ASPHALT PLASTO – A BRICK FROM

WASTE PLASTIC
PROJECT REPORT

Submitted by

ANANDHU M. NAIR
(Roll No.: RIE15ME026)
ASHWIN J WILSON
(Roll No.: RIE15ME040)
B DAYANAND KRISHN
(Roll No.: RIE15ME043)
JASEER KHAN JALEEL RASHEED
(Roll No.: RIE15ME053)
to
APJ Abdul Kalam Technological University
in partial fulfillment of the requirements for the award of the Degree
of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

RAJADHANI INSTITUTE OF ENGINEERING & TECHNOLOGY,

THIRUVANANTHAPURAM
MAY 2019
 CERTIFICATE

RAJADHANI INSTITUTE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
This is to certify that the project report entitled
"ASPHALT PLASTO – A BRICK FROM WASTE PLASTIC" submitted
by "ANANDHU M. NAIR" (RIE15ME026), "ASHWIN J WILSON"
(RIE15ME040), "B DAYANAND KRISHN" (RIE15ME043),
"JASEER KHAN JALEEL RASHEED" (RIE15ME053), to the A P J Abdul
Kalam Technological University in partial fulfillment of the requirements for
the award of the Degree of Bachelor of Technology in Mechanical
Engineering is a bona-fide record of work carried out by them under my
guidance and super vision. This report in any form has not been submitted to any
other University or Institute for any purpose.

BENNY T.K
Assistant Professor
(PROJECT GUIDE)

KRISHNAKUMAR K HEAD OF THE DEPARTMENT

Assistant Professor
(STAFF ADVISOR)

EXTERNAL EXAMINER

ii
 ABSTRACT
This project mainly focuses on the plastic waste management and recycling

technique to reduce the cost of various raw-materials used for pavements and

building construction. Various experiment tests were conducted with different

materials and different composition to find out a better paving brick with

maximum usage of shredded plastic as an aggregate. Different types of plastic

wastes can be used for this purpose as an aggregate mixture.

Bitumen is used as a binding material in the mixture instead of cement or

any other binders which can enhance the desirable properties of a paving brick

like flexibility, durability and less water penetration. The mixed plastic waste can

reduce the weight of the brick, increase the strength, reliability and other physical

properties when compared with a normal brick.

Small aggregates of metal chips, Msand, Aluminium mesh sheets are used

to increase the strength of the brick. The mixture is heated and raised to a higher

temperature in a controlled atmosphere at a temperature range of 150 to 300 degree

celcius and obtained a semi fluid material which is poured in the designed mould.

The brick is obtained after cooling up from the mould. Then the cost analysis,

compressive strength test are done and the results are discussed to conclude with

the best possible solution to deal with the great mess of plastic waste disposal.

iii
 ACKNOWLEDGEMENT

First and foremost, we concede the surviving presence and the flourishing
refinement of almighty GOD for his concealed hand yet substantial supervision
all through the project.

We extend our sincere gratitude to our Principal

Dr. K. C. RAVEENDRANATHAN., and to our Vice Principal,
Dr. K. BALAN., for their countenance towards the successful accomplishment of
the course.

We sincerely thank Dr. M. D. SREEKUMAR., Head of the Department

of Mechanical Engineering for valuable support, comments, advice, guidance and
constant encouragement that enables us to complete our project in time.

We are thankful to our seminar guide Mr. BENNY.T.K., Asst. Professor

in Mechanical Engineering Department and our staff advisors
Mr. KRISHNAKUMAR.K., Asst. Professor in Mechanical Engineering
Department and Mr. VISHNU RAJ., Asst. Professor in Mechanical Engineering
Department for their valuable support and advice.

We are also thankful to all the teachers and staff members of Mechanical
Engineering Department for their valuable help and advice. Further our sincere
thanks to our beloved friends for their comments, ideas and criticisms.

Finally, we are grateful to our parents, family members for their help,
encouragement and moral support given to us during the course of work.

ANANDHU M. NAIR
ASHWIN J WILSON
B DAYANAND KRISHN
JASEER KHAN JALEEL RASHEED

iv
 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO NO
ABSTRACT iii
ACKNOWLEDGEMENT iv
TABLE OF CONTENTS v
LIST OF TABLES vii
LIST OF FIGURES viii
I INTRODUCTION 1
1.1 Types of Plastics 2
1.2 Effects of Plastic Wastes 3
1.3 Plastic Recycling 4
1.4 Objective 8
1.5 Scope of the Project 8
II LITERATURE REVIEW 9
III PROBLEM DEFINITION 11
IV METHODOLOGY 13
V MATERIAL SELECTION 14
VI DESIGN 20
6.1 Design of Mould 20
VII PROCEDURE 21
VIII 7.1 Compression Testing 22
7.2 Comparison of Compressive Load Bearing With
Existing Paving Brick 23
7.3 Heat Absorption Testing 24
7.4 Water Absorption Testing 24
RESULTS AND DISCUSSION 25
8.1 Test 1 25
8.2 Test 2 26
8.3 Test 3 26

v
CHAPTER TITLE PAGE
NO NO
8.4 Test 4 27
8.5 Test 5 28
8.6 Test 6 28
8.7 Test 7 29
8.8 Test 8 30
8.9 Test 9 30
IX COST ANALYSIS 33
X CONCLUSION 35
REFERENCES 37

