GPEC 2005 Paper Abstract #27:

Title: Utilization of Waste Plastics in Construction of Flexible Pavements

(Reuse of waste plastics – a path – breaking initiative)

Author(s): Dr. R.Vasudevan, Professor & Head of Department of Chemistry,

Thiagarajar College of Engineering, Madurai – 625 015,
Tamil Nadu – INDIA
S. Rajasekaran, Project Associate, Dept. of Chemistry,
Thiagarajar College of Engineering, Madurai – 625 015,
Tamil Nadu – INDIATCE, Madurai, INDIA

Susnata Samanta, Georgia Institute of Technology (presenter)

ABSTRACT

Plastics are user friendly but not eco-friendly as they are non-biodegradable,
Generally it is disposed by way of land filling or incineration of materials which are
hazardous. The better binding property of plastics in its molten state has helped in
finding out a method of safe disposal of waste plastics, by using them in road laying.

The aggregate is heated to around 170°C. To that the waste plastics (carry bags, cups &
thermocole made out of Polyethylene, Polypropylene & Polystyrene) after processing, is
added. They get melted and coated over aggregate. Then the bitumen (160°C) is added
and the aggregate – polymer- bitumen mix is used for road laying. The mix has higher
Marshall value, lower penetration value and resistance to water penetration

The benefits are many - Helps in safe disposal of waste plastics by a eco-friendly way;
improved solid waste management; better environmental hygiene; reduction in the
consumption of bitumen by 10%; No toxic emission; better road; withstand heavy load;
No pothole formation; value added to waste plastics; cost is less; mix used for Rural &
Highways roads.

The plastics tar road has been already laid for 1500 km in India at different places like
State Capitals as well as rural roads. The performance of these roads is good. Even after
24 months.

E-mail Id: vasudesikan@yahoo.com

Phone no: 914522483585 & Mobile no: 09842195263

 UTILISATION OF WASTE PLASTICS
IN CONSTRUCTION OF FLEXIBLE PAVEMENT

PAPER SUBMITTED FOR CONFERENCE ON

GPEC 2005-PED Division

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 UTILISATION OF WASTE PLASTICS
IN CONSTRUCTION OF FLEXIBLE PAVEMENT

CONTENTS
1. INTRODUCTION
2. UNDERSTANDING PLASTICS
2.1 Disposal of plastics:
2.2 Modified Bitumens
3. REUSE OF WASTE PLASTICS
3.1. Plastics – as Binder and Modifier
3.2. Study on Waste Plastics for Road Construction:
Determination of solubility of polymer in Bitumen.
Determination of softening point
Penetration Test
Ductility:
Flash and fire point
3.2.6 Characterization of Waste Plastics-Bitumen-Aggregate mix for flexible
Pavement:
3.2.6.a) Soluble region (<2% plastics) waste
3.2.6.b) Higher percentage region
3.2.6.c) Effect of Variation of Polymer content with the variation of bitumen
Study on the nature of the polymer coating on aggregate:
4. RESULTS AND DISCUSSION:
5. SIGNIFICANCE AND UTILIZATION POTENTIAL
6. REFERENCES

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 UTILISATION OF WASTE PLASTICS
IN CONSTRUCTION OF FLEXIBLE PAVEMENT

1. Dr.R.VASUDEVAN 1. Mr. S.RAJASEKARAN 2. Mr. S.SARAVANAVEL

1. INTRODUCTION
Bitumen is an useful binder for road construction. Different grades of bitumen like
30/40, 60/70, and 80/100 are available on the basis of their penetration values. The steady
increase in high traffic intensity in terms of commercial vehicles, the increase in over
loading of trucks and the significant variation in daily and seasonal temperature demand
improved road characteristics. Any improvement in the property of the binder is the need
of the hour.
Elastomers like natural rubber, crumb rubber, SBR, etc. as well as Plastomeric
substances like Polyethylene, Ethylene Vinyl Acetate and Ethylene Butyl Acrylates are
mixed with Bitumen to modify the properties. Modified Bitumen possesses better quality1.
Today the availability of the waste plastics is enormous, as the plastic materials
have become part and parcel of daily life. They either get mixed with Municipal Solid
Waste and or thrown over land area. Their present disposal is either by land filling or by
incineration. Both the processes are not Ecofriendly. Under this circumstance, an
alternate use for the waste plastics is also the need of the hour.
Plastics are organic in nature and Bitumen is also a mixture of organic compounds.
Hence the mixture of the two is possible.

1. Dr. R.Vasudevan, P.hD. 1. Mr. S.Rajasekaran.M.Sc., 2. Mr. S. Saravanavel. M.Sc.(Engg.)

Professor, Head, Project Associate Chief Engineer
Dept. Chemistry Dept. Chemistry National Highways
Thiagarajar College of Engg TCE Tamil Nadu - INDIA
Madurai – 625 015

RV SR

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 The waste polymer bitumen blend can be prepared2 and a study of the properties
can throw more light on their use for road laying.
2 UNDERSTANDING PLASTICS
The most used plastics/polymer materials are polyethylene, polypropylene,
polystyrene and polyvinyl chloride. Almost 90% of the polymeric materials are made up of
either polyethylene or polypropylene or polystyrene.
Around 130-140deg.C they get softened without releasing any gaseous products3.
(Table – 1)
Thermal Behaviour of Polymer3,4,5 Table – 1

Solubility Decom
Softening Ignition
position
Temperat Products Products temp. Products
Polymer Temp.
Water EPT ure range reported reported range in reported
range in
in Deg.C Deg. C
Deg.C
CH4,
PE Nil Nil 100-120 No gas 270-350 >700 CO,CO2
C2H6
PP Nil Nil 140 - 160 No gas 270-300 C2H6 >700 CO,CO2

PS Nil Nil 110-140 No gas 300-350 C6H6 >700 CO,CO2

C2H6, CO,CO2,
PVC Nil Nil 200-220 HCl 320-350 >700
HCl Cl2& HCl

Extraction Procedure of Toxicity (EPT) – 5% of Acetic acid solution.

