Plastic Roads

Submitted By:NIGAM PRASAD MEHER REGD. NO. 0911011013 7th SEMESTER

DEPARTMENT OF CIVIL ENGINEERING

INSTITUTE OF TECHNICAL EDUCATION AND RESEARCH, BHUBANESWAR

DEPARTMENT OF CIVIL ENGINEERING

Certificate

This is to certify that the seminar project entitled “PLASTIC ROADS” has been presented by under signed student of INSTITUTE OF TECHNICAL EDUCATION AND RESEARCH, Bhubaneswar under S“O”A UNIVERSITY in fulfillment of the requirement of the degree of B. Tech. I appreciate their presentation Project. They completed the project successfully as per the requirement. I wish their success in all future endeavors

Dr. L.D Kar

Dr. MANAS RANJAN DAS (H.O.D in charge)

ACKNOWLEDGEMENT

A thought, reasonably cited and which substantiated for us in form of successful completion of “PLASTIC ROADS” for this seminar report, we greatly acknowledge Dr. Manas Ranjan Das, H.O.D, Department of Civil engineering, Bhubaneswar whose guidance was a bestowed boon and a key which opened our minds to explore the world of Civil engineering.

We are also grateful to Dr. L.D Kar, who despite of his busy schedules have kindly spent his valuable time to go through our seminar and its synopsis for necessary debugging and enhancements.

And last but not least, we too offer our thankful gratitude to all the staff members of Department of Civil Engineering institute of technical education, Bhubaneswar, who have rendered their help for the timely, prolific and successful arrival to its terminus.

PLASTIC ROADS ABSTRACT In the present scenario, plastic is considered to be a high level pollutant. It is non-decomposable in nature and burning of plastic causes release of high toxic gases like Dioxins and HCL. Recently a new technique of using plastic in the road construction has been discovered. Plastic when mixed with hot bitumen, plastic melts to form an oily coat over aggregate and the mixture is laid on the on the road surface like normal road. This is a very efficient technique as it reduces the use of bitumen, increases the strength and performance of the road, develop a technology which is eco-friendly and various other advantages.

NIGAM PRASAD MEHER REGD. NO.- 0911011013 4th YEAR, CIVIL ENGG. SECTION – ‘B’

CONTENTS  Introduction  Definition Waste plastics - as binder and modifier Different type of waste plastic (polymer) and its origin  Characterization of waste plastics Thermal study Binding property  Concept of Utilization of Waste Plastic in Bituminous Mixes for Road Construction  Materials used  Processing details i. Collection of waste plastic ii. Cleaning and shredding of waste plastic iii. Mixing of shredded materials in central mixing plant iv. Laying of bituminous mix  Methodologies I. Mix Design by Marshall Method a) Optimum Waste Plastic Content b) Comparison of Two Mixes c) Volumetric Properties of BC Mixes II. Performance Studies of Waste Plastic Bituminous Mixes i. Indirect Tensile Strength ii. Rutting test  Comparison between Ordinary Bituminous Roads and Waste Plastic Bituminous Roads  Advantage of waste plastic bituminous mix  Disadvantage of waste plastic bituminous mix

 Benefits of waste plastic roads  Environmental Benefits  MSWM (Municipal Solid Waste Management)  Employment Generation  Farming Community  National Economy  Waste plastic roads constructed in India  Conclusion  References

PLASTIC ROADS |1

INTRODUCTION Bitumen is a 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, and the significant variation in daily and seasonal temperature demand improved road characteristics. Any improvement in the property of the binder is the needed. 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. If not recycled, their present disposal is either by land filling or by incineration. Both the processes have certain impact on the environment. Under this circumstance, an alternate use for the waste plastics is also the needed.

Thinner polythene carry bags are most abundantly disposed of wastes, which do not attract the attending rag pickers for collection for onward recycling, for lesser value. Again, these polythene/polypropylene bags are easily compatible with Bitumen at specified conditions. The waste polymer bitumen blend can be prepared and a study of the properties can throw more light on their use for road laying.

NEED FOR THE STUDY: 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 7) Improvement in properties of bituminous mix provides the solution for disposal in an useful way

PLASTIC ROADS |2

DEFINITION 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) Low density polyethylene (LDPE):

Origin 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.

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

PLASTIC ROADS |3

CHARACTERIZATION OF WASTE PLASTICS: THERMAL STUDY Thermal behavior of the polymers namely PE, PP and PS is shows in Table 1.

