ABSTRACT

We face Challenges and for developing countries like India, China, etc. The major
problem they are suffering is the disposal of plastic waste and establishing a road
network which is economical and durable with the help of this presentation we
are trying to introduce various ways in which plastic can be utilized and since our
project is mainly focusing on plastic roads, we have also explained various steps
to be followed for using plastic in roads. With the help of this technology a major
problem of disposal of plastics waste can be solved at the same time, using
plastic in roads increases the strength and durability of roads, On the other hand
it is economic pollution free and safe. Plastic technology has a wide range of
scope. Since this can be used in cloth making. Rail Sleepers and also plastic can
be used as construction material and if plastic roads are brought into regular
practice this will increase the demand of transportation engineer who are aware
of this technology. Increasing demand of plastics will also enhance the work of
plastics pickers, hence solving the problem of employment.

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 CONTENTS

CHAPTER 1
INTRODUCTION
1.1 WHY USE PALSTIC
1.2 TYPES OF PLASTIC
1.3 NEED TO STUDY

1.4 WASTE PLASTIC- AS BINDER

CHAPTER 2
2.1 BANGALORE'S KK PROCESS
2.2 FLOW CHART
CHAPTER 3
3.1 AGGREGATE
3.2 BITUMEN
3.3 WASTE PLASTIC
CHAPTER 4
4.1 COLLECTION OF WASTE PLASTIC
4.2 CLEANING & SHREDDING OF WASTE
PLASTIC

4.3 MIXING

4.4 LAYING OF BITUMINOUS MIX

CHAPTER 5
5.1 IMPACT VALUE TEST

2
5.2 LA ABRASION TEST
5.3 PENETRATION TEST OF BITUMEN
5.4 PENETRATION TEST OF BITUMEN
POLYMER MIX

5.5 STRIPPING VALUE TEST

5.6 MARSHALL TEST
CHAPTER 6
6.1 DRY PROCESS
6.2 WET PROCESS
CHAPTER 7
7.1 ADVANTAGES OF PLASTIC ROADS
7.2 DISADVANTAGES OF PLASTIC ROADS
7.3 COST ANALYSIS
CHAPTER 8
CASE STUDIES IN INDIA
CHAPTER 9
CONCLUSION
REFRENCES

3
 LIST OF FIGURES

FIGURE NUMBER FIGURE DECSRIPTIOPN PAGE NUMBER

Plastic Bitumen Road

Figure

Flowchart

Aggregate

Bitumen

Rag Pickers

Cleaning Process

Shredding Machine

Central Mixing Plant

Paver Machine

Impact Test Setup

Penetration Test Setup

Wet Process

4
 LIST OF TABLES
TABLE NUMBER DESCRIPTION PAGE NUMBER

Avg. Municipal Solid Waste

Production

Plastic Consumption in India

Population Growth and Impact on

Overall Waste Generation and
Future Predictions until 2041

Aggregate test

Waste Plastic & its source

Impact Value

Avg. LA Abrasion Value

Penetration test of Bitumen

Penetration test of Bitumen-

Polymer mix

Stripping Value

5
Optimum Bitumen Content

Plastic content v/s Stability

Comparison between ordinary

bituminous roads and waste plastic
bituminous roads

Cost Analysis for Road Construction

6
 CHAPTER 1
INTRODUCTION
India has a road network of over 4,689,842 kilometres (2,914,133 mi) in 2013, the second
largest road network in the world. Adjusted for its large population, India has less than 3.8
kilometres of roads per 1000 people, including all its paved and unpaved roads. In terms of
quality, all season, 4 or more lane highways, India has less than 0.07 kilometres of highways
per 1000 people, as per 2010 statistics.
Plastic products are an integral part in our daily life as a basic need. One such method is using
of municipal plastic waste as binder in flexible pavements. Municipal waste, commonly known
as trash or garbage, is a combination of all of a city's solid and semisolid waste. It includes
mainly household or domestic waste, but it can also contain commercial and industrial waste.
Much of it is not recycled, and ends up in landfills or as litter on land, in waterways and the
ocean.

The estimate of eight million tonnes of plastic being dumped into the oceans by 192 coastal
countries in 2010 may appear staggeringly high, in reality the quantity would be many times
more. Municipal plastic waste comprises of 65-75 percent of the total plastic waste generated
in India. At twelfth position, India is one of the worst performers. It has dumped up to 0.24
million tons of plastic into the ocean every year, the amount of mismanaged plastic waste per
year is 0.6 million tons. In the case of China, the No. 1 polluter, the coastal population sends
up to 3.53 million tons of plastic waste into the oceans each year.
Plastic coated may have same or even higher stiffness than conventional bitumen, but without
a large increase in flexibility. These modified mixes reduce the permanent deformation or
rutting of the bituminous surface course under traffic loads. These offer better resistance to
deformation under at higher temperatures.
The process involved in laying plastic roads begins with collection of plastic waste (bags, cups,
thermoscope) made out of PE, PP, & PS which are separated, cleaned if needed and shredded
to small pieces (passing through 4.35mm sieve) The aggregate (granite) is heated to 170°C in
the Mini hot Mix Plant and the shredded plastic waste is added, it gets softened and coated
over the aggregate. Immediately the hot Bitumen (160°C) is added and mixed well. As the
polymer and the bitumen are is the molten state (liquid state) they get mixed and the blend
is formed at surface of the aggregate. The mixture is transferred to the road and the road is
laid. This technique is extended to Central Mixing Plant too.
The durability of the roads laid out with plastic waste is much more compared with roads with
asphalt with the ordinary mix. Roads laid with plastic waste mix are found to be better than
the conventional ones. The binding property of plastic makes the road last longer besides
giving added strength to withstand more loads.

7
In recent years, applications of plastic wastes have been considered in road construction with
great interest in many developing countries. The use of these materials in road making is
based on technical, economic, and ecological criteria. In the state of Maharashtra, they laid
the test road of length up to 1,500 km. Other states like Tamil Nadu, Karnataka, Pondicherry,
Kerala and Andhra Pradesh have also laid test roads. These roads have withstood loads due to
heavy traffic, rain and temperature variation.