It is to be noted that when PVC is incinerated (>700deg.C), it releases carbon, and
gases like CO,CO2,Cl2 etc. In the presence of oxygen, chlorine, carbon and metals like
Copper and around 350deg.C it may produce gases like Dioxins (the Toxic gases) 7,8.
2.1 Disposal of plastics:
The present day disposal of plastic waste, especially Municipal Solid Waste
containing plastics, is carried out by 1. Land filling and 2. Incineration
Land filling is a process in which the waste materials are buried in a specific area, away
from the city. This process is purely temporary. This may result in (1) affecting water
recharge, (2) reducing soil microbial activity (3) clogging the drainage and (4) water line

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 clogging. Such clogging may result in the production of gases like methane, which affects
Green House effect. Above all, land availability for filling is also a problem.
Incineration is normally carried out above 700 degree C. Incineration of polymers like
PE, PP, PS produces gases like CO, CO2 etc. and these gases cause global warming, air
pollution, monsoon failure, etc. If PVC is mixed with the waste, it may result in the
production of HCl, Cl2 and sometime Dioxin, the poisonous gas.
Incineration could also aggravate pollution problem if strict standards are not
enforced and the process also needs scientific monitoring.
2.2 Modified Bitumens
Addition of natural or synthetic polymers to bitumens is known to impart enhanced
service properties. By adding small amounts of polymers to bitumen, the life span of the
road pavement may be considerably increased. The purpose of bitumen modification using
polymers is to achieve desired engineering properties such as increased shear modulus and
reduced plastic flow at high temperatures and/or increased resistance to thermal fracture at
low temperatures.
Homopolymers, like high and low density polyethylene and polypropylene, as well as
random and block copolymers, like ethylene-vinyl acetate, ethylene/propylene, styrene-b-
butadiene-b-styrene and styrene-b-ethylene-co butylene-b-styrene, have been used as
bitumen modifiers.
However, the major obstacle to widespread usage of polymer-modified bitumen in
paving practice has been their tendency towards gross phase separation under quiescent
conditions at elevated temperatures 4. A precise study on processing conditions of binders
and polymeric additives selection are, thus, required.
Moreover, incompatibility, unstabilization of emulsions, higher cost of polymer and
cumbersome procedure of the preparation of the mix add to the complexity of the process.
3. REUSE OF WASTE PLASTICS
3.1. Plastics – as Binder and Modifier6
Waste plastics (carry bags, etc.) on heating softens around 130-140 degree C. A
study using thermo gravimetric analysis has shown that there is no gas evolution in the
temperature range of 130-180 degree 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.

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 Waste plastics are available in plenty in the form of carry bags, cups and
thermocole. Use of these materials to improve the bitumen property can help in many
ways like (1) easy disposal of waste, (2) better road and (3) prevention of pollution and so
on.
3.2. Study on Waste Plastics for Road Construction:
3.2.1 Determination of solubility of polymer in Bitumen.
The waste polymers such as polyethylene (as sheets) polypropylene (sheets; film)
and polystyrene (thermocole) are soluble to the extent of 1 to 2% of the bitumen.
it was observed that we need to characterise the two types 1. waste plastics-
bitumen blend containing <2% and 2. the mix containing >2%.
Samples were used to carry out the following tests namely,
1. Softening point 2. Penetration Value 3. Flash & Fire point and 4. Ductility test
3.2.2 Determination of softening point:
The blends of different composition with different polymers have been prepared
and their softening points were determined. (Table –2)
Determination of Softening point Table-2
% of polymer in Softening Point
Bitumen PE PP PS CRUMB+PE
0 50.2 50.2 50.2 55
0.5* 52 57 53 57
1.0* 60 61.5 60 63
2.0* 58.2 58.5 57 60
5.0** 62.0 61.0 59 62
Softening point of bitumen used was 50.2
It is observed that the softening point increases by the addition of polymer to the
bitumen. The influence over the softening point is depended on the chemical nature of the
polymer added.
3.2.3 Penetration Test:
Penetration Value Table – 3
% of polymer in Penetration Value
Bitumen PE PP PS CRMB 55
0 70.0 70.0 70.0 55
0.5* 68 70.3 71.3 54
1.0* 67 68.57 68.5 53
2.0* 55.7 62.75 62.7 50

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 5.0** 52 - - 41
10.0** <40 - - <40

The increase in the percentage of polymer decreases the penetration value. This shows that
the addition of polymer increases the hardness of the bitumen.
3.2.4 Ductility:
The following data shows that the ductility is increasing by the addition of polymer
to Bitumen.
Ductility value Table - 4
Percentage Ductility
of Polymers PE PP PS
0 20.0 20.0 20.0
0.5* 28.1 31.5 28.6
1.0* 29.3 79.9 26.9
2.0* 35.4 72.9 20.7

