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. Solid, Liquid & gaseous
ii. 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. It’s
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 Range
1 Specific Gravity 1.03
2 Melting Temperature 75-138 deg C
3 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

1800 2.38

Bulk Density (gm/cc)

2.37
Stability (kg)

1700
Stability (kg) 2.36
1600
Bulk Density (gm/cc)

2.35

1500
2.34

1400 2.33
0 2 4 6 8 10 12
Waste Plastic (%)
 Comparison of Two Mixes
Binder V/s Stability Binder V/s Flow
Binder V/s Bulk Density
Bulk Density, gm/cc

5.0
2.390 1700
4.5

Stability, kg
1600

Flow,mm
2.370
1500 4.0
2.350
1400 3.5
2.330 3.0
1300
2.310 2.5
1200
4.5 5 5.5 6 4.5 5 5.5 6 4.5 5 5.5 6
Binder, % Binder, % Binder, %

Binder V/s VFB

Binder V/s Air Voids

85.0
7.00
80.0
With Waste
Air Voids,%

6.00 75.0
Plastics
VFB,%

5.00 70.0
65.0
4.00 60.0
3.00 55.0
2.00 50.0 Without Waste
Plastics
4.5 5 5.5 6 4.5 5 5.5 6

Binder, % Binder, %
 Volumetric properties of BC Mixes
Properties Modified Mix Conventional
(Waste plastic) Mix
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) 4 4
VMA (%) 16.5 15.6
Retained Stability (%) 98 88
 Performance Studies of the Mixes

• Indirect Tensile Strength

• Fatigue Test

• Rutting Test
 Indirect Tensile Strength

10
9.0

8
6.8

0 Conventional mix
kg/sq cm
Modified Mix
Indirect testing machine
 Fatigue Behaviour of the Mixes

20000
17554

15000

Fatigue equipment 10000 8650

5000

0
Number of Repititions
Conventional mix
Beam tested until failure Modified Mix
 Hamburg Wheel Track Test

Hamburg wheel track equipment

Beam specimen after rutting test

 Rutting Potential of the Mix

0.0

-2.0
Rut Depth (mm)

Post Compaction

-4.0
Creep Slope
-6.0
Conventional Mix
Modified Mix
-8.0

-10.0
0 4 8 12 16 20
Number of Passes (Thousands)
 Comparison of Properties of 60/70
Bitumen and Recovered Bitumen from
Waste Plastic Additive Mix
Tests 60/70 Waste Plastics
Penetration 68 50
Softening Point 46 57
Elastic Recovery (%) - 29
Viscosity @ 1500C - 1.44
(poise)
 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 Modifier Blending Blending time

modified temperature (minutes)
binder
formulations
A polythene bags 150 ±5ºc 40-60

B Waste glucose bottles 140±5ºc 40-60

C Waste tire rubber 160±5ºc 40-60

powder and gasket
powder
D Mother dairy & Parag 140±5ºc 40-60
milk pouches

E Hard glass 170±5ºc 40-60

Physical properties of bitumen to be modified

S.No. Properties tested Test value Limits as per

80/100 IS: 73,1992
Pentration,25ºC,0.1 86 80-100
1. mm,100g,5 sec
Softening Point, ºC 45 35-40
2.
Ductility, Cm, 75 75 min
3. 27ºC
Specific gravity, 1.011 0.99
4. gm/cc
Flash Point, °‡
C 215 175 min
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. Physical properties Limits PMB- Limits,PMB-
no. 40 70
1. S.P. (ºc),minimum 60 55

2. Penetration at 25ºc, 0.1mm,100g, 30-50 50-90

5seconds
3. Viscosity at 150ºc, Poise 3-9 2-6
4. Elastic recovery of half thread in 30 40
ductilometer at 15ºc, %, minimum
5. Separation difference in s.p., R&B, 3 3
ºc, max.
6. Flash point, COC, ºc,minimum 220 220
Thin Film Oven Test:
a. Loss in mass, percent, max. 1 1

b. Increase in s.p., ºc, max. 5 6

c. Reduction in penetration of residue, 35 35

at 25ºc, percent, max.
 Specified Limits of the polymer modified bitumen and as per
IS: 15462:2004 (Elastomeric Thermoplastic based)
S. Physical properties Limits ,PMB- Limits,PMB-
no. 40 70
1. S.P. (ºc),minimum 60 55

2. Penetration at 25ºc, 0.1mm,100g,5secs 30-50 50-90

3. Viscosity at 150ºc, Poise 3-9 2-6

4. Elastic recovery of half thread in 70 70

ductilometer at 15ºc, %, minimum
5. Separation difference in s.p., R&B,ºc, <3 3

6. Flash point, COC, ºc,minimum 220 220

Thin Film Oven Test:

a. Loss in mass, percent, max. 1 max. 1 max.

b. Increase in s.p., ºc, max. 5 max. 6 max.

c. Reduction in penetration of residue, at 35 max. 35 max.

25ºc, percent, max.
 PHYSICAL PROPERTIES OF MODIFIED BINDER (CRMB60)

S. PROPERTY TESTED TEST VALUE REQUIREMENTS

No. CRMB60 CRMB60
1 Penetration at 25 ºC, 0.1 mm, 100g, 32 <50
5 sec.
2 Softening Point (R & B), ºC, 61 60

3 Elastic Recovery at 15ºC, % 59 50

4 Penetration Ratio 62 -

5 Frass Breaking Point, ºC - 11 -

6 Separation, Difference in Softening <3 <4

Point, R&B, ºC
7 Flash Point, (ºC) 263 220

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

8 Penetration at 25ºC, 0.1 mm,100g,, 66 60

5 sec.(% of original, MIN.
9 Increase in Softening Point, (R&B) 3 5
ºC, MAX.
10 Elastic recovery of residue at 25ºC, 40 35
%, MIN.
 Properties of Modified Bitumen
(Wet Process)
Test Description 80/100 80/100+
5% WP
Penetration (100 gm, 5 seconds, 92 58
at 25oC) (1/10th of mm)
Elastic Recovery (%) 15oC -- 40
Softening Point (oC) (Ring and 43 52
ball method)
Phase Separation - 1oC
Softening Point (difference)
TFOT (Elastic Recovery, 25oC) % - 30
Penetration at 25oC % - 74
 Mix Properties at Optimum Binder Content

Binder OBC BD Stab Flow Vv VFB R.

Stab
60/70 5.4 2.359 1193 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 5.7 2.349 1278 2.8 4.8 71.7 90

plastic
Morphology of plain/modified bitumen
 Rutting Potential of Bituminous Mixes with different
Binders

60/70 Elvaloy Polyethylene CRMB-60

0 2 4 6 8 10 12 14 16 18 20

-0.5
Rut Depth(cm)

-1.0

-1.5

-2.0

-2.5
Wheel Passes (Thousands)
 Field Evaluation at Bangalore Test Section
Parameters Without Waste Plastic With Waste Plastic

Time (months) Time (months)

0 4 8 0 4 8

Deflection
before 1.130 - - 1.130 - -
overlay (mm)

Deflection
- 0.856 1.011 - 0.786 0.843
after overlay
(mm)
Unevenness
2914 2346 2788 2914 2287 2541
(mm/km)
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 º C
5. Phase Separation 0.1 º 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