North South University – Department of Civil & Environmental Engineering

CEE 470: Solid Waste Management

Term Paper 1
Semester: Summer, 2018

Title: Use of Recycled Plastic in Pavement as Binder Material

Group – NSU Aces

Sheikh Muhammad Muhtashim [1510629625]
Marium Akhter Mou [1511057025]
Ishtiak Rahman Jishan [1512676025]
Sk Md Zahid Hossain [1410380025]
Shahriar Khan Shovon [1530807025]
 Abstract

The purpose of this study is to provide information’s related to the methods of application, benefits
and developments of one of the most innovative technology of 21st century i.e. the ‘Plastic
Roadway’. In order to make the report detail enough to understand the overall concept of this
significant research, we gathered information’s from more than 8 research journals-conference
papers and few literature reviews. The name of the Authors and publications along with the journal
titles are also provided. The goal is to help the future engineers to understand the technology so
that they can make the further development and use in practical life. We also have provided a
revolutionary idea synchronized by one of the famous consultancy and construction firm, ‘Volker
Wessels’, which may change the overall construction methodology of roads and highways. We
have collected information’s from valid websites through internet. Considering the originality of
the data’s, we have excluded ‘Wikipedia’ from our source of information’s.

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 Table of Contents
Abstract ............................................................................................................................................ I
Chapter 1: Introduction ................................................................................................................... 1
1.1 Background ...................................................................................................................... 1
1.2 Historical Timeline Preview of Plastic Recycling ........................................................... 1
1.3 First Approach to Plastic Roadway .................................................................................. 2
Chapter 2: Plastic ............................................................................................................................ 3
2.1 Types of Plastic ..................................................................................................................... 3
2.2 Plastic Used in Road Construction ....................................................................................... 6
Chapter 3: Methodology ................................................................................................................. 7
3.1 Tests Conducted on Samples ................................................................................................ 7
3.1.1 Tests for Aggregate ........................................................................................................ 7
3.1.2 Tests for Bitumen ........................................................................................................... 7
3.2 Process of Sample Preparation.............................................................................................. 8
Chapter 4: Results Discussion ...................................................................................................... 10
4.1 Aggregate Impact Value - Test Results .............................................................................. 10
4.2 Aggregate Crushing Value – Test Results .......................................................................... 10
4.3 Specific Gravity – Test Results........................................................................................... 11
4.4 Water Absorption – Test Results ........................................................................................ 11
4.5 Los Angeles Abrasion Test Results .................................................................................... 11
4.6 Softening Point – Test Results ............................................................................................ 12
4.7 Penetration Test Results...................................................................................................... 13
4.8 Ductility Test Results .......................................................................................................... 13
4.9 Marshal Stability Test Results ............................................................................................ 14
Chapter 5: Conclusion................................................................................................................... 15
5.1 Effects of Using Plastic in Roadway .................................................................................. 15
5.2 Effects on Materials ............................................................................................................ 15
5.3 Effects on Environment ...................................................................................................... 15
Chapter 6: Future Approach.......................................................................................................... 16
6.1 Volker Wessels – Plastic Roadway..................................................................................... 16
References ..................................................................................................................................... 17
Appendices ....................................................................................................................................... i

II
Appendix A .................................................................................................................................. i
Appendix B ................................................................................................................................. ii
Appendix B-1 .......................................................................................................................... ii
Appendix B-2 ......................................................................................................................... iii

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 Chapter 1: Introduction

1.1 Background
Plastic is considered to be the most harmful material that pollutes the environment. Due to its
resistive property against deterioration, it can be found widely throughout the globe as waste. With
the increasing number of population, the manufacture of plastic materials is also increasing day by
day. We can often see plastic bags floating around our city (Dhaka), bottles and other daily used
accessories are thrown away here and there. Even if we try to burn down the mountain of waste
plastic, toxic gas will be released resulting severe air pollution. But at the same time we cannot
simply stop using plastic because of its numerous good qualities. What we can do is recycle. For
the past decades, human has tried many ways of recycling plastic like making polyester string,
interior show-piece, useful household things and etc. But none of them were able to reduce the
amount of waste plastic as the ‘Plastic Roadway’ technology. Although this is very new and not
yet replaced the conventional methods of constructing roads, many engineers and firms are
convinced to apply it in further constructions.

