YUGA
Vision · Strategy · Execution0%
YUGA
Micro-surfacing paver laying emulsion on an Indian highway - YUGA
Product · YUGA PMC

Micro Surfacing Emulsion

Polymer-modified emulsion for thin, fast-cure resurfacing (IRC SP:81)

Book a feasibility call
Overview

What is Micro Surfacing Emulsion?

Micro surfacing emulsion is a polymer-modified bitumen emulsion mixed with graded aggregate, mineral filler, water and additives to form a thin, durable surfacing layer applied cold by a specialised paver. It cures fast and reopens to traffic quickly.

It is a leading preventive-maintenance technique — sealing the surface, restoring skid resistance and correcting minor rutting without a full overlay. Guidance is given in IRC SP:81.

Micro-surfacing plant - hero product moment
Why this business

Benefits

  • Fast traffic return — thin layer cures and opens within hours
  • Preventive maintenance — extends pavement life, delays costly overlay
  • Skid & ride quality — restores surface texture and seals cracks
  • Rut correction — can fill minor ruts in a single pass
  • Cold, green process — no hot-mix plant, lower energy and emissions
Demand

Applications & buyers

  • Preventive maintenance of highways, airports and city roads
  • Skid-resistance restoration and surface sealing
  • Minor rut filling and ravelling correction
  • Heavily trafficked roads needing quick reopening
Technical

Specifications

GuidelineIRC SP:81 (Micro Surfacing)
BinderPolymer-modified bitumen emulsion (cationic)
MixEmulsion + graded aggregate + filler + water + additive
ApplicationCold, by purpose-built micro-surfacing paver
CureFast — typically reopens to traffic in hours
Setup

Plant & machinery

Capacity to showPlant: special emulsion 5–10 TPH; Execution: paver ~20 MT/hour or project-specific
Area requiredEmulsion + aggregate yard: 20,000–60,000 sq ft; with workshop & paver parking 0.75–1.5 acres
Approx. cost (without land)Emulsion plant + one paver + lab ₹4–7 Cr; imported/high-end paver package above ₹8 Cr
UtilitiesPower, water, polymer/latex/emulsifier chemicals, aggregate handling, support vehicles, field crew
ApprovalsRoad-authority mix-design approval, tender qualification, product testing, equipment calibration, work-zone safety
Best-use noteSell as material + service (strong for maintenance contracts)
Special polymer/latex modified emulsion plant or confirmed supply tie-upAggregate screening & storage binsCement/filler storage & handlingMobile micro-surfacing / slurry paverAggregate, emulsion, water & additive tanks on paverTwin-shaft mixer & spreader boxCalibration kit & field QC toolsWater tanker / support vehicleLab for mix design & compatibility testingWorkshop & spares for paver maintenance
YUGA founder Prince Shah at a micro-surfacing emulsion plant
Micro-surfacing plant - establishing wide view
Micro-surfacing plant - establishing wide view
Feedstock & Output

What goes in, what comes out.

Per m² applied (service)

Input
Modified emulsion
~1.5–2.5 kg/m²
Aggregate + filler
~8–12 kg/m²
Water + additive
as designed
Output
Micro-surfaced road area
1 m² sealed surface (IRC SP:81)
Quality & Compliance

Standards & testing.

IS (BIS)
IRC SP:81; emulsion per IS 8887
ASTM
ASTM D2397 (cationic emulsion); ISSA A143 (micro-surfacing)
MSDS / SDS
MSDS/SDS for modified emulsion & additives
Investment & Returns

Cost, output & payback.

Indicative for a micro-surfacing emulsion unit (may include specialised paver/equipment).

Micro Surfacing

Cost & ROI

Investment (CAPEX)
₹4–7 Cr
Output / year
6,000–12,000 MT special emulsion/yr + application
Revenue / year
₹3–12 Cr
Profit / year
₹0.4–1.5 Cr
Land required
20,000–60,000 sq ft
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)₹1 crore – ₹4 crore (incl. equipment)
Capacity basisPolymer-modified emulsion + application service
Approx. annual revenue₹3 crore – ₹12 crore
Approx. gross profit (GP) margin15% – 25%
Approx. net profit / year₹40 lakh – ₹1.5 crore
Approx. payback period2 – 3 years

Figures are for plant supply only — land and working capital are separate — and reflect a batch / semi-continuous build. Fully-continuous, automated, premium-spec production plants cost more (roughly ₹0.8–1.2 Cr per TPD). Your exact cost is fixed in a site-specific DPR.

Where to build

Best Indian states for this plant.

