Utilization of Polymer

Waste in Road
Construction
Presentation
by

Dr. Sunil Bose

Deputy Director
&
Dr Sangita
Central Road Research Institute, New Delhi

Solid Wastes

Discarded as unwanted or useless.

There are three types of wastes :

i.
ii.

Solid, Liquid & gaseous

The solid waste can be broadly
classified
iii. biodegradable and non-biodegradable
waste (plastic waste)

Delhi produces 7,000 metric tonnes

of solid waste everyday. Its
estimated to be 20,000 tonnes by
2021

Methodology
Dry Technology
Wet Technology
Various formulations of commercial importance
were prepared by adding varying quantity of
individual plastomer or waste polythene and
elastomer under specified mixing time and
temperature using a high speed stirrer

Advantages of polymer modified

bitumen
1. The Softening point, Penetration and Elastic
recovery of the bitumen-polymer blend have better
values to suit the climatic (environmental) & heavy
traffic conditions .
2. The polymer Bitumen blends were tested for
stripping test and Marshall Test. The samples did not
show stripping even after 48 hours. The Marshall
stability improved significantly.
3. Shows lower susceptibility to daily and seasonal
variations.
4. Higher resistance to deformation at elevated
pavement temperature.
5. Better age resistance properties.
6. Better adhesion between aggregate and binder.

DRY TECHNOLOGY
Laboratory Studies
Laboratory performance studies were
conducted on bituminous mixes
Laboratory studies proved that waste plastic
enhances the property of the mix
Improvement in properties of bituminous mix
provides the solution for disposal in an
useful way

Physical Properties of Waste Plastic

Sl. No
Description
1
Specific Gravity

Range
1.03

Melting Temperature

75-138 deg C

Weight Loss (6%)

200-400 deg C

Waste Plastic used in shredded form

Mix Design by Marshall Method

Grading and
proportioning of
aggregates
Preparation of
Marshall samples at
varying bitumen
content
Auto Marshall compactor

Mix Design by Marshall Method

Testing of samples for bulk
density, marshall stability,
flow and air voids
Arriving at optimum
bitumen content
Verifying the Stability
values with specified limits
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

Optimum Waste Plastic Content

2.38

2.37

1700

2.36

Stability (kg)

1600

Bulk Density (gm/cc)

2.35

1500
1400

2.34

2.33

6
8
Waste Plastic (%)

10

12

Bulk Density (gm/cc)

Stability (kg)

1800

Comparison of Two Mixes

2.370
2.350
2.330
2.310

4.5

5.5

1600

Flow,mm

Stability, kg

Bulk Density, gm/cc

5.0

1700

2.390

1500
1400

2.5
4.5

5.5

5.5

Binder, %

Binder V/s VFB

Air Voids,%

85.0
80.0
75.0
70.0
65.0
60.0
55.0
50.0
4.5

With Waste
Plastics

VFB,%

6.00
5.00
4.00
3.00

Binder, %

3.5

1200
4.5

Binder, %

7.00

5.5

4.0

3.0

Binder V/s Air Voids

4.5

1300

Binder, %

2.00
4.5

Binder V/s Flow

Binder V/s Stability

Binder V/s Bulk Density

5.5
Binder, %

Without Waste
Plastics

Volumetric properties of BC Mixes

Properties

Modified Mix Conventional

Mix
(Waste plastic)
8 % by wt of
bitumen

Marshall Stability (kg)

1700

1450

Bulk Density (gm/cc)

2.350

2.374

Air Voids (%)

4.4

3.5

VFB (%)

73

76

Flow (mm)

16.5

15.6

98

88

VMA (%)
Retained Stability (%)

Performance Studies of the Mixes

Indirect Tensile Strength
Fatigue Test
Rutting Test

Indirect Tensile Strength

9.0

10

6.8

Indirect testing machine

kg/sq cm

Conventional mix
Modified Mix

Fatigue Behaviour of the Mixes

20000

17554

15000

Fatigue equipment

10000

8650

5000

Beam tested until failure

Number of Repititions

Conventional mix
Modified Mix

Hamburg Wheel Track Test

Hamburg wheel track equipment

Beam specimen after rutting test

Rutting Potential of the Mix

Rut Depth (mm)