Data on plastic consumption and generation of plastic waste

A material that contains one or more organic polymers of large molecular weight, solid in its
finish state and at some state while manufacturing or processing into finished articles, can be
shaped by its flow is termed as plastics. The plastic constitutes two major categories of
plastics:

(i) Thermoplastics and

(ii) (ii) Thermoset plastics. The thermoplastics, constitutes 80% and thermoset
constitutes approximately 20% of total postconsumer plastics waste generated.
The following table describes the average municipal solid waste production from
0.21 to 0.50 Kg per capita per day in India.

Population Range (Millions) Average Per Capita Value

0.1-0.5 0.21
0.5-1.0 0.25
1.02-2.0 0.27
2-5 0.35
>5 0.50

Table No:1

1.1WHY USE OF PLASTIC

1. Disposal of waste plastic is a major problem

2. It is non-biodegradable
3. Burning of these waste plastic bags causes environmental pollution.
4. It mainly consists of low-density polyethylene
5. To find its utility in bituminous mixes for road construction
6. Laboratory performance studies were conducted on bituminous mixes. Laboratory studies
proved that waste plastic enhances the property of the mix

8
7. Improvement in properties of bituminous mix provides the solution for disposal in an
useful way.
8. Durable & corrosion resistant.
9. Good insulation for cold, heat & sound saving energy and reducing noise pollution.
10. It is economical and has a longer life.

11. Maintenance free.

12. Hygienic & problems.
13. Ease of processing/ installation.
Related titles
32°C Partly cloudy

14. Light weight.

Fig 1: Plastic bitumen Road

1.2 TYPES OF PLASTICS

The seven types of plastic include:

1. Polyethylene Terephthalate (PETE or PET)

2. High-Density Polyethylene (HDPE)

3. Polyvinyl Chloride (PVC)

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4. Low-Density Polyethylene (LDPE)

5. Polypropylene (PP)

6. Polystyrene or Styrofoam (PS)

7. Miscellaneous plastics (includes:

Polycarbonate, Polylactide, Acrylic,

Acrylonitrile butadiene, Styrene,

1.3 NEED OF STUDY

1) Disposal of waste plastic is a major problem.

2) It is non-biodegradable.

3) It mainly consists of low-density polyethylene

4) To find its utility in bituminous mixes for road construction.

5) Burning of these waste plastic bags causes environmental pollution.

6) Laboratory performance studies were conducted on bituminous mixes.

7) Studies proved that waste plastic enhances the property of the mix.

10
8) Improvement in properties of bituminous mix provides the solution for disposal in a
useful way.

Fig:2

1.4 WASTE PLASTICS - AS BINDER AND MODIFIER

Waste plastics (polythene carry bags, etc.) on heating soften at around 130°C. Thermo
gravimetric analysis has shown that there is no gas evolution in the temperature range of 130-
180°C. Moreover, the softened plastics have a binding property. Hence, the molten plastics
materials can be used as a binder and/or they can be mixed with binder like bitumen to
enhance their binding property. This may be a good modifier for the bitumen, used for road
construction.

DIFFERENT TYPE OF WASTE PLASTIC (POLYMER) AND ITS ORIGIN

TYPE OF WASTE PLASTIC (POLYMER) ORIGIN

LOW DENSITY POLYETHYLENE (LDPE) bags, sacks, bin lining and squeezable
detergent bottles etc

HIGH DENSITY POLYETHYLENE (HDPE) bottles of pharmaceuticals,

disinfectants, milk, fruit juices, bottle caps
etc

POLYPROPYLENE (PP) bottle cap and closures, film wrapping for

biscuits, microwave trays for ready-made
Meals etc.

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POLYSTYRENE (PS) yoghurt pots, clear egg packs, bottle caps.

FOAMED POLYSTYRENE food trays, egg boxes, disposable cups,

protective packaging etc

POLYVINYL CHLORIDE (PVC) mineral water bottles, credit cards, toys,

pipes and gutters; electrical fittings, etc.

Table No:2

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 CHAPTER 2
CONCEPT OF UTILISATION OF WASTE PLASTIC IN BITUMINOUS
MIXES FOR ROAD CONSTRUCTION

This Concept of Utilization of Waste Plastic in Bituminous Mixes for Road Construction has
been done since 2000 in India.

2.1 BANGALORE'S KK PROCESS

At the initiative of M/s K.K. Poly Flex Pvt. Ltd., a study on the possible use of the processed
plastic waste bags with the bituminous mixes was carried out at the R.V. College of Engineering
Bangalore. A group of students of B.E. degree course in Chemical Engineering of this college
under the guidance of the concerned teaching staff carried out their final year project work
for studying the possibility of using of the processed plastic bags with bitumen and bituminous
mixes. As some encouraging results were reported in this study, M/s K.K Poly Flex Pvt. Ltd.
later approached the Centre for Transportation Engineering of Bangalore University with the
request to carry out further research studies on the effects of using the processed plastic bags
with bituminous mixes for road construction works.
In practice, such a "plastic road" laid in Bangalore (at the busy Raja Rajeshwari Junction) in
March 2001 as a technology demonstration for the Chief Minister, showed superior
smoothness and uniformity and less rutting as compared to a plastics-free read laid at the
same time, which has begun to develop "crocodile cracks". As a result, by now 25 km of
"plastic roads" have been laid in Bangalore, unfortunately without another same-day plastics-
free normal road. All these 25 km are performing well. The process was also approved in 2003
by the CRRI-Central Road Research Institute Delhi, and has thereafter been included in the
Govt of Karnataka's PWD Schedule of Rates. Road life improves through improved tackiness
and viscosity of the bituminous mix, thereby binding the stones more firmly together and
improving the water-resistance of the mix to rain etc.

2.2 FLOW CHART SHOWING METHOD FOR CONSTRUCTION OF ROAD

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14
 CHAPTER 3

MATERIALS USED

3.1 AGGREGATE
The aggregates are bound together either by bituminous materials or by cement. In a few
cases, the rock dust itself when mixed with water forms slurry which acts as a binding medium.
The aggregates may be classified into natural and artificial aggregates. The natural aggregates
again are classified as coarse aggregates consisting of crushed rock aggregates or gravels and
fine aggregates or sand. The blast furnace slag obtained as by-product from blast furnaces is
the one extensively used as road construction material.
Stone aggregate used for road work should be hard, tough, durable and hydrophobic for
bituminous surface. Gravel should be well graded (6.4mm to 38mm) and should have a
fineness modulus of not less than 5.75. Sand should be sharp, well graded, clean of all silts,
clay and organic matter.
The quantity of aggregates used in first coat of surface dressing should be 0.15 m3 per 10 m2
area of 12mm nominal size. On the other hand, the quantity of aggregate used in second coat
of surface dressing should be 0.15 m3 per 10 m2 areas and of 10mm nominal size.