Maharashtra, Gujarat, Karnataka, Tamil Nadu, Delhi-NCR

Dense high-traffic networks needing fast preventive maintenance & quick reopening.

Site & Footprint

How much land you'll need.

Indicative plot size by capacity — we lock the exact figure to your layout and feedstock plan during feasibility.

Capacity
Plant + paver
20,000–60,000 sq ft
Capacity
High-end / imported
0.75–1.5 acres

Indicative footprint per capacity tier. Actual plot size depends on layout, feedstock storage, effluent/ZLD provisions, future expansion and statutory setbacks — finalised in the feasibility / DPR stage.

Regulatory

Licences & permissions you'll need.

Core approvals plus the extras specific to this plant — pick your state to see the nodal authority. We handle the full filing as part of PMC.

Licences & permissions

Gujarat PCB + Investor Facilitation Portal (single-window) under the Gujarat Industrial Policy.

Udyam (MSME) registrationMinistry of MSMESetup
GST registrationGST DepartmentSetup
Company / firm incorporationMCA / RegistrarSetup
Factory licenceState Factories & Boilers DeptPre-build
Fire NOCState Fire ServicesPre-build
Consent to Establish (CTE)State Pollution Control BoardPre-build
Consent to Operate (CTO)State Pollution Control BoardPre-commissioning
PESO licence (storage of petroleum/flammables)PESO (Petroleum & Explosives Safety Org)Pre-commissioning
Trade / municipal licenceLocal municipal bodySetup
Electricity & power connectionState DISCOMPre-build
IRC / MoRTH specification complianceIRC / MoRTHMarket

Indicative — the exact licence set depends on product, capacity, category (red/orange) and the latest state norms. We handle the full filing as part of PMC. Verify on application.

Client couple at their commissioned YUGA plant - idea to income
Carbon & Market

Extra revenue, and where it's running.

Carbon
~0.35 t
CO₂ saved per MT of bio-bitumen
Carbon
₹2,500+
Indicative credit value / MT
Carbon
~2.5 MT
Crop residue diverted / MT output
Carbon
MRV
Puro.earth-style verified pathway

Indicative — actual eligibility, methodology, credit volume and price depend on the registry, feedstock and verification. We structure the MRV pathway as part of PMC; contact us for a project-specific assessment.

Approx plants running (India)
~60
Top states
Maharashtra · Karnataka · Gujarat
What You Get

Documents & deliverables we provide.

Reports, drawings, working procedures and compliance docs — the full pack that takes the plant from paper to production.

Reports & financials

  • Detailed Project Report (DPR)
  • Bank DPR + CMA data (bank format)
  • 5-year financial model — P&L, balance sheet, cash flow
  • ROI / IRR / break-even & sensitivity analysis
  • Feasibility & techno-economic report
  • Subsidy & loan eligibility memo

Drawings & engineering

  • Plant layout & general-arrangement drawings
  • Process flow diagram (PFD) & P&ID
  • Civil & foundation drawings
  • Electrical & utility layout
  • Equipment & machinery specification sheets
  • Site plan & location scoring

Working & process docs

  • Standard Operating Procedures (SOPs)
  • Production & blending process manual
  • Quality-control test protocols (penetration, softening, ductility)
  • Raw-material & input–output (mass balance) sheets
  • Operator training & safety manual
  • Vendor / OEM list with negotiated pricing

Compliance & market

  • Licence & permission checklist (product + state)
  • Standards pack — IS / ASTM / MSDS
  • Tender & empanelment documentation (NHAI / PWD)
  • Buyer network & sales-support pack
  • Carbon-credit MRV documentation (optional)

Exact deliverables are scoped per engagement and product. The full pack is provided as part of PMC — contact us for a project-specific document list.

Micro-surfacing plant - plant inauguration ceremony
Questions

Top questions, answered.

A thin, cold-applied layer of polymer-modified emulsion plus aggregate that seals and resurfaces roads quickly.

You may also need

Pairs well with.

Plant

Bio-Bitumen

Pyrolysis-based renewable binder for sustainable roads

Explore
Plant

Plastic-to-Fuel (Plastic Pyrolysis)

Converting waste plastic into pyrolysis oil, gas and char

Explore
Plant

Rubber-to-Fuel (Tyre Pyrolysis)

Waste tyres into Tyre Pyrolysis Oil (TPO), carbon black, steel & gas

Explore

Plan your Micro Surfacing Emulsion plant with YUGA.

From feasibility to first commercial production - and the capital to fund it.

Chat on WhatsApp
+91 77952 42424