
The world is facing a plastic crisis. By 2050, plastic floating in the oceans will outweigh the fish, according to a 2016 report by the Ellen MacArthur Foundation. With China no longer accepting the world's plastic waste, the rest of the world will have no place for an estimated 111 million metric tons of plastic waste that will accumulate in the next dozen years, according to University of Georgia researchers. This has led to a search for innovative solutions, such as infusing recycled plastic into highways, to prevent plastic waste from ending up in landfills.
| Characteristics | Values |
|---|---|
| Plastic waste in oceans by 2050 | Will outweigh the fish |
| Plastic waste in the next dozen years | 111 million metric tons |
| China's share of world's plastic recycling since 1992 | 45% |
| Recycled plastic roads | In development |
| Plastic road pilot projects | In the Netherlands and Texas |
| Recycled plastic roads in development | In the U.S., India, Pakistan, Australia, Dubai, and the U.K. |
| Recycled plastic road benefits | Cheaper, more durable, flexible, and eco-friendly |
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What You'll Learn
- Plastic polymers can be used to bind asphalt, creating cheaper and more durable roads
- The process of using recycled plastic to build roads is already being used in India and Pakistan
- A Dutch company is working on 100% recycled plastic roads that can be installed like Lego blocks
- Recycled plastic can be used to stabilise the soil on highway slopes, preventing the road surface from failing
- UK startup MacRebur uses recycled plastic as a replacement for bitumen in paving roads

Plastic polymers can be used to bind asphalt, creating cheaper and more durable roads
The process involves mixing refined plastic pellets with hot-mix asphalt. The plastic is first sorted by polymer structure, with plastic bags and bottles separated into different groups. Each group is then pressed into pellets that vary in durability and pliability. These pellets are then mixed with hot, milled pavement, melting into the aggregate and acting as a binding agent. This creates a road that is not only 100% recycled but also eliminates the need for storing old asphalt for later reuse.
One of the benefits of using plastic polymers in road construction is their ability to improve the durability of the asphalt. The plastic adds flexibility to the pavement, reducing the likelihood of potholes and road deterioration. According to TechniSoil Industrial, their roads, which incorporate plastic, are eight to 16 times more durable than traditional roads.
However, there are some concerns associated with using plastic in road paving. One major concern is the potential spread of microplastics and air pollution. Heating plastics can release toxic fumes, but companies like MacRebur, which uses recycled plastic in road construction, claim that their controlled temperatures and exclusion of certain plastics ensure that no fumes are released during the process.
The use of recycled plastic in road construction offers a potential solution to the growing plastic waste problem. With China no longer accepting the majority of the world's plastic recycling, finding alternative uses for this waste is crucial. By incorporating plastic into road construction, we can minimize plastic waste in landfills, oceans, and rivers while also creating more durable and cost-effective roads.
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The process of using recycled plastic to build roads is already being used in India and Pakistan
India has also been a leader in plastic road construction, with Dr. Rajagopalan Vasudevan, the "plastic man of India," patenting a plastic road construction method in 2006. Since then, India has built more than 2,500 kilometers of plastic roads.
Using recycled plastic in road construction offers several benefits, including increased durability and flexibility, a smoother surface, and improved resistance to cracking and potholes. It also increases the melting point of the roads, making them better at withstanding extreme temperatures. Additionally, plastic roads can help reduce plastic waste and contribute to a cleaner planet.
However, there are also concerns and challenges associated with plastic roads. One concern is the potential impact on human health and the environment if harmful materials from plastic seep into the soil, water, or air. Thorough health risk evaluations and standardized production procedures are necessary to address these concerns. Another challenge is ensuring that the plastic stays inside the road and does not break down into microplastics.
Despite these challenges, the use of recycled plastic in road construction is an innovative solution to reduce plastic waste and improve road infrastructure. With the ever-increasing amount of plastic waste being produced globally, it is essential to find sustainable solutions to repurpose and recycle this waste.
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A Dutch company is working on 100% recycled plastic roads that can be installed like Lego blocks
The world is facing a plastic crisis. By 2050, plastic floating in the oceans will outweigh the fish, and with China no longer accepting the world's plastic recycling, the rest of the world will have no place for an estimated 111 million metric tons of plastic waste that will accumulate in the next dozen years.
One solution to this problem is to use recycled plastic to build roads. This concept is being explored by several companies around the world, including a Dutch company, KWS Infra, which is working on 100% recycled plastic roads that can be installed like Lego blocks. The idea, called PlasticRoad, involves creating Lego-like prefabricated segments that would be hauled to a construction site and assembled relatively quickly compared to current road construction methods. Each segment is hollow, providing a path for wires, pipes, and drainage, while also being strong enough to support the weight of people and cars. The roads are said to be more durable and cheaper than conventional pavement, and they can withstand temperatures ranging from -40 to 176 degrees Fahrenheit.
The PlasticRoad concept was first unveiled in 2015 and attracted attention from the Rotterdam city council. The city offered VolkerWessels, a subsidiary of KWS, a pilot location to test PlasticRoad. The first road was a 30-meter bicycle path, which took three years to build. The Dutch city of Rotterdam is considering using the material in a pilot "street lab" project to see if it can withstand daily traffic.
