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POTHOLE
FIXING
UNIT
AN ECONOMICAL , EFFECTIVE AND ACCESSIBLE SOLUTION
Project team:
1. Arjun CH
2. Karthik Kiran RM
3. J Prasanna Venkatesh
INTRODUCTION
 INDIA has the 2nd largest road and highway network in the world. Yet, it is
better known for being one of the most pothole stricken road networks.
 Pothole condition aggravates during the onset of monsoon.
 This remains to be so, given the negligence and high investment to fix even
a small pothole.
 Potholes do not just irritate drivers and damage vehicles, they actually kill.
 The project involves the 3D-design and a scaled down prototype of a
pothole fixing unit which is aimed at reducing human effort and expertise to
patch potholes.
2
What is a pothole?
 A pothole is a type of failure in an asphalt pavement caused by the
presence of water in the underlying soil structure and the presence of
traffic passing over the affected area.
 This failure is seen as irregularities or voids in the roads.
3
How are potholes formed?
4
Causes of pothole
 Insufficient pavement thickness to support traffic in freeze or
thaw conditions without localized failures.
 Insufficient water drainage.
 Failures at utility trenches and castings (manhole and
drained casings).
 Miscellaneous pavement defects and cracks left
unmaintained and unsealed so as to admit moisture and
compromise the structural integrity of the pavement.
5
Methodology 6
Identification of
issues related with
pothole fixing
Selection of cold
asphalt considering
the advantages
Pothole survey to
identify common
size of small
potholes
2D hand drawn
sketches of top
view and side view
Development of
2D sketches into 3D
designs on
SolidWorks
Cost estimation of
Pothole Fixing Unit
Fabrication of
scaled down 1:2
prototype in wood
Testing and
rectification of
errors
Hot asphalt vs Cold asphalt
 Hot asphalt is mixed around at 300 F, and paving, pothole repair and compaction
must be performed while the asphalt is sufficiently hot.
 Paving and pothole repair is restricted to summer months in many states,
because in the winter the ground will cool the asphalt before it is packed to the
optimal air content, preventing proper pothole repair.
 Cold asphalt is mixed and used at lower temperature than hot asphalt. In this
state, cold asphalt is easy to work, compact and repair potholes with, and is not
as viscous as hot asphalt.
 A well designed cold asphalt takes on the properties of hot asphalt and is virtually
indistinguishable from it, despite being easier to use for pothole repair.
 As proposed by Prithvi Singh Kandhal in his research article, the cold patching
mix is effective in mixed weather conditions and has a 78% survival rate of 4
years while field testing in the US under the Strategic Highway Research
Program.
7
Advantages of cold asphalt mix
 Ready for immediate use with pre-mixed aggregates (cold technology).
 Cheaper while considering the equipment and labour cost.
 No heating or mixing or additions to the product before or after application.
 Requires simple equipment such as hand brushes, shovel and a rammer. The use
of a roller is not necessary.
 No pre treatment of repair areas is required i.e. cutting out, use of tack coat.
 Instant curing/setting, partly by air-drying and partly by compaction.
 All-weather usage product. Instant repair of roads with Shelmac PR can be made
in monsoons & wet conditions, extremes of heat (60˚C+) and cold conditions.
 Highly resistant to stripping by water, offer high skid resistance.
8
Motivation:
Survey on pothole related incidents.
 As seen in the image, the deaths
caused are much more in number
compared to deaths due to
terrorism.
 This makes potholes one of the
biggest issues that need enough
attention and investment.
 As of 2015, the number of deaths
have increased two folds.
9
A simple survey
A simple survey was conducted
to determine the average size of
potholes in different parts of
Bangalore. It involved the basic
measurement of pothole
dimensions.
