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Presented to Centre for Innovations in Public Systems
Hyderabad
By Knowledge Advisory Services and Consultancy
Lucknow3rd November 2014
Knowledge Partner
Knowledge Advisory Consulting
Technology and Management
Research firm Emerging Technology, Markets, Policy, Legislation
Project Engagement Team Kshitij Aditeya Singh, Dr. Shikha Wadhwa, Sharad Nigam
Presentation Outline• Introduction
• Technology Innovation and Process
• Case Study • Tamil Nadu • Karnataka • Jharkhand
• Roll out Strategy
• Concluding Remark
Background India generates 1.88 Lakh tons garbage every day
Plastic Waste in different forms 9% to 12% in municipal solid waste
Poor biodegradability and enormous environmental challenges
Choked drains
Filthy public places
Landfill of waste plastic
Incineration of plastic at high temperatures
Air pollution due to the emission of polluting gases
Primary Objectives To understand administrative processes involved in usage of plastic waste in road construction
To evaluate implementation strategy and cost
To assess key organizations involved and their specific roles , coordination and inter linkages
To formulate details of roll out orders
To review details of Statutory and Non‐statutory approvals in execution
To review impact of the initiative ‐ Pre and Post impact of the initiative(s)
To translate lessons learnt from states implementing
To assess the process of the Indian Roads Congress
To assess the integration of technological and engineering decision into the policy framework and
execution
To ascertain processes that can be reproduced on a national scale
To establish financial models and implementation monitoring methods
Scope Focus on IRC standard
Assessment of durability of plastic as compared to other materials
Evaluation– Technical, Financial, Administrative and Organisational
Qualitative assessment through interviews and field visit
Assessment geography would be limited to states and union territories
Highlight best practise and operational parameters
Scientific review through journal papers and patents
Methodology
Participatory and Applied Research Methods
Methods applied Primary Research Secondary Desktop Research Interviews Focus Group Discussion
Components of road construction material
Bitumen – grades 60/70 or 80/100
Aggregate mix – coarse, fine or filler
Binder or modifier – polymers, crumb rubber, steel slag,
fly ash...
Bitumen based concrete mixes
A. U. Ravi Shankar, D. Salian KK. Utilization of waste plastic in semi dense bituminous concrete
by dry mixing. Highw Res J. 2009;23–35.
The need for modification of bitumen
Limitations of pure bituminous mixes:
Reduced performance of road at high temperature.
Cracking and crazing occurs.
Potholes are easily formed.
Reduced life of the road constructed.
Higher costs of the material and processing.
Physical properties of 60/70 and 80/100 Bitumen grades
Designation Test Results Permissible Limits asper IS 73: 1992
TestMethod
60/70 80/100 60/70 80/100Penetrationat 250C, 100g, 5 s, d mm
65 89 60‐70 80‐100 IS 1203: 1978
SofteningPoint, 0C
48 42 40‐55 35‐50 IS 1205: 1978
Ductility at270C, cm
100+ 100+ 75 (min.)
75 (min.) IS 1208: 1978
SpecificGravity at270C, g/cc
1.010 0.998 0.99
(min.)
0.99
(min.)
IS 1202:
1978Flash Point,0C
285 310 175
(min.)
175
(min.)
IS 1209:
1978
P. Kumar RG. Laboratory studies on waste plastic fibre modified bitumen. Highw Res J. 2010;45–60.
Aggregate
Aggregates
Gravel(Crushed natural stone)
Granite
Limestone(Crushed sedimentary rock)
Secondary (crushed constructive waste)
Slag (crushed smelter slag)
Required properties of aggregates
S.No. Property BIS Testmethods
Results MoRT&Hspecification
1 Aggregate impactvalue %
IS:2386 Part IV
18.0 27 Max
2 Combined flakiness& elongation index %
IS:2386 Part I
24.0 30
3 Specific gravity‐1. C.A2. F.A
IS:2386 Part IIIS:1202‐1978
2.692.67
NilNil
4 Water absorption % IS:2386 Part III
0.50 2 Max
M. S. Ranadive SHG. Enhancing stability of flexible pavements using plastic waste and fly ash.Indian Highw. 2011;23–8
Road construction processes
Hot mixes
Cold mixes
Dry process (plastic mixed to hot aggregate)
Wet process (Plastic mixed to hot bitumen)
Others – recycled plastic, modified processes, new additives
Processing technologies
Plastic as binder
Plastic as modifier
Dry process
Eco Roads of Plastics. WALKABILITYASIA, http://walkabilityasia.org/2012/07/27/eco‐roads‐of‐plastic/
The design criteria for PMB pavement layersMinimum stability (kN at 600C) 12.0Flow (mm) 2‐4Marshall Quotient (kN/mm) 2.5‐5.0Compaction level (Number ofblows)
75.0 blows on each of the two faces of the specimen
Air voids (%) 3.0‐5.0Retained stability (%) 98.0ITS (min) MPa 0.9VMA 16.0VFB 65.0‐75.0Quantity of waste plastic (% byweight of bitumen)
6.0‐8.0
Specifications for the use of waste plastic in hot bituminous mixes in wearing courses, IRC SP
98‐2013. 2013 p. 1–8.
Plastic as binder‐modifier
Surface property of aggregates isenhanced.
Coating technique is straightforward& temperature requirements are thesame as that of road laying process.
Flexible films of all types of plasticscan be used.
Doubles the binding property ofaggregates.
Bitumen bonding is strong thannormal.
Plastic as binder‐modifier
The coated aggregates show increased strength.
Higher cost efficiency is possible.
Is suitable for all type of environmental
conditions.
No toxic gases released during the heating
process
Easy disposal of plastic waste
Offers an eco‐friendly technology
Offers job for rag pickers
Types of plastic waste
Plastics Toxic gases released T (0C)
Polyethylene Terephthalate (PET)
Lighter hydrocarbons (C5‐C10)
>200
Polypropylene (PP) C2H6 270‐300Poly Vinyl Acetate (PVA) CH3COOH >190
Poly Vinyl Chloride (PVC) HCl 250
Polystyrene (PS) C6H6 300‐350Low Density Polyethylene (LDPE)
CH4, C2H6 270‐350
High Density Polyethylene (HDPE)
CH4, C2H6 270‐350
Plastic roads vs conventional roads
Overall reduction in bitumen consumption
by 10‐15%
Enhanced load carrying strength
Less wear and tear, i.e. longer life
Laying 1 Km of road requires 10 Lakh carry bags
Prevents release of 3 tonnes of CO2 (through
disposal by burning) into the atmosphere
Increased road strength (Marshall Stability Value)
Plastic roads vs conventional roads Excellent resistance to water and water
stagnation
No stripping and potholes.
Enhanced binding and better bonding of the
mix.
Less rutting and ravelling.
Improved soundness property.
Negligible maintenance cost of the road.
No leaching of plastics.
No effect of UV radiation.
Characterisation of plastic waste coated aggregate bitumen mix
Stripping test
Marshall stability test
Water absorption test
Extraction of Bitumen
Estimation of amount of coated plastic waste
Post construction technical monitoring
Benkelman Beam test (BBT) ‐ To determine the visco elastic
property of the bituminous layer.
Sand Texture Depth test ‐ To measure surface texture depth used for
establishing various parameters of the road including unevenness,
skid resistance, and failures like rutting, ravelling and cracking.
Skid resistance ‐ The skid resistance of the road is determined as a
skid number and compared with reference value. Lower the skid
number higher is the skid resistance.
Post construction technical monitoring
MERLIN test ‐ The unevenness of the road is tested using the
MERLIN instrument.
Field Density –A measurement is performed using Sand
Pouring Cylinder and clarifies the reason behind poor binding,
improper compaction, stripping, loosening, movement at
edges, and anomalies in the road surface.