While the Dutch company's biggest project so far has been the bike path, the concept of using recycled plastic in road construction is being explored in other countries as well. For example, in the U.S., plastic is already being used in road maintenance, and companies are researching different types of roadway plastics. In India, the city of Jamshedpur has paved nearly 50 kilometers of roads partly, if not entirely, with recycled plastic.
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Recycled plastic can be used to stabilise the soil on highway slopes, preventing the road surface from failing
The world is facing a plastic waste crisis. According to a 2016 report by the Ellen MacArthur Foundation, by 2050, plastic floating in the oceans will outweigh the fish. This crisis has been exacerbated by China's decision to no longer accept the world's plastic waste for recycling, leaving an estimated 111 million metric tons of plastic waste with no outlet. As a result, there is a growing interest in finding alternative uses for recycled plastic, such as incorporating it into highway construction.
One innovative way recycled plastic can be used in highway construction is to stabilise the soil on highway slopes, preventing the road surface from failing. This method has been successfully tested by Sahadat Hossain, a civil engineering professor at the University of Texas at Arlington. Hossain's technology involves taking plastic from landfills and recycling it to manufacture giant pins that are inserted into failing soil to stabilise it. This technique has been proven effective in highway slope stabilisation projects in Texas, Iowa, and Missouri, with the Texas Department of Transportation adopting the recycled plastic pin as one of their approved slope stabilisation methods.
The use of recycled plastic pins offers a sustainable solution to the problem of unstable soil on highway slopes. By utilising plastic waste that would otherwise end up in landfills, this method not only helps to reduce environmental waste but also enhances the stability and longevity of highway infrastructure. This dual benefit highlights the potential for recycled plastic to play a significant role in future highway construction and maintenance.
In addition to soil stabilisation, recycled plastic has been explored as a direct additive to asphalt, enhancing the durability and flexibility of road surfaces. This technique, more common in India and Pakistan than in the United States, involves mixing refined plastic pellets with hot-mix asphalt or combining asphalt with plastic urethane. Companies like TechniSoil Industrial claim that their roads, made with recycled plastic, are eight to 16 times more durable due to the reduced "flow" or flexibility of the asphalt, preventing potholes and road deterioration.
The potential for recycled plastic to be used in highway construction and maintenance is vast, with companies and governments around the world expressing interest. From stabilising highway slopes to creating more durable road surfaces, recycled plastic offers a cost-effective and environmentally friendly solution to infrastructure challenges. As the world grapples with the growing plastic waste crisis, incorporating recycled plastic into highways may provide a practical outlet for this waste stream while improving the longevity and performance of our transportation networks.
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UK startup MacRebur uses recycled plastic as a replacement for bitumen in paving roads
The world is facing a plastic crisis. According to a 2016 report by the Ellen MacArthur Foundation, by 2050, there will be more plastic in the oceans by weight than fish. China, which has long been the world's largest importer of plastic waste, has recently stopped accepting plastic waste from other countries, leaving the rest of the world with a huge plastic waste problem.
One innovative solution to this crisis is to use recycled plastic as a replacement for bitumen in paving roads. UK startup MacRebur is at the forefront of this movement. Founded by engineer Toby McCartney and his co-founders Gordon Reid and Nick Burnett, MacRebur uses recycled plastic waste as a replacement for bitumen in road construction. The idea for MacRebur was born during a trip to India, where McCartney saw road crews filling potholes with waste plastic, dousing it with gasoline, and setting it on fire. When the plastic melted and hardened, it filled the potholes.
Upon his return to Scotland, McCartney and his co-founders decided to create a new type of material specifically designed for road construction using recycled plastic waste. After a year of research, they developed a method for transforming a mix of industrial and consumer plastic waste into pellets of a new material called MR6, which can replace bitumen. Bitumen, also known as asphalt, is an oil-based sealing material commonly used in road construction. By using recycled plastic instead of bitumen, MacRebur's product reduces fossil fuel usage and carbon emissions.
MacRebur's products are capable of replacing between 6 and 20 percent of the bitumen in roads, and the company is continuously working on improving its products. The recycled plastic physically binds with the bitumen, preventing it from breaking loose and getting into the environment. Additionally, the plastic roads are stronger and more durable than traditional asphalt roads, making them less prone to potholes. MacRebur's products have been used in various countries, including Australia, Dubai, and the United Kingdom, and the company has received interest from around 50 countries worldwide.
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Frequently asked questions
Since 1992, China has accepted 45% of the world's plastic recycling. However, China announced that it no longer wanted to buy recycled plastic. This has resulted in an urgent need to find an alternative to traditional recycling, which may dry up, leaving landfills as the only other option.
Recycled plastic can be used to build roads. Bound together with plastic polymers, the asphalt will be cheaper and last longer than conventional pavement, according to independent experts.
There are several methods. One method involves adding refined plastic pellets to hot-mix asphalt. Another method involves grinding off the top surface of roads and adding urethane. A third method involves using roads that are made entirely of recycled plastic.
Recycled plastics have been used to build roads in places ranging from Australia to Dubai. In the U.S., recycled plastic has been used in road maintenance and to shore up raised highway roadbeds in Texas. In Europe, an ambitious Dutch company has created a 30-meter bike path made of 100% recycled plastic.






































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