The Central Road Research Institute (CRRI), in collaboration with Bharat Petroleum Corporation Limited (BPCL), has developed a new road construction material called Geocells. These three-dimensional block-shaped sheets, made from end-of-life and mixed plastic waste, aim to offer a sustainable solution to India’s growing plastic pollution problem while improving road infrastructure.
How Geocells Work
Geocells are made from processed waste plastic using mechanical recycling techniques. The resulting plastic sheets—4 to 8 mm thick—form a strong mesh-like structure. When these cells are filled with soil or construction debris, they form a stable base layer suitable for paving roads, especially in difficult terrains such as hilly or loose soil areas.
Trial Implementation and Field Tests
A joint patent has been filed by CSIR-CRRI and BPCL for the Geocell technology. Field trials, in collaboration with the Military Engineering Services, are planned to begin in August to test the solution in real-world road-building scenarios.
In a successful pilot, a stretch near the elevated portion of the DND–Faridabad–KMP Expressway was constructed using Geocells. The 160-meter section used approximately 20–25 tonnes of recycled plastic waste.
Laboratory and Plant Trials Show Promise
According to Ankita Behl, principal scientist at CSIR-CRRI, the recycled plastic used in Geocells is challenging to process due to its inconsistent quality. Despite this, the lab and field trials—including those done with TATA Projects—showed no cracks or deformation, indicating strong load-bearing capacity and shape retention.
A First for India in Technical Textiles
CRRI states that this initiative represents India’s first field trial using technical textiles from end-of-life plastic in road construction. It also aligns with national efforts to address the mounting issue of mixed and multilayered plastic waste, which is typically not recycled under current Indian Roads Congress (IRC) guidelines.
A Step Toward Greener Infrastructure
By reusing hard-to-process waste plastic, Geocells present a dual benefit: enhancing road durability and tackling plastic waste. This approach could set new standards for sustainable infrastructure and circular economy practices in India’s road development sector.
