Design of Rigid Pavement Using Geosynthetic Material

Abstract

The present experimental study investigates the influence of incorporating polypropylene fibre (PPF) as a partial replacement for cement in concrete, with a primary focus on evaluating the mechanical strength and overall performance of the resultant mix. In this research, various percentages of PPF—ranging from 0.5% to 12% by weight of cement—were introduced to examine their effect on concrete properties. The results demonstrate that lower dosages of PPF, specifically 0.5% and 1%, yield a significant improvement in the compressive strength and durability characteristics of concrete when compared to conventional Plain Cement Concrete (PCC). These improvements can be attributed to the fibre\'s ability to bridge micro-cracks, enhance the ductility, and reduce shrinkage-related issues. However, the study also indicates that increasing the PPF content beyond 2%, particularly in the range of 6% to 12%, results in a marked reduction in strength and performance metrics. This deterioration is likely due to the excess volume of fibre interfering with the homogeneity and workability of the concrete mix, leading to voids and weak zones. As such, it can be concluded that there exists an optimal threshold—up to a maximum of 2%—for the effective and beneficial use of polypropylene fibre in concrete. Beyond the performance benefits, the use of PPF as a cement substitute also offers considerable environmental advantages. Since cement production is highly energy-intensive and contributes significantly to carbon dioxide emissions, reducing its usage through partial replacement with polypropylene fibres contributes to more sustainable construction practices.

Introduction

The study explores the use of polypropylene fibre-reinforced concrete (FRC) in rigid pavement construction, particularly in highways, airports, and industrial roads. While Portland Cement Concrete (PCC) pavements are durable and strong under compression, they are prone to cracking due to tensile stress, shrinkage, and temperature variations. The incorporation of polypropylene fibres, a type of geosynthetic, improves concrete’s tensile strength, ductility, and crack resistance, making pavements more durable, cost-effective, and low-maintenance.

Literature Review Highlights:

• Erol Tutumluer et al. (2025): Geosynthetics like geogrids and geotextiles enhance subgrade strength, load distribution, and pavement life. Their proper design improves mechanical stabilization and reduces deformation.

• Varsha Sri et al. (2024): Studied lightweight concrete using LECA and pumice stone. LECA proved better in strength and sustainability, reducing thickness and self-weight of concrete.

• Danrong Wang et al. (2023): A full-scale field study showed that geosynthetics reduced subgrade pressure by 70% and strain by up to 99%, indicating better load dispersion and stress control.

• Shantanu Upadhyaya et al. (2023): Geotextiles improved pavement performance on weak subgrades. Emphasized the need for Life Cycle Cost Analysis (LCCA) to assess economic feasibility.

• Mohit et al. (2023): Highlighted geosynthetics' roles in moisture control, stress absorption, and job creation in pavement construction.

• Šeputyt?-Jucik? et al. (2023): Studied lightweight concrete with recycled glass and polystyrene waste, finding improvements in thermal insulation, strength, and freeze-thaw resistance.

• Abhishek M et al. (2022): Investigated lightweight concrete with bagasse ash and EPS beads, achieving strength with improved sustainability.

• Adhikary et al. (2022): Reviewed lightweight self-compacting concrete (LWSCC), noting how nano-materials and ultrafine particles enhance durability and frost resistance.

• Shashank Kumar et al. (2022): Geotextile-reinforced subgrades showed reduced moisture content, enhancing soil strength and pavement life.

• R. Dharmaraj et al. (2021): Adding iron scrap and fly ash improved concrete’s compressive, flexural strength, and abrasion resistance, supporting sustainable construction.

• Md Jihad Miah et al. (2020): Replacing natural sand with recycled iron powder (RIP) enhanced mechanical properties, thermal resistance, and durability of mortar.

Proposed Methodology:

The study plans to test polypropylene fibre-reinforced concrete using materials like cement, water, sand, and aggregates. The methodology includes:

• Using coarse aggregates (crushed stones of 10 mm & 20 mm),

• Fine aggregates conforming to Zone II grading (natural sand),

• Portland Pozzolana Cement, known for its long-term strength and durability,

• Incorporating polypropylene fibres to improve crack resistance and flexibility.

Conclusion

From the experimental study, it has been observed that incorporating 0.5% and 1% polypropylene fibre as a partial replacement of cement yields better results in terms of strength and performance when compared to Normal Plain Cement Concrete. However, as the proportion of polypropylene fibre increases from 6% to 12% and beyond, a noticeable decline in performance is recorded, with results falling significantly below those of Normal Plain Cement Concrete and mixes with 0.5% and 1% fibre content. This suggests that an optimal limit exists for the effective use of polypropylene fibre in concrete, and based on the findings, it can be concluded that the use of polypropylene fibre as a partial replacement of cement should be limited to a maximum of 2% to maintain or enhance the desirable properties of the concrete mix. Therefore, it is proposed that a small percentage of cement in concrete may be effectively replaced with polypropylene fibre. This not only helps in reducing the overall consumption of cement—a material whose production is energy-intensive and contributes significantly to carbon emissions—but also allows for the beneficial use of waste materials within the construction industry. By incorporating such waste-derived fibres into concrete, a dual benefit is achieved: promoting sustainability in construction practices and mitigating environmental pollution through effective waste management. Further research and investigation from a practical and field-oriented perspective will be carried out to assess long-term performance, durability, and feasibility of using polypropylene fibre in real-life construction applications.

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Copyright

Copyright © 2025 Mr. Yogesh B. Chauhan , Dr. A. N. Dabhade . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.