1.2 Historical Timeline Preview of Plastic Recycling

Before we go further, let us look through the history of recycling so that we can have a better
understanding about the significance of this study.

Table 1.1: Historical Timeline of Plastic Recycling [1]

Year Data

1972 First known approach of collecting residential plastics for recycling.

1980’s Major cities of USA started curbside collection (e.g. see Appendix A) program.

1986 Rhode Island became the first state in the history of recycling to mandate
recycling, including some plastic bottles and containers.

1988 Use of identical triangular symbol for plastic resin started.

1990 Coca Cola started recycling plastic bottles industrially.

1993 Clothing production using recycled plastics took place at Patagonia.

1997 1. America Recycles Day was founded by the National Recycling Coalition to
encourage Americans to recycle more every day.
2. The company ‘Preserve’ started making polypropylene toothbrushes.

2000- Plastic recycling flourished in most of the places of globe.

Present

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1.3 First Approach to Plastic Roadway
As the history says, “Necessity is the mother of invention”, the appearance of this technology was
done by the Khan Brothers, Mr. K. Ahmed Khan and Mr. K. Rasool Khan. In 1996 the use of
plastic was banned in overall India [2]. The Khan Brothers used to manufacture plastic bags
through their ‘K K Polyflex’ company [3]. Due to this extreme decision, they had to close their
production. Around 100 employees were depended on them [2]. So they had to come up with a
new idea. They figured out that plastic and bitumen are same type of petroleum material and both
are non-bio-degradable [3]. They were planning on reducing the harmful effects of plastic [10]. So
they initially developed the idea of filling potholes with the mixture of bitumen, plastic and
aggregates to see its workability [2]. By 1997-98, they filled 200 to 300 potholes at Jayanagar area,
near the Raja Rajeshwari choultry for their experiment [2]. Their method was very successful and
following the idea they further opened the company ‘K K Plastic Waste Management Ltd.’ and
laid around 1400 km of roadways in Bengaluru [2][3].

Figure 1.1: Mr. K. Ahmed Khan (right) and Mr. K. Rasool Khan (left)

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 Chapter 2: Plastic

2.1 Types of Plastic

In 1988 the Society of the Plastics Industry (SPI) developed few specification codes for the plastic
consumers and manufacturers so that they can easily manage the recycling program.

Table 2.1: Types of Plastics According to SPI Code [4]

SPI Specification Type of Plastic & Use

Code

1 PETE or PET 1. Polyethylene Terephthalate

2. Common household items like beverage bottles, medicine jars,
peanut butter jars, combs, bean bags, and rope are made by it.
3. After recycling, tote bags, carpet, fiberfill material for winter
clothing are made.

2 HDPE 1. High-Density Polyethylene

2. Containers for milk, motor oil, shampoos and conditioners, soap
bottles, detergents, bleaches and toys.
3. Recycled HDPE is used to make plastic crates, plastic lumber and
fencing.

3 PVC or V 1. Polyvinyl Chloride

2. All kinds of pipes and tiles.
3. Harmful to food products.
4. Recycled PVC is used to make flooring, mobile home skirting,
and other industrial-grade items.

4 LDPE 1. Low-Density Polyethylene

2. Plastic wrap, sandwich bags, squeezable bottles, and plastic
grocery bags.
3. Recycled LDPE is used to make garbage cans, lumber and
furniture.

5 PP 1. Polypropylene
2. Can withstand higher temperature.
3. Plastic diapers, Tupperware, margarine containers, yogurt boxes,
syrup bottles, prescription bottles and stadium cups.