Table 1. Thermal Behavior of Polymers

Solubility Polymer

Water EPT*

Softening Temp

Ignition Products reported

Temp

Decomposition Temp Deg. C

in Deg. C

Deg .C

PE

Nil

Nil

100-120

No gas

270-350

>700

PP

Nil

Nil

140-160

No gas

270-300

>700

PS

Nil

Nil

110-140

No gas

300-350

>700



5% acetic acid

BINDING PROPERTY: The molten plastics waste exhibits good binding property. Various raw materials like granite stone, ceramics etc... Were coated with plastics and then molded into a stable product. On cooling, it was tested for compression and bending strengths.

Table 2. Binding Property Compression Strength (Tonnes)

Bending Strength (Kg)

10

250

325

20

270

335

25

290

350

30

320

390

Percentage of plastics coating over aggregate

The increase in the values of the compression strength and bending strength shows that the plastics can be used as a binder.

PLASTIC ROADS |4

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, They can return to the earth as beneficial additives in bitumen roads. One such technologies are reviewed below, two for wastepolymer-modified bitumen roads.

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 Rajarajeshwari 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 road 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. For the same reason, the temperature of the mix both at the plant and at the point of lying needs to be 20°C higher than normal.

PLASTIC ROADS |5 The Bruhat Bengaluru Mahanagara Palike (BBMP) has used plastic on about 600 km of roads, including many thoroughfares and arterial roads. It uses the plastic blend in at least 25% of the road-laying works, including the present project to upgrade about 45 roads in the city. The plastic model was successful on major roads in Bangalore, including Shankar Mutt Road, K H Road, M G Road (towards Trinity Circle), J C Nagar Road, Miller's Road and Cunningham Road. The rise in bitumen costs over the past few years has also made the plastic model more cost-efficient. To top it, plastic is not recycled but buried with the roads, forever.

PLASTIC ROADS |6

MATERIALS USED:-

AGGREGATE:

Aggregate of 20mm, 10 mm.



Stone Dust and Lime as Filler

BITUMEN:

60/70, 80/100 grade bitumen

WASTE PLASTIC:Waste plastic in the shredded form

PLASTIC ROADS |7

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 I.

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

Rag-pickers

II.

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.

Fig. cleaning process

PLASTIC ROADS |8 Plastic waste which is cleaned is cut into a size between 1.18mm using shredding machine as shown below

Fig. shredding machine III. MIXING OF SHREDDED WASTE PLASTIC, AGGREGATE AND BITUMIN IN CENTRAL MIXING PLANT:The aggregate mix is heated to 1650c (as per the HRS specification) in central mixing plant. Similarly the bitumen is to be heated up to a maximum of 160ºc. 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.

Fig. central mixing plant IV.

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.

PLASTIC ROADS |9

METHODOLOGIES:I. MIX DESIGN BY MARSHALL METHOD a)

Optimum Waste Plastic Content

b)

Comparison of Two Mixes

c)

Volumetric properties of BC Mixes

II.PERFORMANCE STUDIES OF WASTE PLASTIC BITUMINOUS MIXES:i. Indirect Tensile Strength

ii. Rutting Test

I. MIX DESIGN BY MARSHALL METHOD:-

MARSHALL TEST:Laboratory studies were carried out at the Centre for Transportation Engineering of Bangalore University on the possible use of the processed plastic bags as an additive in bituminous concrete mixes. The material used in this study was supplied by M/s KK Poly Flex (P) Ltd., Bangalore. The processed plastic was used as an additive with heated bitumen in different proportions (ranging from zero to 12 % by weight of bitumen) and mixed well by hand, to obtain the modified bitumen.

P L A S T I C R O A D S | 10 The properties of the modified bitumen were compared with ordinary bitumen. It was observed that the penetration and ductility values of the modified bitumen decreased with the increase in proportion of the plastic additive, up to 12 % by weight. The softening point of the modified bitumen increased with the addition of plastic additive, up to 8.0 % by weight.

Auto Marshall Compactor

Auto Marshall tester

OPTIMUM WASTE PLASTIC CONTENT:  Varying percentages of waste plastic by weight of bitumen was added into the heated aggregates  Marshall specimen with varying waste plastic content was tested for bulk density and stability  Maximum value of stability was considered as criteria for optimum waste plastic content

P L A S T I C R O A D S | 11 Studies were carried out on Bituminous mixes using 60/70 grade bitumen having average Marshall Stability Value (MSV) of 1300 kg at optimum bitumen content of 5.0 % by weight of the mix. Further studies on mixes were carried out using the modified binder obtained by the addition of varying proportions of processed plastic bags (percentage by weight of bitumen) with the conventional 80 /100 grade bitumen. The optimum modified binder content fulfilling the Marshall Mix design criteria was found to be 5.0 % by weight of the mix, consisting of 8.0 % by weight of processed plastic added to the bitumen. The average MSV of the mix using the modified binder was found to be as high as 1750 kg at this optimum binder content, resulting in about three fold increase in stability of the BC mix, which contains 4.6 % bitumen plus 8 % processed plastic by weight of bitumen, i.e., 0.4 % processed plastic by weight of the mix.