Sr . No Test Permissible
values
1 Abrasion test

a. Using Los Angeles machine (max 35%

b. Aggregates impact test (max) 30%

2 Stripping test (max) 25%

3 Water absorption (expect in the case of slag) 1%

max
4 Soundness test: Loss with sodium sulphate 5 12%
cycles (in case of slag only) max
5 Weight unit or Bulk density (in slag only) 1120 per mucus

Table No:3

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 Fig 3: Aggregate

3.2 BITUMEN
Bitumen is used as binders in pavements constructions. Bitumen may be derived from the
residue left by the refinery from naturally occurring asphalt. As per definition given by the
American Society of Testing Materials bitumen has been defined as "Mixtures of hydrocarbons
of natural or pyrogenous origin, or combination of both, frequently accompanied by their non-
metallic derivatives, which may be gaseous, liquid, semi-solid or solid, and which are
completely soluble in carbon di-sulphide." Bitumen found in natural state known as asphalt
contains large quantities of solid mineral matter
When petroleum crude is refined in a refinery, they are separated by fractional distillation in
the order of decreasing volatility. On distillation of the residual bituminous residue, straight-
run bitumen is obtained. This bitumen is known as penetration grade bitumen or steam
refined petroleum bitumen.

The grades of bitumen used for pavement construction is known as paving grades and that
used for water proofing of structures is known as industrial grades. The grade of straight run
bitumen is chosen depending upon the climatic conditions of the region in which surface

dressing is to be constructed. In most parts of India 80/100 and 180/200 grade bitumen is
used.

Bitumen: 60/70, 80/100 grade bitumen.

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 Fig 4: Bitumen

3.3 WASTE PLASTIC

Plastics are durable and degrade very slowly, the chemical bonds that make plastic so durable
make it equally resistant to natural processes of degradation. Since the 1950s, one billion tons
of plastic have been discarded and may persist for hundreds or even thousands of years.
Perhaps the biggest environmental threat from plastic comes from nurdles, which are the raw
material from which all plastics are made. They are tiny pre-plastic pellets that kill large
numbers of fish and birds that mistake them for food Prior to the ban on the use of CFCs in
extrusion of polystyrene (and general use, except in life-critical fire suppression systems, see
Montreal Protocol), the production of polystyrene contributed to the depletion of the ozone
layer, however, non-CFCs are currently used in the extrusion process
Thermoplastics can be remoulded and reused, and thermoset plastics can be ground up and
used as filler, although the purity of the material tends to degrade with each reuse cycle. There
are methods by which plastics can be broken back down to a feedstock state.

Classification of Plastic Waste:

THERMOPLASTICS
Thermoplastic is a material whose structure and viscosity can be modified both ways through
heating or cooling. This large family of materials is commonly used by many industries and is
easily integrated into France's recycling cycles. The following polymers are some examples of
plastic material:

POLYOLEFINS:
This type of plastic includes materials such as polyethylene (PE, the world's most commonly
used thermoplastic resin), ethylene vinyl acetate copolymers (EVA), as well as polypropylene

17
(PP) which, like PE, is processed by Paper’s recycling factories. Obtained through the
polymerisation of ethylene, polyethylene is a waxy solid, colourless and odourless. It is soluble
at 60 to 80°C in some organic solvents, and is not usually plasticised. Polyethylene comes in
two types: low density PE (LDPE), and high-density PE (HDPE) 11 is used to make plastic bags,
cling films (future recyclable plastic waste), flasks, bottle containers, toys, buckets, basins,
flexible tubing, or cisterns Tupperware also contains PE Bags for industrial use, household
waste, or bottles for cleaning products are commonly made from recycled LDPE and HDPE.
EVA copolymers are used in their pure form or mixed with other thermoplastic materials, for
use in the manufacturing of industrial glues, among other things. Certain additives, such as
calcium fillers, organic or mineral pigments, antioxidants, surface modifiers (for smoothing the
surface of resins and improving electrical conductivity), or pore-forming agents (to create
alveolar material) are added to polyethylene before use.
Polypropylene (PP) on the other hand is a solid obtained through the polymerisation of
propylene which offers good heat-resistance, only melting at 160 or 170°C. It comes in the
form of powder, fibres, or granules, and is used most notably for various filtering products,
pumps, fenders, automobile reservoirs, or various packaging films. As a matter of fact, some
of these products, after going through the plastic packaging recycling cycle, will be used to
make wrapping for industrial liquids. Additives used during its manufacturing are the same as
for PE. The "injection" of PP creates plastics that are easily recycled, except for "film"
PP. It can be noted that thermoplastic elastomers can be obtained by combining EPDM rubber
(ethylene propylene diene monomer) with polypropylene.

VINYL POLYMERS

The vinyl polymer family contains a great number of thermoplastic materials, among which
are: -
Polyvinyl chloride (PVC) that can come in many shapes powdered, granules, a paste, an
emulsion, or dissolved. Supple PVC can be used to make coated textiles for clothing and
leather goods, insulation sheathing, adhesive tape, or tarpaulin (some of these will become
recyclable products). The rigid PVC can be used for sanitation pipes, windows, blinds, gutters,
electrical cables, surfacing, and food or chemical packaging (these are also future recyclable
plastic material). When making this type of plastic, stabilizers, lubricants, plasticisers, fillers,
and pigments can also be added. And although some PVC products, such as plumbing, cannot
be recycled, most can undergo the plastic recycling cycle (such construction waste).
Polyvinyl alcohol (PVOH) comes in the form of a white water-soluble resin, and is particularly
used as a binder coating for paper and cardboard, for industrial glues, or textile finishing.

