The methodology for plastic road construction can be divided into the following steps:
Collection and sorting of plastic waste - Plastic waste is collected from various sources, such as households, businesses, and industries. The waste is then sorted to separate different types of plastic.
Shredding of plastic waste -The sorted plastic waste is shredded into small pieces. The size of the shredded plastic pieces depends on the type of plastic and the road construction method being used.
Mixing of plastic waste with bitumen - The shredded plastic waste is mixed with bitumen, the material used to make traditional asphalt roads. The ratio of plastic to bitumen varies depending on the desired properties of the road.
Laying of plastic road - The plastic-bitumen mixture is laid on the road surface using conventional road construction methods.
Compaction of plastic road - The plastic road is compacted using rollers to ensure that it is dense and durable.
There are two main methods of plastic road construction:
Dry process
In the dry process, the shredded plastic waste is mixed with bitumen at ambient temperature. This method is relatively simple and cost-effective, but it is not as durable as the wet process.
Wet process
In the wet process, the shredded plastic waste is heated and melted before being mixed with bitumen. This method produces a more durable road, but it is also more expensive and complex.
Once the plastic road is laid and compacted, it is ready for use. Plastic roads typically have a lifespan of 20–30 years, which is longer than the lifespan of traditional asphalt roads.
3.1. Comparison between Cement, Bitumen and Plastic roads
|
Cement roads
|
Bitumen roads
|
Plastic roads
|
Life span
|
20-40 years
|
5-10 years
|
>50years
|
Unit cost per km
|
15.38crore
|
20lakh
|
51000/- including carpet and seal coat 10.8lakh
|
Co-efficient of friction
|
0.4 ~ 0.75
|
04 ~ 0.75
|
0.4 ~ 0.75
|
Time taken settling/construction
|
for
|
24-48 hours
|
4-6 hours
|
<24 hours
|
Durability (Let’s assume a scale of durability from 1 to 10)
|
9
|
6
|
7
|
Ton cost per km
|
Rs. 6 to 7crore
|
Rs. 50,000/-
|
Rs. 10,000/-
|
Hydraulic permeability
|
1.7x10-9
cm/sec
|
to
|
3.5x10-13
|
0.4 to 0.04 cm/sec
|
-
|
Load-bearing capacity
|
800kN/m2
|
700kN/m2
|
750kN/m2
|
Softening point
|
49.8°C
|
35°C – 70°C
|
110°C – 130°C
|
Water drainage efficiency (Let’s assume a scale of water drainage efficiency from 1 to 10)
|
8
|
6
|
7
|
Material composition by weight
|
Cement: 15-20%
Aggregates (like sand & gravel): 80-85%
|
Bitumen: 90-95%
Aggregates: 5-10%
|
Recycled plastic: 5-
10%
Bitumen: 90-95%
|
Maintenance cost year
|
per
|
Rs. 49,590/-
|
Rs. 66,120/-
|
Rs. 41,325/-
|
Challenges
|
Higher initial cost can crack over time due to temperature changes and settling.
|
Require more
maintenance, susceptible to temperature changes and rutting.
|
Limited testing, potential environmental concerns if not managed properly.
|
Benefits
|
High durability, strength and load – bearing capacity.
|
Flexible, good traction, relatively lower initial cost, repairs are easier.
|
Reduce plastic waste, lower maintenance, better resistance to water and corrosion, potentially longer lifespan.
|
Each type of road has its own advantages and disadvantages, and the choice depends on factors like budget, local conditions, and sustainability goals.
3.2 STATUS OF PLASTIC ROADS IN INDIA
Plastic roads are a prime example of how humans can make treasure from trash!
You may have seen bottles, bags, toys, and many other things made of plastic. But did you know that roads can be made of plastic too? That’s right! These roads have become a great way to recycle plastic. Dr. Rajagopalan Vasudevan, an Indian scientist, introduced the idea of using waste plastic in road construction. Initially, Chennai was one of the few cities in the world to extensively use this technology. The municipality ordered the construction of 1000 km of plastic roads in 2004. However, the effective use of plastic in road construction in India only began later in 2015 when the Union Government instructed the use of waste plastic with hot mixes. This combination was to be used for bitumen (a thick and black adhesive liquid) roads surrounding the metro areas. Then, Nitin Gadkari, the Minister of Road Transport and Highways, initiated highway construction using waste plastic. As of July 2021, 703 km of national highways have been built using this technology.