vi
 LIST OF TABLES

TABLE TITLE PAGE

NO NO
5.1 Properties of Metal Chips, Cement And Sand 14
5.2 Properties of Different Types of Msand 15
5.3 Viscosity Grade (Vg) Bitumen Specification As Per
Is 73:2006 16
5.4 Specification of The Shredding Machine Used For
Plastic Shredding 18
5.5 Aluminium Mesh Properties 19
7.1.1 Technical Specification of CTM 23
8.1 Result of Compression Test 31
9.1 Material Cost As Per The Specification 33
9.2 Test - 5 (Metal: 50, Plastic: 30, Bitumen: 20) 33
9.3 Test – 6 (Msand:50, Plastic:30, Bitumen:20, Al-
Sheet:2nos) 33
9.4 Test – 7 (Metal: 50, Plastic: 30, Bitumen: 20, Al-
Sheet: 2nos) 34

vii
 LIST OF FIGURES
FIGURE TITLE PAGE
NO NO
5.1 Metal Chips of Size Less Than ¼ Inch 14
5.2 M Sand 15
5.3 Bitumin 15
5.4 Shredded Plastic of Size 5-10mm 17
5.5 Aluminium Mesh of Size 18.5x8.5cm 18
6.1 Mould Used For Brick Making 20
7.1 Various Manufacturing Process In Brick Formation 21
7.1.1 Compressive Load Testing Machine and Dial Gauge
Used for Testing the Bricks 22
8.1 Load Vs Deflection Graph of Test 1 25
8.2 Load Vs Deflection Graph of Test 2 26
8.3 Load Vs Deflection Graph of Test 3 27
8.4 Load Vs Deflection Graph of Test 4 27
8.5 Load Vs Deflection Graph of Test 5 28
8.6 Load Vs Deflection Graph of Test 6 29
8.7 Load Vs Deflection Graph of Test 7 29
8.8 Test 7 Brick With Max Compressive Load Capacity
And Plastic Coated Over the Surface 32

viii
 CHAPTER I
INTRODUCTION
Humans have always produced trash and disposed of it in some way so
solid waste management is not a new issue. What has changed are the types and
amounts of waste produced, the methods of disposal, and the human values and
perception of what should be done with it. The applications of plastic waste plastic
being accumulated which create big challenges for their disposal. Disposal of
plastic waste in environment is considered to be a big problem due to its very low
biodegradability and presence in large quantities. Recently plastics were used to
prepare the coarse aggregate there by providing a sustainable option to deal with
the plastic waste. Therefore, recycling of plastic waste is an important topic in
order to decrease environmental pollution and prevent waste of resources.
Recently, the plastic waste is one component of municipal solid waste which I
becoming a major research issue to study the possibility of disposing the waste in
mass concrete especially in self compacting concrete, light weight concrete and in
pavements. It can be used as a component of a composite construction material,
as an inorganic filling material, and aggregate of concrete. Recycling of plastic
waste in concrete has advantages since it is widely used and has a long service
life, which means that the waste is being removed from the waste stream for a long
period. The waste plastic will be large in household time. In many countries the
compositions of waste are different, that it is affected by the socioeconomic
characters, waste management programs and consumption patterns, but generally
the level of plastic in the waste composition is high.one of the largest component
of plastic waste is polyethylene which is followed by polypropylene. Polyethylene
terephthalate and Polystyrene. The large volume of materials required for
construction is potentially a major area for the reuse of waste materials. Plastics
also help to conserve energy at the home Furthermore, the U.S. Department of
Energy estimates that use of plastic foam insulation in homes and buildings each
year will ultimately save close to 60 million barrels of oil versus other kinds of

1
insulation. The same principles apply in appliances such as refrigerators and air
conditioners.

1.1 TYPES OF PLASTICS

Plastic is an essential component of many items, including water bottles,

combs, and beverage containers. Knowing the difference, as well as the SPI codes,
will help you make more informed decisions about recycling. The seven types of
plastic include:

 Polyethylene Terephthalate (PETE or PET)

 High-Density Polyethylene (HDPE)
 Polyvinyl Chloride (PVC)
 Low-Density Polyethylene (LDPE)
 Polypropylene (PP)
 Polystyrene or Styrofoam (PS)
 Miscellaneous plastics (includes: polycarbonate, polylactide, acrylic,
acrylonitrile butadiene, styrene, fiberglass, and nylon)

When it comes to promotional giveaways, and even items we use around

the house, there is no material more important than plastic. The same can be said
for the items we use at the office. Most of our supplies contain at least a little bit
of this material. In fact, humans have thus far produced 9.1 billion tons of plastic.
For the sake of the environment, it’s important to know the different types of
plastic and their uses, as well as the resin identification codes found on each.
Understanding the different types of plastic can help consumers like you make
more informed decisions related to your health and the environment. It’s important
to become familiar with an item’s SPI (Society of the Plastics Industry) code,
which is also known as a resin identification number and is used to classify the
different types of plastic. This information will help you sort plastic materials
more effectively for recycling.

PETE plastics make up 96% of all plastic bottles and containers in the
United States, yet only 25% of these products are recycled. By being mindful and

2
making sure to recycle code 1 plastics, you’re helping to ensure a cleaner
environment and less landfill pollution. HDPE is the most commonly recycled
plastic because it will not break under exposure to extreme heat or cold. According
to the EPA, 12% of all HDPE products created are recycled in a year. This is a
very small dent in the planet’s carbon footprint. PVC is one of the least recycled
materials; generally less than 1% of PVC plastic is recycled each year. It has been
called the "poison plastic" because it contains numerous toxins and is harmful to
our health and the environment. Packaging and containers made from LDPE make
up about 56% of all plastic waste, 75% of which comes from residential
households. Fortunately, many recycling programs are evolving to handle these
products. This means less LDPE will end up in landfills and negatively affect the
environment.

