Presented to Centre for Innovations in Public Systems 

Hyderabad

By Knowledge Advisory Services and Consultancy

Lucknow3rd November 2014

Knowledge Partner

Knowledge Advisory  Consulting 

Technology and Management 

Research firm  Emerging Technology, Markets, Policy, Legislation 

Project Engagement Team  Kshitij Aditeya Singh, Dr. Shikha Wadhwa, Sharad Nigam 

Presentation Outline• Introduction

• Technology Innovation and Process 

• Case Study • Tamil Nadu • Karnataka • Jharkhand

• Roll out Strategy 

• Concluding Remark  

Background India generates 1.88 Lakh tons garbage every day

Plastic Waste in different forms  9% to 12% in municipal solid waste

Poor biodegradability and enormous environmental challenges 

Choked drains 

Filthy public places

Landfill of waste plastic 

Incineration of plastic at high temperatures 

Air pollution due to the emission of polluting gases

Primary Objectives To understand administrative processes involved in usage of plastic waste in road construction

To evaluate implementation strategy and cost 

To assess key organizations involved and their specific roles , coordination and inter linkages 

To formulate details of roll out orders 

To review details of Statutory and Non‐statutory approvals in execution 

To review impact of the initiative ‐ Pre and Post impact of the initiative(s) 

To translate lessons learnt from states implementing 

To assess the process  of the Indian Roads Congress 

To assess the integration of technological and engineering decision into the policy framework and 

execution

To ascertain processes that can be reproduced on a national scale 

To establish financial models and implementation monitoring methods 

Scope Focus on IRC standard 

Assessment of durability of plastic as compared to other materials

Evaluation– Technical, Financial, Administrative and Organisational

Qualitative assessment through interviews and field visit

Assessment geography would be limited to states and union territories

Highlight best practise and operational parameters

Scientific review through journal papers and patents 

Methodology

Participatory and Applied Research Methods 

Methods applied  Primary Research  Secondary Desktop Research  Interviews  Focus Group Discussion 

Components of road construction material

Bitumen – grades 60/70 or 80/100

Aggregate mix – coarse, fine or filler

Binder or modifier – polymers, crumb rubber, steel slag,

fly ash...

Bitumen based concrete mixes

A. U. Ravi Shankar, D. Salian KK. Utilization of waste plastic in semi dense bituminous concrete 

by dry  mixing. Highw Res J. 2009;23–35. 

The need for modification of bitumen

Limitations of pure bituminous mixes:

Reduced performance of road at high temperature.

Cracking and crazing occurs.

Potholes are easily formed.

Reduced life of the road constructed.

Higher costs of the material and processing.

Physical properties of 60/70 and 80/100 Bitumen grades

Designation Test Results Permissible Limits asper IS 73: 1992

TestMethod

60/70 80/100 60/70 80/100Penetrationat 250C, 100g, 5 s, d mm

65 89 60‐70 80‐100 IS 1203: 1978

SofteningPoint, 0C

48 42 40‐55 35‐50 IS 1205: 1978

Ductility at270C, cm

100+ 100+ 75 (min.)

75 (min.) IS 1208: 1978

SpecificGravity at270C, g/cc

1.010 0.998 0.99 

(min.)

0.99 

(min.)

IS 1202: 

1978Flash Point,0C

285 310 175 

(min.)

175 

(min.)

IS 1209: 

1978

P. Kumar RG. Laboratory studies on waste plastic fibre modified bitumen. Highw Res J. 2010;45–60.

Aggregate

Aggregates

Gravel(Crushed natural stone)

Granite

Limestone(Crushed sedimentary rock)

Secondary (crushed constructive waste)

Slag (crushed smelter slag)

Required properties of aggregates

S.No. Property BIS Testmethods

Results MoRT&Hspecification

1 Aggregate impactvalue %

IS:2386 Part IV

18.0 27 Max

2 Combined flakiness& elongation index %

IS:2386 Part I

24.0 30

3 Specific gravity‐1. C.A2. F.A

IS:2386 Part IIIS:1202‐1978

2.692.67

NilNil

4 Water absorption % IS:2386 Part III

0.50 2 Max

M. S. Ranadive SHG. Enhancing stability of flexible pavements using plastic waste and fly ash.Indian Highw. 2011;23–8

Road construction processes

Hot mixes

Cold mixes

Dry process (plastic mixed to hot aggregate)