In order to evaluate the ability of the mix prepared with the above-modified bitumen to withstand adverse soaking condition under water, Marshall Stability tests were conducted after soaking in water at 60 Co for 24 hours. The average MSV of the BC mix with modified binder (using 8 % processed plastic by weight of bitumen, as above) was found to increase by about 2.6 times of the mix with ordinary bitumen. Further laboratory

P L A S T I C R O A D S | 12 studies carried out on the BC mixes using this modified binder also indicated note worthy increase in fatigue life under repeated application of loads.

COMPARISON OF TWO MIXES:

P L A S T I C R O A D S | 13

VOLUMETRIC PROPERTIES OF MIXES:-

Volumetric properties of Mixes

Properties

Modified Mix (Waste plastic) 8 % Conventional by wt of bitumen Mix

Marshall Stability (kg) Bulk Density(gm/cc) Air Voids (%) VFB (%) Flow (mm) VMA (%) Retained Stability (%)

1700

1350

2.374

2.350

4.4

3.5

73

76

4

4

16.5

15.6

98

88

II.POST TESTING OF WASTE PLASTIC BITUMINOUS MIXES:A) PERFORMANCE STUDIES OF THE MIXES i. Indirect Tensile Strength ii. Rutting Test

P L A S T I C R O A D S | 14

I. INDIRECT TENSILE STRENGTH:Use this test method to determine the tensile strength of compacted bituminous mixtures. As the figure shown below tensile strength of the Waste Plastic Bituminous Mixes is greater then Conventional Mix

Indirect testing machine

II. RUTTING TEST:Wheel tracking is used to assess the resistance to rutting of asphalt materials under conditions which simulate the effect of traffic. A loaded wheel tracks a sample under specified conditions of speed and temperature while the development of the rut is monitored continuously during the test. The rut resistance can be quantified as the rate of rutting during the test or the rut depth at the conclusion of the test. Test specimens can be either slabs prepared in the laboratory or 20cm diameter cores cut from the highway.

P L A S T I C R O A D S | 15

Ordinary mix

waste plastic mix

Hamburg wheel track equipment

Beam specimen after rutting test

No traces of stripping even after 20,000 cycles therefore No pothole formation, rutting

or raveling has

been observed after 5 to 6 years after construction.

Graphical representation of rutting test

P L A S T I C R O A D S | 16

COMPARISON BETWEEN ORDINARY BITUMINOUS ROADS AND WASTE PLASTIC BITUMINOUS ROADS:SL. NO

1.

2. 3. 4.

5. 6. 7.

8.

9.

10.

11.

12.

PROPERTIES MARSHALL STABILITY VALUE BINDING PROPERTY SOFTENING POINT PENETRATION VALUE TENSILE STRENGTH RUTTING STRIPPING (POT HOLES) SEEPAGE OF WATER DURABILITY OF THE ROADS COST OF PAVEMENT MAINTENANCE COST ENVIRONMENT FRIENDLY

PLASTIC ROAD

ORDINARY ROAD

MORE

LESS

BETTER

GOOD

LESS

MORE

MORE

LESS

HIGH

LESS

LESS

MORE

NO

MORE

NO

YES

BETTER

GOOD

LESS

NORMAL

ALMOST NIL

MORE

YES

NO

P L A S T I C R O A D S | 17

ADVANTAGE OF WASTE PLASTIC BITUMINOUS MIX:1) Stronger road with increased Marshall Stability Value 2) Better resistance towards rain water and water stagnation 3) No stripping and no potholes. 4) Increase binding and better bonding of the mix. 5) Reduction in pores in aggregate and hence less rutting and raveling. 6) No leaching of plastics. 7) No effect of radiation like UV. 8) The strength of the road is increased by 100%. 9) The load withstanding property increases. It helps to satisfy today’s need of increased road transport. 10) For 1km X 3.75m road, 1 ton of plastic (10 lakh carry bags) is used and 1 ton of bitumen is saved. 11) Value addition to the waste plastics (cost per kilogram increases from Rs 4 to Rs12). 12) The cost of road construction is also decreased. 13) The maintenance cost of road is almost nil. 14) Disposal of waste plastic will no longer be a problem. 15) The use of waste plastics on the road has helped to provide better place for burying the plastic waste without causing disposal problem.