Only about 3% of polypropylene products are recycled in the US, but

interestingly enough, 325 million pounds of non-bottle plastics were collected for
recycling over a year. In other words, a lot of this plastic is created, but only a
small fraction is actually recycled. Polystyrene is lightweight and easy to form
into plastic materials, it also breaks effortlessly, making it more harmful to the
environment. Beaches all over the world are littered with pieces of polystyrene,
endangering the health of marine animals. Polystyrene accounts for about 35% of
US landfill materials. Miscellaneous Plastics, the remaining plastics include:
polycarbonate, polylactide, acrylic, acrylonitrile butadiene, styrene, fiberglass,
and nylon. Of course, there are many differences in the plastics classified as
miscellaneous by recycling programs.

1.2 EFFECTS OF PLASTIC WASTES

The pollution in the ocean is mostly from plastic, and it has a terrible impact
on marine species. As a result, it can hurt the economy and food supply for
communities that rely on fishing. Plastic can hurt tiny organisms like plankton,
which larger animals rely on for food. If small organisms are poisoned from
ingesting plastic, the animals that eat them will also consume toxins. The toxins

3
work their way up the food chain and can even be present in the fish people eat.
Not only does plastic cause damage to the ocean, but it can also damage
groundwater sources. Many regions are already facing issues with, but water
sources everywhere are in danger because of plastic pollution. Plastic toxins in
dumps and from litter can seep into the groundwater, which people drink every
day.

On land, wind can carry plastic waste or litter throughout the environment.
It can get stuck in trees, fences, traffic lights, or other structures. When animals
come into contact with this plastic waste, they risk consuming the toxins or
becoming entangled in the plastic and suffocating. If an animal consumes a piece
of plastic, the plastic can clog its stomach while also poisoning it with toxins.
Almost 200 different species of animals are known to ingest plastic debris. Air
pollution is another issue for humans and animals. When plastic is burned in the
open air, it releases large amounts of toxins, which pollutes the air. If the toxins
are inhaled for a long period of time, it can lead to respiratory problems. As the
world’s population increases, land becomes more valuable, and it will soon
become difficult to find places to put garbage. Over time, landfills and dumps will
take up more land, invading animals’ habitats and coming even closer to
groundwater sources. In addition to harming plants, animals, and people, it costs
millions of dollars every year for cleanup of areas exposed to plastic toxins. Many
regions have seen a decrease in tourism because of the amount of pollution in their
environment, which can have a serious impact on local economies.

1.3 PLASTIC RECYCLING

It is the process of recovering different types of plastic material in order to

reprocess them into varied other products, unlike their original form. An item
made out of plastic is recycled into a different product, which usually cannot be
recycled again. The Stages in Plastic Recycling are as follows. Before any plastic
waste is recycled, it needs to go through five different stages so that it can be
further used for making various types of products.

4
  Sorting: It is necessary that every plastic item is separated according to its
make and type so that it can be processed accordingly in the shredding
machine.

 Washing: Once the sorting has been done, the plastic waste needs to be
washed properly to remove impurities such as labels and adhesives. This
enhances the quality of the finished product.

 Shredding: After washing, the plastic waste is loaded into different

conveyer belts that run the waste through the different shredders. These
shredders tear up the plastic into small pellets, preparing them for recycling
into other products.

 Identification and Classification of Plastic: After shredding, a proper

testing of the plastic pellets is conducted in order to ascertain their quality
and class.

 Extruding: This involves melting the shredded plastic so that it can be

extruded into pellets, which are then used for making different types of
plastic products.

Among the many processes of recycling plastic waste, the following two
are the most popular in the industry.

 Heat Compression: This type of plastic recycling is gaining special

demand in the United States, Australia, and Japan because of its ability to
recycle all types of plastic at once. It takes unsorted and cleaned plastic
waste and mixes it in huge tumblers that churn the entire mixture. The
major advantage of this process is that it does not require matching forms
of plastic to be recycled together.

 Monomer: Through the elaborate and accurate monomer recycling process,

major challenges of plastic recycling can be overcome. This process
actually reverses the polymerization reaction in order to recycle the same

5
 type of condensed polymer. This process not only purifies but also cleans
the plastic waste to create a new polymer.

The Benefits of Plastic Recycling are, after knowing the processes and
stages of plastic recycling, it is also important to know its various benefits

 There’s A Ton of Plastic: One of the biggest reasons for recycling plastic
is its huge quantity. It has been observed that 90% of the waste accumulated
by the municipal corporation is a plastic waste. Apart from this, plastic is
used for manufacturing various types of goods and items that are being used
on a daily basis. This will not only help increase the production of plastic
but will also take care of the environment.

 Conservation of Energy and Natural Resources: The recycling of plastic

helps save a lot of energy and natural resources as these are the main
ingredients required for making virgin plastic. Saving petroleum, water,
and other natural resources help conserve the balance in nature.

 Clears Landfill Space: Plastic waste is accumulated on land that should be

used for other purposes. The only way this plastic waste can be removed
from these areas is by recycling it. Also, various experiments have proven
that when another waste material is thrown on the same ground as plastic
waste, it decomposes faster and emits hazardous toxic fumes after a certain
period. These fumes are extremely harmful to the surrounding area as they
can cause different types of lung and skin diseases.