18
- Polyvinyl acetate (PVAC), whose polymer is a transparent resin, is commercialised as
granules, cartons, pearls, and various solutions. It is used mainly for paints, or quick-dry
varnishes.
- Polyvinylidene chloride (PVDC) is a powder with strong chemical resistance and is highly
impermeable to water vapour, certain gases and oils. Industries uses it to make certain
complex paper-based materials (such aluminium foil) or plastic films.

Fig:5
- Polyvinyl butyral (PVB) or formal (PVF) comes in the form of powder, emulsions, or leaves,
and, due to its strong adhesive power to metal, is used to make various varnishes for copper
or aluminium wiring

* POLYSTYRENES
There are only two major types of polystyrenes: polystyrene (PS), and styrene copolymers
(SAN, ABS, MBS, SBS, or SIS). However, there different PS categories: standard PS, or "crystal'
due to its transparent aspect (it is particularly rigid and fragile), the suppler high- impact PS,
heat resistant PS, and expanded PS (gas bubbles).
Solid up to 140°C after which it liquefies, PS can be delivered as powder, granules, pearls,
paste, solution, or semi-finished products (sheets, tubes, planks...). Chemical additives can
also be used in its manufacturing, such various plasticisers or solvents, some fillers, and certain

19
pigments. It is used for making yoghurt pots, food containers, bathroom cabinets, the inside
of fridge and freezer doors. A styrene copolymer is a chemically or physically improved
polystyrene. It is used to make many products, such as computer casings, coffee filters, jars,
cosmetic packaging, vacuum cleaner cowlings, and even toothbrushes. Some PS and ABS
plastic waste are part of the list of recyclable plastics and are recycled by Paper PS waste can
be recovered into plastic films, packaging, or insulation material.

ACRYLATE AND METHACRYMATE POLYMERS

This type is divided into only two categories, poly(methyl methacrylate) (PMMA) and
polyacrylonitrile (PAN). PMMA is obtained by the polymerisation of methyl methacrylate, and
is characterised by its transparency, the ease with which it can be used, and its resistance to
time. Delivered as sheets, casts, bracers, disks, rods, powder, granules, or syrup, it is used to
make synthetic fibres, lenses for glasses, windows, angle brackets, rulers, contact lenses, and
various hair dressing items. It is one of the plastic industry's recyclable materials. PAN is
particularly used as a synthetic fibre, as it is soluble in certain solvents, which allow it to be
spun. But it is also used for certain food-grade films and jars. PAN is made using only few
additives. PMMA on the other hand uses polymerising catalysers, colorants or pigments,
plasticisers, silica fillers, or solvents.

POLYAMIDE
Polyamide (PA) are alone in their category, but their names indicate the number of carbon
atoms in their monomers (PA 6, PA 11, PA 12, etc). Obtained from
amino-acids or lactams, this very special material does not gradually soften under heat, like
other thermoplastics, but
goes very quickly from a solid to a gaseous state. Though polyamides are mainly used to make
textile fibres, they are also used in switch, electrical plugs, gears, screws, household
appliances, syringes, or automobile parts, and can undergo the plastic recycling cycle.

POLYCARBONATES
Obtained from bisphenol A, polycarbonates (PC) is very rigid and hardly combustible, and is
used in technical products. It comes in the shape of granules, sheets, leaves, or films, and is
used to make CDs, motorcycle helmets, or security glass, and can undergo one of the recycling
cycles.

CELLULOID

20
Celluloid acetate (CA) is a transparent, supple, and stable material that allows industries to
make fibres, varnishes, or photographic films, among other things. Celluloid nitrate (CN) was
used to make celluloid (now considered to unstable), and is now used to make various
varnishes, paints, inks, glues, and certain artificial coatings.

LINEAR POLYESTER
Polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytetramethylene
terephthalate (PTMT), are three of the main linear polyesters, materials synthesized from
ethylene glycol or butylene glycol. With little additives, these were first used to make fabrics
or films (such as trephine), until its resistance to abrasion, oils, saline solutions, and impact
lead the plastic industry to use PET in the composition of ribbons, electronic components, and
recyclable PET bottles, and to use PBTB in mechanical or insulations products that were
submitted to high temperatures. Recycling PET (and specifically PET bottles) is one of parsec’s
many activities in plastic waste recycling. Plastic bottles are recycled into sleeping bags, fabrics
for the car industry, and, of course, nevý bottles.

POLYFLUORETHANE
There 3 types of polyurethanes:
Polytetrafluorethylene (PTFE), polychlorotrifluoroethylene (PCTFE), and polyvinyl fluoride
(PVDF). PTFE comes in a granulated powder form. It has good heat-resistance despite the
fact that it is not really a thermoplastic (when heated to a certain temperature, its irreversibly
turns into a gel), and is known for absorbing very little water, anti-adhesive properties, high
flexibility, and a good resistance to light and bad weather. It is used to make no-stick coating,
pipes, bearings, pads, seals, and technical textile. PCTFE comes in two forms: high-polymer
plastics (granules or powder), and low-polymer liquids. PVDF is a very radiant discovery. still
in development stages. Both of them chemically and thermally more stable than PTFE, and
are used to make certain artificial coatings.

POLYACETAL
Polyoxymethylene (POM) and its similar copolymers are the only polyacetals. Rigid, very
resistant, especially to organic solvents and strong charges, a good electric conductor, POM
comes in the form of moulding powder, granules, and semi-finished products (rods, sticks,
tubes, etc). It is used to make gears, screws, small connecting rods, sliding parts, piping, or
portable tools.

POLYSULFONE

21
Polysulfones, trademarked under such names as Sulfover or Surfil, are macromolecules
containing sulphur dioxide. They are used in paints and varnishes and have a good resistance
to chemical acids and bases, oils, and fats.

POLYPHENYLENE SULFIDE
PPS is a dark and stiff polysulfide. It has good heat and chemical resistance. It is used to make
non-corroding parts, cooking utensils, or non-stick coating.

MODIFIED POLYPHENYLENE OXIDE (PPO)

Modified PPO is difficult to transform. It must be altered and mixed with polystyrene before
it can be industrialised, hence its name.