S.NO | States/Union Territories | Plasticwaste generation in TPA | Plasticwaste Recycling in TPA | Road making in TPA |
1 | Andaman&Nicobar Islands | 492.342 | NP | 80.05 |
2 | Andhra Pradesh | 39626.45 | 5943.935 | 589.35 |
3 | Arunachal Pradesh | 3755.9 | 90 | 60 |
4 | Assam | 58765 | NP | NP |
5 | Bihar | 74263.69 | 7673.6 | NP |
6 | Chandigarh | 13107.15 | NP | NP |
7 | Chhattisgarh | 47450 | 200 | 86 |
8 | Dadra and Nagar Haveli and Daman and Diu | 4726 | 50 | 24 |
9 | Delhi | 345000 | 1150 | NP |
10 | Goa | 29441 | 150 | 74 |
11 | Gujarat | 337693.96 | NP | NP |
12 | Haryana | 185168 | NP | 735 |
13 | Himachal Pradesh | 6206.78 | 828.6 | NP |
14 | Jammu & Kashmir | 51710.6 | 2360 | 541 |
15 | Jharkhand | 20263.45 | 9185.2 | NP |
16 | Karnataka | 368080 | 10800 | NP |
17 | Kerala | 120063.87 | 73000 | 915 |
18 | Lakshadweep | 523.54 | 76 | 46 |
19 | Madhya Pradesh | 138483.58 | 63400.7 | 405 |
20 | Maharashtra | 311254 | 29565 | 13513 |
21 | Manipur | 10303 | 182.5 | NP |
22 | Meghalaya | 5043 | 364 | 195 |
23 | Mizoram | 1514.51 | 0.768 | NP |
24 | Nagaland | 4785.94 | NP | 0.7 |
25 | Odisha | 51269.9 | 44165 | NP |
26 | Puducherry | 12754 | 3969 | NP |
27 | Punjab | 108332.06 | 5233 | 2453 |
28 | Rajasthan | 66324.57 | NP | NP |
29 | Sikkim | 82.75 | 15 | 6 |
30 | Tamil Nadu | 430107 | 295482 | 15875 |
31 | Telangana | 472675 | 15236 | 1371.24 |
32 | Tripura | 61.65 | 55 | 2.53 |
33 | Uttar Pradesh | 375950 | NP | NP |
34 | Uttarakhand | 18647.75 | NP | NP |
35 | West Bengal | 417925 | NP | NP |
| Total | 4131851.442 | 569175.3 | 36971.87 |
* NP: Not Planned |
Table 3.2 Status of Plastic Waste Management
Details of Registered Manufacturing/Recycling Units
As per the provision 13(1) of PWM Rules, 2018, all the plastic manufacturing/recycling units shall be registered with the concerned SPCBs/PCCs. There are 5939 (3736–Plastic Manufacturers/producers, 1207-Recyclers., 70-Compostable Mfg., 311-MLP) registered units in 29 States/UTs. There are no plastic carry bag manufacturing units in 5 States/UTs namely Arunachal Pradesh, Andaman and Nicobar, Mizoram, Sikkim, Lakshadweep. No information for DD& DHN provided in this regard.
However, as per provision 4(h) of PWM Rules, 2018 CPCB has issued total 194 certificates to manufacturer/seller for marketing and selling of compostable carry bags/products till now.
Details of Unregistered Plastic Manufacturing /Recycling Units
There are 615unregistered plastic manufacturing/recycling units running in 5 States/UTs (Bihar, Punjab, Karnataka, Kerala, Uttarakhand). No unregistered plastic units have been reported in 24States/UTs ( Andaman and Nicobar, Andhra Pradesh, Arunachal Pradesh, Chandigarh, Chhattisgarh, Goa, Haryana, Himachal Pradesh, Jharkhand, Lakshadweep Madhya Pradesh, Maharashtra, Manipur, Meghalaya, Mizoram, Nagaland, Odisha, Puducherry, Rajasthan, Sikkim, Tamil Nadu, Telangana, Tripura, Uttar Pradesh,).6 States/UTs (Assam, Delhi, DDDNH, Gujarat, West Bengal & Tamil Nadu) have not provided the information regarding unregistered units operating in their jurisdiction.
