The Central Road Research Institute (CRRI) and Bharat Petroleum (BPCL) have developed Geocells from recycled end-of-life plastic for road construction in challenging areas. Tested with TATA Projects and NHAI, this innovation improves road strength and addresses multi-layered plastic waste. Field trials begin with Military Engineering Services in August.
Image credit: Freepik
According to a TOI report, the Central Road Research Institute (CRRI) and Bharat Petroleum Corporation Limited (BPCL) have embarked on a new initiative to repurpose end-of-life plastic waste by designing Geocells—three-dimensional, block-shaped modules created from recycled plastic. These innovative modules can be filled with soil or construction debris and are designed for use in road construction, especially in areas with challenging terrain.
Ms Ankita Behl, principal scientist at CSIR-CRRI, stated, “CRRI and BPCL developed a plastic-based module or sheet and a technical textile called Geocell, using end-of-life and mixed waste plastics. Recycling such plastics is particularly challenging due to the wide variation in material quality.”
She highlighted that the waste plastic was processed through mechanical recycling, resulting in modules with a thickness ranging from 4 to 8 millimetres. Plant trials in collaboration with TATA Projects and the construction of a 160-metre road section, supported by the National Highways Authority of India, helped in validating the innovation. The Geocells were filled with non-plastic, granular base materials and tested for load-bearing strength. During laboratory and field tests, no cracks or deformations were observed, with the modules maintaining their shape and integrity.
The technology, jointly patented by CSIR-CRRI and BPCL, is scheduled for field trials with the Military Engineering Services starting in August. The project aims to demonstrate Geocells’ application in high-stress and difficult-to-access regions. For initial deployment, CRRI and BPCL have already used Geocells on a stretch near the DND-Faridabad-KMP Expressway
This trial, which consumed approximately 20–25 tonnes of waste plastic, marks India’s first use of technical textiles made entirely from end-of-life plastic. The initiative also provides a solution for multi-layered plastics, currently excluded from Indian Roads Congress specifications, supporting both plastic waste management and enhanced road durability.
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