Plastic Waste Utilization in Bituminous Mix for Sustainable Pothole Repair: Experimental and Field Evaluation

Abstract

Pothole formation is a dominant distress mechanism in flexible pavements, especially in regions subjected to high rainfall, temperature fluctuations, and increasing traffic loads. Concurrently, the proliferation of non-biodegradable plastic waste presents a critical environmental challenge. This study investigates the engineering feasibility and sustainability benefits of incorporating waste plastics (LDPE, HDPE, and PET) into bituminous mixes for pothole repair using the dry process method. Plastic content was varied from 0% to 10% by weight of bitumen. Performance was evaluated through laboratory tests including Marshall Stability, Flow value, Indirect Tensile Strength (ITS), and Tensile Strength Ratio (TSR), followed by statistical analysis (one-way ANOVA and quadratic regression), 12-month field implementation in Pratapgarh City and Chilbila, Uttar Pradesh, and comprehensive Life Cycle Assessment (LCA) & Life Cycle Cost Analysis (LCCA).Results demonstrate substantial improvements with optimum performance at 6–8% plastic content: Marshall Stability increased by 32% (16.5 kN), ITS by 34.1% (1.10 MPa), and TSR by 23.7% (94%). Field trials showed no pothole reformation after 12 months (including two monsoons) in plastic-modified sections, compared to repeated failures in conventional repairs. Environmental benefits include diversion of 250–450 kg plastic waste per km and 1.2–2.0 tonnes CO? eq. reduction per km. Economic analysis indicates 18–22% lower initial costs and nearly 50% reduction in lifecycle costs (BCR 4.8 vs 1.4). The study validates plastic-modified mixes as a technically superior, economically viable, and environmentally sustainable solution for pothole repair, supporting Swachh Bharat Mission, PMGSY, and circular economy principles in semi-urban Uttar Pradesh.

Introduction

The text describes a civil engineering study on using plastic waste to improve road construction and reduce potholes, particularly in Pratapgarh and Chilbila (Uttar Pradesh, India), where heavy rainfall, poor drainage, and overloaded traffic cause frequent road damage.

It highlights two major problems:

• Severe pothole-related accidents and economic losses in Uttar Pradesh.
• Large-scale plastic waste generation and poor recycling, leading to pollution.

To address both issues, the study uses a “waste-to-wealth” approach, incorporating shredded plastic (LDPE, HDPE, PET) into bituminous road mixes using the dry process developed by R. Vasudevan. This aligns with Indian road and environmental standards such as Indian Roads Congress guidelines and Ministry of Road Transport and Highways specifications.

The methodology involves adding plastic waste (4%–10% by weight of bitumen) into VG-30 bitumen mixes and testing performance through:

• Marshall Stability and Flow tests
• Indirect Tensile Strength (ITS)
• Moisture resistance (TSR)
• 12-month field trials

Key findings:

• The optimal plastic content is 6–8%, where performance is highest.
• At 8% plastic:
  • Marshall Stability increases by ~32%
  • ITS improves by ~34%
  • TSR reaches 94%, showing strong water resistance
• Roads with plastic-modified mixes show:
  • No pothole reformation over 12 months
  • Reduced cracking and rutting
  • Lower maintenance costs
  • Better durability in monsoon conditions

Field results confirm:

Plastic-modified roads last significantly longer (3–5 times improvement) and perform better under real traffic and weather conditions compared to conventional asphalt.

Conclusion

Incorporation of 6–8% non-degradable plastic waste via dry process significantly enhances Marshall Stability (32%), ITS (34.1%), TSR (23.7%), and field durability. Statistical models validate results reliably. The approach provides a sustainable, cost-effective solution for pothole repair, diverting waste while reducing lifecycle costs and emissions. Recommendations include adoption in municipal tenders, local processing units, and training programs. This technology exemplifies circular economy principles and can be scaled across similar regions in India.

