merc feb16

Bitumen Manufacturing

Company

MERCO is the biggest Bitumen cut-back manufacturing facility since 2004 in the Kingdom of Bahrain. Our state-of-the-art PLC controlled system help us to manufacture products to highest degree of accuracy. We have in-house quality control to serve our Clients better.

Our materials are packed in Drums, Flexi tanks and 1-Ton bags as per the requirements and needs of our Customers. Our special packaging facility is designed to lower the temperature of material before loading in Flexi bags.

MERCO is also into processing of Petrochemicals from SABIC for inter-nal use.

MERCO also provide following services:

• Plant Repairs and Maintenance• Waste Oil Recycling• Waste Oil Storage• Tank Cleaning• Oil Recycling• Material Packing

Bitumen Manufacturing | Middle East Recycling Company WLL

About Us

Bitumen products: MERCO has become one of the leading man-ufacturer of Bitumen Products in the Kingdom of Bahrain. Our Bitumen products are manufactured using materials from BAPCO. Our Cutback manufacturing facility can blend up to 1000 liters per minute.

Specialized Packing for BAPCO: We also specialize in the packaging of BAPCO Bitumen into Drums or Flexi Tanks for shipment throughout the world.

Specialized Packing for SABIC: We also provide packaging services for Petrochemical’s for SABIC.

BITUMEN GRADES

Penetration graded Bitumen complying withASTM & AASHTO specification. 40/50, 60/70, 80/100

Cut backs(Medium & Rapid Curing)Bitumens full range as per ASTM & AASHTOspecifications

MC30, MC70, MC250 & MC3000 and RC70,RC250 & RC3000

Anionic Emulsions(Rapid and Slow Settling)Bitumens full range as per ASTRM, AASHTOand B.S. Specifications

A140, RS1, RS2, SS1 ans SS1H

Cationic Emulsions(Rapid and Slow Settling)Bitumens full range as per ASTRM, AASHTOand B.S. Specifications

K140, K160, CRS1, CRS2, CSS1 and CSS1H

Polymer Modified Bitumen full range of PGgrades complying with SuperPave MP1/SP1and AASHTO M320

PG70-10 and PG76-10

Products


The Quality Policy at MERCO basically defines our mission statement in fine print: “Promote a quality-in-all-we-do philosophy with a total company effort and commitment to continuous improvement”. MERCO is committed to QUALITY, ON-TIME DELIVERY and COST-EFFEC-TIVENESS, and is committed to:

• Provide products and services which meet customer needs and expec-tations:

• Manufacture products which meet customer specifications.

• Strive to meet customer’s target values.

• Monitor customer satisfaction. • Deliver on-time:

• Ship on the date required by the customer.

• Monitor on-time delivery performance. • Reduce all costs to the lowest possible level:

• Establish and periodically review Cost Reduction Programs.

• Monitor the Cost of Quality

To meet our commitment, we must:

• Foster a team approach to defect prevention and problem solving.

• Emphasize appropriate training for all employees.

• Recognize each employee’s responsibility for quality.

• Empower employees to question processes which appear to pro-

duce discrepancies.


Quality Policy Statement

-• Treat fellow employees as both customers and suppliers.

• Acknowledge employee’s self-improvements and contributions to

the company.

• Exchange expertise with suppliers and customers.

• Use only Selected, Approved, Preferred or Certified suppliers.

• Accept only conforming products and services from suppliers.

• Elicit written corrective actions from suppliers.

• Keep the Quality Department independent of, but a partner with,

Manufacturing.

• Reduce waste and inefficiency, wherever found.

• Seek out technologies for assuring error-free work.

• Continue to implement statistical approaches to reduce variation.

• Draw on customer’s expertise in various areas.

• Strive for complete understanding of our customers’ application re-

quirements.

• Earn customer recognition of our quality progress.

• Develop and achieve Quality Improvement Goals.

• Practice good housekeeping.

• Never compromise safety.

• Review and renew this Quality Policy on a regular basis


Bitumen is available in a variety of grades. Specifications vary to meet the needs of the consuming industries and are based on a series of physi-cal tests that define the safety, solubility, physical properties and durability of bitumen.

The physical properties are designed to define performance character-istics that are required under the climatic and loading conditions that the bitumen will experience in service.

Bitumen is graded according to the standardized testing methods. These tests also give rise to two commonly used terms which describe the meth-od of measurement, rather than a “type“ of Bitumen.


Bitumen & Product Specification

PROPERTYGRADES BITUMEN STANDARD

40/50 60/70 80/100 85/100 120/150 200/300 ASTM

Penetration @ 25 °C for 5 Sec 40/50 60/70 80/100 85/100 120/150 200/300 D-5

Flash Point °F 450 450 450 450 450 350 D-92

Ductility @ 25 °C - cm/min 100 100 100 100 100 100 D-113

Solubility in Trichloroethylene 99 99 99 99 99 99 D-2042

Retained penetration after thin film oven test 55+ 52+ 47+ 47+ 42+ 37+ D-175

Ductility @ 25 °C - cm/min after thin film oven test - 50 75 75 100 100 D-113

Package 1000 Kg / 500 Kg Meltable Jumbo bags loaded in Containers.

Penetration Graded Bitumen

Bitumen is classified by the depth to which a standard needle will pene-trate under specified test conditions.

This “pen” test classification is used to indicate the hardness of bitumen, lower penetration indicating harder bitumen.

Specifications for penetration graded bitumen’s normally state the pen-etration range for a grade, e.g. 50/70.