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 4. Recycled PP is used to make ice scrapers, rakes & battery cables.

6 PS 1. Polystyrene
2. Mainly Styrofoam but disposable coffee cups, plastic food boxes,
plastic cutlery and packing foams are also made.
3. Recycled PS is used to make insulation, license plate frames &
rulers.

7 Miscellaneous 1. Polycarbonate (PC) and Polylactide

or OTHER 2. PC is used in baby bottles, large water bottles (multiple-gallon
capacity), compact discs and medical storage containers.
3. Recycled PC is used in making lumber.

Figure 2.1: SPI Specification

Figure 2.2 SPI Code 1 - PETE [5]

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 Figure 2.3: SPI Code 2 - HDPE [5]

Figure 2.4: SPI Code 3 - PVC or V [5]

Figure 2.5: SPI Code 4 - LDPE [5]

Figure 2.6: SPI Code 5 - PP [5]

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 Figure 2.7: SPI Code 6 - PS [5]

Figure 2.8: SPI Code 7 - OTHER [5]

2.2 Plastic Used in Road Construction

Almost all types of plastics were recycled to pave roads except the SPI Code 3 – PVC and SPI
Code 7 – OTHER. The reason, plastics from these sectors were eliminated, is the variability of
materials and temperature fluctuation. The plastic used in making products are basically not one
kind of [4]. Different materials are used to make different products [4]. Considering the vast
diversity of the plastic material, the scientists did not take the code – 7 type plastics for testing to
minimize error level. In the other case, PVC requires high temperature to soften up which will
restrict the workability. So, scientists also eliminated SPI Code 3 – PVC type plastics for this test.

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 Chapter 3: Methodology

3.1 Tests Conducted on Samples

All the prepared samples have been tested in laboratory environment with proper test
specifications.

3.1.1 Tests for Aggregate

Different types of tests performed to characterize the aggregate and see the difference in their
property.
Table 3.1: Tests for Aggregate with Specification [6]

Test Name Specification

Los Angeles Abrasion Test -

Specific Gravity and Water Absorption Test IS: 2386 (Part 3) 1963

Aggregate Impact Value Test IS: 2386 (Part 4) 1963

Aggregate Crushing Value Test IS: 2386 (Part 4) 1963

Flakiness & Elongation Index Test IS: 2386 (Part 1) 1963

See ‘Appendix B-1’ for details about IS: 2386-1963.

3.1.2 Tests for Bitumen

To characterize the bitumen, different types of tests were performed in the laboratory.

Table 3.2 Tests for Bitumen with Specification [6]

Tests Name Specification

Penetration Test IS: 1203-1978

Softening Point Test IS: 1205-1978

Ductility Test IS: 1208-1978

Marshal Stability Test -

Flash Point and Fire Point -

See ‘Appendix B-2’ for details about IS: 120(3-8)-1978.

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3.2 Process of Sample Preparation
With the recycled and selected types of plastics, different samples were prepared to test. Although
different research team used different numbers of samples but their methods of preparing sample
are the same. Here is the basic process of sample preparation:
Step 1: At first, PVC and OTHER hazardous type materials should be filtered out [6].

Figure 3.1: Recycled Plastic [6]

Step 2: Collected plastics should be cut into small pieces of 2.36 mm and 4.75 mm specification
using shredding machine [6].

Figure 3.2: Plastic Cutting using Shredding Machine [6]

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Step 3: The aggregate mix is heated up to 1650 C and transferred to mixing chamber [6].
Step 4: Similarly the bitumen is to be heated up to 1600 C [6].
Step 5: Shredded plastic is to be added with the mixture and mix up to 30 to 45 seconds. Within
this time, the plastic will get coated over the aggregate by bitumen and a glassy surface will appear
[6].

Figure 3.3: Mixing Bitumen with Aggregate Mixture [6]

Figure 3.4: Mixing Shredded Plastic with Asphalt Mixture [6]

Step 6: The mixture is used in paving roads. Paving temperature is kept between 110 0 – 1200 C.
The roller used in paving should be at least 8-ton in capacity.