3.3 PLASTIC ROADS IN SOME OTHER COUNTRIES
United Kingdom:
In January 2019, the Department for Transport announced a £1.6 million UK trial of a plastic road technology developed by MacRebur, an asphalt enhancement company based in Scotland. Cumbria was the first council in the UK to use the patented asphalt enhancement. Since then, the polymers have also been laid in Dumfries and Galloway, Gloucester, London, Newcastle upon Tyne, Durham and in the Central Belt. As part of the project, research into the technology will be carried out by Gaist, as well as The University of Nottingham, University of Central Lancashire, University of the Sunshine Coast, in Australia and the University of California.
Pakistan:
In December 2021, a 1-km stretch of Islamabad's Ataturk Avenue was entirely re-laid with plastic. The project was collaboration between Capital Development Authority and Coca Cola Company Pakistan. It used 10 ton of plastic bottle waste mixed with asphalt.
3.4 PLASTIC ROADS IN ANDHRA PRADESH
3.4.1 State Observations
-
The estimated plastic waste generation in the State is 39626.45 TPA (ULBs − 37,446.45 & Census Towns − 2,180) during the year 2020-21.
-
Rule 4(c & d) for thickness criteria has been implemented in the state.
-
There are 135 plastic manufacturing units (Producers 117& Recyclers- 18), 1 compostable plastic unit and no unregistered unit in the State.
-
Certain Urban Local bodies like Tadipatri, Vijayawada, Tirupati & Bobili have put ban on plastic carry bags irrespective of their thickness. All local bodies have taken stand on ban on their own.
-
Plastic waste is being collected and segregated by ULBs and sent to recyclers. Most of the Plastic waste is channelized through Kabadiwalas to recyclers. The non- recyclable plastic waste generated from the municipalities and from bio mining operating is being sent to Cement plants and partly for road formations.
-
Violation of PWM Rules has been observed. Further State Urban Development Dept., constituted 721 Task force teams 240 ton of plastic carry bags was seized and Rs. 169 lakh of fines was collected from defaulters.
Annual Reports furnished by all ULBs & Census Towns.
The AP Panchayat Raj department is getting ready to provide plastic pellets to build 45 clusters by October 2. All 661 mandals in AP would be connected with the plastic mixed roads by January 26, said Panchayati Raj commissioner B. Ramanjaneyulu. AP Chief Secretary Dinesh Kumar has been working on this project for two years.
Locals in the 45 clusters have started selling plastic waste to the PR department. This is graded and shredded and sold as pellets at 40 per kg, for construction of Panchayat Raj roads.
"The demand is two tons for 1 km of road," Mr Ramanjaneyulu said. The department would be able to produce 110 tons by January 2018, by which time all the clusters in 661 mandals will become operational.
He said the plastic-mixed roads would not be damaged by rain, and would be less expensive.
Staff is being trained to produce plastic pellets at three centers in Bapatla, Samalkot and Sri Kalahasthi, he said.
3.5 Vijayawada Plastic Road
Villages in Andhra Pradesh will get plastic roads which will be more durable and not be affected by rain.
Recently, I visited Plastic Road in Vijayawada. The Vijayawada Municipal Corporation constructed a road using waste plastic in 2016. An estimated Rs.13.5 lakh would be spent on construction.
3.6 Cost Analysis for Indian Road Network
Total plastic waste generation in India per annum | = 4.13 MT |
Recycling plastic waste per annum | = 569175.3 ton |
Usable plastic waste for road construction | = 36971.87 ton |
Total length of road network in India | = 6.4 million km |
Plastic roads construction in India | = 21000 mile = 33800 km |
Remaining road length | = 6,400,000–33,800 km = 6,366,200 km |
For 1 km of road construction uses 1 ton of plastic waste and 9 ton of bitumen.
If we can replace these 6,366,200 km of roads to plastic roads.
