linings.
Advantages
Cold application, energy savings, safer handling, eco-friendly, cost-effective, and suitable for all climates.
Standards & Compliance
IS 8887 · ASTM D977 / D2397 · EN 13808