Figure 3.5: Paving Road Using Mixture

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 Chapter 4: Results Discussion

4.1 Aggregate Impact Value - Test Results

For different percentage of waste plastic content, different AI values were found. From the table
and the graph, we can see, with the increase in percentage of plastic content, the property of
aggregate increases. Even it helps to improve the quality of poor aggregates [6].

Table 4.1: Aggregate Impact Test Results [9]

Stone Aggregate % of Plastic Aggregate Impact Value

Without Plastic Coating 0 10.79%

With Plastic Coating 5 10.59%
10 10.03%
15 9.93%

Aggregate Impact Value

11.00%
10.80%
10.60%
10.40%
10.20%
10.00%
9.80%
0 5 10 15 20

Figure 4.1: Aggregate Impact Value Test Results [9]

4.2 Aggregate Crushing Value – Test Results

For different percentage of waste plastic content, different AC values were found. Lower values
indicate the aggregate has higher property to withstand continuous vehicle load. From the graph,
we can see, plastic coating improves the condition of the aggregate. The provided range of ACV
is 30-35%. With plastic coated aggregates, we can achieve lower ACV.

Figure 4.2: Aggregate Crushing Value Test Results [6]

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4.3 Specific Gravity – Test Results
We can measure or conclude strength of aggregates indirectly by looking at the specific gravity
[9]. Higher values indicate higher strength [6]. The specific gravity of plastic coated aggregate is
higher than normal ones. So, the strength will also increase.

Figure 4.3: Specific Gravity – Test Results [6]

4.4 Water Absorption – Test Results

Water absorption property of aggregate is very dangerous since it can cause severe damage to the
road. One of the good properties of plastic is; it holds back water. When plastic is mixed with the
aggregate, the coating decreases water entrainment and improves aggregate quality.

Figure 4.4: Water Absorption – Test Results [6]

4.5 Los Angeles Abrasion Test Results

The purpose of Los Angeles Abrasion Test is to determine the percentage of worn aggregates. The
permissible value is 35% for using in construction. From the graph we can see, use of plastic
coating decreased the value in a significant scale.

Table 4.2: Los Angeles Test Results [9]

Stone Aggregate % of Plastic Los Angeles Value
Without plastic coating 0 12.99%
With plastic coating 5 11.70%
10 10.65%
15 8.94%

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 Los Angeles Test Results
14.00%
12.00%
10.00%
8.00%
6.00%
4.00%
2.00%
0.00%
0 5 10 15 20

Figure 4.5: Los Angeles Test Results [9]

4.6 Softening Point – Test Results

Softening point is very important in road construction. Higher softening value means, it requires
higher temperature to get soft. For hot climate, engineers prefer higher values of softening point.
From the graph we can see, use of plastic coating initially increased the softening point value.

Table 4.3: Softening Point – Test Results [9]

% of Bitumen % of Polymer Softening Point
100 0 50
95 5 52
90 10 60
85 15 62

Softening Point - Test Results

70
60
50
40
30
20
10
0
0 5 10 15 20

Figure 4.6: Softening Point – Test Results [9]

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4.7 Penetration Test Results
The penetration test gives us the idea about how hard or soft the bitumen is. Higher value means
too soft and lower value means too hard. The permissible range is 20 – 225 mm as per IRC
recommendation. From the graph, we can see the use of plastic coating is in the range.

Table 4.4: Penetration Test Results [9]

% of Bitumen % of Polymer Penetration Value in mm
100 0 70
95 5 68
90 10 67
85 15 64

Penetration Test Results

71
70
69
68
67
66
65
64
63
0 5 10 15 20
Figure 4.7: Penetration Test Results [9]

4.8 Ductility Test Results

The purpose of ductility test is to see the range of elongation of the AC before breaking. Too
much ductility is not good and too less ductile is also bad. From the graph we can see, use of
plastic coating has less effect on the actual range.