The increase in the ductility value may be explained as follows. The long polymer
molecules when mixed hot, physically interlock the material and this may help to reduce
cracking at the surface.
3.2.5 Flash and fire point
The study of flash and fire points of the polymer–bitumen blend (Soluble region
only table - 6) helps to understand the inflammability nature of the blend.
Flash & Fire point Table - 5
Polyethylene Polypropylene Polystyrene
Percentage
Flash Fire Flash Fire Flash Fire
of Polymer
Point Point Point Point Point Point
0.25 280 340 320 345 240 300
0.5 290 350 330 340 270 310
0.75 295 330 333 350 280 315
1.00 340 350 342 355 295 320

3.2.6. Characterisation of Waste Plastics-Bitumen-Aggregate mix for flexible

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 Pavement:
The utility of the Waste Plastics-Bitumen–Aggregate mix for flexible pavement
construction is characterised by studying 1. Stripping value and 2. Marshall stability
value of the mix.
Method – I
3.2.6.a) Soluble region (<2% plastics) waste
Stripping value
Waste plastics are dissolved in bitumen (2% PE) and the blend is coated over
aggregate. It is tested by immersing in water. Even after 72 hrs., there is no stripping
showing increased resistance to water. This shows that the blend has better resistance
towards water. This may be due to better binding property of the polymer – bitumen blend.
Marshall Test:
The Marshall stability values were determined for the waste polymer bitumen blend
having the percentage of maximum 2% (in the soluble region). (Table –6)
Marshal Stability value Table -6
Percentage of Waste Polymer Marshall Stability Value in kg
0 1100
1 1600
1.5 1680
2 1780

This shows that waste plastic-bitumen blend has higher strength compared to pure
bitumen, whose value is approx. 1100 kg.
Note: the percentage of polymer added is always with respect to the weight of bitumen
used.
Addition of waste plastics 10% - (for Illustration only)
Wt. of aggregate: 1200gms Wt. of Bitumen 60gms Wt. of Waste Plastics: 0.6 gms
3.2.6. b) Method – II: Modified process(Higher percentage region )

Alternate method was innovated to find an effective way of using higher percentage
of waste plastics-bitumen mix. In this method, initially the aggregates were heated to
around 170 degree C. Then the plastic wastes, in the form of small pieces (passing 4.75
mm sieve – normally with a thickness of 60 micron and below) were added to the heated

8
aggregate. This has enabled to give an uniform coating of plastics waste over the
aggregates. To this hot plastics coated aggregates, the hot bitumen was added. An
uniformly coated mix was obtained. This was used for carrying tests (1) stripping test and
(2) Marshall test
1) Stripping Test: The aggregate was coated with waste plastics with a known
percentage and then the bitumen is coated at hot condition. The waste plastic-
bitumen-aggregate mix was immersed in water. Even after 96 hrs., there was no
stripping. This again shows that the waste plastic-bitumen coated mix has good
resistance towards water. This may be due to (1). Increased binding of the waste –
plastics – bitumen blend and (2). Coating of polymer (a non- wetting material) over
the aggregate.

2) Marshall Test:
a) Effect of addition of waste plastics
Marshall Stability Value (Table – 7)
% of Binder Content Percentage of Waste Marshall Stability
Polymer Value in kg
4.6 0 1150
4.6 5 2010
4.6 10 2540

It is observed that the addition of waste plastics (PE) increases the Marshall Stability value.

b) Effect of variation of Bitumen content.

Keeping the percentage of polymer added as 10%, the bitumen content of the mix was
varied and the Marshall Stability values were determined
(Percentage of Polyethylene 10%) (By weight of Bitumen)
Table – 8 (Graph – 1)
% of Marshall
Bitumen Value in Kg
4.2 1960
4.5 2520
4.6 2540

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 5.0 2520
5.4 2500

It is observed that the Marshall value obtained is generally much higher than for the pure
bitumen mix. It is also observed that the addition of waste plastics reduces the need of
bitumen. For an effective binding as per the IV revision (High ways road & Bridge
construction). 5% of bitumen is to be added. From our experimental results it is observed
that the addition of lower percentage of bitumen with waste plastics blend shows much
higher Marshall value.( Table – 9). It is also helping to reduce the quantity of bitumen to
the extent of 10% to 15%.

MARSHALL STABILITY VALUE - Graph -1

3000

2500

2000
STABILITY VALUE IN Kg

1500

1000

500

0
0 1 2 3 4 5 6
% OF BITUMEN

3.2.6. c Effect of Variation of Polymer content with the variation of bitumen

The study of the effect of both the variation of waste plastics content and
the bitumen content in the waste plastics-bitumen-aggregate mixture was carried out
and Marshall values are given in table-9

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Effect of Variation of Polymer content with the variation of bitumen Table –9 (Graph – 2)
% of Bitumen % of Polymer Marshall Value
4.6 0 1150
4.6 5 2010
4.6 10 2540
4.6 15 2440
4.6 20 2300
5.0 15 2670
5.0 20 2040
5.5 20 1830

MARSHALL STABILITY VALUE - Graph -2

3000

2500

2000

1500

1000

500

0
0 5 % OF10P OL YM ER ( P OL YET H YL EN E) 15 20

It is observed that the addition of waste plastic increases the Marshall stability value to a
fairly high value. It is also observed that the addition of 10% waste plastics gives higher
value at the optimum percentage of Bitumen (4.6%). Higher percentage of waste plastics,
though give higher Marshall Stability Value, they need increased percentage of Bitumen.
In general, it may also be concluded that this method is the best suited process for the use
of higher percentage of plastics waste and for higher performance of the flexible
pavement.