Other major waste materials
Fly Ash
Crumb Rubber
Natural rubber
Glass
Steel slag
Crushed concrete
Jute Geotextiles
Other polymers, e.g. Styrene Butadiene Styrene (SBS)
TAMIL NADU – Approach
Convergence of Government Departments Environment and Forest, RDPR , NRRDA
State government City corporations ( 700 km ) and rural development (16,000 kmrural roads) , Directorate Town and Panchayat
Operational Model Rates informally set up by DRDA @ ₹ 30 /kg SHGs provide processed waste plastic Road Contractor procures and mixes
TAMIL NADU ‐IMPLEMENTATION STRATEGY Selection and execution of projects :
District Collector
SHGs formation ‐ phased manner Initially ‐ 10 districts
Added 10 more districts in the nextphase
Another 5 will be added this year
Instrumental in collection andsegregation
First road ‐ Kovilpatti village ofTuticorin October 2002
Jumbunlingam Street , Chennai 2002
TAMIL NADU – Implementation Strategy Tamil Nadu Corporation for Development of Women
PMU and PIU
Joint Director heads corporation office in District
Project Officer & Asst. ( Coordinator )
Daily wages of the collection centre workers, supportactivities, training and monitoring..
SHGs Monitored
DRDA Engineering Manual for Plastic Roads
Instituted three State level awards : Recognition
Plastic free village panchayat | Plastic free School |Self Help Groups.
₹ 5 L | ₹ 3 L | ₹ 2 L
TAMIL NADU – Financial Model Rural Development and Panchayati Raj :
₹ 20 Crores have been allocated for this financial year.
8‐10% of budget for Plastic Roads
NRRDA, under Phase VIII of PMGSY
₹ 11 Crores have been allocated for the Plastic Roads
10% of the sanctioned budget
Environment and Forest Department : ₹ 24.818 Crores 2014‐15
₹ 44.50 Crore | 181 Projects | 236.154 km
Environment Protection and Renewal Energy Development fund ‐ 2010
Waste plastic elimination and plastic roads
₹ 5 crore setting up 50 plastic collection centres.
TAMIL NADU – Replication Aspects Network of SHGs
Well‐entrenched network of SHGs
District Convergence of Self Help Groups, Women DevelopmentCorporation, DRDA
Monitoring of converged capacity
Fast and wide roll out and development of network
High degree of Institutional support and championing
Programme Management support
KARNATAKA ‐ Approach In 2002, the CM promotes Plastic Roads
50 kilometres : Focus on Bengaluru
Till now, 2500 km reusing 10,000 tons of plastic waste
BBMP has remained an important participant 3 years phases | 500 km in each phase BBMP has 8 Zones headed by a Joint Commissioner Each Zone is divided circles and divisions
BBMP decided a passed a resolution No.53 (15/05‐06) in 2006
for using plastic admixtures in all black top roads
Committee Engineer in Chief BBMP, Chief Engineer of National highways,Bangalore, Professor of Civil Engineering at IISc
Procurement : ₹ 27 per kilogram
KARNATAKA – Implementation MoEF notified Plastic Waste (Management and Handling) Rules, 2011
State Pollution Control Board public notice on plastic road provisions
KK Plastic key stakeholder Process patent proprietary rights (Number 196416)
Mixing waste plastic in bituminous mixture for road surfacing
Awarded and Recognised
Memorandum of Understanding (MoU) BBMP and KK Plastics to lay 250 km of roads
Coordination mechanism Collection by SWM | Contractor Purchases plastic |
Processed plastic provided and added by Contractor
KARNATAKA – Implementation Karnataka Rural Road Development Agency and Karnataka Road Development
Corporation, Karnataka State Highway Improvement project
KRRDA as a state level Nodal agency – GoI PMGSY
Implementing projects through the Project Implementation Units (Divisions).
