Innovative Framework
Functional Process
NovoCrete® influences the chemical and mineralogical reactions of the individual calcium silicate hydrate (CSH) phases during the cement hydration process.
When cement and water combine, the initial hydration process forms a cement paste. As hydration continues, crystalline products develop on the clinker particles, binding soil grains together into what becomes known as cement stone, a rigid structural framework within the treated soil.
The incorporation of NovoCrete® significantly enhances this process by enriching the ion concentration within the pore solution. The elevated ion activity promotes the formation of refined, needle-like hydration crystals that create a denser, more cohesive matrix. This modified microstructure and mineral composition give the NovoCrete® hydraulically bound base layer its distinctive combination of flexibility and long-term stability.
Additionally, the sorption and ion-exchange capacities of the soil minerals facilitate the formation of stable aggregates. These aggregates are embedded within the CSH framework, together with the new minerals produced during hydration. The resulting improvement in pore structure filling compared with soils stabilized by cement alone using the same dosage, enhances deformation resistance and substantially reduces the risk of premature cracking.
Climatic Impacts
NovoCrete® performs reliably across a broad temperature range, from –5°C to +50°C, when proper drainage and moisture control are maintained.
Stabilization of frozen soils should be avoided if frost is expected, as trapped moisture can compromise long-term stability.
In hot or dry conditions, moisture levels must be adjusted and maintained to achieve optimal compaction and consistent hydration during curing.
If heavy rainfall occurs, construction should be temporarily covered or postponed to prevent material washout or dilution.
To reduce additive loss in windy conditions, apply NovoCrete® close to the ground using either mechanical or manual methods. When wind speeds exceed 30–38 km/h, spreading should be delayed until conditions stabilize.
Lab/Construction Analysis
Before construction begins, laboratory testing is recommended to determine the optimal blend of cement and NovoCrete® for the specific project. The testing process is carried out in two phases:
Phase 1 – Natural Soils and Materials
Testing focuses on natural soils, untreated aggregates, or recycled materials to assess their suitability.
Key parameters include grain size, moisture content, and density.
If multiple soil types exist within the project area, each must be tested separately to establish accurate mix ratios.
Phase 2 – Soil–Cement–NovoCrete® Mixtures
Based on Phase 1 results, a range of soil–cement–NovoCrete® mixtures are prepared and tested.
Proctor tests are conducted to determine the ideal cement and NovoCrete® content for maximum performance.
Mixing procedure:
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Combine cement and NovoCrete®.
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Add soil and adjust water content to ensure uniform consistency.
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Compact and store the prepared material for testing.
Testing parameters include:
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Unconfined Compressive Strength (UCS)
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Frost–thaw resistance
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(Optional) Water resistance and chemical compatibility of recycled materials
These tests verify that the selected mixtures deliver a strong, durable, and climate-resilient foundation for construction.
Equipment
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Asphalt milling machine
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Milling machine (e.g., CAT CM400, BOMAG RS460, Wirtgen WR 240 or similar)
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Cement spreader with onboard weighing system
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Additive spreader (NovoCrete® can also be spread by hand if no dedicated spreader is available and if NovoCrete® and cement are not pre-mixed)
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Water tanker (preferably 4x4) with sprinkler nozzles/bar and a connection for the milling machine (at least 3 water tankers, each with a 5,000–10,000 L capacity, depending on project size and distance to water source)
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Grader (preferably with GPS)
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Steel drum roller (min. 12 T, ideally 16 T), weight to match layer thickness
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Optional: Sheep foot roller (for plastic clay soils) and/or rubber-tired roller (min. 12 T, ideally 16 T)
Spreading and Mixing
NovoCrete® may be applied manually or with machine-controlled spreaders, depending on site conditions and project scale.
For manual application, spread NovoCrete® first, followed by cement, and clearly mark treated areas to maintain dosage accuracy. Avoid waterlogged zones, as excess moisture affects blending and compaction.
With machine spreading, apply NovoCrete® first, then cement. Under heavy moisture or expected rainfall, a “sandwich method” (cement–NovoCrete®–cement) can be used—particularly where higher cement content is required.
Accurate quantity control is essential. Stabilization involves blending NovoCrete®, cement, soil, aggregates, recycled materials, and water under controlled conditions.
Cement must meet specification requirements, and all materials should comply with limits for grain size, moisture, and sulfate content. Use clean water free from harmful substances.
Recommended NovoCrete® dosage: approximately 2% of the cement weight, adjusted as required by soil properties and lab testing.
QA/QC Stabilization Process
The NovoCrete® stabilization process involves in-situ mixing of soil with cement and NovoCrete® binders using milling equipment to produce a uniform, compacted base for roads, logistics yards, and other infrastructure.
Milling depth varies by soil type, traffic load, and design, typically up to 50 cm. Water is added during mixing to maintain optimal moisture, and binders may be applied separately or pre-mixed.
After mixing, the layer is compacted with steel-drum rollers, leveled with graders, and, if required, finished with rubber-tired rollers for density uniformity. The stabilized layer is cured for at least three days to ensure proper hydration and strength gain.
Quality control includes regular sampling for Proctor density, field compaction checks with nuclear or sand-cone tests, and UCS testing at 7, 14, and 28 days to confirm performance and durability.
Best Practice:
Consistent field monitoring, accurate moisture control, and adherence to mix design parameters are essential to achieving reliable NovoCrete® performance.