AIRPORTS AUTHORITY OF INDIA

O/o MEMBER (PLANNING)

No. MI/M(Plg.)|Iech.Cir./2018/ Date:2r｀ ovember′ 2018

Technical Circular - 08/2018

Sub: Use of waste plastics in road construction.

1. Safe disposal of waste plastics is a serious environmental problem, being a

non-biodegradable material, it does not decay over time.
2. Studies have revealed that waste plastics have great potential for use in
bituminous construction as its addition in small dose, about 5-10o/o by weight
of bitumen helps in substantially improving the marshal stability, fatigue life
and other desirable propefties of bituminous mix, leading to improved
longevity and pavement performance. fie use of waste plastics thus
contributes to construction of green roads.
3. Use of Efforts shall be made for use of waste plastics for use in perimeter
roads, roads in residential colony and car parking.
4. The availability of waste plastics and shredder machine shall first be ensured
before its use in pavement construction.
5. Only plastics conforming to low densify polyethylene (LDPE), high density
polyethylene (HDPE), PET and polyurethane shall be used in pavement
construction.
Waste plastic & its Source
Waste Plastic Origin
Low Density Polyethylene (LDPE) Carry bags, sacks, milk pouches, bin lining,
cosmetic and detergent bottles
Hiqh Density Polvethvlene(HDPE) Carry baqs, bottle caps, house hold afticles etc'
Polyethylene Teryphthalate Drinking water bottles etc.
(PTD
Polypropylene (PP) Bottle caps and closures, wrappers of detergent,
biscuit, wafer packets, microwave trays for
readymade meal etc.
Polystyrene (PS) Yoghurt pots, clear egg packs, bottle caps.
Foamed Polystyrene: food trays, egg boxes,
disposable cups, protective packging etc.
Polyvinyl Chloride (PVC) Mineral water bottles, credit cards, toys, pipes
and gutters: electrical flttings, furniture, folders
and oens. medical disposables. etc.
6. Llmitation of uslng waste plastic as modifler and binder: Following need to be
ensured in order to achieve the advantages of these specifications:

. The material shall consist of only low density polyethylene (LDPE) or

high density polyethylene (HDPE), PU (available in limited quantity as
waste) and PET.
. Black coloured plastlc waste is a result of repeated recycling and should
not be used.
. PVC shall not be used since they release lethal levels of dioxins.
. The Thermo Gravimetric Analysis (TGA) of thermoplastics has revealed
gas evolution and thermal degradation may occur beyond 180"C. Thus
misuse or wrong implementation of this technology may result in
release of harmful gases, premature degradation, if the temperatures
are not maintained during construction.

7. MATERIALS:

7.I BITUMEN
The bitumen for bituminous mixes for wearing course with waste plastic
shall comply with the hdian Standard Speciflcations for viscosity graded
paving bitumen IS:73 Guidelines for selection for grade of viscosity graded
paving bitumen shall be in accordance with the IRC:1i1-2009.

7.2 AGGREGATES
The aggregates shall comply to IRC:111-2009 for dense graded mixes.

7,3 FILLER
The filler for dense graded mixes shall comply with IRC:111-2009.

7,4 WASTE PLASTIC

.
The waste plastic shall conform to the size passing 2.36 mm sieve
and retained on 600 micron sleve.

. Dust and other impurities shall not be more than 1 percent. The
process is indicated in Appendix-2 of 1RC:SP:98-2013 (copy
enclosed). An easy method to determine the quantity 0f impurity is
to determine the ash content at 600"C.
 ● 丁o ascertain the ability of plasuc to mix with the binder′ the melt―
Лow value sha‖ be tested as per ASTM D 1238-2010′ for which the
range sha‖ be as fo‖ ows:
For LDPE:0,14-58 gm/10 min
For HDPE:0.02-9.Ogm/10 min
7.5 DESICN OF MIX
丁he requirements for waste plastic modned design graded mi× is as
follows:
丁he properties for dense graded mixes are indicated in the following ttable.

