Stabilising Aid

PolyCom Stabilising Aid

 

POLYCOM A PURPOSE MADE PRODUCT

The product is significantly more efficient than traditional emulsion polymers as it incorporates technologies that far surpass the limitations of these second tier ‘liquid emulsion products.’

A bottle of PolyCom, weight 2kg.

PolyCom Stabilising Aid is an economical solution to improve the engineering properties of gravels and soils for construction purposes. PolyCom reduces maintenance requirements on unsealed roads and delivers quality and economic results consistently in most soil and gravel types and building the reputation as the premier widely used ‘polymer’ stabiliser internationally.

When applied in the correct concentration and mixed appropriately using standard equipment, the PolyCom treated material acts to give higher quality, longer lasting results. The poorest quality materials have been successfully treated in order to produce good quality long lasting all weather pavements, at a fraction of the cost of either re-sheeting or traditional stabilisation products such as cement or lime. It provides a more environmentally acceptable approach, promoting the option of sustainability through recycling In-situ materials, reducing carbon footprint and consumption of finite resources in the form of quarried stone.

 

PRODUCT DESCRIPTION

PolyCom Stabilising Aid is a polymer which comes in manageable highly concentrated 2kg granular form making it easy and economical to handle and apply. It is environmentally friendly, odourless, non-toxic, non-allergic, non-flammable, non-corrosive, and is made from virgin materials and is not a by-product of petroleum, blast furnace slag or other manufacturing processes.

HOW DOES IT WORK?

PolyCom Stabilising Aid interacts with every soil particle creating a more workable, “kneadable” material matrix, promoting increased interlocking than usually achievable. This effect increases compaction density by eliminating voids and access for water travel via usual capillary creating the “hydrophobic effect” and improved engineering properties.

APPLICATION

PolyCom is supplied in 2kg bottles and is applied at 0.002% by the mass ratio which treats 50m3 of material.  In this concentrated form, PolyCom Stabilisation Aid eliminates expensive intermediate bulk container transportation, handling and application costs associated with diluted or other forms.

EQUIPMENT

PolyCom is easily planned, applied and requires no large specialised equipment. PolyCom can either be spread dry with purpose-built spreading units or wet with an eductor and will not disrupt normal construction practices. Once spread, the standard road construction equipment is required, grader, rollers and a water truck.

 

KEY BENEFITS

Stabilisation with PolyCom can be completed with In-situ materials (which can include waste rock, coal spoils, and other excess material) and reduces the requirement to import specific quarried materials leading to savings in cost and time. Stabilisation will also:

  •  Reduce maintenance frequency on haul roads (Watering, Grading, Rutting, Potholes)
  •  Reduce water requirements during construction/maintenance and for dust control
  •  Reduce tyre wear by a decrease in rolling resistance
  •  Reduce diesel consumption by a decrease in rolling resistance, and less watering
  •  Reduce carbon emissions through diesel and water savings
  •  Reduce dust and associated environmental concerns
  •  Increase site safety and production

 

 

ADDITIONAL BENEFITS

  •  Environmentally friendly & non-toxic.
  •  Negligible carbon footprint application as opposed to all other recognised stabilisation products and techniques.
  •  Economic benefits immediate up front (application cost savings) and long term (maintenance cost savings).
  •  Promotes sustainability, In-situ stabilising or improve available material consumes 90% less carbon and 80% less water as opposed to re-sheeting and associated damage to the existing road network.
  •  Achieves greater consistent rates of compaction with less water and effort.
  •  Operationally superior and safer road as it is hard and free of usual degradation effects and dust.
  •  Water Resistant Properties – provides safe all-weather accessible erosion control benefits.
  •  Application Ease – Safe to handle and apply, has no application time constraints limitations, no need for large specialist haulage and application equipment.
  •  Reactivatable and re-usable with no application timeframe restrictions.
  •  Flexible non-rigid, compliments other stabilisers and not affected with

 

UNSEALED PAVEMENT STABILISATION

Applying PolyCom Stabilisation Aid to your unsealed road network will free up plant, resources and funds to better manage your asset. PolyCom will create a more efficient asset management practice by eliminating reactive work practices.