Plastic recycling not only promotes proper utilization of plastic waste but
also helps conserve the environment, making it cleaner and greener. Recycling
also keeps plastic out of landfills where it can take 500 years to break down.
Scientists have estimated that the potential commodity value of waste plastic may
be in excess of $300 per ton when used in process pathways yielding high-value
chemical products or to produce electricity in efficient IGCC (Integrated
Gasification Combined Cycle) processes. Plastic pyrolysis can convert petroleum-

6
based waste streams such as plastics into fuels and carbons. Given below is the
list of suitable plastic raw materials for pyrolysis:

 Mixed plastic (HDPE, LDPE, PE, PP, Nylon, Teflon, PS, ABS, FRP etc.)
 Mixed-waste plastic from waste paper mill
 Multi-layered plastic

Heat compression takes all unsorted, cleaned plastic in all forms, from soft
plastic bags to hard industrial waste, and mixes the load in tumblers (large rotating
drums resembling giant clothes dryers). The most obvious benefit to this method
is that all plastic is recyclable, not just matching forms. However, criticism rises
from the energy costs of rotating the drums, and heating the post-melt pipes. For
some waste plastics, technical devices called recyclebots enable a form of
distributed recycling. Preliminary life-cycle analysis (LCA) indicates that such
distributed recycling of HDPE to make filament of 3D printers in rural regions is
energetically favorable to either using virgin resin or conventional recycling
processes because of reductions in transportation energy

A process has also been developed in which many kinds of plastic can be
used as a carbon source in the recycling of scrap steel. There is also a possibility
of mixed recycling of different plastics, which does not require their separation. It
is called compatibilization and requires use of special chemical bridging agents
compatibilizers. It can help to keep the quality of recycled material and to skip
often expensive and inefficient preliminary scanning of waste plastics streams and
their separation/purification.

By definition the plastics can be made to different shapes when they are
heated in closest environment, they can be made into different forms such as cups,
furniture’s, basins, plastic bags, food, drinking containers. After they may become
waste material. Accumulation of such wastes can result into hazardous effects to
both human and plant life. Therefore, need for proper disposal of this plastic waste.
This can be done through process of plastic management.

7
 The utilization of plastic waste in bituminous mixes enhances its properties
and also its strength. In addition, it will also be a solution to plastic disposal &
various defects in pavement viz., pot holes, corrugation, ruts, etc. the waste plastic
used are poly-ethylene, polystyrene, polypropylene. The waste plastic is shredded
& coated over aggregate & mixed with hot bitumen and resulted mix is used for
pavement construction. This will not only strengthen the pavement and also
increases its durability.

1.4 OBJECTIVE OF THE PROJECT

 The objectives of this project are:

 To design the flexible pavement.
 To design the asphalt pavement with aggregate- Plastic, Bitumen mix.
 To coat the aggregate with plastic and incorporate titanium di-oxide.

1.5 SCOPE OF THE PROJECT

 To eradicate potholes.
 To minimize global warming, greenhouse gases and pollution.
 The life span of pavements can be improved.
 Eco-friendly in nature.

So in this project we had developed a new paving brick with Metal chips,
M-sand, plastic as aggregates and bitumen as a binding materials and aluminum
mesh as reinforcement.

 To design the flexible pavement

 To design the asphalt pavement with aggregate- plastic- bitumen mix.
 To coat the aggregate with plastic and incorporate titanium di-oxide.
 To test the bitumen and the modified bitumen

8
 CHAPTER II
LITERATURE REVIEW

Aditya A. Lanjewar et al [8]: (Parametric Study on Waste Plastic Utilization

in Bitumen, 2016) –In this paper techniques have been developed to use plastic
waste for construction of bituminous roads and flexible pavements. They also
studied about binding properties, stability and density of this material.

S. Varun et al [4]: (Experimental Study on Characterization of Bitumen Mixed

with Plastic Waste, 2016) –This study discusses the detail about effect of Poly
Ethylene Terephthalate, (PET) on various engineering properties of bitumen
for using in bituminous pavement construction. The plastic waste can be mixed
with the bituminous pavement construction, resulting in reduced permanent
deformation in the form of rutting of the pavement surface.

R. Manju et al [15]: (Use of Plastic Waste in Bituminous Pavement, 2017) –

They studied about the utilization of plastic waste in bituminous mixtures and
also found out the enhanced properties and strength. In addition, they also give
solution to plastic disposal and various defects in pavement.

Dinesh.S et al [17]: (Utilization of Waste Plastic in Manufacturing of Bricks

and Paver Blocks,2016) –They studied about the properties of brick made from
high density polyethylene (HDPE) and Poly ethylene bags at various
percentages.

R. Venkatakrishnan et al [6]: (Mechanical Properties of Waste Plastic

Reinforced Epoxy Matrix Composites, 2017) – They studied about the
mechanical properties and durability of recycled mixed plastic waste
composites. Several composite materials were prepared by changing a
composition along with 10%, 20%, 30% and 40% of recycled pellets
aggregate.

Kers, J et al [11]: (Reuse of Reinforced Acrylic Plastic Waste in New

Composite Material Development, 2006) – They studied techniques for

9
recycling of composite plastic wastes and to find a potential application area
for secondary raw materials. They developed new acrylic powder filler
materials for use in the filler-resin systems as reinforcement acrylic cells. The
paper describes the result of materials separation, granularity of the milled
material and morphology of the plastic powder particles.

Sarang Shashikant Pawar et al [14]: (Use of Fly ash and Plastic in Paver
Block, 2017) –This paper discusses about the result of an experimental study
conducted on paver block made using Fly ash, plastic strip and wire plastic.
They also studied about the improved tensile properties of the paver block. The
concrete for paver block which is made up by adding plastic in concrete help
to reduce plastic bag and also improve the tensile properties of the paver block.

Zainab Z. Ismail et al [16]: (Use of waste plastic in concrete mixture as

aggregate replacement, 2007) - They conducted experiments to determine the
efficiency of reusing waste plastic in the production of concrete. Thirty
kilograms of waste plastic of fabriform shapes was used as a partial
replacement for sand by 0%, 10%, 15%, and 20% with 800 kg of concrete
mixtures. The results proved the arrest of the propagation of micro cracks by
introducing waste plastic of fabriform shapes to concrete mixtures.

10
 CHAPTER II
PROBLEM DEFINITION
The main problem we are facing is abundant production of plastic and
failure in recycling day by day. About 250 to 300 million tonnes of plastic being
produced daily but when coming to reusing side there comes the contradiction.
The untreated plastic wastes are causing pollution in atmosphere, water bodies,
Soil, and affecting lives of marine, land animals, and Humans adversely. The used
plastic also occupies much area of land by landfills, getting exposed to habitats
for many viruses and deadly diseases. The people are not aware about the types of
plastic available and the methods to recycle those turns to another problem.