0.0
-2.0
Post Compaction

-4.0
Creep Slope

-6.0

Conventional Mix
Modified Mix

-8.0
-10.0
0

8
12
16
Number of Passes (Thousands)

20

Comparison of Properties of 60/70

Bitumen and Recovered Bitumen from
Waste Plastic Additive Mix
Tests
Penetration
Softening Point
Elastic Recovery (%)
Viscosity @ 1500C
(poise)

60/70
68
46
-

Waste Plastics
50
57
29
1.44

Concluding Remarks for Dry

Process
The optimum quantity of waste plastic was 8 per cent
by weight of bitumen (0.4% by weight of mix)
Retained stability of the mix with waste plastic was
98 per cent
No traces of stripping even after 20,000 cycles
It can be inferred that addition of waste plastic
improves the water resistance property of the mix

WET PROCESS
Developed Technology Patented by
CRRI and transferred to M/s
K.K.Polyflex Bangalore

GENERAL REQUIREMENTS OF
MODIFIERS
Be compatible with bitumen.
Resist degradation of bitumen at mixing
temperature.
Be capable of being processed by
conventional mixing and laying
machinery.
Be cost effective on a life cycle-cost basis.

Blending time/ Temperature for different modifiers to be used for preparing

modified binder formulations
Designation of
modified
binder
formulations

Modifier

Blending
temperature

Blending
(minutes)

polythene bags

150 5c

40-60

Waste glucose bottles

1405c

40-60

Waste
powder
powder

rubber
gasket

1605c

40-60

Mother dairy & Parag

milk pouches

1405c

40-60

Hard glass

1705c

40-60

tire
and

time

Physical properties of bitumen to be modified

S.No.

Properties tested

Test value
80/100

Limits as per
IS: 73,1992

86

80-100

1.

Pentration,25C,0.1
mm,100g,5 sec
Softening Point, C

45

35-40

Ductility,
27C
Specific
gm/cc

75

75 min

1.011

0.99

215

175 min

2.
3.
4.

Cm,
gravity,

Flash Point,
C
5.

The binder used conform to the limits specified in IS: 73,1992.

Specified Limits of the polymer modified bitumen and as per

IS: 15462:2004 (Plastomeric Thermoplastic based)
S.
no.
1.

Physical properties

2.
3.
4.
5.
6.

Limits PMB40
60

Limits,PMB70
55

Penetration at 25c, 0.1mm,100g,

5seconds
Viscosity at 150c, Poise

30-50

50-90

3-9

2-6

Elastic recovery of half thread in

ductilometer at 15c, %, minimum
Separation difference in s.p., R&B,
c, max.
Flash point, COC, c,minimum

30

40

220

220

S.P. (c),minimum

Thin Film Oven Test:

a.

Loss in mass, percent, max.

b.

Increase in s.p., c, max.

c.

Reduction in penetration of residue,

at 25c, percent, max.

35

35

Specified Limits of the polymer modified bitumen and as per

IS: 15462:2004
(Elastomeric Thermoplastic based)
S.
no.

Physical properties

Limits ,PMB40

Limits,PMB70

1.

S.P. (c),minimum

60

55

2.

Penetration at 25c, 0.1mm,100g,5secs

30-50

50-90

3.

Viscosity at 150c, Poise

3-9

2-6

4.

Elastic recovery of half thread in

ductilometer at 15c, %, minimum

70

70

5.

Separation difference in s.p., R&B,c,

<3

6.

Flash point, COC, c,minimum

220

220

Thin Film Oven Test:

a.

Loss in mass, percent, max.

1 max.

1 max.

b.

Increase in s.p., c, max.

5 max.

6 max.

c.

Reduction in penetration of residue, at

25c, percent, max.

35 max.

35 max.