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 Hence it may be inferred on the basis of Marshall Stability Value that the 10% blend of
waste plastics is an optimum percentage for road construction, considering the cost factor
and the consumption of bitumen. Further, ‘time – temperature’ study on mini hot mix
plant for an effective mixing was carried out.
3.2.7) Study on the nature of the polymer coating on aggregate:
A known quantity of aggregate (1000gms) was taken and heated to around
700deg.C to remove all volatile impurities. It was cooled to room temperature. The cooled
aggregate was again heated to 170deg.C. To the hot aggregate, 7gms of waste plastics
polyethylene material (passing 4.75mm and retaining 2.36mm) was added uniformly and
cooled to room temperature. The aggregate – polymer blend was divided into five
fractions. Each fraction was separately heated to > 700deg.C to burn all the polymers
coated over the aggregate. It was then again cooled to room temperature and the weights of
aggregates were noted. The results are tabulated below.
Study of Polymer coated aggregate Table - 10
Weight of aggregate fraction
Different in Weight
Before burning After burning Percentage
100 99.40 0.60 6.03
200 198.65 1.35 7.30
100 99.60 0.40 4.05
300 297.80 2.20 7.40
307 304.55 2.45 8.04
1007 1000.00 7.00 ≈ 7%

Average = 6.56%
4. RESULTS AND DISCUSSION:
From the above experimental results (Tables 2 to 9) it is observed that the polymer-
blended bitumen has better properties regarding Softening point, Penetration point,
Ductility, Stripping Value and Marshall Stability value. Hence the blend can be used for
laying flexible pavement.
Method 1:
The blending was tried by directly mixing the shredded polymer with hot bitumen
at 160 deg. C. Here the mixing of higher percentage of polymer was rather difficult due to
large difference in the viscosity of the molten polymer and that of Bitumen. A powerful

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mechanical stirring was needed to ensure effective mixing to get a better blend. This also
needed the addition of stabilizers and proper cooling, yet the blend was not stable and the
maximum percentage that can be added was around 2%. Only test roads were laid using
this method.
Method 2:
A novel technique is developed to use higher percentage of waste plastics in road
construction and using this technique an alternate method is being used.
In this method, the waste polymer was added on the hot aggregate (170deg.C). The
polymer was coated over the aggregate. Here the spreading was easy. The hot aggregate
was coated with polymer uniformly. Then the Bitumen was added. The mixing of bitumen
with polymer was taking place at the surface of the aggregate. The temperature was around
155 –163 deg .C. Both the polymer and bitumen were in the liquid state. With the increase
of surface area of contact, the mixing of polymer film with bitumen film would be better as
both are similar in chemical nature and are in liquid state. And thus a better blend is
formed. This blend is having better binding property, which is observed from its properties
like Marshall stability value etc.
The formation of fairly uniform coating is also observed from the experimental
results (table-9). This technique was used for the construction of road using Mini Hot Mix
plant. ( Tests strips were laid at different places in Tamil Nadu using this method – list
enclosed)
On the basis of above reasoning various aspects regarding the polymer – Bitumen
road are also being discussed below:

4.1 Stripping test

Most of the aggregates used in road construction have greater affinity for water due to
inherent wetting nature of the aggregate than for bitumen. This results in the penetration of
water between aggregate and Bitumen layer. Thus bitumen film is often stripped off the
aggregates in the presence of water. This stripping results in pothole formation.
When polymer is coated over aggregate, the coating reduces its affinity for water due to
non-wetting nature of the polymer and this resists stripping. More over the polymer –
bitumen blend is having higher binding property too. This also resists stripping and hence
pothole formation is very much reduced.
4.2 Leaching test

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 Polymers are not soluble in water or acids and even in most of the organic solvents.
The Toxicity test solution is 5% acetic acid. The polymer waste is tested with this 5%
acetic acid solution (EPT) and it is observed that there is no dissolution of polymer.
Therefore it may be concluded that polymer will not leach out of the bitumen layer, even
after laying the road using waste plastics-bitumen-aggregate mix.
4.3 Pot hole formation
Stagnation of water over bituminous surface results in stripping of bitumen. This
subsequently results in pothole formation. In the case of polymer bitumen blend, the
penetration of water is not much as explained earlier. Hence the potholes are not formed
easily. This is observed in the various test stretches laid by the author at different places.
4.4 Dioxin formation
The fear about the formation of Dioxin, the toxic compound, during the heating of
polymers is always in the mind of people.

Dioxin may be formed under the following condition.

300 - 400°C
Carbon + Oxygen + Chlorine Dioxin
Copper Catalyst

Presence of Chlorine, Copper and appropriate temperature are needed to form the Dioxin.27
In the process of the preparation of polymer Bitumen aggregate mix, the temperature used
is only ≈ 170°C and no chlorine or copper is present in the system. Mover over, the
polymer materials used are polyethylene, polypropylene and are polystyrene only and we
do not use polyvinyl chloride. Hence, there is no possibility of presence of chlorine in the
system. Hence Dioxin does not form during the use of waste polymer for road
construction. So it is a safe disposal of waste polymers.
4.5. Effect of Bleeding
The increase in the softening point shows that there will be less bleeding during
summer. Bleeding accounts, on one side, increased friction for the moving vehicles and on
the other side, if it rains, the bleedings accounts for the slippery condition. Both these
adverse conditions are much reduced by polymer-Bitumen Blend.
4.6 Special Aspects
The whole process is very simple.
It needs no new machinery.
The technology is also very simple.