THERMOSETTING PLASTIC
Thermosetting plastic is a compound that, during condensation polymerization (and/or
implementation), when submitted to a catalyst or a temperature increase, irreversibly cures.
The structure, shape, or rigidity of the manufactured plastic object can not be modified again,
and the material is rarely recycled. This type of plastic includes the following types of
compounds:

UNSATURATED POLYSTER
Unsaturated polyesters are reticulum polymers made from dibasic organic acids (capable of
giving off protons with 2 acid functions). The resin is used to make varnishes, moulded objects,
glues, and various binding agents.

PHENOL FORMALDEHYDE RESINS

Obtained by condensation polymerisation of phenol and formaldehyde, they are usually
abbreviated to PF. It comes in the form of powder, granules, liquid, and solid or liquid resin.
With certain additives, they are used to make some printing inks, foams, abrasive materials,
parts for brakes or clutches, and various paints.

MELAMINE RESINS

22
Melamine, such as Urea-Formaldehyde (UF) or Melamine Formaldehyde (MF), are obtained
through condensation polymerisation of formaldehyde and urea or melamine. UF is used as
an adhesive in the wood industry, and MF is known mainly under the trade name Formica.

POLYEPOXIDES
After the condensation polymerisation of epichlorohydrin with poly-alcohol or phenol (such
as bisphenol A), polyoxides, or epoxy resins, are used in various forms (self-setting resins,
powders, glues, etc) to cover surfaces, for adhesives, and for various paints, allowing them
good resistance to metals.

POLYIMIDE
Polyimides (PI) are made from the reaction of a diamine and a dianhydride, and are among
the more recently synthesized plastics. They have very high heat-resistance, as well as good
resistance to radiation and chemicals. They are mainly used in the form of films, as well as
making supple circuit boards or wiring for electronics.

POLYURETHANE
These complex compounds are made from polyols, chemical catalysts, polyisocyanates or
expanding agents. Polyurethane (PUR) are used in the manufacturing of many products
(foams, paints, condoms, varnishes, glues, and many types of solutions). The textile industry
uses it in an elastomer form to make Lycra.

POLYSULFONE
Polysulfones, trademarked under such names as Sulfover or Surfil, are macromolecules
containing sulphur dioxide. They are used in paints and varnishes and have a good resistance
to chemical acids and bases, oils, and fats.

Waste plastic and its source:

WASTE PLASTIC ORIGIN

LOW DENSITY POLYETHYLENE (LDPE) Carry bags, sacks. milk pouches, bin lining,
cosmetic and detergent bottles.

23
HIGH DENSITY POLYETHYLENE (HDPE) Carry bags, bottle caps, house hold articles
etc.
POLYETHYLENE TERYPHTHALATE (PET) Drinking water bottles etc..

POLYPROPYLENE (PP) Bottle caps and closures, wrappers of

detergent, biscuit. vapours packets,
microwave trays for readymade meal etc..
POLYSTYRENE (PS) Yoghurt pots, clear egg packs, bottle caps.
Foamed Polystyrene food trays, egg boxes,
disposable cups. protective packaging etc
POLYVINYL CHLORIDE (PVC) Mineral water bottles, credit cards, toys,
pipes and gutters; electrical fittings, furniture,
folders and pens. medical disposables; etc

Table No: 4

Fig: 6

24
 CHAPTER 4

PROCESSING DETAILS

i. Collection of waste plastic.

ii. Cleaning and shredding of waste plastic
iii. Mixing of shredded waste plastic, aggregate and bitumen in central mixing plant
iv. Laying of bituminous mix

4.1 COLLECTION OF WASTE PLASTIC: -

Waste plastic is collected from roads, garbage trucks, dumpsites or compost plants, or from
school collection programs, or by purchase from rag-pickers or waste-buyers at Rs 5-6 per kg

Fig 7: Rag pickers

4.2 CLEANING AND SHREDDING OF WASTE PLASTIC:-

Waste plastic litter in the form of thin-film carry-bags, use-and-throw cups, PET bottles, etc.
these are sorted, de-dusted, washed if necessary.

25
Plastic waste which is cleaned is cut into a size between 1.18mm using shredding machine as
shown below.

Fig 8: Cleaning process

Fig 9: Shredding machine

WASTE PLASTICS TO ROAD CONSTRUCTION-IRC GUIDELINES (IRC:SP:98-2013)

➢ Indian Roads Congress has prepared guidelines in 2013 for the Use of Waste
Plastic in Hot Bituminous Mixes (Dry Process) in Wearing Courses

➢ Waste plastic should conform to size passing 2.36 mm sieve and retained on 600
micron sieve.

26
➢ Dust and other impurities shall not be more than 1%.

➢ Plastic is coated over stones improving surface property of aggregates.

➢ Waste plastic should be 6% to 8% of the weight of bitumen in the mix depending on the
climatic condition of high or low rainfall areas

Fig No:10

4.3 MIXING OF SHREDDED WASTE PLASTIC, AGGREGATE AND BITUMIN IN

CENTRAL MIXING PLANT:-

The aggregate mix is heated to 165°c (as per the HRS specification) in central mixing plant.
Similarly the bitumen is to be heated up to a maximum of 160°c.

The 8% of waste plastic to the weight of bitumen are added in the conveyor belt or special
mechanical device is developed which will spray the plastics inside the chamber to coat the
plastics effectively.

Central mixing plant helps to have better control of temperature and better mixing of this
material thus helping to have a uniform coating and heated bitumen is also sprayed

27
 Fig 11: Central mixing plant

4.4 LAYING OF BITUMENOUS MIX:-

The plastics waste coated aggregate is mixed with hot bitumen and the resulted mix is used
for road construction. The road laying temperature is between 1100c to 1200c. The roller used
is 8-ton capacity

Fig 12: Paver Machine

28
 CHAPTER 5

TESTS CONDUCTED ON MATERIALS

5.1 IMPACT VALUE TEST OF AGGREGATE

The aggregate impact test is carried out to evaluate the resistance to impact of aggregates.
Aggregates passing 20 mm sieve and retained on 12.5 mm sieve is filled in a cylindrical steel
cup of internal dia 10.2 mm and depth 5 cm which is attached to a metal base of impact testing
machine. The material is filled in 3 layers where each layer is tamped for 25 number of blows.
Metal hammer of weight 13.5 to 14 Kg is arranged to drop with a free fall of 38.0 cm by vertical
guides and the test specimen is subjected to 15 number of blows. The crushed aggregate is
allowed to pass through 2.36 mm IS sieve. And the impact value is measured as percentage of
aggregates passing sieve (W2) to the total weight of the sample (W).

