Industry Speaks

In this conversation, Vikas Sharma from Genesis Infra walks us through the innovative materials and cutting-edge technologies that are redefining road construction in India. What innovative construction materials are driving sustainable road construction in India? Innovative materials driving sustainable road construction include stone matrix asphalt (SMA) with cellulose fibres, thin white topping (TWT), and cement-grouted bituminous mix (CGBM). SMA is a type of asphalt pavement characterised by a dense, gap-graded mix that relies on a "stone-on-stone" skeleton for stability and rut resistance. It is often used as a wearing course for roads with heavy traffic, particularly in scenarios requiring high rut resistance, durability, and resistance to low-temperature cracking. SMA is primarily used as a wearing course, top layer of pavements, and on high-volume roadways and intersections. TWT refers to concrete overlay, typically of 4–7 inches (100–180 mm) thickness, bonded to an existing asphalt pavement. TWT, which is high-strength concrete with fibres, is a pavement rehabilitation technique used to extend the life of existing asphalt roads, especially those with rutting or shoving problems. TWT can be used in urban roadways, including rural roads, bus lanes, parking areas, intersections, ramps and exit/entry lanes with high traffic loads and heavy trucks. CGBM is a pavement material that combines the flexibility of bituminous pavement with the rigidity of concrete. It is made by filling the voids of a high-void bituminous mix with a cementitious grout. The bituminous mix is laid and compacted, and then the grout is poured and allowed to penetrate the voids. This composite material offers benefits such as improved resistance to rutting and moisture damage, as well as a smooth riding quality. CGBM is suitable for airport pavements, roads, parking areas, and industrial floorings. How are advanced materials like polymer-modified bitumen (PMB), cold mix asphalt (CMA), and micro surfacing emulsions redefining the longevity of roads? Roads built with PMB experience fewer cracks and potholes, enhanced durability, improved flexibility, resistance to water damage, better skid resistance, and stability under heavy traffic, reducing the need for frequent repairs. This translates to significant cost savings throughout the road's lifespan. CMA is a versatile material used in road construction, maintenance, and repair, particularly in low-traffic areas and situations where hot-mix asphalt is not feasible. It is suitable for repairing potholes, worn-out flexible pavements, and damaged surfaces, as well as for initial construction under specific conditions. Microsurfacing is a road maintenance technique that consists of applying a thin layer of a polymer-modified asphalt emulsion and fine aggregates to an existing road surface. This method helps seal cracks, improve skid resistance, and restore the road's surface texture, thereby extending the pavement's life and reducing the need for costly repairs. The technique is typically used on roads with low to moderate distress, such as those with minor cracking and ravelling, those showing signs of oxidation, aggregate loss, or polishing, and those with some rutting. What are self-healing roads, and how are they spearheading the future of Indian highways? Self-healing roads, also known as smart asphalt, are groundbreaking materials infused with steel fibres and epoxy capsules, which can repair small cracks and prevent water infiltration. It is done by applying heat to the steel fibres using an induction machine, which then causes the mortar with the asphalt to melt and repair itself. Self-healing roads offer a myriad of benefits, including reduced maintenance costs, extended road lifespan, and safer roads. They significantly reduce long-term maintenance expenses by eliminating the need for manual patching. Their self-repairing capabilities can extend the life of roads by preventing the formation of larger and more damaging potholes. And eliminating potholes improves road safety. Can you walk us through the cutting-edge technologies that you deploy in road construction? How do these cater to faster, efficient, and sustainable construction? At Genesis Infra, we focus on practical solutions that deliver real benefits to the people who use these roads every day. Here are three key technologies that we meticulously use to change the way India builds its roads. Stone matrix asphalt (SMA) is a specialised type of road surface composed of coarse aggregates and strong binders designed for long-term durability. It is designed to handle everything from heavy trucks to harsh weather—perfect for our busy city roads and highways. It offers zero potholes, a longer lifespan, and improved grip and driving safety. Thin White Topping (TWT) is a technique where a thin layer of concrete is added over the existing surface rather than completely removing the old road. This method is quicker, cost-effective, and long-lasting—ideal for busy Indian streets. The method is highly advantageous due to its reduced cement usage, resource- and time-efficient smart upgrade without full replacement of existing pavements, and the resulting cleaner pavements. Precast concrete offers both speed and precision. Using precast technology, we prepare parts of the road, such as drains and slabs, in factories and place them at the site. It is like assembling building blocks—quick, clean, and accurate. The method saves time, ensures consistent quality, and causes only minimal disruption to everyday traffic.