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 The waste plastics available in the surrounding area can be used then and there.
Moreover Crumb rubber required 180 deg.C whereas 60/70 needs 160 deg.C only.
This accounts for fuel conservation.
Roads – Already laid: (The technique and the process are patented)
Using waste polymer bitumen aggregate mix, roads have been laid at different
places at Tamil Nadu using different surface area and different composition. The
conditions of roads are under observation and they are performing well till today – though
it is a short period of observation. ( list enclosed)

5. SIGNIFICANCE AND UTILIZATION POTENTIAL

The polymer bitumen blend is a better binder compared to plain bitumen

The blend has increased Softening point and decreased Penetration value with a
suitable ductility
When used for road construction it can withstand higher temperature. Hence it is
suitable for tropical regions
It has decreased Penetration value. Hence its load carrying capacity is increased.
The blend with aggregate has no stripping value. So it can resist the effect of water
The Marshall stability value is high.
The bitumen required can be reduced depending upon the % of polymer added. It is
a good saving too.
If 1 ton of Crumb is used, the cost is Rs. 13000
If 1 ton 60/70 grade Bitumen is used, the cost is Rs.10, 000
4% of bitumen is saved Hence the cost is Rs. 9600
100 kg of Plastics waste costs Rs. 500
Total cost Rs. 10,100
The quality is definitely better than CRMB with the saving of Rs. 2500/Ton
Moreover CRMB requires 180deg.C where as 60-70 grade bitumen 160deg.C.
This helps fuel conservation
The waste polymer, other wise causing pollution by way of land filling and
incineration has a better place to stay.
The operation temperature is below 160 – 170 deg. C
No toxic gas is produced. Dioxin is not formed during this process.
Disposal of waste plastic is no longer a problem.
The binding properties of polymer also improve the strength of mastic flooring.

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 The use of waste plastics on the road has helped to provide better place for
burying the plastic waste without affecting the environment. At the same time, a
better road is also constructed. It also helps to avoid the general disposal technique
of waste plastics namely land filling and the incineration, which are not
ecofriendly processes. They result in either land pollution or air pollution.
By spraying the waste polymer pieces (passing 4.5mm) the mixing is done. The
process is simple and easy.

6. REFERENCES

1) IRC Special publication 53 “Tentative Guidelines on use of polymer and rubber

modified Bitumen in road construction Indian road congress, New Delhi – 1999
2) De Quimica, Spain Rheological properties of Bitumen Modified with Polyethylene and
Polyethylene based blends, (2002)
3) Polymer Hand Book – Products of Thermal Degradation of Polymers – John. Ligget,
Pp. 11-452, 453, 461. & Physical constants of PE. By Leizhn and other V: 14
4) Dioxin Home page. Htm ( Google.com) page (1-6)
5) Nabil Mustala, Canadian Plastics Institute, Toronto, Canada - Plastics Waste
6) P. Wloczysiak.A.Vidal .E.Papires. P. Gauvin, J. Appl. Polym.Sci. 65 1595-1607 (1997)

Benefits:
Helps in safe disposal of waste plastics.
Contributes for improved solid waste management.
Ensures better environmental hygiene.
Reduces consumption of bitumen by 10%.
Provides supplementary income to self help groups.
No toxic emission and hence very much eco friendly.
Decreases penetration point and increases load-bearing capacity of the road.
Reduces wear and tear and increases life of the road.
Avoids melting of bitumen during summer.
No stripping value and hence water resistive.

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Promotional efforts:
1. 1000 kms of road using waste plastics bitumen blend have been taken up as
per the order of the Honourable Chief Minister of Tamil Nadu.
Training programme on the technology organised to all the Engineers by
Govt.
District level training programmes organised for Self Help Groups to
Shred and sell the collected plastics. So far 153 SHGs have taken up this
activity.
2. Similar work has been initiated by the Chief Minister of Pondicherry on 18-
6-2004 at Pondicherry.
3. Chennai Corporation has laid 12 roads.
4. Various important cities have laid test plastics tar roads.
5. At Thiagarajar College of Engineering, the 300m hostel road is laid using
275 kg waste plastics.
6. CPCB Delhi has signed MoU with Thiagarajar College of Engineering,
Madurai for preparing the proposal to be used as guidance by different
organization for road laying.
7. Highways Department has published policy note on “the use of waste
plastics for road construction” – Demand No:20 , 2003-04.
8. Various organizations have invited me to give special lecture and to conduct
workshop on plastics – tar road construction.
9. some of the organization listed below
CII, FICCI, ICPE, IPF, City Corporations etc,.
10. Carrying out awareness campus at schools and colleges to impart garbage
culture.
Our beloved president Dr. A.P.J Abdul kalam has blessed the process thrice
during his visit to the College campus.
Report about our work