Wet process (Plastic mixed to hot bitumen)

Others – recycled plastic, modified processes, new additives 

Processing technologies

Plastic as binder

Plastic as modifier

Dry process

Eco Roads of Plastics. WALKABILITYASIA, http://walkabilityasia.org/2012/07/27/eco‐roads‐of‐plastic/

The design criteria for PMB pavement layersMinimum stability (kN at 600C) 12.0Flow (mm) 2‐4Marshall Quotient (kN/mm) 2.5‐5.0Compaction level (Number ofblows)

75.0 blows on each of the two faces of the specimen

Air voids (%) 3.0‐5.0Retained stability (%) 98.0ITS (min) MPa 0.9VMA 16.0VFB 65.0‐75.0Quantity of waste plastic (% byweight of bitumen)

6.0‐8.0

Specifications for the use of waste plastic in hot bituminous mixes in wearing courses, IRC SP 

98‐2013. 2013 p. 1–8.

Plastic as binder‐modifier

Surface property of aggregates isenhanced.

Coating technique is straightforward& temperature requirements are thesame as that of road laying process.

Flexible films of all types of plasticscan be used.

Doubles the binding property ofaggregates.

Bitumen bonding is strong thannormal.

Plastic as binder‐modifier

The coated aggregates show increased strength. 

Higher cost efficiency is possible. 

Is suitable for all type of environmental 

conditions. 

No toxic gases released during the heating 

process

Easy disposal of plastic waste 

Offers an eco‐friendly technology

Offers job for rag pickers

Types of plastic waste

Plastics Toxic gases released T (0C)

Polyethylene Terephthalate (PET)

Lighter hydrocarbons (C5‐C10)

>200

Polypropylene (PP) C2H6 270‐300Poly Vinyl Acetate (PVA) CH3COOH >190

Poly Vinyl Chloride (PVC) HCl 250

Polystyrene (PS) C6H6 300‐350Low Density Polyethylene (LDPE)

CH4, C2H6 270‐350

High Density Polyethylene (HDPE)

CH4, C2H6 270‐350

Plastic roads vs conventional roads

Overall reduction in bitumen consumption 

by 10‐15%

Enhanced load carrying strength

Less wear and tear, i.e. longer life

Laying 1 Km of road requires 10 Lakh carry bags 

Prevents release of 3 tonnes of CO2 (through 

disposal by burning) into the atmosphere

Increased road strength (Marshall Stability Value)

Plastic roads vs conventional roads Excellent resistance to water and water 

stagnation

No stripping and potholes.

Enhanced binding and better bonding of the 

mix.

Less rutting and ravelling.

Improved soundness property.

Negligible maintenance cost of the road.

No leaching of plastics.

No effect of UV radiation.

Characterisation of plastic waste coated aggregate bitumen mix

Stripping test

Marshall stability test

Water absorption test

Extraction of Bitumen

Estimation of amount of coated plastic waste

Post construction technical monitoring

Benkelman Beam test (BBT) ‐ To determine the visco elastic

property of the bituminous layer.

Sand Texture Depth test ‐ To measure surface texture depth used for

establishing various parameters of the road including unevenness,

skid resistance, and failures like rutting, ravelling and cracking.

Skid resistance ‐ The skid resistance of the road is determined as a

skid number and compared with reference value. Lower the skid

number higher is the skid resistance.

Post construction technical monitoring

MERLIN test ‐ The unevenness of the road is tested using the

MERLIN instrument.

Field Density –A measurement is performed using Sand

Pouring Cylinder and clarifies the reason behind poor binding,

improper compaction, stripping, loosening, movement at

edges, and anomalies in the road surface.