Plastic is a product derived from environmental organic resource which is

limited in supply. This is essentially needed to be recycled, otherwise it will
consume more landfills and affect the environment adversely. Another problem
identified is the paving bricks used today cannot withstand much load as expected
and are less durable. If we are able to use plastic waste as an aggregate in the
mixture the problem is expected to be solved to an extent. Bitumen is a cheap and
easily available byproduct of crude oil production and has a better binding
property which is widely used in road construction.

A large amount of plastic is being brought into the tourist trekking regions
are discarded or burned which leads to the contamination of environment and air.
Hence, these waste plastics are to be effectively utilized. High-density
polyethylene (HDPE) and polyethylene (PE) bags are cleaned and added with
sand, bitumen and aggregate at various percentages to obtain high strength bricks
that possess thermal and sound insulation properties to control pollution and to
reduce the overall cost of construction, this is one of the best ways to avoid the
accumulation of plastic waste which is an on-degradable pollutant. This
alternatively saves the quanta of sand/clay that has to be taken away from the
precious river beds/mines. The plastic waste is naturally available in surplus
quantity and hence the cost factor comes down. Also Coloring agents can be added

11
to the mixture to attain desired shades. Hence in this, an attempt is made to study
regard the properties of the brick which is manufactured using plastic wastes.

Several composite materials were prepared by changing a composition

along with 10%, 20%, 30% and 40% of recycled plastic pellets aggregate. The
mechanical properties and durability of recycled mixed plastic waste composites
were studied and used accordingly for recycling purpose. Reinforced Acrylic
Plastic Waste in New Composite Material Developed in 2006 – studied techniques
for recycling of composite plastic wastes and to find a potential application area
for secondary raw materials. Fly ash and Plastic is used in Paver Block, – discusses
about the result of an experimental study conducted on paver block made using
Fly ash, plastic strip and wire plastic. The improved tensile properties of the paver
block is defined. The concrete for paver block which is made up by adding plastic
in concrete help to reduce plastic bag and also improve the tensile properties of
the paver block. Similarly many plastic recycling methods are understood from
the literature reviews.

The existing paver bricks can bear a compressive load of 80 - 85KN and
we aim to obtain a new plastic mixed brick with better compressive load
capability. In this project it is experimented to bind plastic and other aggregates
with bitumen without use of water and certain other raw materials to obtain a better
reliable and strong paving bricks than existing one and will be eco-friendly.

12
 CHAPTER IV

METHODOLOGY

Problem
Identification

Journal
Collection

Problem
Definition

Possible
Solution

Best Possible
Solution

Fabrication

Result &
Conclusion

13
 CHAPTER V

MATERIAL SELECTION
The following materials were selected for finding out better composition
and conducting experiment.

1. Metal Chips (size less than ¼ inch) - Fig No (5.1), 20mm metal chips are used
to strengthen the mixture as an aggregate. The properties of metal chips are shown
in Table No (5.1). It is a usual construction raw material.

Fig No 5.1 (Metal chips of size less than ¼ inch)

Table No 5.1 (Properties of metal chips, cement and sand)

2. M Sand - Fig No (5.2), Manufactured sand (M-Sand) is a substitute of river

sand for concrete construction. The properties of different types of msand are
shown in Table No (5.2). Manufactured sand is produced from hard granite stone
by crushing.

14
 Fig No 5.2 (M sand)

Table No 5.2 (Properties of different types of msand)

M Sand Sieve Size/ IS Water Specific Density

Types Granule Codes Absorption Gravity (KN/m3)
Thickness
Concrete M 150 microns IS - 2.2 2.59 15.1
Sand - 4.75 mm 383:
1970
Brick / 150 microns IS - - - -
Block Work - 3.50 mm 2116:
M Sand 1980
Plastering 150 microns IS - 2.1 2.63 15.1
M Sand - 2.36 mm 1542:
1992

3. Bitumin (VG 30) - Fig No (5.3), VG-30 is primarily used to construct extra
heavy duty Bitumen pavements that need to endure substantial traffic loads. The
properties of different types of bitumin are shown in Table No (5.3). It can be used
in lieu of 60/70 Penetration grade.

Fig No 5.3 (Bitumin)

15
Table No 5.3 (Viscosity grade (vg) bitumen specification as per is 73:2006)

Characteristics VG-30 VG-40

Kinematic Viscosity, 135˚C, CST, min
2400 3200

Flashpoint, C, min
350 400

Flashpoint, C, min
220 220

Solubility in trichloroethylene, %, min

99.0 99.0

Penetration at 25˚C
50-70 40-60

Softening point, C, min

47 50

I. Viscosity ratio at 60˚C, max

4.0 4.0

II. Ductility at 25˚C, cm, min

40 25

4. Shredded Plastic (size 5-10mm) - Fig No (5.4), Plastic waste are needed to be
shredded for this purpose which can be used as an aggregate in this mixture to
enhance the physical properties of a pavement brick. The Specification of the
shredding machine used for plastic shredding is shown in Table No (5.4). Plastic
shredders play a key role in plastic recycling plants and production facilities. It
offers several benefits in addition to processing plastics that are used as raw
materials for other products like storage containers, toys, packaging bags, and
consumer electronics. Plastic shredders not only help with size reduction, but also
with recouping waste plastic.