Other tests are used to classify the bitumen for specification purposes, such as softening point, solubility, flash point etc.


Typical Specification

Cutbacks are bitumen preparations in which the viscosity of the binder has been reduced by the addition of a volatile solvent, normally derived from petroleum.

Cutback products are typically used for spraying and some mixing applications. The advantage of cutbacks over emulsions is much higher residual bitumen content, typically over 80% compared with over 40-65% for Bitumen emulsions. The result is more Bitumen left on the roadway after curing, for the same volume of binder applied.

PROPERTY UNIT MC30 MC70 MC250 MC3000 STANDARD

Kinematic viscosoty at 60°C CST 30/60 70/140 250/500 3000/6000 D2170

Flash Point, Min °C 38 38 66 66 D1310Residue from Distilla-tion to 360°C Min %VOL 50 55 67 80 D402

Test on Residue from DistillationPenetration at 25°C, 100g, 5 Sec CM 120/250 120/250 120/250 120/250 D5

Ductility at 25°C, Min CM 100.0 100.0 100.0 100.0 D113Solubility in Trichloro-ethylene, Min % 99.0 99.0 99.0 99.0 D2042

Water, Max %VOL 0.2 0.2 0.2 0.2 D95

PROPERTY UNIT RC70 RC250 RC3000 STANDARD

Kinematic viscosoty at 60°C CST 70/140 250/500 3000/6000 D2170Flash Point, Min °C - 27 27 D1310Residue from Distillation to 360°C Min %VOL 55 65 80 D402

Test on Residue from DistillationPenetration at 25°C, 100g, 5 Sec CM 80/120 80/120 80/120 D5Ductility at 25°C, Min CM 100.0 100.0 100.0 D113Solubility in Trichloroethylene, Min % 99.0 99.0 99.0 D2042

Water, Max %VOL 0.2 0.2 0.2 D95


Cutback Bitumen



Bitumen Primer is a locally manufactured bitumen solution suitable for sealing and priming porous and non-porous surfaces.

PROPERTY STANDARDType of solvent Kerosene

Solid Content >50%

Specific Gravity 0.9

Flash Point, °C 36 - 38

Film Thickness Wet: 100 microns and Dry: 54 microns

Application Temperature range, °C 5 - 55

Drying Time BS3416/6949:1991 About 4 -6 hours

Finish BS3416/6949:1991 smooth, Opaque and free from sags or runs.

Chemical & water resistance Resistance to: most salt solutions, dilute acids/ alkali’s, water and alcohol.

Non Resistance to: oils, solvents and some detergent solutions.

Effect on potable water BS3416/6949:1991/ BS 6920:2000 Passed. Suitable for use in contact with potable water.

Package Flexi Bag Containers/Road Tankers


Bitumen Primer


Bitumen emulsions consists of three basic ingredients: bitumen, water, and an emulsifying agent. Based on specifications it may contain other additives, such as stabiliz-ers, coating improver, anti-strips, or break control agents.

It is well known that water and asphalt will not mix, except under care-fully controlled conditions using highly specialized equipment and chem-ical additives.

EMULSION TYPE

D244 D244 D244 D244 D244 D244 D244 D5 D2042Min Max Max -/+ Min/Max Min/Max Max Min/Max Min

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Tack-Coat 38% 0.10% 1% +ve 25 Max - 3 60-200 97.5Rapid Setting 50% 0.10% 1% +ve 20-50 - 3 60-200 97.5Rapid Setting 57% 0.10% 1% +ve - - - - -Rapid Setting 60% 0.10% 1% +ve - 20-100 3 60-200 97.5Rapid Setting 65% 0.10% 1% +ve - 100-400 3 60-200 97.5Rapid Setting 67% 0.10% 1% +ve - - - - -Medium Setting 57% 0.10% 1% +ve - - - - -Medium Setting 60% 0.10% 1% +ve - 50-450 20 60-200 97.5Medium Setting 65% 0.10% 1% +ve - 50-450 12 60-200 97.5Slow Setting 56% 0.10% 1% +ve - - - - -Slow Setting 57% 0.10% 1% +ve 20-100 - - 60-200 97.5


Bitumen Emulsions


Oxidized bitumens are made by blowing air through hot paving grade bitumen.

The so-called blowing process results in harder bitumen that softens at a higher temperature than that at which paving grade bitumen softens.

Industrial bitumens also have more rubber-like properties and their vis-cosities are much less affected by changes in temperature than is the case with paving grade bitumen.

PROPERTY UNIT 85/25 95/25 90/40 115/15 STANDARD

Specific Gravity at 25°C 1.01 - 1.05 1.01 - 1.05 1.01 - 1.05 1.01 - 1.05 ASTM D-70

Penetration at 25°C, 100 gm, 5 sec 0.1MM 20/30 20/30 35/45 10/20 ASTM D-5

Softening Point, Ring & Ball °C 80/90 90/100 85/95 110/120 ASTM D-36

Ductility at 25°C, after TFOT, Min CM 1.5 1.5 1.5 1.5 ASTM D-113

Loss on Heating, Max %Wt 0.2 0.2 0.2 0.2 ASTM D-6

Flash Point Cleveland open cup, Min °C 260 260 260 260 ASTM D-92

Solubility in CS2, Min %Wt 99 99 99 99 ASTM D-4


Oxidized Bitumen


MERCO

North Askar Industrial Area - Kingdom of BahrainP: +973 77052250 • F: +973 17910039

www.merc.company • [email protected]

merc feb16

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