Other major waste materials

Fly Ash

Crumb Rubber 

Natural rubber 

Glass 

Steel slag 

Crushed concrete 

Jute Geotextiles 

Other polymers, e.g. Styrene Butadiene Styrene (SBS) 

TAMIL NADU – Approach 

Convergence of Government Departments Environment and Forest, RDPR , NRRDA

State government City corporations ( 700 km ) and rural development (16,000 kmrural roads) , Directorate Town and Panchayat

Operational Model Rates informally set up by DRDA @ ₹ 30 /kg SHGs provide processed waste plastic Road Contractor procures and mixes

TAMIL NADU ‐IMPLEMENTATION STRATEGY  Selection and execution of projects :

District Collector

SHGs formation ‐ phased manner Initially ‐ 10 districts

Added 10 more districts in the nextphase

Another 5 will be added this year

Instrumental in collection andsegregation

First road ‐ Kovilpatti village ofTuticorin October 2002

Jumbunlingam Street , Chennai 2002

TAMIL NADU – Implementation Strategy Tamil Nadu Corporation for Development of Women

PMU and PIU

Joint Director heads corporation office in District

Project Officer & Asst. ( Coordinator )

Daily wages of the collection centre workers, supportactivities, training and monitoring..

SHGs Monitored

DRDA Engineering Manual for Plastic Roads

Instituted three State level awards : Recognition

Plastic free village panchayat | Plastic free School |Self Help Groups.

₹ 5 L | ₹ 3 L | ₹ 2 L

TAMIL NADU – Financial Model  Rural Development and Panchayati Raj :

₹ 20 Crores have been allocated for this financial year.

8‐10% of budget for Plastic Roads

NRRDA, under Phase VIII of PMGSY

₹ 11 Crores have been allocated for the Plastic Roads

10% of the sanctioned budget

Environment and Forest Department : ₹ 24.818 Crores 2014‐15

₹ 44.50 Crore | 181 Projects | 236.154 km

Environment Protection and Renewal Energy Development fund ‐ 2010

Waste plastic elimination and plastic roads

₹ 5 crore setting up 50 plastic collection centres.

TAMIL NADU – Replication Aspects Network of SHGs

Well‐entrenched network of SHGs

District Convergence of Self Help Groups, Women DevelopmentCorporation, DRDA

Monitoring of converged capacity

Fast and wide roll out and development of network

High degree of Institutional support and championing

Programme Management support

KARNATAKA ‐ Approach In 2002, the CM promotes Plastic Roads

50 kilometres : Focus on Bengaluru

Till now, 2500 km reusing 10,000 tons of plastic waste

BBMP has remained an important participant 3 years phases | 500 km in each phase  BBMP has 8 Zones headed by a Joint Commissioner Each Zone is divided circles and divisions

BBMP decided a passed a resolution No.53 (15/05‐06) in 2006

for using plastic admixtures in all black top roads

Committee Engineer in Chief BBMP, Chief Engineer of National highways,Bangalore, Professor of Civil Engineering at IISc

Procurement : ₹ 27 per kilogram

KARNATAKA – Implementation  MoEF notified Plastic Waste (Management and Handling) Rules, 2011

State Pollution Control Board public notice on plastic road provisions

KK Plastic key stakeholder Process patent proprietary rights (Number 196416)

Mixing waste plastic in bituminous mixture for road surfacing

Awarded and Recognised

Memorandum of Understanding (MoU) BBMP and KK Plastics to lay 250 km of roads

Coordination mechanism Collection by SWM | Contractor Purchases plastic |

Processed plastic provided and added by Contractor

KARNATAKA – Implementation  Karnataka Rural Road Development Agency and Karnataka Road Development

Corporation, Karnataka State Highway Improvement project

KRRDA as a state level Nodal agency – GoI PMGSY

Implementing projects through the Project Implementation Units (Divisions).