1. Google Search: Polymer Bitumen Road laying Results, 1; 3 &5

2. The Hindu, 20-11-2001 and 14-5-2002, 9.1.04, 19.1.04 & 5.6.04

17
 3. Chemical World 29-7-2002
4. Ananda Vikatan 18-8-2002 & 27-10-2002
5. Construction World Volume: 5:No: 7 Page 76 April 2003
6. Eco- Echoes. Vol:3 Oct/Dec:2002 N0:4 P-5
7. Indiasuperpower.com
8. UGC- GYAN DARSHAN programme - 3 lectures
9. Chemical Industry digest , Nov’03.
10. All India Radio- Madurai & Tuticorin
11. All the road laying works have been reported in dailies TV and other magazine.
Important Publication:
Utilisation of waste plastics in construction of flexible pavement – Indian roads
congress, 48th Highways Research Board Meeting 15th June’03 Pondicheery
By Dr.R.Vasudevan, Mr.S.Rajasekaran, Research Associate Dept. of Chemistry,
Thiagarajar College of Engineering, Madurai – 15 & Mr. S.Saravanavel, Chief
Engineer (Highways), Tamil Nadu
Paper communicate to Indian Roads congress, New Delhi
By Dr.R.Vasudevan , Mr.S.Rajasekaran & Mr. S.Saravanavel, Chief Engineer
(Highways), Tamil Nadu
Envis – Indian Centre for Plastics in the Environment Vol.2 issue 3, April’04
P. 1-4.
Tamil Nadu Government released a pamphlet about the work.
Title on “Reuse of waste plastics – a path – breaking initiative”
Paper presentation
International conference organised by Indian Plastics Institute at Mumbai
December’03.
All India seminar on Flyash utilisation and disposal: organised by Tamil Nadu at
Chennai on 11 & 12th Oct’03.
Polymers – The economic times, May – June’2004, P41 – 45.
IPI journal; Vol:9 April 2004, P.30-35.
Special lecture delivered on Waste Plastics for Road construction
1. Corporation of Chennai, Chennai – 17-9-2002
2. Symposium Conducted by Chepmma – 19-9-2002
3. Enviro 2002: Confederation of Indian Industry - 15-11-2002
4. Tuticorin Port Trust, Tuticorin –5-12-2002

18
 5. High Ways Research Station, Chennai – 11-12-2002
6. Regional Administration Karaikal, Pondichery
7. National Seminar an Waste Management by FICCI – Mumbai – 26-2-2003
8. IPF – Calcutta 20th August’04
9. ICPE &Mumbai corporation, Mumbai- 8th Oct’04
10. CII & IIT, Chennai, 26th July’04
PATENT REGISTRATION
1. A New mix design of waste plastics –aggregate –bitumen for flexible
pavement.
Registration No: 488/MAS/2002 dt.27-06-2002
2. Waste Polymer – Granite blend for block making
Registration No: 220/MAS/2003 dt.17-03-2003

Approved by the Chief Minister of Tamil Nadu Dr. J. Jayalalithaa and a scheme
for laying Waste plastics – Tar road in Rural area for 1000 km was launched on
16th July 2003 and the State Government as organized training programme both
for Engineers and Self Help Group this regard.
More than 1000 km length or rural roads (35km on an average/ District – 28
District) have already been laid before March’2004.

19
List of Roads laid using waste plastics - Table-11
Blend Date Nature of
Process Area
Composition Road
Polymer Blending 5% PE 23nd Concrete
TCE 60’x 5’
with Bitumen 1% PE March -02 Road
Polymer Blending 4th WBM
Kovilpatti with Metal and the 10% PE 600’x12’ October- road
Mixing with Bitumen 02
Polymer Blending 5th Concrete
Madurai with Metal and the 15% PE 180’x10’ October- Road
Mixing with Bitumen 02
Polymer Blending 15th Concrete
Salem with Metal and the 10% PE 1000’x12’ October- Road
Mixing with Bitumen 02
Polymer Blending 15th Concrete
Komara- 10%
with Metal and the 300’x12’ October- Road
palayam Mixture *
Mixing with Bitumen 02
Polymer Blending 22nd Concrete
Chennai 12%
with Metal and the 600’x18’ November Road
** Mixture *
Mixing with Bitumen -02
Polymer Blending 10th Concrete
10%
Trichy with Metal and the 600’x18’ January- Road
Mixture *
Mixing with Bitumen 03
Polymer Blending 17th April- WBM
10%
Salem # with Metal and the 5000’x 18’ 03
Mixture *
Mixing with Bitumen
Polymer Blending 7th May-03 Bitumen
10%
Erode with Metal and the 1500’x 24’ road
Mixture *
Mixing with Bitumen
Polymer Blending 10th May- WBM
10%
Theni with Metal and the 300’x18’ 03
Mixture *
Mixing with Bitumen
Polymer Blending 16th May- WBM
10%
Nagercoil with Metal and the 1500’x18’ 03
Mixture *
Mixing with Bitumen
Polymer Blending
Madurai- 10%
with Metal and the 1.4 km WBM
Kombadi Mixture *
Mixing with Bitumen
• Road waste Plastics ** Ten more Roads laid during May 2003
# Central Mixing Plant
Approved by the Chief Minister of Tamil Nadu Dr. J. Jayalalithaa and a scheme
for laying Waste plastics – Tar road in Rural area for 1000 km was launched on

20
16th July 2003 and the State Government as organized training programme both
for Engineers and Self Help Group this regard.
More than 1000 km length or rural roads (35km on an average/ District – 28
District) have already been laid before March’2004.