In conclusion, we found that:
• 80% of the potholes are within
the size of 3’ by 3’
• Average depth of potholes is
0.5’
10
Measuring a pothole’s width
Measuring a pothole’s depth
Initial sketch 11
1 Trapezoidal storage tank for cold asphalt
2 Rammer bottom unit (20-25 kgs)
3 Rammer handle
4 Guide way for rammer
5 Cam to operate rammer
6 Motor to operate rammer
7 Regulator to control motor speed
8 Inclined guide way for flow of cold asphalt
9 Support for trapezoidal tank
10 Flap operated by lever to control flow of cold asphalt
11 Wheels with braking mechanism
Parts list
Sketch (Side view)
12
3–D Design on SolidWorks
(Top view)
13
Chassi
s
Tank for cold asphalt
Tir
e
Handle
14
3–D Design on SolidWorks
(Side view)
Rammer
Battery
Brakes
Cam
Flap control lever
15
3–D Design on SolidWorks
(Perspective view)
Motor
16
3–D Design on SolidWorks
(Perspective view)
Motor
17
3–D Design on SolidWorks
(Perspective view)
Flap
Working
 A pothole of size within 3’ x 3’ feet is identified.
 The pothole fixing unit is driven and parked above the pothole.
 Basic cleaning of pothole is done using wire brush.
 Cold asphalt from the storage tank is poured into the pothole in necessary
quantity using the flap control mechanism.
 The cam-operated rammer is used to push and pack the cold mix into the
area of repair.
18
19
Cost comparison (Cold vs Hot)
A recent university study by James Bearden, shows a cost savings of 72% when using
EZ Street cold asphalt compared to hot mix asphalt repair.
Cost comparison :
Pothole fixing unit vs Python 5000
20
• The design proposed will cost 60,000-70,000 while
produced in small batches and even lesser while mass
produced.
• While the fully automated Python 5000 costs 3,50,00,000
when imported to Bangalore.
Conclusion
 The project involved the 3D-design (SolidWorks) and a scaled down prototype of a pothole fixing unit
which is aimed at reducing human effort and expertise to patch potholes.
 A recent university study by James Bearden, shows a cost savings of 72% when using
EZ Street cold asphalt compared to hot mix asphalt repair.
 By comparing the cost of time and materials for each product he was able to calculate the percentage of
cost savings.
 In comparison to the more sophisticated methods available in the present day such as the Python 5000,
The proposed design is very economical, simple to use and employs cold asphalt mix.
 There lies a huge potential for the future development of the design. For one, It can be modified as a
trailer attached to a bigger vehicle such as a Tractor or a Mini truck. This would create a new group of
sub-contractors to fix potholes and make the pavement patching process quicker especially in India.
21
Thank you

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POTHOLE FIXING UNIT-1

  • 1. POTHOLE FIXING UNIT AN ECONOMICAL , EFFECTIVE AND ACCESSIBLE SOLUTION Project team: 1. Arjun CH 2. Karthik Kiran RM 3. J Prasanna Venkatesh
  • 2. INTRODUCTION  INDIA has the 2nd largest road and highway network in the world. Yet, it is better known for being one of the most pothole stricken road networks.  Pothole condition aggravates during the onset of monsoon.  This remains to be so, given the negligence and high investment to fix even a small pothole.  Potholes do not just irritate drivers and damage vehicles, they actually kill.  The project involves the 3D-design and a scaled down prototype of a pothole fixing unit which is aimed at reducing human effort and expertise to patch potholes. 2
  • 3. What is a pothole?  A pothole is a type of failure in an asphalt pavement caused by the presence of water in the underlying soil structure and the presence of traffic passing over the affected area.  This failure is seen as irregularities or voids in the roads. 3
  • 4. How are potholes formed? 4
  • 5. Causes of pothole  Insufficient pavement thickness to support traffic in freeze or thaw conditions without localized failures.  Insufficient water drainage.  Failures at utility trenches and castings (manhole and drained casings).  Miscellaneous pavement defects and cracks left unmaintained and unsealed so as to admit moisture and compromise the structural integrity of the pavement. 5
  • 6. Methodology 6 Identification of issues related with pothole fixing Selection of cold asphalt considering the advantages Pothole survey to identify common size of small potholes 2D hand drawn sketches of top view and side view Development of 2D sketches into 3D designs on SolidWorks Cost estimation of Pothole Fixing Unit Fabrication of scaled down 1:2 prototype in wood Testing and rectification of errors