Aggregate impact value=W1/W2 X 100

Fig 13: Impact test setup

29
Aggregates to be used for wearing course, the impact value shouldn't exceed 30 percent. For
bituminous macadam the maximum permissible value is 35 percent. For Water bound
macadam base courses the maximum permissible value defined by IRC is 40 percent.

Aggregate used: Passed through 20mm sieve and retained on 12.5mm sieve.

Description Sample

1 2

Weight of dry sample (gm) 536 560

Weight of sample retained on 2.36mm 102 106

sieve 'B'

Impact Value (B/A x100) 19% 18.9%

Table No:5

Average Impact Value: 18.95%.

5.2 LOS ANGELES ABRASION TEST OF AGGREGATE

Abrasion test is carried out to test the hardness property of aggregates and to decide whether
they are suitable for different pavement construction works. Los Angeles abrasion test is a
preferred one for carrying out the hardness property and has been standardized in India
(IS:2386 part-IV). The principle of Los Angeles abrasion test is to find the percentage wear due
to relative rubbing aition between the aggregate and steel balls used as abrasive charge. Los
Angeles machine consists of circular drum of internal diameter 700 mm and length 520 mm
mounted on horizontal axis enabling it to be rotated. An abrasive charge consisting of cast iron
spherical balls of 48 mm diameters and weight 340-445 g is placed in the cylinder along with
the aggregates. The number of the abrasive spheres varies according to the grading of the
sample. The quantity of aggregates to be used depends upon the gradation and

usually ranges from 5-10 kg. The cylinder is then locked and rotated at the speed of 30-33 rpm
for a total of 500-1000 revolutions depending upon the gradation of aggregates.

After specified revolutions, the material is sieved through 1.7 mm sieve and passed fraction is
expressed as percentage total weight of the sample. This value is called Los Angeles abrasion
value.

30
A maximum value of 40 percent is allowed for WBM base course in Indian conditions. For
bituminous concrete, a maximum value of 35 is specified.

Description Sample

1 2

Weight of total material (kg) 'A' 5.01 4.97

Weight of fraction passing through 1.7mm 1.291 1.330

sieve 'B'

LA Abrasion Value (B/A x100) 25.8% 26.7%

Table No:6

Average LA Abrasion Value: 26.25%

5.3 PENETRATION TEST OF BITUMEN

It measures the hardness or softness of bitumen by measuring the depth in tenths of a
millimetre to which a standard loaded needle will penetrate vertically in 5 seconds. BIS had
standardised the equipment and test procedure. The penetrometer consists of a needle
assembly with a total weight of 100g and a device for releasing and locking in any position.
The bitumen is softened to a pouring consistency, stirred thoroughly and poured into
containers at a depth at least 15 mm in excess of the expected penetration. The test should
be conducted at a specified temperature of 25° C. It may be noted that penetration value is
largely influenced by any inaccuracy with regards to pouring temperature, size of the needle,

weight placed on the needle and the test temperature. A grade of 40/50 bitumen means the
penetration value is in the range 40 to 50 at standard test conditions. In hot climates, a lower
penetration grade is preferred. The Figure 0.1 shows a schematic Penetration Test setup.

Fig :14

31
Actual test temperature= 25 C

Penetrometer dial Test 1 Test 2 Test 3

reading
(a) Initial 200 264 333
(b)Final 264 333 407
Penetration Value 64 69 74
Table No:7

Mean penetration value= 69

5.4 PENETRATION TEST OF BITUMEN-POLYMER MIX

% of polymer added Penetration Value

0 69
0.5 68
1.0 67
2.0 55.7

Table No: 8

32
 Graph1 : penetration value v/s plastic content

5.5 STRIPPING VALUE TEST OF BITUMEN MIX

Bitumen adheres well to all normal types of road aggregates provided they are dry and free
from dust. In the absence of water there is practically no adhesion problem of bituminous
construction. Adhesion problem occurs when the aggregate is wet and cold. This problem can
be dealt with by removing moisture from the aggregate by drying and increasing the mixing
temperature. Further, the presence of water causes stripping of binder from the coated
aggregates. This problems occur when bitumen mixture is permeable to water. Several
laboratory tests are conducted to arbitrarily determine the adhesion of bitumen binder to an
aggregate in the presence of water. Static immersion test is one specified by IRC and is quite
simple. The principle of the test is by immersing aggregate fully coated with binder in water
maintained at 40°C temperature for 24 hours. IRC has specified maximum stripping value of
aggregates should not exceed 5%.

Type of aggregate Time Stripping%

Plain Bitumen coated 24hrs 5%
aggregate
Polymer coated aggregate 72hrs Nil
Table No:9 Stripping Value

5.6 MARSHALL TEST

Marshal test is extensively used in routine test programs for the paving jobs. The stability of
the mix is defined as a maximum load carried by a compacted specimen at a standard test
temperature of 600 °C. The flow is measured as the deformation in units of 0.25 mm between
no load and maximum load carried by the specimen during stability test (flow value may also
be measured by deformation units of 0.1 mm). This test attempts to get the optimum binder
content for the aggregate mix type and traffic intensity. This is the test which helps us to draw
Marshall Stability vs. % bitumen.

The sample needed is From Marshall stability graph, select proportions of coarse aggregates,
fine aggregates and filler in such a way, so as to fulfil the required specification. The total
weight of the mix should be 1200g.

Procedure to determine Marshall Stability of bituminous mixture:

33
a. Heat the weighed aggregates and the bitumen separately up to 170°C and 163°C
respectively.

b. Mix them thoroughly, transfer the mixed material to the compaction mould arranged on
the compaction pedestal

c. Give 75 blows on the top side of the specimen mix with a standard hammer (45cm, 4.86kg).
Reverse the specimen and give 75 blows again. Take the mould with the specimen and cool it
for a few minutes.

d. Remove the specimen from the mould by gentle pushing. Mark the specimen and cure it at
room temperature, overnight.

e. A series of specimens are prepared by a similar method with varying quantities of bitumen
content, with an increment of 0.5% (3 specimens) or 1 bitumen content.

f. Before testing of the mould, keep the mould in the water bath having a temperature of 60°C
for half an hour.