16
 Fig No 5.4 (Shredded plastic of size 5-10mm)

Shredders are an indispensable component of efficient and cost-effective

operations in the recycling and waste management industry. Plastic shredders are
designed for shredding a wide variety of plastics and so, they vary from low speed
to moderate speed with high torque and come in varying specifications and blade
sizes. Available in different makes and models, plastic shredders typically range
from single shaft machines to an advanced four shaft mechanism that includes
grinders, granulators, hammers, and cutters along with sorting and shaking
functionality. Plastic shredders can typically drive from 50HP to 1,250HP and
their key features include:

 A rugged structure

 Screen and vibration classifiers

 Discharge conveyors

 Heavy-duty gear

 Auto-reverse functionality

 Low noise level

 Single, double and four shaft mechanisms

17
  Advanced customization for altering the shape and size of materials

Table No 5.4 (Specification of the shredding machine used for plastic

shredding)

5. Aluminium Mesh (size 18.5x8.5cm) - Fig No (5.5), sheet of mesh 20*20 is used
as a reinforcement in the specimen. The properties aluminum mesh are shown in
Table No (5.5)

Fig No 5.5 (Aluminium mesh of size 18.5x8.5cm)

18
Table No 5.5 (Aluminium mesh properties)
Molecular Weight 26.98
Appearance Silvery
Melting Point 660.37 °C
Boiling Point 2467 °C
Density 2700 kg/m3
Solubility in H2O N/A
Heat of Fusion 2.55 Cal/gm mole
Heat of Vaporization 67.9 K-Cal/gm at om at 765 °C
Poisson's Ratio 0.35
Specific Heat 0.215 Cal/g/ K @ 25 °C
Tensile Strength 6800 psi Coldroled 16,000 psi.
Thermal Conductivity 2.37 W/cm/ K @ 298.2 K
Thermal Expansion (25 °C) 23.1 µm·m-1·K-1
Vickers Hardness 167 MPa
Young's Modulus 70 GPa

19
 CHAPTER VI

DESIGN
6.1 DESIGN OF MOULD

The standard size as recommended by the Bureau of Indian Standards

IS: 2691:1988 revision 2 sub–clause. 4 of page .1 is 190mm x 90mm x 90mm,
which has been used as specimen size for testing.
For the convenience of tapping procedure handles were designed as shown
in the image Fig No (6.1).To reduce the heat absorption plastic waste was coated
on the top of the brick.

Fig No 6.1 (Mould used for brick making)

20
 CHAPTER VII

PROCEDURE
The works related to the project are conducted over a remote space to
control the level of pollution. Primarily the required amount of raw materials like
shredded plastic, Msand or metal chips, VG 30 bitumen are weighed in different
containers and kept in appropriate proportions. Initially the steel bowl is heated
and taken amount of bitumen is added. As the temperature rises the bitumen
changes to fluid state and the shredded plastic is added subsequently. The mixture
is stirred well and get bound each other. Later the aggregate particle like Msand
or metal chips are added to the semi-fluid mixture and mixed well.

After maintaining the temperature to a higher level, it is measured using a

metal tail thermometer, the mixture is poured to the prepared standard mould and
tapped well to remove the air gaps. Then the mould is let to cool and brick obtained
is taken out. Similarly, various composition of different materials are tried to
obtain the best possible result. These are the procedure working involved in this
project.

Fig No 7.1 (Various manufacturing process in brick formation)

21
7.1 COMPRESSION TESTING

The testing was conducted in a Compression Testing machine (CTM) with

a strain gauge deflector Fig No (7.1.1) connected over the compressing surface.
Compressive strength test, mechanical test measuring the maximum amount of
compressive load a material can bear before fracturing. The test piece, usually in
the form of a cube, prism, or cylinder, is compressed between the platens

Fig No 7.1.1 (Compressive load testing machine and dial gauge used for
testing the bricks)

of a Compression-testing machine by a gradually applied load. Ductile metals,

such as mild steel, have very great compressive strengths; but the actual values are
difficult to measure. When a load is applied to a ductile metal, it deforms
elastically up to a certain point, and then plastic deformation occurs. Increasing
loads may even completely flatten a test piece without any definite fracture
occurring, so that no value can be obtained for the compressive strength. The
custom of quoting tensile-strength values in these cases is inaccurate but safe,

22
compressive strength being always greater. The capacities of CTM are 500 KN,
1000KN, and 2000KN. When the machine is turned on, the load is applied over
the specimen surface and start compressing and the strain gauge gives the
deflection. The values are noted and the Load vs Deflection graphs are marked.

The Salient Features of Compression Testing Machines are –

 High stability.
 Self-aligning platen assembly.
 Load Gauges are calibrated in KN against certified Proving Rings,
traceable to NPL / NCCBM.
 Suitable for testing cubes and cylinders of various sizes.
 Using special platens, bricks can also be tested.

Table No 7.1.1 (Technical specification of CTM)

Model AIMIL
Make Integrated instruments and
services
Length 1.08m
Width .75m
Floor area .81m2
Capacity 2000KN
Loading gauge 2000KN×10KN / division

7.2 COMPARISON OF COMPRESSIVE LOAD BEARING WITH

EXISTING PAVING BRICK

A compressive load test is conducted on a high quality paving brick in CTM

and which got deformed under a load of 80 – 85 KN, which is used for comparison
with our brick. And during our brick test the best possible solution withstands a
load of 85KN and a maximum value of 120KN. Hence it is having better
compressive load bearing capacity than the existing paver brick.

23
7.3 HEAT ABSORPTION TESTING

A controlled atmosphere was created using carton box and an incandescent

bulb where the temperature was raised to 150-degree Celsius. It was observed
using a thermo couple temperature sensor that the deformation starts at a
temperature range of 90 – 100 degree Celsius and the melting of VG 30 starts at
130 degree Celsius. Our atmospheric temperature won’t reach up to that level and
hence the brick satisfies heat transfer test and is safe to use for paving purpose.