Stabilising with PolyCom will extend the maintenance period 4 to 6 times longer.

 

 SUB-GRADE STABILISATION

PolyCom Stabilisation Aid promotes increasing subgrade level or enhances existing subgrades for a fraction of the cost of traditional boxout and reinstatement or alternative stabilisers. Pavement performance is further enhanced as it prevents water ingress from ground significantly reducing future maintenance costs associated with surface cracking (if sealed/asphalted), Conventional excavation and removal of inadequate subgrades can be avoided by incorporating PolyCom Stabilisation Aid process which prevents water ingress, the usual cause of subgrade insufficiency. This in essence, saves time and money.

 

 

PERTANYAAN YANG SERING DITANYAKAN

Apakah PolyCom Stabilizing Aid?
PolyCom Stabilizing Aid merupakan produk berbasis polimer granular yaitu konsentrat polyacrylamide (PAM) dan digunakan untuk menstabilkan dan meningkatkan sifat rekayasa (engineering properties) seperti kekuatan (CBR) dan ketahanan air material tanah dan kerikil yang digunakan dalam konstruksi jalan dan pekerjaan tanah pada umumnya.

Di mana PolyCom dapat digunakan?
PolyCom dapat digunakan untuk menstabilkan dan memperkuat semua jenis jalan (sealed maupun unsealed), bahu jalan, sub-grade, tanggul, jalan angkut pertambangan, jalan perkebunan, sub-grade rel kereta api, tanggul, dan pekerjaan tanah lainnya.

Jenis material apa yang dapat digunakan dengan PolyCom?
Keuntungan PolyCom adalah bahwa itu dapat diaplikasikan untuk berbagai jenis material, termasuk lanau, tanah liat, kerikil dan batu hancur dengan dosis campuran yang sama sehingga tidak memerlukan desain campuran yang rumit.

Apakah Pavement yang dibuat dengan PolyCom tetap fleksibel?
Ya. Pavement yang distabilkan dengan PolyCom memberikan hasil yang tetap fleksibel sehingga lebih tahan terhadap penyusutan dan tidak mudah retak / pecah.

Akankah PolyCom membantu tercapainya pemadatan dalam pembangunan jalan dan pekerjaan tanah?
Ya. PolyCom akan memungkinkan kepadatan yang lebih tinggi dan lebih seragam dengan kompaksi yang lebih ringan, selain itu juga mengurangi kadar air optimum (OMC) dari material yang distabilisasi.

Bagaimana PolyCom diaplikasikan?
PolyCom diaplikasikan dengan alat penyebar sederhana dengan dosis 2kg Polycom per 50m3 (100 ton) material yang akan distabilisasi. Satu kemasan PolyCom 2kg akan menstabilkan 500m2 dengan ketebalan 100mm. Aplikasi PolyCom bisa dengan cara tebar kering (menggunakan PolyCom Dry Spreader) atau tebar basah (dicampur air menggunakan venturi eductor di truk tangki)

Bagaimana cara kerja PolyCom?
Setelah disebarkan dan penambahan air sesuai kebutuhan, PolyCom bekerja dengan mengikat partikel saat dipadatkan, sehingga meningkatkan ketahanan air dan meningkatkan serta menjaga kekuatan kering material.

Bagaimana dosis yang begitu kecil dapat memberikan hasil sangat efektif?

PolyCom telah dirancang sedemikian rupa sehingga dapat terdistribusikan secara merata menggunakan air ke seluruh material yang distabilisasi. Pencampuran silang atau pencampuran material yang distabilsasi dengan PolyCom melengkapi proses distribusi. PolyCom juga bertindak sebagai pelumas di dalam material, mempermudah pengerjaan sehingga menghasilkan pavement yang lebih padat dan kuat.

Apakah PolyCom aman dari perspektif OHS?
Iya. Tidak ada tindakan pencegahan khusus atau PPE yang diperlukan dan tidak ada pengangkatan berat.