State scheme : Namma Gramma Namma Raste (NGNRY)‐ CM Rural Road fund

Notable enablers

Media engagement significant role

Engagement with research institutions

Engagement with engineering colleges and schools

KARNATAKA – Financial Model  Municipal Corporation manages

Budget allocation and workforce employment BBMP has a 100% funding for plastic roads

Funds allocated Resurfacing, maintenance, widening, strengthening, and fresh laying

Financial model Purchase of waste plastic at ₹ 6‐10/ kg Processing of waste plastic at a fixed rate Consistent procurement for roads at ₹ 27 /kg

MoRD funding rural plastic roads in Karnataka under PMGSY – II

190 kilometres at ₹ 81.70 crores for 32 projects

KARNATAKA ‐ REPLICATION City Corporation and Contractor Cooperation through MoU

Convergence of Solid Waste Management and Road Engineering under theBBMP

KRRDA : nodal agency practise

Experimenting and evaluating the use of new, novel, alternative materials

Engagement with STA, research, documentation and monitoring

Tripartite agreements

E‐tendering, e‐procurement and e‐payment system in Karnataka

JHARKHAND ‐ APPROACH JUSCO provides an integrated management system for Jamshedpur

Subsidiary of Tata Group

Planning, maintenance, providing civic and municipal services

JUSCO Project management services include

EPC, O&M, BOOT, DBOOT

Implementation mentored by Prof. Vasudevan

first plastic road in Jamshedpur in the year 2011

JUSCO has door‐to‐door collection

from the source,

segregating the waste and shredding the same into 2‐4mm size.

900 workers have been deployed

JHARKHAND ‐ ORGANISATIONJUSCO

Engineering Procurement 

Construction Division

Industrial Construction

Design and Township 

Management

Power Service Division

Household Consumer

Industrial Consumer

Municipal Function

Integrated Township Management 

Division

Civil and Electrical

Water

Municipal Solid Waste

City Roads

Horticulture

JHARKHAND ‐ IMPLEMENTATION 100 metric tonnes per year of plastic processing unit

4 workers and 1 operator is required on daily basis.

Public Health Workers

collect waste from citizens, residences, schools, hotels, offices, factories and streets.

JHARKHAND – FINANCIAL MODEL Funded by Tata Steel – Client Sponsor

JUSCO raises invoice to Tata Steel for construction of roads

JUSCO ltd. uses the schedule of rates provided by Jharkhand PWD Rate revision not frequent Market trend followed Selects contractors through tendering process

JUSCO ltd. has adopted the innovative process No additional investment, reduction in the cost and saving of bitumen 12 km of plastic road paved

JHARKHAND – REPLICATION  Corporate India enthused by the Swach Bharat Campaign

Large size Indian EPC companies and MNCs

Self sustaining projects can be implemented

Initiatives such as this create jobs, awareness and improved workingrelationships

Industry intervention in other states

Simpler decision making and faster mobilisation

Common Challenges  Absence of the schedule of rates at early stages

Limited number of shredding in scaling up

delay in getting shredded plastics

Lack of adequate planning

Identification of waste plastic hot spots

Proper disposal and transportation

Consistent demand from DRDA

SHGs have experienced tremendous financial strain

Monitoring ‐ process to the required standard

Weakest link

Resistance to adoption

Decline in road maintenance work

Common Challenges Insufficient training of various stakeholders

Plastic factories and waste management

High Attrition of Collection Workers

Poor Benefits and inadequate salaries

Waste Management Issues

Over flowing bin, transport vehicles and Garbage disposal

High cost of transportation and Door to door collection

Poor participation of public in common cleanliness

Execution in remote areas

Lack of Engineering data and Documentation for past projects

Limited investment in research and innovation

Benefits Realised  Reduced risks to public health

Awareness about environment, cleanliness and hygiene

End of Plastic Waste from the environment

Reduced cost in laying road

Enhanced rural connectivity and longevity

Encouragement to private involvement

SHGs ‐Women empowered

Employment generated

Shared municipal responsibilities

Limited machinery required

Enhanced research and development of scientific methods

HIMACHAL PRADESH BAN ON PLASTICS

Waste plastics roads constructed : 2010 to 2012

Notification on ban on plastics and polythene

Department of environment, science and technology

Himachal Pradesh Non‐biodegradable Garbage (Control) Act, 1995 restrictsuse of such materials in the state.