34
 Graph:2 Marshall stability curve

Optimum Bitumen Content

Mould No. Bitumen Content Stability (Kg) Avg. Stability
1 4.25% 822 822

2 931.6

3 712.4
4 4.50% 822 949.87

5 1013.8

6 1013.8
7 4.75% 685 785.67

8 808.3

9 863.1

Table No:10 Optimum bitumen Content

35
 Graph: 3 Bitumen Content v/s Stability

Plastic mix

Bitumen Content Plastic Content% Stability (Kg)

4.50% 0 1098
6 861
8 947
10 1005
12 1059

Table No: 11 Plastic content v/s Stability

Graph:4 Marshall stability v/s plastic content

36
 CHAPTER 6

METHODOLOGY

Waste plastic bags were collected from roads, garbage trucks, dumpsites and compost plants,
waste-buyers at Rs.5-6 per kg. Household plastic was also collected for the project work, like
empty milk bags, used plastic bags etc. The collected Plastic waste was sorted as per the
required thickness. Generally, polyethylene of 60 micron or below is used for the further
process. Less micron plastic is easily mixable in the bitumen at higher temperature (160°c-
170°c). It is clean by de-dusting or washing if required. Collected Plastic was cut into fine pieces
as far as possible. The plastic pieces were sieved through 4.75mm sieve and retaining at
2.36mm sieve was collected. Firstly, Bitumen was heated up to the temperature about 160°c-
170°c which is its melting temp. Pieces were added slowly to the hot bitumen of temperature
around 160-170°c. The mixture was stirred manually for about 20-30 minutes.

In that time period temperature was kept constant about 160-170°c. Polymer bitumen
mixtures of different compositions were prepared and used for carrying out tests i.e.,
Penetration test, Ductility test.

FIELD TRIALS

There are two types of field trials-:

1. Dry Process

2. Wet Process

6.1 DRY PROCESS-:

For the flexible pavement, hot stone aggregate (170°) is mixed with hot bitumen (160° C) and
the mix is used for road laying. The aggregate is chosen on the basis of its strength, porosity
and moisture absorption capacity as per IS coding. The bitumen is chosen on the basis of its

37
binding property, penetration value and viscoelastic property. The aggregate, when coated
with plastics improved its quality with respect to voids, moisture absorption and soundness.

The coating of plastic decreases the porosity and helps to improve the quality of the
aggregate and its performance in the flexible pavement. It is to be noted here that stones with
< 2% porosity only allowed by the specification.

 Plastic waste like bags, bottles, etc are cut into size between 2.36mm and 4.75mm
using shredding machine.
 The aggregate mix is heated to 170° and then it is transferred to mixing chamber.
 Similarly, the bitumen is to be heated up to a maximum of 160.
 At the mixing chamber, the shredded plastics waste is added over the hot aggregate.
 The plastics waste coated aggregate is mixed with hot bitumen.

Fig 15: Dry Process

Advantages of Dry Process

a. Plastic is coated over stones - improving surface property of aggregates.

b. Coating is easy & temperature required is same as road laying temp.

c. Use of waste plastic more than 15% is possible.

d. Flexible films of all types of plastics can be used.

e. Doubles the binding property of aggregates.

f. No new equipment is required.

38
g. Bitumen bonding is strong than normal.

h. The coated aggregates show increased strength.

i. As replacing bitumen to 15% higher cost efficiency is possible.

j. No degradation of roads even after 5-6 yrs. after construction.

k. Can be practiced in all type of climatic conditions.

j. No evolution of any toxic gases as maximum temperature is 180° C

Disadvantages of Dry Process

a. The process is applicable to plastic waste material only.

6.2 WET PROCESS-:

Waste plastic is ground and made into powder; 6 to 8% plastic is mixed with the bitumen.
Plastic increases the melting point of the bitumen and makes the road retain its flexibility
during winters resulting in its long life. Use of shredded plastic waste acts as a strong "binding
agent" for tar making the asphalt last long. By mixing plastic with bitumen the ability of the
bitumen to withstand high temperature increases. The plastic waste is melted and mixed with
bitumen in a particular ratio. Normally, blending takes place when temperature reaches 45.5°
C but when plastic is mixed, it remains stable even at 55° C. The vigorous tests at the laboratory
level proved that the bituminous concrete mixes prepared

using the treated bitumen binder fulfilled all the specified Marshall mix design criteria for
surface course of road pavement. There was a substantial increase in Marshall Stability value
of the mix, of the order of two to three times higher value in comparison with the untreated
or ordinary bitumen. Another important observation was that the bituminous mixes prepared
using the treated binder could withstand adverse soaking conditions under water for longer
duration.

 Waste plastics by direct mixing with hot bitumen at 160°C.

 Mechanical stirrer is needed.
 Addition of stabilizers and proper cooling.
 Since the wet process require a lot of investment and bigger plants.
 Not commonly used.

39
Advantages of Wet Process
a. This Process can be utilized for recycling of any type, size, shape of waste material (Plastics,
Rubber etc.

Disadvantages of Wet Process

a. Time consuming- more energy for blending.

b. Powerful mechanical is required.

c. Additional cooling is required as improper addition of bitumen may cause air pockets in
roads.

d. Maximum % of waste plastic can be added around 8%.

Fig 16: Wet Process

CHAPTER 7

Comparison between ordinary bituminous roads and waste plastic

bituminous roads
Sl. No. Properties Ordinary Road Roads with Given
Materials

1. Marshall Stability Less More

Value

40
2. Binding Property Good Better

3. Softening Point Less More

4. Penetration Value More Less (Tensile Strength)

5. High Less More

6. Rutting Less More
7. Stripping (Pot Holes) No More

8. Seepage of Water No Yes

9. Durability of the Better Good

Roads

10. Cost of Pavement Less Normal

11. Maintenance Cost Almost Nil More

12. Environment Friendly Yes No

Table No:12

7.1 ADVANTAGE OF WASTE PLASTIC BITUMINOUS MIX

 Stronger road with increased Marshall Stability Value.

 Better resistance towards rain water and water stagnation.