State scheme : Namma Gramma Namma Raste (NGNRY)‐ CM Rural Road fund
Notable enablers
Media engagement significant role
Engagement with research institutions
Engagement with engineering colleges and schools
KARNATAKA – Financial Model Municipal Corporation manages
Budget allocation and workforce employment BBMP has a 100% funding for plastic roads
Funds allocated Resurfacing, maintenance, widening, strengthening, and fresh laying
Financial model Purchase of waste plastic at ₹ 6‐10/ kg Processing of waste plastic at a fixed rate Consistent procurement for roads at ₹ 27 /kg
MoRD funding rural plastic roads in Karnataka under PMGSY – II
190 kilometres at ₹ 81.70 crores for 32 projects
KARNATAKA ‐ REPLICATION City Corporation and Contractor Cooperation through MoU
Convergence of Solid Waste Management and Road Engineering under theBBMP
KRRDA : nodal agency practise
Experimenting and evaluating the use of new, novel, alternative materials
Engagement with STA, research, documentation and monitoring
Tripartite agreements
E‐tendering, e‐procurement and e‐payment system in Karnataka
JHARKHAND ‐ APPROACH JUSCO provides an integrated management system for Jamshedpur
Subsidiary of Tata Group
Planning, maintenance, providing civic and municipal services
JUSCO Project management services include
EPC, O&M, BOOT, DBOOT
Implementation mentored by Prof. Vasudevan
first plastic road in Jamshedpur in the year 2011
JUSCO has door‐to‐door collection
from the source,
segregating the waste and shredding the same into 2‐4mm size.
900 workers have been deployed
JHARKHAND ‐ ORGANISATIONJUSCO
Engineering Procurement
Construction Division
Industrial Construction
Design and Township
Management
Power Service Division
Household Consumer
Industrial Consumer
Municipal Function
Integrated Township Management
Division
Civil and Electrical
Water
Municipal Solid Waste
City Roads
Horticulture
JHARKHAND ‐ IMPLEMENTATION 100 metric tonnes per year of plastic processing unit
4 workers and 1 operator is required on daily basis.
Public Health Workers
collect waste from citizens, residences, schools, hotels, offices, factories and streets.
JHARKHAND – FINANCIAL MODEL Funded by Tata Steel – Client Sponsor
JUSCO raises invoice to Tata Steel for construction of roads
JUSCO ltd. uses the schedule of rates provided by Jharkhand PWD Rate revision not frequent Market trend followed Selects contractors through tendering process
JUSCO ltd. has adopted the innovative process No additional investment, reduction in the cost and saving of bitumen 12 km of plastic road paved
JHARKHAND – REPLICATION Corporate India enthused by the Swach Bharat Campaign
Large size Indian EPC companies and MNCs
Self sustaining projects can be implemented
Initiatives such as this create jobs, awareness and improved workingrelationships
Industry intervention in other states
Simpler decision making and faster mobilisation
Common Challenges Absence of the schedule of rates at early stages
Limited number of shredding in scaling up
delay in getting shredded plastics
Lack of adequate planning
Identification of waste plastic hot spots
Proper disposal and transportation
Consistent demand from DRDA
SHGs have experienced tremendous financial strain
Monitoring ‐ process to the required standard
Weakest link
Resistance to adoption
Decline in road maintenance work
Common Challenges Insufficient training of various stakeholders
Plastic factories and waste management
High Attrition of Collection Workers
Poor Benefits and inadequate salaries
Waste Management Issues
Over flowing bin, transport vehicles and Garbage disposal
High cost of transportation and Door to door collection
Poor participation of public in common cleanliness
Execution in remote areas
Lack of Engineering data and Documentation for past projects
Limited investment in research and innovation
Benefits Realised Reduced risks to public health
Awareness about environment, cleanliness and hygiene
End of Plastic Waste from the environment
Reduced cost in laying road
Enhanced rural connectivity and longevity
Encouragement to private involvement
SHGs ‐Women empowered
Employment generated
Shared municipal responsibilities
Limited machinery required
Enhanced research and development of scientific methods
HIMACHAL PRADESH BAN ON PLASTICS
Waste plastics roads constructed : 2010 to 2012
Notification on ban on plastics and polythene
Department of environment, science and technology
Himachal Pradesh Non‐biodegradable Garbage (Control) Act, 1995 restrictsuse of such materials in the state.