7.4 WATER ABSORPTION TESTING

Another test used for paving bricks is water absorption test. Primarily the
weight of the brick was noted and it was submerged in water for 24 hours and
again the weight was measured, but the change in weight was very negligible.
Since it has bitumen as binding material, water absorption capability is very
negligible and act as hydrophobic in nature. Therefore water absorption test is not
necessary to be done for water absorption capability analysis.

24
 CHAPTER VIII

RESULT AND DISCUSSION

Total 7 experiments were conducted with different compositions of various
raw materials. All experiments give finalized brick with expected strengths. Two
specimens of each compositions were made and average values are considered for
analysis. Weight of each bricks were analysed and weight over a range between
2.2 to 2.4kg.

8.1 Test 1

Composition : M-sand: 50%, Bitumen: 20%,

Plastic: 30%
Temperature : 180 degree celcius

Average weight of Specimen : 2.2725 Kg

Avg Max Compressive load bearable : 70 KN

TEST - 1
18 16.4
16 14.8
14 12.2
DEFLECTION (mm)

12 10.3
10 8.85
7.8
7
8 6.2
5.2 5.6
6 4.1 4 4.35 4.8
4
1
2
0
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
LOAD (KN)

Fig No 8.1 (Load vs deflection graph of test 1)

25
8.2 Test 2

Composition : M-sand: 65%, Bitumen: 15%,

Plastic: 20%
Temperature : 215 degree celcius

Average weight of Specimen : 2.44 Kg

Avg Max Compressive load bearable : 75 KN

TEST - 2
12 11.1
10.5
10 9.1
8.15
DEFLECTION (mm)

8 7.3
6.7
6.2
5.75
6 4.9 5.3
4.3 4.55
3.7 3.75 4
4 2.825 3.2

0
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
LOAD (KN)

Fig No 8.2 (Load vs deflection graph of test 2)

8.3 Test 3

Composition : M-sand: 25%, Bitumen: 15%,

Plastic: 20%, Metal: 40 %
Temperature : 221 degree celcius

Average weight of Specimen : 2.535 Kg

Avg Max Compressive load bearable : 77.5 KN

26
 TEST - 3
14 12.2
12 10.625
DEFLECTION (mm) 10
7.1
8
5.4
6 4.125
3.375
4 2.125 2.625
0.75 1 1.25 1.65
2 0.5
0
20 25 30 35 40 45 50 55 60 65 70 75 80
LOAD (KN)

Fig No 8.3 (Load vs deflection graph of test 3)

8.4 Test 4

Composition : M-sand: 25%, Bitumen: 15%,

Plastic: 20%, Metal: 40%,
Al-Sheet: 2nos
Temperature : 225 degree celcius

Average weight of Specimen : 2.547 Kg

Avg Max Compressive load bearable : 87.5 KN

TEST - 4
20 18.5
18
14.9
16
DEFLECTION (mm)

14 12.1
12 9.6
10 7.7
8 5.9
6 4.45
3.5
4 2 2.6
0.9 1.45
2 0.45
0
20 25 30 35 40 45 50 55 60 65 70 75 80
LOAD (KN)

Fig No 8.4 (Load vs deflection graph of test 4)

27
8.5 Test 5

Composition : Bitumen: 20, Plastic: 30, Metal: 50

Temperature : 210 degree celcius

Average weight of Specimen : 2.262 Kg

Avg Max Compressive load bearable : 110KN

TEST - 5
16
13.575
14
11.7
DEFLECTION (MM)

12
9.65
10 8
8 6.5
5.7
6 3.825 4.3 4.9
2.7252.95 3.25
4
1.35 1.65 1.85 2.05 2.152.2752.45
2
0
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
LOAD (KN)

Fig No 8.5 (Load vs deflection graph of test 5)

8.6 Test 6

Composition : M- sand: 50, Bitumen: 20, Plastic: 30,

Al-Sheet: 2nos
Temperature : 220 degree celcius

Average weight of Specimen : 2.225 Kg

Avg Max Compressive load bearable : 105 KN

28
 TEST - 6
18 16.6
16 13.92513.9
DEFLECTION (mm) 14 12.05
12 10.35
8.95
10 7.7
8 6.6
5.85
5.125
6 3.954.475
2.825 3.3
4 1.975 2.4
1.2251.575
0.925
2
0
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
LOAD (KN)

Fig No 8.6 (Load vs deflection graph of test 6)

8.7 Test 7

Composition : Metal: 50, Plastic: 30, Bitumen: 20,

Al-Sheet: 2nos
Temperature : 195 degree celcius

Average weight of Specimen : 2.285 Kg

Avg Max Compressive load bearable : 120 KN

TEST - 7
16 14.7
14
11.55
DEFLECTION (mm)

12 10.2
10 8.775
7.3
8 6.35
5.45
6 4.675
3.075 3.5 4.025
4 2.3252.675
1.6751.865 2.1
2
0
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
LOAD (KN)

Fig No 8.7 (Load vs deflection graph of test 7)

29
8.8 Test 8

Composition : Metal: 50%, Crystalline Bitumen: 20%,

Plastic: 30%
Temperature : ~

Average weight of Specimen : FAILURE

Avg Max Compressive load bearable : ~

8.9 Test 9

Composition : M-15 Concrete Mixture, Plastic: 300gm

Temperature : ~

Average weight of Specimen : FAILURE

Avg Max Compressive load bearable : ~

30
Table No 8.1 (Result of compression test)

TEST SPECIMEN COMPOSITION WEIGHT COMPRESSIVE

(%) (GRAM)
LOAD (KN)
I M-sand: 50 2415
1 Bitumen: 20 70
II 2130
Plastic: 30
I M-sand: 65 2495
2 Bitumen: 15 75
II 2385
Plastic: 20
I M-sand: 25 2515
3 Bitumen: 15 77.5
II Plastic: 20 2555
Metal: 40
I M-sand: 25 2585
Bitumen: 15
Plastic: 20 87.5
4
II Metal: 40 2510
Aluminum
Sheet: 2nos
I Bitumen: 20 2255
5 Plastic: 30 110
II 2270
Metal: 50
I M- sand: 50 2175
Bitumen: 20
6 Plastic: 30 105
II 2275
Aluminum
Sheet: 2nos
I Metal: 50 2325
Plastic: 30
7 Bitumen: 20 120
II 2245
Aluminum
Sheet: 2nos