PHYSICAL PROPERTIES OF MODIFIED BINDER (CRMB60)

S.
No.

PROPERTY TESTED

TEST VALUE
CRMB60

REQUIREMENTS
CRMB60

32

<50

Penetration at 25 C, 0.1 mm, 100g,

5 sec.
Softening Point (R & B), C,

61

60

Elastic Recovery at 15C, %

59

50

Penetration Ratio

62

Frass Breaking Point, C

- 11

Separation, Difference in Softening

Point, R&B, C
Flash Point, (C)

<3

<4

263

220

Thin Film Oven Test (TFOT) on Residue (IS9382-1992)

8
9
10

Penetration at 25C, 0.1 mm,100g,,

5 sec.(% of original, MIN.
Increase in Softening Point, (R&B)
C, MAX.
Elastic recovery of residue at 25C,
%, MIN.

66

60

40

35

Properties of Modified Bitumen

(Wet Process)
Test Description

80/100

80/100+
5% WP

Penetration (100 gm, 5 seconds,

at 25oC) (1/10th of mm)
Elastic Recovery (%) 15oC

92

58

--

40

Softening Point (oC) (Ring and

ball method)

43

52

Phase Separation
Softening Point (difference)
TFOT (Elastic Recovery, 25oC) %

1oC

30

Penetration at 25oC %

74

Mix Properties at Optimum Binder Content

Binder

OBC BD

Stab Flow Vv VFB

60/70

5.4

2.359 1193

R.
Stab
3.7 4.3 74.9
82

CRMB-60

5.8

2.354 1371

3.5 4.2 74.9

86

Elvaloy

5.5

2.362 1187

3.5 4.2 74.2

90

Waste
plastic

5.7

2.349 1278

2.8 4.8 71.7

90

Morphology of plain/modified bitumen

Rutting Potential of Bituminous Mixes with different

Binders
60/70
0

Elvaloy
4

Polyethylene
8

10

CRMB-60
12

Rut Depth(cm)

-0.5

-1.0

-1.5

-2.0

-2.5
Wheel Passes (Thousands)

14

16

18

20

Field Evaluation at Bangalore Test Section

Parameters

Deflection
before
overlay (mm)
Deflection
after overlay
(mm)
Unevenness
(mm/km)

Without Waste Plastic

With Waste Plastic

Time (months)

Time (months)

1.130

1.130

0.856

1.011

0.786

0.843

2914

2346

2788

2914

2287

2541

Road Section with Waste Plastic

Results of Plant Manufactured Waste

Plastic Modified bitumen with CRRI
Technology (
PMB 70)
S.No
1.

Penetration

36,35,40

2.

Elastic Recovery

25 percent

3.

Ductility

72.8 mm

4.

Softening Point

54.9, 55.2 C

5.

Phase Separation

0.1 C

Employment Generation
Today the rag pickers earn
Rs 2 per kilo of plastic
collected. By offering Rs. 6
for every kilo of plastic waste
collected, KKPWM has
overnight increased their
earning capacity by 6 fold.
Pilot studies reveal that a rag
picker can collect up to 15-20
kgs of plastic in less that half
a working day (3 hours).
Indirect Employment
opportunities are immense.

Concluding remarks
CRRI studies indicate the following:
The use of waste plastic directly into the bituminous
mix needs carefully monitored to prevent
adulteration any failure will send the wrong signal
The wet process permits consistency in the quality
of the mix and practicing engineers are ready to
adopt it
With M/s KK Polyflex 530 km of roads have been
laid in and around Bangalore with the dry process
A production unit capable of producing 50 to 60 t/hr
of WP modified bitumen is being set up by M/s KK
Polyflex

Concluding remarks
There is a need for a mission project to increase
use of waste plastic in roads
Presently work being carried out in independent
pockets needs to be synergized
The Indian Roads Congress is presently
preparing the standards for use waste plastics in
roads
The NRRDA is also preparing a standard for use
of waste plastic in rural roads
CPCB should make it mandatory for use of
waste plastic in construction of city roads
through an Act of Parliament