How is it different from a normal emulsion?

It uses polymer-modified emulsion and a designed aggregate mix laid by a special paver, for a structural thin surfacing — not just a coat.

Why use micro surfacing?

It is preventive maintenance: extends pavement life, restores skid resistance and reopens to traffic in hours.

Minor ruts and ravelling, yes — often in a single pass; it is not a substitute for major structural repair.

How fast can traffic return?

Usually within a few hours, making it ideal for busy roads.

What does it contain?

Polymer-modified bitumen emulsion, graded aggregate, mineral filler, water and additives.

Is special equipment needed?

Yes — a dedicated micro-surfacing paver/machine and a quality emulsion supply.

Highway authorities, airports, municipalities and maintenance contractors.

Can you help me produce micro-surfacing emulsion?

Yes — we cover feasibility, emulsion formulation, plant/equipment and marketing as part of our PMC service.

Micro Surfacing Emulsion Plant — PMC India

Product · YUGA PMC

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

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Overview

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.

Why this business

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

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

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

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

Feedstock & Output

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

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

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

Where to build

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

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

Questions

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

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