Akankah PolyCom bekerja dengan jalan yang tidak diaspal dan akan mengurangi pemeliharaan?
PolyCom sangat cocok untuk jalan yang tidak diaspal dan pada kenyataannya akan mengurangi pemeliharaan. PolyCom menciptakan permukaan yang terikat rapat, mengurangi penetrasi air dan karenanya mengurangi terjadinya abrasi/erosi dan kegagalan struktur. Ini berarti akan menghemat biaya perawatan secara signifikan.

Apakah diperlukan peralatan khusus untuk mengaplikasikan PolyCom?
Tidak. Setelah menyebar dengan penyebar PolyCom atau truk tangki, PolyCom dirancang agar mudah menyatu dengan material yang akan distabilisasi sehingga yang dibutuhkan adalah peralatan yang umum digunakan pada konstruksi jalan, yaitu tangki air, roller (termasuk fully – ballasted pneumatic multi-tire roller) dan grader. Keuntungan lain untuk kawasan terpencil adalah bahwa material yang distabilisasi dengan PolyCom dapat dicampur hanya menggunakan blade dari grader setelah
penambahan air.

Akankah PolyCom merusak peralatan atau cat pada peralatan?
Tidak. PolyCom tidak akan bereaksi dengan logam atau cat dan karenanya tidak akan menyebabkan kerusakan.

Saya ingin membeli PolyCom tetapi bagaimana saya tahu apa yang harus dilakukan dengan itu dan bagaimana menggunakannya?
Distributor PolyCom Anda akan meminjamkan kepada Anda penyebar PolyCom (juga tersedia untuk dijual) atau membantu menyebarkan PolyCom untuk pelanggan baru. Staf PolyCom akan memberikan pelatihan dan panduan di lapangan untuk semua pelanggan selama diperlukan sehingga pelanggan akan mendapatkan hasil terbaik. Menggunakan PolyCom tidak membutuhkan personil tambahan, keterampilan khusus atau peralatan berteknologi tinggi yang mahal.

Apakah menambahkan PolyCom menunda proyek saya?
Tidak. Penambahan PolyCom bukan merupakan faktor yang mempengaruhi durasi proyek, hanya dibutuhkan beberapa menit saja untuk penebaran PolyCom. Setelah penebaran, konstruksi jalan dapat dilanjutkan seperti biasa.

Dapatkah saya menggunakan mesin stabilisasi untuk melaksanakan stabilisasi dengan PolyCom?
Iya. Mesin stabilisasi dapat meningkatkan efisiensi dan biaya apabila jalan yang akan distabilisasi cukup panjang dan ketebalan stabilisasi cukup dalam (lebih dari 200mm).

Apakah PolyCom memiliki waktu curing terbatas dan apakah dapat dikerjakan ulang?
PolyCom tidak memerlukan waktu curing. Penguatan pavement dimulai pada saat pemadatan dan saat mengering setelah pencampuran dengan PolyCom. Dengan demikian pavement dapat dikerjakan ulang setiap saat apabila cuaca atau faktor lain mengharuskan terhentinya pekerjaan. Anda tidak akan kehilangan pavement atau PolyCom.

Pada jalan yang menggunakan PolyCom, pemeliharaan biasanya dilakukan setelah 12- 18 bulan. Perawatan biasanya dilakukan dengan menambahkan sekitar 10% dari jumlah PolyCom awal.

Jalan atau struktur yang menggunakan campuran PolyCom dan material, dapat setiap saat di daur ulang dan dikerjakan ulang dengan mudah apabila diperlukan, misalnya apabila terjadi kerusakan.
Kelebihan ini membedakan dengan konstruksi menggunakan semen/beton yang tidak dapat di daur ulang atau dikerjakan ulang.

Bisakah saya mencampur PolyCom di luar lokasi dan memindahkannya ke tempat kerja?
Iya. Bahan dapat dipre-mix dengan PolyCom di luar lokasi dan ditimbun sampai siap untuk diangkut dan diaplikasikan. Karena PolyCom tidak memiliki curing time tertentu, maka sifat PolyCom tidak akan berubah sehingga pre-mix PolyCom dapat ditimbun tanpa batas waktu dan diaduk ulang sesuai kebutuhan. PolyCom tidak akan terlepas (leach) dari material yang dicampur dengan PolyCom.