The plastic roads are no longer being constructed as plastic is banned inHimachal Pradesh
Due to the ban no further work can be undertaken in the state
Transportation costs make plastic purchase unviable
Policy Pronouncements
Rural Roads : In collaboration with converging departments 15% of annual roads
State financing 10% of plastic roads using the road recycling methodology
Aging urban roads recycled as rural roads 10 % of roads built by the state nodal agency
Implementing the PMGSY‐II scheme
Urban Roads: In collaboration with converging departments All road strengthening, resurfacing and improvement projects to use waste
plastic with bitumen
15% of fresh road laying in urban areas of municipal limits to use plastic with bitumen
Evaluation and Planning
Conduct a planning survey for the plastic roads programme Plastic Hot Spots | Capacity Gaps | Road Survey | Recycling
Urban and Rural Plastic Roads Volume of plastic waste generated Capacity for managing it
Process : E‐tendering, E‐procurement and E‐payments
3 phase implementation in Urban areas Urban : 2‐3 District Pilot | 50% Districts – 18‐24 m | Remaining 18‐24m Rural : 3 Location pilot ‐ 6m| Parallel implementation : State & PMGSY – II | Final – EBD
Implementation – Flagship Programme Define Flagship programme
CM Endorsement and Continuous Administrative support Department convergence between functions
Rural Model ‐ SHGs networks Shredding Machines | Land – Shed | Payment | Demand – supply balance |
Extensive collection network around District Processing
Urban Model Contractor – Municipal Corporation MoU Single Window Clearance | Land – Permits| Schedule of Rates | Execution – Contractor
Private Utility : Industrial Townships Extension limited to exiting utility operations | Client – Sponsor
Training and Awareness Generation
Public media involvement Case Studies | Celebrating Success | Educational Series
Schools and Colleges awareness Workshops | Projects | Awareness Campaigns
Training of Contractor and Road Workers Plastic Waste Management and Road Construction
Training to PWD Engineers IRC – SP – 98
Involvement of Plastic Manufacturers Awareness Generation CSR programmes
Segregation of Waste plastic Colour Coded bins at home | office | communal areas
Capacity Building Worker training for segregation and collection
SHGs and Dry Collection Centre
CSR fund mobilisation Training and Welfare of Social Health Workers
Burden of reuse on Manufacturers Plastic waste should not end in landfill or incinerators Buy back schemes for recyclable plastic
Need for Institution, agency for monitoring : Environmental and Cleanliness
Exchange between government, academia and industry : Seminars | Webinars | Conferences | Round Tables
E‐ learning content : Wide sharing of learning
E‐monitoring : IT Infra for Quality Monitoring
Finance
Savings Programme ₹ 26,000 – 60,000 per lane kilometre
Capacity building CSR funds, Livelihood Missions, Public Works
10% Reduction of road construction outlay
Environmental Fund Multi ‐ action climate and environment state fund
Monitoring Technical
Temperature | Quality | Right Mix | Type of Plastic | Size | Verification Tests
Administrative Rural – 3 Tier : DQM | SQM | NQM Urban ‐2 Tier : STA | SQM | Quality Registers | Utilisation Certificate Evidence |
Punitive Fines : Implementing Agency for Non‐compliance
Citizen Charter Web Interface : Transparent Availability of Information Citizen Observers : 8 Provision for RTI – Section 2(j)
Awards and Recognition
Paryavaran Seva District Awards – Annual Civil Society
Administrative Awards Engineers, Admin and Government Employees CM initiative
Soft Incentive for Departments Performance linked benefits : Non Financial
Concluding Remark ‐ 1
Plastic modified bitumen roads
Greener method of plastic waste management and better roads.
WPMB aggregate mix
economic and viable solution
WPMB road construction
Wet process, Dry process and Cold mix process
Dry process is preferred over other methods.
Other waste materials
Crumb Rubber and SBS polymer have shown promising results
Concluding Remark – 2
Drivers : Environment and Quality of Life
Barriers : Systemic, official and vested interest
Proven Technology: Lab, Pilot and State Scale
No Significant Government Investment with Savings Outcome
Adequate learning from pioneering states
Multi fold benefit
Recommended