21
 Hearty Welcome to ALL

THIAGARAJAR COLLEGE OF ENGINEERING

MADURAI – 625 015

TAMIL NADU - INDIA
 The Institute
Founder : Late Karumuttu Thiagarajan Chettiar

Chairman : Dr(Mrs).Radha Thiagarajan

Former Vice Chancellor, Alagappa University

Vice-Chairman : Karumuttu T.Kannan

former Chairman, CII Southern Region.
 Dr.R.Vasudevan
Prof. & Head,
Dept. of Chemistry
Thiagarajar College of Engineering,
Madurai – 15
Tamil Nadu - INDIA

On
“Utilisation of Waste Plastics
For a Construction of Flexible
Pavement”
 A small step towards…
Eco-friendliness
Better
India
Better
Road
Prevention
of pollution
 A March towards
1. Better road

2. Easy disposal of waste plastics

3. Prevention of incineration
4. Modified land filling
5. Friendship towards common man,
Industry & Govt.
MAN DISTURBS NATURE
– Earth - by land filling
- Water - by sewage
- Air- by incinerations
- Light- by U.V (T.V), freon
- Food - by adding preservatives
- Water - by chlorination
- Self - by repellents
‘MAN_AGE’_MENTAL TECHNIQUE
 Plastics consumption
40 lacs.
tons 2.7 lacs.
tons
INDIA
TN

WORLD
INDIA
3.5 kg 19 kg
 Polymer 1995 2001-02 2006-07
Polyethylene (PE) – Carry bags 823 1835 3267
Polypropylene(PP) – Bags 340 885 1790
Polyvinyl chloride(PVC) – Tubes 489 867 1287
Polyethyleneterephthalate - Bottles 34 140 289
Others 203 647 1415
Total 1889 4374 8054
Plastics in packaging 976 2272 4037
% of plastics in packaging 52% 52% 50%

* Thousand tones
 T
O
X
PVC I
C
I
Others
T
Y
PET
I
N
PE, PP & PS C
R
E
Bio-based Polymers A
S
E
 PRESENT SCENARIO
India - - 4o lakhs. tons
World Rank – III ( 3.5 kg :19 kg)
Tamil Nadu – 2.4 lakhs. tons
( 7000 industries with 7 lakhs. workers )

Major plastics in use – Polyethylene

(Cups,bottle,bags. Etc) - Polypropylene 80%
- Polystyrene

Tubes - Poly vinyl chloride - 10%

Recycling - 55%
Problems – non- biodegradable
accumulation of waste with MSW BAN
disposal technique and
people garbage culture
Plastics are
indispensable
 Solid Waste Management

Municipal SW Industrial SW

Bio- Plastics, Ceramics,

degradable
Rubber fly-ash etc.

Reuses
 Awareness

Plastics – not a virus

but
A wonder material

Common man’s friend

Pollution

Not careless but cared – less

 Present Scenario – Plastics Utilization
80
70
60
60
50
50
PE,PP,PS 40
40
Recycle
30 PVC 30
Reuse

PET 20
20
10
10
0
0
 Waste Plastics - Disposal

Reduction Destruction Recycle Reuse

in use
by
Land filling

Incineration
 Recycle Reuse
Limited Unlimited
Quality poor Newer
Approx. – 50% products
Better quality
New field
No limitation
 Recycle

Raw material Products

Reuse

More of raw
Material
 Today’s Problem
Disposal of waste plastics
Methods under practice / effects
Land filling
• Water flow seepage affected
• Land soil gets polluted
• Solid waste --- Not disposed properly.
• Non-availability of natural manure
• Space not available
• Soil microbe activity reduced
• Water line clogging – CH4 evolution green house effect
 Incineration

z Burning or ≈ 700-1100º C Toxic gases like

z Incineration CO, CO2 & ash ( oxides)
z
z
• Air Pollution (dust, etc.,)
z • Loss of solid waste
• Global warming
• Monsoon failure
• Cost is more
• Improper technology
• Dioxin ?
Chemical reaction (700 deg)

PE, PP, PS C, CO, CO2 but no Cl2

Use of PE, PP and PS can not liberate dioxin even on

burning .

PVC C, CO, CO2 and Cl2 and HCl

C + O2 + Cl2 Cu II Catalyst Dioxin

300 –350 deg.C

PVC alone on heating may result in dioxin formation

(300-350 deg. C) (reverse cooling)
 DIOXIN

z Source
- Chlorine related pesticides
– Chlorinated solvents
– Bleaching
– Chlorination of water
– Leaded petrol
– PVC

PE - (-CH2- CH2-)n PP - (-CH2- CH(CH3)-)n

PS - (-CH2- CH(C6H5)-)n PVC - (-CH2- CH(Cl)-)n

 THERMAL BEHAVIOUR

Type of Soften. Products Decom. Products Ignition Products

Polymer point reported temp. reported temp. range reported
range in in Deg. C
Deg. C

PE 110-140 No gas 270-350 CH4, C2H6 >700 CO,CO2

PP
PS

PVC – not considered

 Waste Plastics – a binder

Aggregate Waste plastics

140° C

C.S – 300tons
Block
F.S – 250 kg.
Behaviour Modification of Bitumen
% of Soft. Point Pen. value
polymer
0 50.2 70.0
0.5 52.0 68.0
1.0 60.0 67.0
2.0 58.2 57.5