P L A S T I C R O A D S | 18

DISADVANTAGE OF WASTE PLASTIC BITUMINOUS MIX:1. Cleaning process

•

Toxics present in the co-mingled plastic waste would d start leaching.

2. During the road laying process

•

But the presence of chlorine will definitely release noxious HCL gas.

3.After the road laying

• •

The components of the road, once it has been laid, are not inert. It is opined that the first rain will trigger leaching. As the plastics will merely form a sticky layer, (mechanical abrasion).

•

once the road is started to be used will cause the release of fine polymer particles.

•

When air-borne, these will cause a particulate problem.

BENEFITS OF WASTE PLASTIC ROADS:

Environmental benefits



MSWM (Municipal Solid Waste Management)



Employment Generation



Farming Community



National Economy

P L A S T I C R O A D S | 19 ENVIORNMENT BENEFITS:Today, plastic waste treatment is largely hazardous to the environment as most of the plastic is burnt resulting is toxic gases being released in the environment. By effectively managing the collection, separation and processing of plastic waste, the environmental damages can be limited by eliminating the waste from our streets. We can have international standard roads and pavements which are litter free MSWM (MUNICIPAL SOLID WASTE MANAGEMENT):House holds and other units wrap all garbage into plastic bags and dispose them. The non-biodegradable plastic bags acts like a covering on the garbage preventing it from being converted into compost. At present only 20% of the MSW is converted into compost. This can be considerably increased to 80-85% and more by systematically managing the plastic waste. FARMING COMMUNITY: One of the foremost areas that would directly benefit is agriculture. At present only 20% of MSW is converted into compost. This can be converted to 8085% once the plastic from the MSW is segregated. Farmers can directly purchase from MSWM if plastic separated.

NATIONAL ECONOMY: Cumulative benefits to the National Economy –Environmental –Employment generation –Agricultural efficiency When life of a road is doubled, then the savings that accrue to the national exchequer are in thousands of crores.

P L A S T I C R O A D S | 20 Segregating the plastic from the MSW at the municipal yard involves application of resources, the cost of which runs into crores of rupees. A substantial amount of this can be saved. The Central Government’s annual allocation of funds towards roads and highways is approx. 35 thousand crores Lab tests and real time tests have revealed that the life expectancy of a plastic polymer road as compared to a normal road is at least 100% more In addition to the savings accrued at the central level, every state Municipal Solid Waste Management would save crores of rupees by eliminating the plastic segregation process at its yards.

WASTE PLASTIC ROADS CONSTRUCTED:The Bruhat Bengaluru Mahanagara Palike (BBMP) has used plastic on about 600 km of roads, including many thoroughfares and arterial roads. It uses the plastic blend in at least 25% of the road-laying works, including the present project to upgrade about 45 roads in the city. The plastic model was successful on major roads in Bangalore, including Shankar Mutt Road, K H Road, M G Road (towards Trinity Circle), J C Nagar Road, Miller's Road and Cunningham Road, inner ring road, Rajarajeshwari Junction, mysore Bangalore state highway.

The sign in front of Puttanna Chetty Town Hall

P L A S T I C R O A D S | 21 Raja rajeswari nagar road

T v tower road

Manipal tower road

P L A S T I C R O A D S | 22

Dollars Colony

Bangalore- Mysore state highway

M G Road (towards Trinity Circle)

P L A S T I C R O A D S | 23

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.

P L A S T I C R O A D S | 24

REFERENCES:1) Ministry of Road Transport and High Ways, Manual for construction and supervision of Bituminous works, New Delhi, November 2001. 2) Sri Ram Institute for Industrial Research, Plastics Processing and Environmental Aspects, New Delhi - 7 3) Vasudevan, R., Utilization of waste plastics for flexible pavement, Indian High Ways (Indian Road Congress), Vol. 34, No.7. (July 2006). 4) Amjad Khan, Gangadhar, Murali Mohan and Vinay Raykar, "Effective Utilisation of Waste Plastics in Asphalting of Roads". Project Report prepared under the guidance of R. Suresh and H. Kumar, Dept. of Chemical Engg., R.V. College of Engineering, Bangalore, 1999. 5) Utilizations of Waste Plastic Bags in Bituminous Mix for Improved Performance of Roads, Centre for Transportation Engineering, Bangalore University, Bangalore, India [Unpublished] Apr02 6) K. K. Plastic Waste Management Pvt. Ltd.(Subsidiary of KK Polyflex Pvt. Ltd.) No.

1,

Chairman

Compound,

Y.V.

Annaiah

Road,

Yelachenahalli,

Krishnadevaraya Nagar II Stage Kanakapura Road Bangaolore - 560 078