References

[1] Behl, A., Kumar, P., & Sharma, G. (2019). Use of waste plastic in construction of flexible pavement. International Journal of Engineering and Advanced Technology, 9(1), 456–460. [2] Central Road Research Institute. (2018). Performance evaluation of plastic waste modified bituminous mixes (CRRI Report No. 456). [3] Choudhary, R., Kumar, B., & Gupta, A. (2022). Use of plastic waste in bituminous mixes: A review. Journal of Cleaner Production, 345, Article 131234. https://doi.org/10.1016/j.jclepro.2022.131234 [4] Indian Roads Congress. (2013). Guidelines for the use of waste plastic in hot bituminous mixes (dry process) in wearing courses (IRC:SP:98-2013). [5] IRJET. (2024). Experimental study on HDPE waste in pothole repair. International Research Journal of Engineering and Technology, 11(5), 789–795. [6] Ministry of Road Transport and Highways. (2013). Specifications for road and bridge works (5th Rev.). Government of India. [7] Vasudevan, R., Saravanavel, S., & Rajeswari, S. (2006). Reuse of waste plastics for road laying. Indian Highways, 34(6), 5–20. [8] Vasudevan, R., et al. (2018). Plastic roads: A sustainable solution. Thiagarajar College of Engineering. [9] Central Pollution Control Board. (2024). Annual report on plastic waste management in India. Ministry of Environment, Forest and Climate Change, Government of India. [10] Kumar, A., & Singh, R. (2025). Life cycle assessment of plastic roads in India. Journal of Environmental Management, 315, Article 114567. [11] Sharma, D. K., et al. (2023). Utilization of municipal plastic waste in bituminous concrete. Materials Today: Proceedings, 72, 1456–1462. [12] Singh, S. P., et al. (2023). Environmental impacts of waste plastic utilization in asphalt mixtures. Environmental Science & Technology, 57(12), 4567–4578. [13] Yadav, A., et al. (2025). Field performance of plastic modified pothole repairs in monsoon conditions. Transportation Research Procedia, 78, 234–245. [14] Gautam, S. Y. A. K. (2025). Sustaining Aquifer Integrity and Terrestrial Ecosystems: A Holistic Framework for Groundwater Conservation, Pollution Abetment and Soil-Vegetation Preservation. International Journal for Multidisciplinary Research (IJFMR), 7(3), 1–7. [15] Gautam, A. R. M. A. K. (2025). Outdoor Occupational Noise Assessment in Hospitals & Its Evaluation of Auditory and Non-Auditory Impact. International Journal for Multidisciplinary Research (IJFMR), 7(3), 1–5. [16] Gautam, S. Y. A. K. (2025). Mitigating Environmental Pollution Caused by Construction Industry: An Evaluation of Pre-Engineered Structures as Sustainable Solutions for Air, Water, Soil and Noise Pollution. International Journal of Science and Research (IJSR), 14(5). [17] Gautam, A. Y. A. K. (2025). Performance Based Analysis of Concrete and Plastic Paver Blocks Under Dynamic Conditions. Journal of Scientific Research and Technology, 3(4), 47–51. [18] Lohani, D., & Gautam, A. K. (2025). Assessment of Wastewater Treatment in the Paper Recycling Industry with Concurrent Bioelectricity Generation. International Journal for Multidisciplinary Research (IJFMR), 7(2), 1–5. [19] Singh, A., & Gautam, A. K. (2025). Health Impact Pathways in Indian Green Buildings: A Conceptual Framework. Sangam, 13(3–4), 35–45. [20] Gautam, P. N. A. K. (2025). Vulnerability Assessment and Impact of Solid Waste Generation in Lucknow, Uttar Pradesh. Journal of Geotechnical Studies, 10(2), 1–11. [21] Gautam, S. P. S. D. M. A. K., & Singh, M. N. B. (2020). Lead Removal Efficiency of Various Natural Adsorbents (Moringa oleifera, Prosopis juliflora, peanut shell) from Textile Wastewater. SN Applied Sciences, 2(2), 288. [22] Gautam, A., & Singh, N. (2016). Assessment of Consumer\'s Awareness about Food Adulteration and Its Harmful Effects in the Body. International Journal of Research, 3(4), 321–324. [23] Gautam, T. V. G. M. G. N. A. K. (2023). Optimal Allocation of Resources and Hospital Capacity Planning for Critical Diseases using AI and Data Mining. IEEE International Conference on ICT in Business Industry & Government, 1–6. [24] D., A. K. G. P. B. G. (2023). Multimodal Data Fusion and Machine Learning for Comprehensive Management of Parkinson\'s disease in Healthcare. IEEE International Conference on ICT in Business Industry & Government, 1–7. [25] Rajendran, A. K. G. N. K. (2025). Leveraging Quantum Communication with 6G Network: Optimize the Model for Secured Communications. First International Conference on Advances in Computer Science, Electrical Engineering and Communication. [26] Gautam, A. R. M. A. K. (2025). Outdoor Occupational Noise Assessment in Hospitals & Its Evaluation of Auditory and Non-Auditory Exposure. International Journal of Scientific Research & Development (IJSRD), 13(3). [27] Lohani, D., & Gautam, A. K. (2025). Performance Evaluation of Microbial Fuel Cells for the Treatment of Industrial Wastewater.

Copyright

Copyright © 2026 Umme Afsheen , Anupam Kumar Gautam . 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.