Table 4.5: Ductility Test Results [9]

% of Bitumen % of Polymer Ductility Value
100 0 83
95 5 68
90 10 57
85 15 52

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 Ductility Test Results
100
80
60
40
20
0
0 5 10 15 20

Figure 4.8: Ductility Test Results [9]

4.9 Marshal Stability Test Results

By this test, we measure the amount of deformation any AC surface undergoes for a constant rate
of loading. From the graph, we can see, by using plastic coating, we can improve the stability.

Table 4.6: Marshal Stability Test Results [9]

% of Bitumen % of Polymer Stability
100 0 1010
95 5 1680
90 10 1957
85 15 1181.23

Marshal Stability Test Results

2500
2000
1500
1000
500
0
0 5 10 15 20

Figure 4.9: Marshal Stability Test Results [9]

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 Chapter 5: Conclusion

5.1 Effects of Using Plastic in Roadway

The effects of using waste plastic in road construction have significant effect on environment and
construction material. Around 64 million kilometers of road network has been constructed on earth
[10]. All these roads need to go through maintenance each and every year. If it is possible to use
waste recycled plastic in maintenance program, a huge significant environmental pollution
problem will be solved and the roads will provide more efficiency than earlier.

5.2 Effects on Materials

From the overall test results, we can clearly see the significant effects on the construction materials
due to the use of waste plastic:
1. The plastic coated aggregates have higher ability to withstand unified abrasion and sudden
impact.
2. The use of plastic coated aggregate increased the permeability of the road. Also increased
temperature insulation property.
3. The use of plastic coated aggregate increased the stability of the road.
4. There are very less effect of plastic use on bitumen.
5. Made the road light weight.

Overall, the use of plastic waste in road construction made it an economically benefitted and
maintenance free construction method.

5.3 Effects on Environment

The main purpose of this study was to make the best use of resources to ensure a healthy
environment. Any type of construction is basically the direct process of destroying nature. We
construct infrastructure by using the natural resources and by destroying the natural equilibrium
as well. According to the concept of sustainability, our work should be done in such a way so that
our future generation won’t face large problems to develop their civilization. The plastic roadway
is one of those brilliant, innovative ideas that directly supported and promoted the ideology of
Sustainable design.

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 Chapter 6: Future Approach

6.1 Volker Wessels – Plastic Roadway

Volker Wessels is an UK (United Kingdom) based construction firm who work on challenging
development projects like, Manchester Metro link, ‘SAAone’ expansion road construction and so
many transportation related works. One of their future upcoming development projects is the
concept of Plastic Roadway. According to their proposal, they included these facilities that will
change the phase of road construction.
1. Light-weight road made with completely waste recycled plastic [11].
2. Easy installation system to minimize the construction time and improve maintenance time
[11].
3. Underground hollow section to support drainage, electrical line, water supply line and other
facilities [11].

Figure 5: Volker Wessels – Plastic Roadway, Promotional 3d Image [11]

So, it is just a matter of time when we will be walking and driving on a path made with the material
that dominates the present world.

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 References

1. Website: Plastics – Make It Possible. Link: https://www.plasticsmakeitpossible.com/about-

plastics/history-of-plastics/the-history-of-recycling-plastic. Accessed on July 15, 2016.
2. Website of KK Plastic Waste Management: http://www.kkplasticroads.in/about-
us/management.php. Accessed on July 15, 2016.
3. Website of The Weekend Leader: http://www.theweekendleader.com/Innovation/1181/plastic-
smiles.html. Published and Accessed on July 15, 2016.
4. Website of Quality Logo Products: https://www.qualitylogoproducts.com/lib/different-types-
of-plastic.htm. Accessed on July 15, 2016.
5. Website of Earth First: http://www.earthfirst.net.au/the-great-recycling-myth-recycling-
plastic.html. Accessed on July 15, 2016.
6. Title: Use of Plastic Waste in Flexible Pavements. Authors: Miss Apurva J Chavan. International
Journal of Application or Innovation in Engineering and Management (IJAIEM). Published on
2014. Volume 2, Issue 4. ISSN 2319 – 4847.
7. Book: Indian Standard – Methods of Tests for Aggregates for Concrete. 11th Edition, 1997. UDC
691.322:620.1. Website Link: https://law.resource.org/pub/in/bis/S03/is.2386.1.1963.pdf.
8. Book: Indian Standard – Methods for Testing Tar and Bituminous Materials. Edition: 2.1 (1996-
11). UDC 665.775:620.1. Website Link: https://law.resource.org/pub/in/bis/S11/is.1201-
1220.1978.pdf.

