Reuse of Waste Plastic in Manufacturing Paver Block

Abstract

The challenge of disposal of plastic waste and industrial by-products such as fly ash call for sustainable approaches to their effective utilizations. This research, therefore, undertakes an investigation into the possibility of reusing waste plastic and fly ash in the production of environment-friendly paver blocks. The plastic is shredded and used as a partial replacement together with fly ash replacing some portion of conventional materials such as cement and aggregates which are facing depletion with high consumption. This work carried out a study on physical, mechanical, and durability properties focusing on compressive strength, water absorption, and thermal resistance of paver blocks. It is indicated from the results that the incorporation of waste plastic materials alongside fly ash improves the strength and reserves water absorption properties to paver blocks thereby offering a cheap alternative traditional material. This new way helps with trash handling and building good homes, following circular economy ideas and nature caring aims.

Introduction

The increasing volume of plastic waste and the depletion of traditional building materials have spurred research into using recycled plastics in construction, particularly in concrete and paver blocks. Plastics, being non-biodegradable, lightweight, and thermally resistant, offer potential advantages when substituted for cement, sand, or aggregates in building components. This approach is both eco-friendly and cost-effective, reducing environmental harm and conserving resources.

Key Findings

• Low percentages of plastic (e.g., PET, HDPE) in concrete can improve compressive strength, but higher proportions often reduce it.

• Increased plastic content generally enhances thermal insulation, soundproofing, and corrosion resistance.

• Studies have tested different replacement ratios (2.5%–20%) to optimize strength and insulation.

Literature Insights

1. Metwally et al. (2023) – Found that HDPE outperforms PET in thermal and mechanical properties. The optimal mix was 7.5% HDPE for strength and 20% for insulation.

2. Mohamad et al. (2022) – Explored the use of industrial waste (plastics, steel slag, rubber) in concrete paver blocks, reporting up to 50% higher compressive strength compared to conventional blocks.

3. Anuradha & Vignesh War (2021) – Developed fly ash bricks using PET bottles filled with soil, which showed strong mechanical and resistance properties. Suitable for temporary housing.

4. Shipkule & Kognole (2019) – Proposed recycling plastics into bricks as a solution to plastic pollution, offering a sustainable and low-cost construction material.

5. Aswini & Balaji (2018) – Used shredded plastic to partially replace coarse aggregates in paver blocks, showing viable strength and sustainability results.

6. Banerjee & Chakraborty (2016) – Showed that fly ash (15–25%) could partially replace cement to improve compressive strength in concrete.

Problem Statement

The twin challenges of:

1. Escalating plastic pollution from industrialization and urbanization.

2. Depletion of natural construction resources (cement, sand, aggregates)

...call for innovative solutions. Conventional disposal methods (landfilling, incineration) are harmful, while construction significantly contributes to resource depletion and emissions. Integrating plastic waste into paver blocks offers a sustainable and practical alternative.

Objectives of the Study

1. Minimize plastic waste pollution by reusing plastics in construction.

2. Assess plastics’ viability as binders or fillers in paver blocks.

3. Produce eco-friendly and affordable construction materials.

4. Evaluate the mechanical durability of plastic-based vs. conventional blocks.

5. Perform a cost-benefit analysis to support future scale-up.

Materials Used

Common plastic types explored:

• PET: Strong and clear, used in bottles and packaging.

• HDPE: Durable and widely recyclable (e.g., containers).

• PVC: Used in pipes and windows; flame-resistant.

• LDPE: Flexible and moisture-resistant (e.g., bags).

• PP: High-temperature resistant; used in automotive and textiles.

• PS: Lightweight and rigid; used in packaging and insulation.

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Conclusion

1) Environmental Benefits: By turning non-biodegradable materials into practical building products, it helps to reduce the pollution caused by plastic waste. 2) Strength and Durability: Waste plastic can be combined with other materials, such as aggregates, cement, and sand, to increase the strength and durability of paver blocks. 3) Cost-Effective: It is a cost-effective alternative for construction since it lessens reliance on traditional raw materials. 4) Water Resistance: Compared to conventional concrete blocks, plastic-based paver blocks are more water resistant, which makes them appropriate for outdoor use. 5) Lightweight: Compared to traditional paver blocks, these blocks are lighter, which facilitates installation and transportation. 6) Sustainable Construction: By lowering carbon footprints and encouraging eco-friendly materials, this approach supports the idea of green building.

References

[1] Optimization of Plastic Waste Integration in Cement Bricks (2023) Author: Yara El-Metwally, Khaled Dewidar, Mostafa Ismail and Iman El-Mahallawi. [2] Manufacture of concrete paver block using waste Materials and by products (2022) Author: Habib Musa Mohamad, Nurmin Bolong, Ismail Saad, Lillian Gungat, Janus. [3] Sustainable eco-friendly fly ash brick using soil filled plastic bottles (2021) Author: P.V. Vignesh war, B. Anuradha. [4] Utilization of Plastic waste for Making Plastic Bricks (2019) Author: R. S. Kognole, Kiran Shipkule. [5] Experimental Investigation on Paver Blocks with Partial Replacement of Coarse Aggregates with Plastic Waste. (2018) Author: C. Balaji, R. Aswini. [6] Replacement of Cement by Fly Ash in Concrete (2016). Author: Jayanta Chakraborty, Sulagno Banerjee. [7] Reuse of Plastic Waste in Paver Blocks. ISSN:2278-0181 : Vol. 6 Issue 02, February-2017 B.Shanmugavalli, B. Eswara Moorthy. [8] Use of plastic in a concrete to improve its properties ISSN2249–8974 IJAERS/Vol. I/ Issue III/April-June, 2012/109-111. Raghatate Atul M. [9] Utilization of plastic bags in concrete block Literature Review June 2015, Volume 2, Issue 6 JETIR (ISSN-2349-5162). Praveen Mathew et al. [10] Recycled plastics used as coarse aggregate for constructional concrete project reference no 37S1114. R.L.Ramesh. [11] Utilization of plastic bags in pavement blocks Volume 119 No. 15 2018, 1407-1415 ISSN: 1314-3395. Mohan D.M, Vignesh. [12] Utilization of Waste Plastics as a Partial Replacement of Coarse Aggregate in Concrete Blocks.Vo 8(12), DOI: 10.17485/ijst/2015/v8i12/54462, June 2015. V. Natrajan. [13] Innovative techniques of waste plastic used in concrete mixture IJRET ISSN: 2319-1163 | PISSN: 2321-7308 Pramod S. Patil. [14] Recycled plastic used in concrete paver block EISSN:2319-1163 | pissn: 2321-7308. Ganesh Tapkire. [15] Use of waste plastic in concrete mixture as aggregate replacement, June 2015, Volume 2, Issue 6 JETIR (ISSN-2349-5162). Zainab Z. Ismail, [16] Utilization of waste plastic in manufacturing of bricks and paver blocks IJAER, ISSN 0973-4562 Vol.11 No.3 2016 Dinesh S, Dinesh A.

Copyright

Copyright © 2025 Shivprasad A. Babar, Rohan J. Bhandwalkar, Rushikesh R. Borate, M. R. G. S. Wayal. 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.