Table‐ Requirements for Waste Piastic Modined Dense Craded

Bitunlinous Pavement Lavers

Minimum stability (KN at 60"C) 12.0

Flow value(mm) 2‐ 4
Marshall Quotient (kN/mm) 2:5-5
Compaction level (Number of 75 blows on each ofthe two faces
blows) of the specirnen
Per cent air voids 3-5
Retained Stabinty(%) 98
VFB 65-75
Quanuty of Waste ttasuc%by 6 to B depending on low rainfall or
Weicht of bitumen hiqh rainfall areas

7.6 DRY PROCESS

In order to ensure that the quality of the finished waste plastic product is
consistent the following process must be adhered to before considering its
use in bituminous construction:

a) Collection of waste plastic

b) Cleaning and shredding of waste plastic
c) Shredding Machine
d) Mixing of shredded waste plastic, aggregate and bitumen in central
mixing plant.

7.7 CONSTRUCTION
Construction operation shall be in accordance with the IRC:111-2009 for
dense graded mix.
 フ.8 CONTROLS
Controls sha‖ be in accordance with the IRC:111-2009 for dense graded
m挟 .Besides′ plasuc shall be tested forimpunty and melt low value.T hree
sample be tested for each day work or vvhen there is change in the source
of plastic.

丁he above instructions may be follovved with immediate efFect.

Enci: 1)Appendix-2 ofIRC:SP:98-2013.

2)Item&AOR for P!asuc Roads.

Distribution:
As per‖ st enclosed.
 IRC:SP:98‐ 2013

Appendix-2
(Refer Clause 4.4)

Processing details:-
i) collection of waste plastic
ii) cleaning and shredding of waste plastic
iii) mixing of shredded waste plastic, aggregate and bitumen in central mixing plant
iv) laying of bituminous mix
a) Collection of waste Plastic:
Waste plastic is collected from roads, garbage trucks, dumpsites or compost
plants, or from school collection programmes, or by purchase from rag-
pickers or waste-buyers

Fig. 1 Collection of Waste Plastic

b) Cleaning and shredding of waste plastic:

Waste plastic litter in the form of thin-fllm carry-bags, use-and-throw cups,
PET bottles, etc. these are sorted; de-dusted, washed if necessary.

Fig.2 Cleaning Process

IRC:SP:98‐ 2013

c) Shredding machine
Plastic waste which is cleaned is cut into a size between 2.36 mm and
600 microns and of maximum size 2.36 mm length and 2.00 mm width using
a shredding machine.

:
Fig. 3 Shredding Machine

d) Mixing of shredded waste plastic, aggregate and Bitumen in Central

mixing Plant:
The aggregate mix is heated to 140-175oC in Central mixing plant. The
requisite percentage of waste plastic to the weight of bitumen is injected with
a pipe under compressed air in the drum of a drum mix plant through a pipe
al2t3length of the drum or through an opening over the pugmill in the case
of a batch mix plant. The waste plastic initially coats the heated aggregates.
ln the next stage bitumen is added to the aggregates, the temperature of the
binder shall conform to the temperature depending on the grade of binder
and the type of mix. The plastics waste coated aggregate is mixed with hot
bitumen for 15 secs and the resulting mix transported for road construction.
Central mixing plant helps to have better control of temperature and better
mixing of this material thus helping to have a uniform coating and heated
bitumen is also sprayed.

12
 IRCISP:98‐ 2013

Fig.4 Central Mixing Plant

e) Laying of bituminous mix:
The road laying temperature is between 110oC to 120oC for waste plastic
bituminous mix . The roller used can be of any specified capacity.