9. Title: Application of Waste Plastic as an Effective Construction Material in Flexible Pavement.

Authors: Sasane Neha .B, Gaikwad.Harish, Dr. J R Patil and Dr. S D Khandekar. Journal:
International Research Journal of Engineering and Technology (IRJET). Published on June 2015.
Volume 2, Issue 3. e-ISSN: 2395 -0056; p-ISSN: 2395-0072.

10. Website of Quora: https://www.quora.com/How-many-kilometers-of-road-has-humanity-

built-on-Earth. Accessed on July 15, 2016.

11. Website of Volker Wessels: https://en.volkerwessels.com/en/projects/detail/plasticroad.

Accessed on July 15, 2016.

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 Appendices

Appendix A
Curbside Collection
Curbside collection is a service to collect household trashes and recycle them. Basically in urban
and suburban areas, this type of facility can be found.
There are few rules and regulations provided by the collecting authority for the proper management
of waste products. In maximum cases, we can see placement of different types of containers with
indication of containing materials. By this system, they can easily sort out different materials and
avoid blending.

Figure A-1: Placing Recycle Bins

Figure A-2: Collecting Recyclable Materials

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Appendix B

Appendix B-1
IS: 2386-1963
‘IS’ stands for ‘Indian Standard’ provided by the ‘Bureau of Indian Standards’. According to their
specification, these tests should be performed on aggregates:
Part I: Particle Size & Shape
Part II: Estimation of Deleterious Materials and Organic Impurities.
Part III: Specific Gravity, Density, Voids, Absorption and Bulking.
Part IV: Mechanical Properties.
Part V: Soundness
Part VI: Measuring Mortar Making Properties of Fine Aggregate.
Part VII: Alkali Aggregate Reactivity.
Part VIII: Petrographic Examination.
See reference [7].
For this study, scientists used Part (I, III, IV).

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Appendix B-2
IS: 120(3-8)-1978
According to their specification, these tests should be performed on Bitumen:
IS: 1201-1978 Sampling
IS: 1202-1978 Determination of Specific Gravity
IS: 1203-1978 Determination of Penetration
IS: 1204-1978 Determination of Residue of Specified Penetration
IS: 1205-1978 Determination of Softening Point
IS: 1206-1978 Determination of Viscosity
IS: 1207-1978 Determination of Equiviscous Temperature
IS: 1208-1978 Determination of Ductility
IS: 1209-1978 Determination of Flash Point and Fire Point
IS: 1210-1978 Float Test
IS: 1211-1978 Determination of Water Content (Dean and Stark Method)
IS: 1212-1978 Determination of Loss on Heating
IS: 1213-1978 Distillation Test
IS: 1215-1978 Determination of Matter Insoluble in Toluene
IS: 1216-1978 Determination of Solubility in Carbon Di-Sulphide or Tri-Chloroethylene
IS: 1217-1978 Determination of Mineral Matter (Ash)
IS: 1218-1978 Determination of Phenols
IS: 1219-1978 Determination of Naphthalene
IS: 1220-1978 Determination of Volatile Matter Content
See Reference [8]
For this study, scientists used ‘IS: 1203-1978’; ‘IS: 1205-1978’ and ‘IS: 1208-1978’ tests.

iii