Dapatkah 1 botol @ 2kg PolyCom menggantikan 2 – 4 ton semen atau batu kapur (lime) sebagai binding agent?
2kg PolyCom setara dengan 5 ton semen (dengan rasio pencampuran 5%).
Karena kuantitas yang diperlukan relatif kecil, keunggulan dari PolyCom adalah biaya logistik nya yang jauh lebih murah dibandingkan dengan semen maupun lime.
PolyCom menahan terjadinya retak dan lebih aman digunakan karena tidak menimbulkan bahaya bagi kesehatan pekerja.
Berdasarkan hasil riset ARRB (Australian Road Research Board), yang membandingkan performa semen, lime dan PolyCom, menunjukkan bahwa performa PolyCom melampaui performa lime dan minimal sama dengan performa semen.
Namun dalam hal mencegah retak, performa PolyCom jauh melampaui performa lime maupun semen.

Siapa saja yang memerlukan PolyCom?
Pemerintah propinsi maupun daerah, perusahaan2 tambang, perusahaan pengeboran
minyak di darat, kawasan industri, developer perumahan, perkebunan dan lain2 yang semuanya dengan tujuan untuk menghemat biaya konstruksi, menghemat biaya perawatan serta mengurangi debu.

 

POLYCOM – FAQ’S

  1. What type of materials does PolyCom work with? The PolyCom advantage is that it can be applied to wide variety of material types, including silt, clay, gravel and crushed rock at the one simple application rate so no complicated mix design is required.
  2. Will pavements treated with PolyCom remain flexible?
    Yes. PolyCom-stabilised pavements deliver comparable results to traditional stabilising methods with regard to strength but also remain flexible and resist shrinkage cracking and becoming brittle.
  3. Will PolyCom help to achieve compaction in road construction and earthworks?
    Yes. PolyCom will enable higher more uniform densities with less compactive efort, whilst reducing the optimum moisture content (OMC) of the material.
  4. How does PolyCom work?  After spreading and the addition of water as required PolyCom works by binding the particles when compacted, thereby increasing water resistance and improving and preserving the dry strength of the construction material. PolyCom has been designed so that it is transported and distributed uniformly throughout the material by water. Cross-blending or mixing the PolyCom treated material completes the distribution process. PolyCom also acts as a lubricant within the material aiding workability resulting in a denser, stronger pavement.
  5. Can PolyCom be used for subgrade improvement and capping?
    Yes. PolyCom introduces water resistance and increased strength to subgrades, delivering a more resilient and sustainable platform for your project. This produces costs savings through more economic pavement designs and drainage options. Sub-grade capping with PolyCom can substantially reduce rework from weather or traffic damage in cut to fill operations, again reducing project costs.
  6. Is PolyCom safe from an OHS perspective? Yes. No special precautions or PPE are usually required (refer to MSDS) and no heavy lifting is required.
  7. Will PolyCom harm my machinery or paintwork?
    No. PolyCom will not react with metal or paintwork and therefore will not harm construction machinery.
  8. Will adding PolyCom delay my project?
    No. The addition of PolyCom is not a factor in project duration, requiring only a few minutes to spread. After spreading, the road can be constructed as normal.
  9. Can I use a stabilising machine to blend the PolyCom-treated material?
    Yes. A stabilising machine can increase efficiencies and be cost-effective where long lengths and deep stabilising (in excess of 200mm) is required.
  10. Does PolyCom have a finite curing time and can it be re-worked?
    PolyCom does not have a set curing time. Strengthening of the pavement begins with compaction and as it dries following the addition of PolyCom. As such the pavement can be re-worked at any time should weather or other factors intervene. You will not “lose” the pavement nor the PolyCom. With PolyCom treated roads, a maintenance grade is usually required after 12-18 months. This is effectively carried out by adding around 10% of the original PolyCom amount.
  11. Can I mix PolyCom of-site and transport to the job?