The plastic roads are no longer being constructed as plastic is banned inHimachal Pradesh

Due to the ban no further work can be undertaken in the state

Transportation costs make plastic purchase unviable

Policy Pronouncements

Rural Roads : In collaboration with converging departments 15% of annual roads 

State financing  10% of plastic roads using the road recycling methodology

Aging urban roads recycled as rural roads  10 % of roads built by the state nodal agency 

Implementing the PMGSY‐II scheme

Urban Roads: In collaboration with converging departments  All road strengthening, resurfacing and improvement projects to use waste 

plastic with bitumen

15% of fresh road laying in urban areas of municipal limits to use plastic with bitumen

Evaluation and Planning

Conduct a planning survey for the plastic roads programme  Plastic Hot Spots | Capacity Gaps | Road Survey | Recycling 

Urban and Rural Plastic Roads  Volume of plastic waste generated  Capacity for managing it

Process : E‐tendering, E‐procurement and E‐payments 

3 phase implementation in Urban areas  Urban : 2‐3 District Pilot | 50% Districts – 18‐24 m | Remaining  18‐24m  Rural : 3 Location pilot  ‐ 6m| Parallel implementation : State & PMGSY – II | Final – EBD 

Implementation – Flagship Programme Define Flagship programme

CM Endorsement and Continuous Administrative support Department convergence between functions 

Rural Model ‐ SHGs networks Shredding Machines | Land – Shed | Payment | Demand – supply balance | 

Extensive collection network around District Processing

Urban Model Contractor – Municipal Corporation MoU Single Window Clearance | Land – Permits| Schedule of Rates | Execution – Contractor 

Private Utility : Industrial Townships  Extension limited to exiting utility operations | Client – Sponsor 

Training and Awareness Generation

Public media involvement  Case Studies | Celebrating Success | Educational Series 

Schools and Colleges awareness  Workshops | Projects | Awareness Campaigns 

Training of Contractor and Road Workers Plastic Waste Management and Road Construction 

Training to PWD Engineers  IRC – SP – 98 

Involvement of Plastic Manufacturers  Awareness Generation CSR programmes 

Segregation of Waste plastic Colour Coded bins  at home | office | communal areas 

Capacity Building Worker training for segregation and collection 

SHGs and Dry Collection Centre

CSR fund mobilisation Training and Welfare of Social Health Workers 

Burden of reuse on Manufacturers  Plastic waste should not end in landfill or incinerators  Buy back schemes for recyclable plastic 

Need for Institution, agency for monitoring : Environmental and Cleanliness 

Exchange between government, academia and industry :  Seminars | Webinars | Conferences | Round Tables 

E‐ learning content : Wide sharing of learning 

E‐monitoring : IT Infra for Quality Monitoring 

Finance 

Savings Programme  ₹ 26,000 – 60,000 per lane kilometre

Capacity building  CSR funds, Livelihood Missions, Public Works

10% Reduction of road construction outlay

Environmental Fund  Multi ‐ action climate and environment state fund 

Monitoring  Technical 

Temperature | Quality | Right Mix | Type of Plastic | Size | Verification Tests 

Administrative  Rural – 3 Tier : DQM | SQM | NQM  Urban ‐2 Tier : STA | SQM | Quality Registers | Utilisation Certificate Evidence  | 

Punitive Fines : Implementing Agency for Non‐compliance 

Citizen Charter   Web  Interface : Transparent Availability of Information Citizen Observers : 8  Provision for RTI – Section 2(j) 

Awards and Recognition

Paryavaran Seva  District Awards – Annual  Civil Society 

Administrative Awards  Engineers, Admin and Government Employees  CM initiative 

Soft Incentive for Departments  Performance linked benefits : Non Financial 

Concluding Remark ‐ 1

Plastic modified bitumen roads

Greener method of plastic waste management and better roads.

WPMB aggregate mix

economic and viable solution

WPMB road construction

Wet process, Dry process and Cold mix process

Dry process is preferred over other methods.

Other waste materials

Crumb Rubber and SBS polymer have shown promising results

Concluding Remark – 2  

Drivers : Environment and Quality of Life 

Barriers : Systemic, official and vested interest 

Proven Technology: Lab, Pilot and State Scale

No Significant Government Investment with Savings Outcome 

Adequate learning from pioneering states  

Multi fold benefit