13
 Rate Analysis for Plastic Roads
Providing and laying hot mix Wearing course of asphaltic concrete for Roads using crushed stone
aggregates of quality, size and grading as specified with addition of processed waste plastic as per
specification by weight of bitumen as specified and viscosity grade bitumen, in proportions as per
approved job mix formula, laid to specified levels grade and camber as per specifications, drawings
and as directed by the Engineer-in-Charge including cocompacting with 8-10 tonne, preferably
vibratory road roller of adequate capacity to achieve the specifled value of compaction, strength and
surface accuracy complete. (For tendering purpose, VG bitumen grade VG 30 content shall be taken
as 105 kg per cum of mix supplied in Bulk produced by Govt. Refineries) and weight of processed
waste plastic 9 KglCum by weight.
Details of cost for 450.00 MT (195 cum)
DensitY = 2.30 gm/ cc
Description unit Quantity Rate Amount
Materials
i(a) Viscosity Grade Bitumen @ 105 kg/ m3 tonne 20.47

i(b) Processed waste plastic @ 9 Kg/Cum tonne l,76

ii) Aggregate
Total weight of mix = 450 tonnnes
Weight of bitumen + plastic= 20.47 + L.76
tonnes = 22.23 tonnes
Weight of aggregate = 450-22.23 = 427.77
tonnes
Taking density of aggregate = 1.5 ton/ cum
Volume of aggregate = 285.18 cum
19 mm Nominal Maximum Aggregate size
19 - 9.5 mm 2Opercent cum 57.04
9.5 - 4.75 mm 50 percent cum 142.59
4.75 mm and below 28 percent cum 79.85
Machinery
Weigh Batch Hot Mix Plant @ 75 tonnes per
hour 6.00
hour (averaqe)
Self Propelled Electronic Sensor Paver hour 6.00
Generator 250 KVA hour 6.00
Front end loader 1 cum bucket capacity hour 6.00

Tipper 10 tonne capacity 450 MT/ 10 MT = 45

Trips, For 2 km Lead, Number of Trips
performed by tipper per day = 6,48 No. of days day 6.94
required = 45/6.48 = 6.94 days (as per DAR Vol-
I item 1.1 page 53)
Smooth wheeled roller 8-10 tonnes for initial
hour 6.00xO.65*
break down rolling

Vibratory roller 8 tonnes for intermediate rolling hour 6.00xO.65*

Finish rolling with 6-8 tonnes smooth wheeled
hour 6.00xO.65*
tandem roller
Labour
Mate day 0.84
Mazdoor working with HMP, mechanical broom,
paver, roller, asphalt cutter and assistance for
day 16.00
setting out lines, levels and layout of
construction
Skilled mazdoor for checking line and levels day 5.00
丁ota!
Add for Water Charges@1%
丁ota!
Add for contractor prolt and overheads@150/o
Total

丁ota!CostFor 195 cum Rs.

Cost for i cum
Contd・ .P/2
 2
1. Although the rollers are required only for 3 hours as per norms of output, but the same have to be
available at site for six hours as the hot mix plant and paver will take six hours for mixing and paving
the output of 450 tonnes considered in this analysis. To cater for the idle period of these rollers, their
usage rates have been multiplied by a factor of 0.65
2.Quantity of Bitumen and processed plastic waste has been taken for analysis purpose. The actual
quantity will depend upon job mix formula.
3. Labour ror traffic control, watch and ward and other miscellaneous duties at site including sundries
have been included in adminlstrative overheads of the contractor.
4. In case Wearing course is laid over freshly laid tack coat, provision of mechanical broom and 2

mazdoors shall be deleted.

5. The individual density for each size of aggregates to be used for construction i.e. 19 mm Nominal
maximum Aggregate size should be found in the laboratory and accordingly the quantities should be
ammended for use in field. The average density of 1.5 tonne/cum is only a reference density'
6. The individual percentage of aggregates and filler should be calculated from the total weight of dry
aggregates i.e. excluding the weight of bitumen in accordance with Job Mix Fotmula'
7, Depending upon quantum of work, the co-efficients for machinery prescribed in the Standard
Analysis of Rates for the item may be modified with the specific approval of Technical sanctioning
authority
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