    Yes. Materials can be pre-mixed with PolyCom of-site and stockpiled until ready for transportation to site. Applications for this treatment include quarry materials (ie similar concept to cement-treated crushed rock), subdivision construction where material from elsewhere is required for level adjustment or additional strength, etc. Because PolyCom does not have any set curing time, it will not “go of” and materials can be stockpiled indefinitely and re-mixed as required. Leaching of PolyCom from the stockpile material will not occur.
  12. Who is using PolyCom Stabilising Aid?
    Rural local government to create a more sustainable method of unsealed road maintenance, particularly through reduced gravel imports and reduced grading interventions. Rural and urban local government for patch stabilisation of failed pavement areas on environmental grounds in lieu of other materials. Land developers for subgrade improvement and all-weather access roads to save excavation and crushed rock costs.
    Mining and energy companies to upgrade long-haul roads and reduce feet running costs and road maintenance costs. Transport operators and industrial operations requiring a low-maintenance, all-weather access road and yard with the added benefit of reducing dust.
  13. Can a 2kg bottle of PolyCom replace 2-4 tons of cement or lime as a binding agent?
    2kg of PolyCom is equivalent to 2 tones of lime or cement at 2% ratio. Benefits of PolyCom are the low cost of transport to site and weighs approximately 1000 times less. PolyCom resists cracking and is much more pleasant to use with none of the associated risks to worker’s health.
  14. Can we apply this process to finished roads for improvement of life, if so how does this work? Demonstrable?
    Yes. The process is to incorporate PolyCom stabilisation with the next planned intervention. It is then applied as part of the standard pavement conditioning and compaction process. It can be included in Full Depth Pavement Reclamation – Stabilisation of existing asphalt pavement with sub-base and PolyCom for creating a stabilized base for the new asphalt surface. PolyCom is used Australia wide for rejuvenating tired worn out asphalt pavements as well as adding longer life to new constructed unsealed roads.
    16. Can we use this process for embankment of rural water tanks (ponds) and irrigation canals for bank stability and robustness? Erosion in embankments.
    Yes. Some testing to determine the material treatment thickness needed along with the development of appropriate construction methodology. But in short, dams can be easily constructed for a fraction of the cost of importing specials clays and or specifying liners. The Adelaide University summary Investigation identified permeability in clay reduced by 85% so the opportunity for leachate containment in tailing dams or landfills are significant. Landfills typically are capped by 1m of clay in Australia. This study identified that this could be reduced to 150mm equivalent
    – even if it is reduced to half the potential savings in reduced earthworks and increased capacity can be significant.

 

Before and after apply PolyCom.

Black soil Stabilised

  

Original soil has a high content of vegetation (Mow grass). The original soils is no need to be removed completely. Mixing with PolyCom make the soil hard, durable and water resistance.

Peat soil Stabilised

 

Due to the availability of gravel far away from the project site, PolyCom provides same performance criteria at 40% lower cost.

Rehabilitate in-situ pavement

Stabilising thin layers (as little as 100mm) is possible without fatigue or stress problems normally encountered with conventional stabilisation of thin layers.

Improve soils for heavy vehicle 

  • A safer road for hauliers and light vehicles
  • No imported gravel – substantial cost savings

        

 

Download PolyCom information

PolyCom Presentation

PolyCom-Pamplate.pdf

Plutonic Mine Airstrip Case study

General Info PolyCom

Indonesia PolyCom Applications

PolyCom Past Project Fact

Pictures of road stabilised by PolyCom

A PolyCom application after 12 months.

 

PolyCom treated container yard Looking good after 2 Yrs No Maintenance Required2

PolyCom treated road, tight and durable surface
PolyCom-treated-road-surface-up-close-and-personal

clegg hammer testing road strength after polycom stabilising aid is applied CBR 110%

Video related to PolyCom Soil Stabilising Aid

https://www.youtube.com/results?search_query=polycom+soil+stabiliser

 

For more past project reference you can visit www.sealsgroup.com