Review Paper on Sustainable Pothole Repair Using Plastic Waste in Bituminous Mixes

Abstract

The road infrastructure in India, vital to its economic development, is severely impacted by the recurring issue of potholes, which disrupt traffic, damage vehicles, and pose safety risks, especially during the monsoon season. At the same time, the country faces a growing environmental challenge with millions of tons of non-biodegradable plastic waste produced annually. This study presents a novel, sustainable solution to pothole repair by integrating shredded plastic waste into VG-30 bitumen. Experimental results show that a 9% plastic waste addition optimally enhances mechanical properties such as Marshall Stability, flow while preserving the workability of the material. This innovative method not only provides a cost-effective and durable solution for pothole repair but also aligns with the principles of a circular economy by repurposing plastic waste. The paper offers practical recommendations for scaling this solution, with particular relevance for developing nations like India.

Introduction

1. Background

India has one of the world’s largest road networks, crucial to its economic and social development. However, this infrastructure faces severe challenges—especially potholes, which undermine road safety, transport efficiency, and public well-being. Potholes are largely caused by poor construction practices, inadequate drainage, and monsoon-related stresses.

2. The Dual Crisis: Potholes & Plastic Waste

• Potholes cause accidents, vehicle damage, traffic delays, and economic loss.

• Simultaneously, India generates over 9 million tons of plastic waste annually, most of which remains unmanaged, polluting land and water.

3. Proposed Solution: Plastic-Modified Bitumen

A promising innovation involves using shredded plastic waste in bitumen (VG-30 grade) for pothole repair. This solution offers two key benefits:

• Improves road durability and resistance to stress, temperature, and moisture.

• Reduces plastic pollution by recycling waste into road-building material.

Key Components

A. Potholes: Causes and Impacts

• Causes: Water infiltration, freeze-thaw cycles, overloading, and poor drainage.

• Impacts:

  • Safety: Major cause of road accidents.

  • Cost: Increased vehicle maintenance and repair expenses.

  • Traffic: Congestion and reduced network efficiency.

B. Plastic Waste Management

• Plastic is non-biodegradable and a growing environmental hazard.

• Recycling it into roads offers a sustainable use that reduces landfill pressure.

C. Bituminous Mix Modification

• Plastics like PE, PP, LDPE are used to enhance bitumen.

• Benefits:

  • Increased durability and mechanical strength.

  • Better thermal and rutting resistance.

  • Reduced bitumen use and maintenance cost.

• Challenges:

  • Compatibility of plastics with bitumen.

  • Emission of harmful gases during heating.

  • Need for standardized processing and field trials.

Research Highlights

1. Laboratory Studies

• Marshall Stability improves significantly with 5–10% plastic addition.

• Thermal resistance is higher, ideal for India’s hot climate.

• Cost-effective for pothole repairs compared to conventional methods.

2. Field Studies & Reviews

• Kumar et al. (2019): Demonstrated effective pothole repair using plastic-modified VG-30 bitumen in rainy, high-traffic areas.

• Bhattacharya et al. (2021): Highlighted environmental and performance benefits, urging proper segregation and processing.

• Gupta et al. (2020): Warned of plastic waste heterogeneity and emissions risks.

• Ibrahim et al. (2017): Confirmed mechanical improvements but noted potential for brittleness if overused.

• Radhakrishnan & Rajendran (2018): Promoted dry-mix plastic addition and highlighted field success.

• Sharma & Rathi (2020): Reviewed molecular-level compatibility and long-term benefits, suggesting further grading systems.

Conclusion

This review has explored the potential of plastic waste in pothole repair using plastic-modified bitumen. The integration of waste plastic into bitumen enhances the mechanical properties, durability, and thermal resistance of road surfaces, making it an ideal solution for pothole repair. The dual benefit of improving road infrastructure and addressing plastic waste offers a sustainable and eco-friendly approach to road maintenance. While the benefits of using plastic-modified bitumen are evident, challenges such as plastic compatibility and long-term performance under real-world conditions need further investigation. Additionally, cost-effectiveness and scalability in large-scale applications require attention. Nevertheless, the concept of using plastic waste for pothole repair holds significant promise and warrants further research and pilot testing, particularly in developing countries like India, where both road infrastructure and plastic waste management are pressing concerns.

References

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Copyright

Copyright © 2025 S. V. Mhamane, R. D. Shinde, A. B. Khemalapure. 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.