Total quantity of bitumen required | = 57.24 million ton |
Total quantity of waste plastic required | = 6.36 million ton |
Cost of bitumen per ton | = ₹ 50,000/- |
Cost of waste plastic per ton | = ₹ 30,000/ |
Cost of bitumen per 57.24 million ton | = ₹ 28,620crore |
Cost of waste plastic per 6.36 million ton | = ₹ 1,908crore |
Total cost for laying of plastic roads in India | = 28,620 + 1,908crore = ₹ 30,258crore |
3.7 Cost Analysis for Andhra Pradesh Road Network
In the last five years, Andhra Pradesh has got 209.4 km of national highways built out of plastic waste and 100m plastic road laying in Vijayawada.
Total length of road network in AP = 76,636 mile
= 123334 km
Total length of Plastic roads = 209.5 km
Remaining road length = 123334 − 209.5 km
= 123124.5km
We can replace these 123124.5 km of roads to plastic roads
Quantity of bitumen required | = 1.11 million ton |
Quantity of Plastic waste required | = 123124.5 ton |
Bitumen cost per 1.11 million to | = ₹ 555crore |
Plastic waste cost per 0.123 million ton | = ₹ 369.3735crore |
Total cost for laying of plastic roads in AP | = ₹ 555 + 369.37crore = ₹ 924.37crore |
3.8 Cost Analysis for Kakinada City Road Network
Total road length of Kakinada city = 719.21 km
There are no plastic roads in Kakinada, but if we replace these 719.21 km of roads to plastic roads
Quantity of bitumen required | = 6472.89 ton |
Quantity of plastic waste required | = 719.21 ton |
Cost of bitumen per 6472.89 ton | = ₹ 323.64 million |
Cost of plastic waste per 719.21 ton | = ₹ 21.57million |
Total cost for laying of plastic roads in Kakinada city | = ₹ 323.64 + 21.57million = ₹ 345.21million |
3.9 ECONOMICS COMPARISON BETWEEN BITUMINOUS ROADS & PLASTIC ROADS
One of the main factors to be considered in any technology and global market is economy. In order to compare the cost of construction between ordinary bituminous road and plastic coated bituminous road (Plastic roads).
Cost Analysis Assuming,
Cost of plastics waste (collection, segregation and processing) per kg | = Rs. 5/- |
Cost of bitumen per drum (200 kg) | = Rs. 10,000/- |
Cost of bitumen per kg | = Rs. 50/- |
Cost of bitumen per ton | = Rs. 50,000/- |
Generally roads in India are constructed in basic width of 3.75 m, Consider 1 Km length road To lay 1km of road 10 tons of bitumen is required,
Cost of bitumen required per km | = Rs. 5,00,000/- |
Assuming Optimum percentage of plastic as per the test results of literature reviewed is around 10% (by % wt. of bitumen).
Total quantity of bitumen required | = 9 ton |
Total quantity of plastic waste required | = 1 ton |
Cost of bitumen for 9 ton | = Rs. 4,50,000/- |
Cost of plastic waste for 1 ton | = Rs. 5,000/- |
Total cost of bitumen and plastic waste per km | = Rs. 4,55,000/- |
Total savings in Construction per km | = Cost of ordinary bituminous road – Cost of Plastic coated bituminous road = 5,00,000–4,55,000 = Rs. 45,000/- |
Kakinada city, |
Municipal Solid Waste (MSW) generated per day | = 220 MT |
Plastic waste is about 5% in MSW per day | = 11 MT |
1 metric ton of plastic waste and 9 metric ton of bitumen is used to construct 1km of plastic road, i.e., 11km of plastic road is constructed using per day plastic waste generation in Kakinada city.
Economy: Cost construction comparison between bituminous road and plastic road
Total quantity of bitumen required per 11km | = 110 ton |
Total cost of bitumen per 11km | = Rs. 5.5million |
Total quantity of plastic waste required per 11km | = 11 ton |
Total quantity of bitumen required per 11km | = 99 ton |
Cost of bitumen per ton | = Rs. 50,000/- |
Cost of bitumen per 99 ton | = Rs. 4.95million |
Cost of plastic waste per ton | = Rs. 10,000/- |
Cost of plastic waste per 11 ton | = Rs. 1,10,000/- |
Total cost of bitumen and plastic waste per 11km | = Rs. 49,50,000/- + Rs. 1,10,000/- = Rs. 50,60,000/- |
Total savings in construction per 11km | = Total cost of bituminous road per 11km – Total cost of plastic road 11km = 55,00,000–50,60,000 = ₹440000/- |