5.0 62.0 52.0

 Modified mix properties

% of Bitumen Marshall Flow Voids

(10% WP Value Kg value(mm) (%)
(2-4) (2-5)
4.2 1960 2.2 8.9

4.5 2520 2.5 6.3

4.6 2540 2.7 6.0

5.0 2520 3.7 4.4

5.4 2500 4.5 3.1

 % VARIATION OF WP
% of % of Polymer Marshall Value
Bitumen Kg
4.6 0 1150
4.6 5 2010
4.6 10 2540
4.6 15 2440
4.6 20 2300
5.0 15 2670
5.0 20 2040
5.5 20 1830
 Protection
better road and
pollution
prevention Vishnu
REUSE

Brahma Siva

Creation of Blend Destruction of

Polymer Material
 REUSE OF WASTE PLASTICS

WASTE PLASTICS - BITUMEN AGGREGATE

BLEND FOR ROAD LAYING
( Waste plastics + Bitumen + Aggregate )

Polymer+ Bitumen Blend Aggregate + waste plastics mix

Aggregate Bitumen
Process –I Process -II

ROAD
laying
 Road Laying Process

170 °C
AGGREGATES HOT AGGREGATES
Waste
plastics

POLY.COATED
AGGREGATES

HOT
BITUMEN
160 °C

POLYMER –BITUMEN –
AGGREGATES MIXTURE ROAD LAYING (140°.C)
Appreciation by Our President
Dr. A.P.J. Abdul kalam
 C.M (Tamil Nadu)

Appreciation by Chief Minister of

Tamil Nadu
Dr. J.Jayalalithaa
 Significance and utilization
Road
potential
1. better binding property
2. Higher Softening point; withstands high temp.
3. Lower penetration value; withstands higher load
4. No stripping – Resists the permeation of water
5. Higher Marshal Stability–increased strength of
road
6. Operation temperature range: 160-170 deg.C
7. Cost less compared to CRMB.
Waste Plastics ( MSW, road side etc.)
8. Better disposal of waste plastics
9. No toxic gas evaluation - No to Dioxin
10. Waste plastics Disposal - No longer a problem
 Specialties

z In-situ process
z No Industry involvement
z Existing machinery useful
z No extra cost
z Reduction in bitumen use
 ROADS LAID – DETAILS
S.No Different places in Tamil Nadu
1 T C E, Madurai
2 Mumbai
3 Kolkatta
4 Chennai
5 Kovilpatti
6 Trichy
7 Salem
8 Madurai
9 Tuticorin
10 Virudhunagar
11 Bharat Petroleum Plant, Tanjore
Special Note: Roads are being laid using waste plastics throughout
Tamilnadu under the Scheme titled, ‘1000 km Plastic Tar Road’ as
announced by Honourable Chief Minister of Tamilnadu on 16th August 03
at Namakkal, by the Department of Rural Development Agency.
First public road – Kovilpatti - TN
4Th October’02
 Expected cost criteria
1. Cost of 1 ton 60/70 bitumen – Rs. 14,000
2. Approx. Save in the % of bitumen – 10 %
3. Cost reduction -- Rs. 1400
4. Approx. % of waste plastic used - 10 %
5. Cost of waste plastics - Rs. 5/kg
6. Amount of WP needed / ton - 500 kgs
7. Total cost of WP - Rs. 500
8. Expected cost criteria / ton - Rs. 13,100
9. Savings - Rs. 900
The quality of the WP- Aggregates – bitumen mix road is better than
CRMB
10. Cost of CRMB / ton - Rs. 16,000
11. Fuel consumption for CRMB is more
WP – aggregates – bitumen mix is not only eco-friendly but also
cheaper
 How safe the road
Plastic materials ( PE, PP & PS ) used
No Leaching
Stay on the Road
No soil pollution
Heating to approx.160 deg.
Less water diffusion
Rising temperature during Traffic no effect
No dioxin formation
Better UV stabilization
No thermal decomposition

Acts as safe area for land filling.

Avoids incineration.
 Waste Plastics Utilization
Type Utility value Advantages

Road 1 ton/1km Road life

(10 lacs. Carry increases
bags)
Block 20ton/kg Huge amount
of waste
plastics used
Roofing 200gm/sheet Sheet life
increases
Mastic 0.5 ton/km Best industrial
flooring flooring
 Recent Successes
z 1000 km DRDA road laid by Tamil Nadu
z Banners removed from Buses
z Approval from CPCB
z Plastics company Red to Green
z The performance of the laid road
z Public responses
z Foreign Govt’s interact
 Success of the process

Leads to
z better & Strong road
z less land & air pollution
z bitumen resource saving
z technology for other countries
z plastics industry growth
z eco-friendly World
z newer products
z plastics harvesting
Recent studies on reuse

¾ Aluminium coated film.

¾ PET laminated film.
¾ PET bottle
¾ crumb – rubber
 GOVT INDUSTRY
¾‘Waste disposal’ ¾Growth
¾Solution for pollution ¾ Employment
¾Hygiene
Plastic
The wonder materials
PUBLIC INSTITUTION
¾Reuse of Polymers
¾Safe
¾Research
¾Utility
¾solution of social
¾Cheap ¾problem
Dr. R. VASUDEVAN

S.RAJASEKARAN
¾ We Welcome
Your interaction
With us.
E-mail id: vasudesikan@yahoo.com
mobile no: 091 98421 95263
0452-2483585 (Res)
0452 – 2482240 (college)
Important Article – publication
 TCE where
Quality and Ethics
Matter