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YUGA
Asphalt surfacing - emulsion application
Product · YUGA PMC

Water-based bitumen for cold-application road works (IS 8887)

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Overview

Bitumen emulsion is a stable mix of bitumen droplets dispersed in water with an emulsifier, allowing bitumen to be used cold (without high-temperature heating). It is graded as Rapid (RS), Medium (MS) and Slow (SS) setting, and specified under IS 8887.

Emulsions are widely used for tack coats, prime coats, surface dressing, fog seals, patch repair and cold-mix works — making them ideal for maintenance, rural roads and eco-friendly, low-energy applications.

Why this business

  • Cold application — no heating to high temperature — safer, less fuel
  • Eco-friendly — water-based, lower emissions and energy use
  • Versatile — tack, prime, surface dressing, fog seal, cold mix, repair
  • Good for maintenance — ideal for patchwork and rural roads
  • Standardised — RS / MS / SS grades per IS 8887
Demand

  • Tack coat and prime coat between/under pavement layers
  • Surface dressing and fog seal
  • Pothole / patch repair and cold-mix maintenance
  • Rural roads (PMGSY-type works) and all-weather repair
Technical

StandardIS 8887 (Bitumen Emulsion)
GradesRS-1/RS-2 (rapid), MS (medium), SS-1/SS-2 (slow)
CompositionBitumen + water + emulsifier (cationic common)
PlantColloid mill, soap/water phase tanks, dosing system
UseTack/prime coat, surface dressing, cold mix, repair
Setup

Capacity to showSmall 1 TPH; Common 5 TPH; Commercial 10–20 TPH; custom up to 50 TPH
Area required5–10 TPH: 10,000–25,000 sq ft; with bitumen/emulsion tanks, lab & drum filling 0.5–1 acre
Approx. cost (without land)1 TPH ₹25–60 lakh; 5 TPH ₹75 lakh–1.75 Cr; 10 TPH ₹1.5–3 Cr; 20 TPH ₹3–5 Cr
UtilitiesPower, heating fuel/thermic oil, clean water, compressed air, lab chemicals, firefighting water, packing/drums
ApprovalsSPCB CTE/CTO, factory/fire, storage safety, IS 8887 / project testing
Best-use noteBuyers understand application: tack coat, prime coat, cold mix, maintenance, rural roads
Bitumen storage & heating tankWater tank & soap-solution tankAcid/amine/emulsifier dosing systemColloid mill / high-shear millBitumen, water & soap pumpsFlow meters & dosing controlsEmulsion cooling & storage tanksDrum filling / bulk loading systemPLC/MCC/control panelLaboratory for emulsion testsFire safety, spill containment, effluent handling
Feedstock & Output

Per 1 tonne emulsion

Input
Bitumen
~60–70%
Water
~30–40%
Emulsifier/acid
~0.5–2%
Output
Bitumen emulsion (IS 8887)
1 tonne
Quality & Compliance

IS (BIS)
IS 8887:2018 (Bitumen Emulsion)
ASTM
ASTM D977 (anionic) / D2397 (cationic)
MSDS / SDS
MSDS/SDS for emulsion, emulsifier/acid
Investment & Returns

Indicative for a ~5–20 TPD bitumen emulsion plant.

Bitumen Emulsion

Cost & ROI

Investment (CAPEX)
₹0.25–0.6 Cr
Output / year
1,500–3,000 MT emulsion/yr
Revenue / year
₹1–3 Cr
Profit / year
₹0.1–0.4 Cr
Land required
small plot
Payback
2–3 yr

Indicative only — actual figures depend on capacity, location, raw-material price and utilisation. Contact us for an exact DPR.

Project investment (CAPEX)₹40 lakh – ₹1.5 crore
Capacity basis~5 – 20 TPD emulsion
Approx. annual revenue₹3 crore – ₹15 crore
Approx. gross profit (GP) margin12% – 20%
Approx. net profit / year₹30 lakh – ₹1.2 crore
Approx. payback period2 – 3 years
Where to build

UP, MP, Bihar, Maharashtra, Rajasthan (+ all states)

Large PMGSY/rural & maintenance road programmes; low-energy cold application.

Questions

Bitumen dispersed in water with an emulsifier, so it can be applied cold without high-temperature heating.

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