 No stripping and no potholes.

 Increase binding and better bonding of the mix.

 Reduction in pores in aggregate and hence less rutting and ravelling ..

41
 No effect of radiation like UV.

 The strength of the road is increased by 100%.

 The load withstanding property increases. It helps to satisfy today's need of increased

road transport.

 For 1km X 3.75m road, I ton of plastic (10 lakh carry bags) is used and I ton of bitumen

is saved.

 Value addition to the waste plastics (cost per kilogram increases from Rs 4 to Rs12).

 The cost of road construction is also decreased.

 The maintenance cost of road is almost nil.

 Disposal of waste plastic will no longer be a problem.

 The use of waste plastics on the road has helped to provide better place for burying

the plastic waste without causing disposal problem.

7.2 DISADVANTAGES OF PLASTIC ROADS

 Cleaning process- Toxics present in the co-mingled plastic waste would start

leaching.

 During the road laying process- in the presence of chlorine will release noxious

HCL gas.

 After the road laying- It is opined that the first rain will trigger leaching. As the

plastics will merely form a sticky layer, (mechanical abrasion).

 The components of the road, once it has been laid, are not inert

42
7.3 COST ANALYIS FOR ROAD CONSTRUTION

Material Plain Bitumen Plastic-tar Road

Process

80/100 11250 10125kg

Bitumen (Kg)

Plastic Waste 0 1125kg

(Kg)

Cost (Rs.) Rs.393750 (BIT)Rs.367875+(plastic)Rs.13500

=Rs.367875

Cost Reduced NIL Rs.25875

(Rs.)

Carbon Credit NIL 3.5 tonnes

Achieved

Table No:13

43
 Fig:17

ROADS LAID USING WASTE PLASTIC

City/Town Place Year

Madurai Thiagarajan College of 2002

Engineering

Kovilpatti Lenin Nagar 2002

Salem Brindavan Street 2002

Komarapalayam Near bus stand 2002

Chennai Jamb lingam Street 2002

Tiruchi Near SETC bus stand 2003

Salem Hasthampatti 2003

Erode Near Veerabadhra Street 2003

Madurai Thiagarajar College of 2004

Engineering

Chennai Tirisulam Road 2004

44
Mumbai Prabhavadi Road 2004

Thanjavur Bharat Petroleum Depot 2004

Hindpur Supreme Textile Mills 2005

Puducherry Near Assembly 2005

Udhagamandalam Cantonment 2005

Kochi Rajagiri College 2005

Madurai Thiagarajar College of 2005

Engineering

Madurai Vilacheri Road 2005

Madurai Vandiyur Road 2005

Ettayapuram Near Bharati memorial 2006

Dindigul PSNA College of Engineering 2007

Simla Airport Road 2010

Jamshedpur Township 2011

Table No:14 Roads laid using waste plastic

Fig:18

45
 CHAPTER 8

Case studies in India

Plastic roads have gained attention globally as a sustainable solution for waste management
and infrastructure development. In India, several case studies showcase the effectiveness and
feasibility of implementing plastic roads. Here are a few notable examples:

Jamshedpur, Jharkhand: The city of Jamshedpur implemented a pilot project in 2016 where
plastic waste was mixed with bitumen to construct roads. This initiative aimed to address both
waste management issues and road infrastructure needs. The success of this project led to
the expansion of similar initiatives in other parts of Jharkhand.

Indore, Madhya Pradesh: Indore, known for its robust waste management practices,
incorporated plastic waste in road construction to tackle its plastic waste problem. The city
used a mix of shredded plastic waste with bitumen to construct roads. The initiative not only
helped in waste reduction but also improved road quality and durability.

Bangalore, Karnataka: Bangalore has been at the forefront of experimenting with plastic
roads. Several stretches of roads in the city were constructed using a blend of plastic waste
and asphalt. These roads have shown resistance to wear and tear, reduced potholes, and
better longevity compared to conventional roads. The Bruhat Bengaluru Mahanagara Palike
(BBMP) has been actively promoting the use of plastic waste in road construction.

Kerala: The state of Kerala has also embraced the concept of plastic roads. Various
municipalities and local bodies have initiated projects to incorporate plastic waste in road
construction. The Kerala Infrastructure and Technology for Education (KITE) has been involved
in promoting these initiatives, especially in educational institutions.

Pune, Maharashtra: Pune has experimented with plastic waste in road construction through
public-private partnerships. Several roads in the city have been built using plastic waste,
leading to positive outcomes in terms of durability and reduction in maintenance costs.

These case studies highlight the potential of plastic roads as a sustainable solution for
managing plastic waste while simultaneously improving infrastructure quality and durability.
However, challenges such as ensuring proper waste segregation, maintaining quality
standards, and scaling up production remain important considerations for widespread
adoption across the country.

46
Fig No:1

47
 CHAPTER 9

CONCLUSION

 The generation of waste plastics is increasing day by day.

 The major polymers namely polyethylene, polypropylene, polystyrene show adhesion
property in their molten state Plastics will increase the melting point of the bitumen.
 The waste plastic bitumen mix forms better material for pavement construction as the
mix shows higher Marshall Stability value and suitable Marshall Coefficient.
 Hence the use of waste plastics for pavement is one of the best methods for easy
disposal of waste plastics.
 The use of the innovative technology not only strengthened the road construction but
also increased the road life as well as will help to improve the environment and also
creating a source of income.
 Plastic roads would be a boon for India's hot and extremely humid climate, where
temperatures frequently cross 50°C and torrential rains create havoc, leaving most of
the roads with big potholes.
 It is hoped that in near future we will have strong, durable and eco- friendly roads
which will relieve the earth from all type of plastic-waste.

48
 REFERENCES

 USE OF PLASTIC WASTE IN FLEXIBLE PAVEMENTS, Miss Apurva J Chavan, Volume 2,

Issue 4, April 2013.
 Use of Plastic Waste in Road Construction, Shweta N. Rokdey, Sevagram P. L. Naktode,
Sevagram M. R. Nikhar

 PLASTIC WASTE: IT'S USE IN CONSTRUCTION OF ROADS, Kurmadasu Chandramouli,

Allipilli Satyaveni, Vol. No. 5, Issue 01, Feb 2

49