  • 7. Hot asphalt vs Cold asphalt  Hot asphalt is mixed around at 300 F, and paving, pothole repair and compaction must be performed while the asphalt is sufficiently hot.  Paving and pothole repair is restricted to summer months in many states, because in the winter the ground will cool the asphalt before it is packed to the optimal air content, preventing proper pothole repair.  Cold asphalt is mixed and used at lower temperature than hot asphalt. In this state, cold asphalt is easy to work, compact and repair potholes with, and is not as viscous as hot asphalt.  A well designed cold asphalt takes on the properties of hot asphalt and is virtually indistinguishable from it, despite being easier to use for pothole repair.  As proposed by Prithvi Singh Kandhal in his research article, the cold patching mix is effective in mixed weather conditions and has a 78% survival rate of 4 years while field testing in the US under the Strategic Highway Research Program. 7
  • 8. Advantages of cold asphalt mix  Ready for immediate use with pre-mixed aggregates (cold technology).  Cheaper while considering the equipment and labour cost.  No heating or mixing or additions to the product before or after application.  Requires simple equipment such as hand brushes, shovel and a rammer. The use of a roller is not necessary.  No pre treatment of repair areas is required i.e. cutting out, use of tack coat.  Instant curing/setting, partly by air-drying and partly by compaction.  All-weather usage product. Instant repair of roads with Shelmac PR can be made in monsoons & wet conditions, extremes of heat (60˚C+) and cold conditions.  Highly resistant to stripping by water, offer high skid resistance. 8
  • 9. Motivation: Survey on pothole related incidents.  As seen in the image, the deaths caused are much more in number compared to deaths due to terrorism.  This makes potholes one of the biggest issues that need enough attention and investment.  As of 2015, the number of deaths have increased two folds. 9
  • 10. A simple survey A simple survey was conducted to determine the average size of potholes in different parts of Bangalore. It involved the basic measurement of pothole dimensions. In conclusion, we found that: • 80% of the potholes are within the size of 3’ by 3’ • Average depth of potholes is 0.5’ 10 Measuring a pothole’s width Measuring a pothole’s depth
  • 11. Initial sketch 11 1 Trapezoidal storage tank for cold asphalt 2 Rammer bottom unit (20-25 kgs) 3 Rammer handle 4 Guide way for rammer 5 Cam to operate rammer 6 Motor to operate rammer 7 Regulator to control motor speed 8 Inclined guide way for flow of cold asphalt 9 Support for trapezoidal tank 10 Flap operated by lever to control flow of cold asphalt 11 Wheels with braking mechanism Parts list
  • 13. 3–D Design on SolidWorks (Top view) 13 Chassi s Tank for cold asphalt Tir e Handle
  • 14. 14 3–D Design on SolidWorks (Side view) Rammer Battery Brakes Cam Flap control lever
  • 15. 15 3–D Design on SolidWorks (Perspective view) Motor
  • 16. 16 3–D Design on SolidWorks (Perspective view) Motor
  • 17. 17 3–D Design on SolidWorks (Perspective view) Flap
  • 18. Working  A pothole of size within 3’ x 3’ feet is identified.  The pothole fixing unit is driven and parked above the pothole.  Basic cleaning of pothole is done using wire brush.  Cold asphalt from the storage tank is poured into the pothole in necessary quantity using the flap control mechanism.  The cam-operated rammer is used to push and pack the cold mix into the area of repair. 18
  • 19. 19 Cost comparison (Cold vs Hot) A recent university study by James Bearden, shows a cost savings of 72% when using EZ Street cold asphalt compared to hot mix asphalt repair.
  • 20. Cost comparison : Pothole fixing unit vs Python 5000 20 • The design proposed will cost 60,000-70,000 while produced in small batches and even lesser while mass produced. • While the fully automated Python 5000 costs 3,50,00,000 when imported to Bangalore.
  • 21. Conclusion  The project involved the 3D-design (SolidWorks) and a scaled down prototype of a pothole fixing unit which is aimed at reducing human effort and expertise to patch potholes.  A recent university study by James Bearden, shows a cost savings of 72% when using EZ Street cold asphalt compared to hot mix asphalt repair.  By comparing the cost of time and materials for each product he was able to calculate the percentage of cost savings.  In comparison to the more sophisticated methods available in the present day such as the Python 5000, The proposed design is very economical, simple to use and employs cold asphalt mix.  There lies a huge potential for the future development of the design. For one, It can be modified as a trailer attached to a bigger vehicle such as a Tractor or a Mini truck. This would create a new group of sub-contractors to fix potholes and make the pavement patching process quicker especially in India. 21