The average weight of a 190*90*90mm normal brick varies between 3 to

3.5 kg. The water absorption test for each brick was conducted, since the brick
was made using VG 30 bitumen, the water absorption was very negligible because
it is hydrophobic in nature. The heat transfer test was conducted which gives the
result that the brick starts deform at 90 degree celcius and starts melting at 130
degree celcius. Since the atmospheric temperature doesn’t increases to that level,
the brick passes the temperature test and is safe to use. From the comparison of
31
compressive load bearing on the normal paving brick, our brick withstand more
compressive load and is suitable to use for paving purposes.

The result of compression test was satisfactory and get the values of high-
grade paving bricks Fig No (8.1). Due to enthusiasm we had conducted two more
experiments with M-15 concrete with 300g of shredded plastic in mixture, and
used 20% crystalline bitumen instead of VG 30 and 30% shredded plastic to obtain
another brick. But both experiments got failure unfortunately.

Fig No 8.8 (Test 7 brick with max compressive load capacity and plastic
coated over the surface)

32
 CHAPTER IX
COST ANALYSIS
Table No 9.1 (Material cost as per the specification)

MATERIALS SPECIFICATION COST(RS)

Metal 1-Kilogram 0.612
M-Sand 1-Kilogram 1.38
Bitumen 1-Kilogram 25
Plastic 1-Kilogram 21
Aluminium Sheet 1-Sheet(18*8 cm) 8.06
Kerosene 1-Litre 32

Table No 9.2 (Test -5 (Metal: 50, Plastic: 30, Bitumen: 20))

MATERIAL WEIGHT(Kg) COST(Rs)
Metal 1.131 0.692
Plastic 0.678 14.238
Bitumen 0.452 11.3
Kerosene 0.25 Litre 8
Total cost 34.23

Table No 9.3 (Test – 6 (Msand:50, Plastic:30, Bitumen:20, Al-Sheet:2nos))

MATERIAL WEIGHT(Kg) COST(Rs)
M-sand 1.112 1.53
Plastic 0.667 14
Bitumen 0.445 11.12
Aluminum Sheet 2nos 16.13
Kerosene 0.25 Litre 8
Total cost 50.78

33
Table No 9.4 (Test – 7 (Metal: 50, Plastic: 30, Bitumen: 20, Al-sheet: 2nos))
MATERIAL WEIGHT(Kg) COST(Rs)
Metal 1.142 0.698
Plastic 0.685 14.385
Bitumen 0.457 11.425
Aluminum Sheet 2nos 16.13
Kerosene 0.25 Litre 8
Total cost 50.638

The production cost required to obtain a specimen from Test 5 is Rs 34.23

which is observed as the best possible solution from the number of experiments.
Since this cost studied is for a unit production of the brick, the cost of shredded
plastic waste bought was Rs 21 per Kg. But when comes to large scale production
plastic waste can be obtained at a very cheap cost of Rs 5 to 7 per Kg, and the
same brick costs up to Rs 25 to 27 indeed. If we collect plastics by our own further
cost of production can be brought down.

34
 CHAPTER X

CONCLUSION
From the seven tests of VG 30 bitumen and plastic conducted, three results
were satisfactory with compressive load bearing of 120KN (Test 7), 110KN (Test
5), 105KN (Test 6). From the cost analysis carried out, Test 5 is obtained as the
best possible solution with an average cost of Rs34.23. And it weighs only 2.2625
Kg which is comparatively less than nominal 190*90*90 mm paving brick test
specimen. The normal paving brick costs averagely up to Rs 36 and is less durable
and less reliable than our result. The selected specimen can accept great more load
than the existing paving bricks and does not encourages abrasion from corners or
edges like other bricks.

From the water absorption test conducted the bitumen added bricks makes
it hydrophobic in nature and doesn’t allow water to penetrate in it. And from the
heat transfer test the brick tends to deform at 90 degree celcius and it start melting
at 130 degree celcius, since the atmospheric temperature don’t rise up to that
temperature, the brick is safe to use for paving purposes. When comparing with
the compressive load bearing on the normal paving brick the Test 5, 6, 7 it exceeds
the target load and hence it is the brick with more compressive load bearing
capacity.

This brick possesses certain other advantages like, it doesn’t corrode,

doesn’t allow algae to grow, and possess less weight compared to concrete paving
bricks, therefore easy transportation, provide extra life to tyres of vehicle. The
setting time is approximately 30 minutes without any rapid cooling application.
The black colour of the brick can be changed by using colour oxides, or by giving
coloured plastic coating on the surface and reduces the heat absorption from sun
exposure.

It can be applied over commercial pedestrian areas, parking slots,

residential roads, Minor collector & bus parking. If we add titanium dioxide in the
mixture of this paving brick, the pollution level in air can be reduced, because

35
titanium dioxide nanoparticles, when exposed to UV light, can oxidise organic
compounds in air and reduces the air pollution. Through this project we can reuse
a large amount of various types of plastics and make it eco-friendly. This can also
reduce the raw material cost of construction of pavement bricks and other building
materials. Hence the Test 5 with 50:30:20 (20mm Metal Chips: Plastic: VG 30) is
selected as the best possible solution.

36
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