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Plastic pollution remains a critical global challenge, with 430 million metric tonnes produced annually, of which less than 10% is recycled. In India, rapid urbanization and inadequate waste management have led to increased plastic accumulation in landfills and waterways. Prestige Group has taken a significant step toward sustainability by incorporating plastic waste into road construction at Great Acres, The Prestige City, Sarjapur. Inspired by Dr. R. Vasudevan's technique, the project integrates shredded plastic with bitumen, enhancing road durability while reducing plastic waste. Covering 7.17 km, this initiative serves as a scalable model for sustainable urban infrastructure worldwide.
Plastic pollution remains one of the most critical environmental challenges today, with approximately 430 million metric tonnes of plastic produced globally each year. Nearly half of this is intended for single-use applications, and alarmingly, less than 10% is recycled. This lack of recycling leads to devastating consequences for ecosystems and human health. In India, rapid urbanisation and limited waste management infrastructure worsen the problem, allowing significant quantities of plastic waste to accumulate in landfills and waterways. Advertisement
India has long explored innovative ways to address plastic pollution, particularly through road construction. In 2001, Dr. R. Vasudevan, known as the "Plastic Man of India," introduced a pioneering technique to integrate shredded plastic waste into heated bitumen for road-building. This method not only improved road quality but also provided a viable solution to manage plastic waste. Building on this, the Indian government made it mandatory in 2016 to use waste plastic in constructing highways within a 50-kilometre radius of cities with populations exceeding 500,000. Cities like Chennai, Delhi, and Pune have since embraced this technique, demonstrating its effectiveness, especially in improving road durability during monsoons.
Responding to the global call to #BeatPlasticPollution, Prestige Group, a leader in sustainable real estate, has advanced these efforts by incorporating plastic waste into road construction within the Great Acres development of The Prestige City, Sarjapur. This initiative not only addresses the mounting plastic waste issue but also sets a benchmark for sustainable urban infrastructure practices.
Prestige Group adopted a methodical process to use plastic waste in road construction, combining scientific rigor with expert collaboration. The process began with carefully selecting materials, where shredded plastic waste was processed into uniform particle sizes and blended with VG-30 grade bitumen at an optimum binder content (OBC) of 5%. Rigorous laboratory tests, such as gradation testing, ensured the aggregates met stringent quality standards necessary for building durable, load-resistant roads.
The plastic-bitumen mixture was prepared at controlled temperatures to ensure effective bonding, with plastic waste constituting 6% of the total aggregate weight. This followed guidelines outlined in IRC SP-98: 2013, which promote using waste plastic in road construction. Marshall Stability tests conducted by Bureau Veritas and Bangalore University confirmed the enhanced stability, flexibility, and load-bearing capacity of the plastic-bitumen mix compared to traditional materials.
Surface preparation involved thorough cleaning and applying rapid emulsion spraying for better adhesion. The bituminous concrete mix was transported under protective coverings to maintain temperature consistency. Using infrared thermometers, the team ensured the mix was laid at an optimal temperature range of 150°C to 160°C. Compaction was executed with precision using static and tire-mounted rollers, achieving uniform density and strength. A detailed process checklist ensured every step adhered to the highest safety and quality standards.
The project covered 7.17 kilometres (44,025 square metres) of roads using this innovative mix, demonstrating the scalability of sustainable road construction practices. This initiative yielded significant environmental benefits, showcasing how the construction sector can combat plastic waste effectively. Roads constructed with the plastic-bitumen mix proved more durable, reducing the frequency and cost of repairs.
Prestige Group's initiative serves as a scalable model for industries and governments worldwide. By combining innovation with rigorous quality assurance, the project demonstrates the practicality of sustainable solutions. The design mix, recommended by leading institutions like Bureau Veritas and Bangalore University, adds credibility to this approach.
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