CRRI and BPCL Transform Plastic Waste into Stronger, Greener Roads
Innovative Geocell Technology from End-of-Life Plastics to Reinforce India’s Road Infrastructure
In a groundbreaking step toward sustainable infrastructure and circular economy practices, the Central Road Research Institute (CRRI) and Bharat Petroleum Corporation Limited (BPCL) have jointly developed Geocells—a revolutionary road-building material made entirely from end-of-life plastics. This innovation marks a defining moment in India’s mission to repurpose waste and strengthen road durability, turning plastic waste from an environmental challenge into an engineering asset.
The technology, which has been jointly patented by CSIR-CRRI and BPCL, has already undergone rigorous testing in collaboration with TATA Projects and the National Highways Authority of India (NHAI). Following successful trials, field implementation with the Military Engineering Services (MES) is set to begin in August 2025, signaling a major leap in sustainable road construction.
From Waste to Worth: The Science Behind Geocells
The newly developed Geocells are three-dimensional block-shaped modules created from recycled, end-of-life plastics—specifically the multi-layered and mixed plastic waste that is typically excluded from road-building norms. These modules can be filled with soil, sand, or construction debris, and then compacted to form a stable sub-base layer in road construction.
“CRRI and BPCL developed a plastic-based module 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,” explained Ms. Ankita Behl, Principal Scientist at CSIR-CRRI.
The innovation focuses on mechanical recycling, where waste plastics are processed and molded into modules with a thickness of 4 to 8 millimetres. The resulting Geocells exhibit high load-bearing capacity, resistance to deformation, and excellent flexibility—properties essential for road construction in geologically unstable or high-stress environments.
Successful Trials with Tata Projects and NHAI
To validate this pioneering approach, CRRI and BPCL collaborated with TATA Projects and the National Highways Authority of India (NHAI) to construct a 160-metre pilot road section. The Geocells were filled with non-plastic granular materials, compacted, and tested under various load conditions.
The results were remarkable. Laboratory and field tests showed no cracks, displacements, or deformations. The modules maintained their shape and integrity even under repeated heavy loads, outperforming conventional road bases in both flexibility and durability.
This successful validation prompted further trials, with the first field deployment planned under the Military Engineering Services (MES)—an ideal testing ground given India’s varied and challenging terrains, from deserts to high-altitude zones.
Paving the Way for Sustainable Roads
The first on-ground trial near the DND–Faridabad–KMP Expressway used 20–25 tonnes of waste plastic, demonstrating the technology’s scalability and practical benefits. For India, which produces over 3.5 million tonnes of plastic waste annually, this approach offers a tangible path toward waste reduction and infrastructure sustainability.
By integrating waste plastics into road construction, CRRI and BPCL’s innovation addresses two pressing issues simultaneously:
- Plastic Waste Management – repurposing end-of-life plastics that are otherwise landfilled or incinerated.
- Infrastructure Durability – improving the strength and lifespan of roads in challenging environments.
The Geocell technology is especially promising for hilly terrains, flood-prone regions, and areas with weak soil, where traditional road-building methods often fail due to erosion or poor load-bearing capacity.
First-of-its-Kind Technical Textile Solution
What sets this initiative apart is the creation of India’s first technical textile made entirely from end-of-life plastic. Technical textiles—engineered fabrics used for industrial purposes—are gaining momentum in civil engineering for soil stabilization, drainage, and reinforcement.
By repurposing multi-layered plastics into Geocells, CRRI and BPCL have unlocked a new category of green construction material that meets performance standards while advancing India’s waste-to-wealth mission.
This achievement is also significant because multi-layered plastics—used in packaging and food industries—have long posed a recycling challenge. They are currently excluded from the Indian Roads Congress (IRC) specifications due to processing difficulties. The success of the Geocell model could lead to new guidelines under IRC, making plastic roads a mainstream reality across the country.
A Collaboration That Reflects India’s Innovation Spirit
The partnership between CRRI, BPCL, and Tata Projects represents a model for industry-academia collaboration driving sustainability. It showcases how cross-sectoral innovation—where research institutions and corporations combine expertise—can deliver scalable climate solutions.
BPCL’s involvement underscores the energy sector’s transition towards circular economy models, where waste materials are reintegrated into value chains. “We are not just creating better roads; we are building a cleaner future,” remarked a BPCL spokesperson, emphasizing the company’s alignment with India’s Swachh Bharat and Net Zero 2070 goals.
Transformative Potential for India’s Road Network
India’s vast road network spans over 6.3 million kilometres, and with continuous expansion under schemes like Bharatmala Pariyojana, the opportunity for integrating recycled materials is immense. The Geocell-based approach could revolutionize how India builds and maintains roads—making them stronger, lighter, and more sustainable.
Moreover, using waste plastics in large-scale infrastructure can help reduce landfill pressure, minimize environmental leakage, and generate green employment in recycling and road construction sectors.
The upcoming field trials with the Military Engineering Services are expected to provide key data for large-scale rollouts, especially for border roads, rural connectivity projects, and highways traversing difficult geographies.
A Step Toward Circular Infrastructure
The CRRI-BPCL Geocell initiative aligns seamlessly with India’s broader push for circular infrastructure—a concept where materials are continuously reused, reducing the carbon footprint of construction.
By transforming waste into a structural asset, this innovation reinforces the idea that sustainability and strength can go hand in hand. It also complements global sustainability targets, such as the UN SDG 12 (Responsible Consumption and Production) and SDG 9 (Industry, Innovation, and Infrastructure).
India’s Plastic Roads Show the Way Forward
The creation of Geocells from end-of-life plastics is more than a technological milestone—it’s a symbol of India’s ingenuity and environmental responsibility. With each kilometre of road built using recycled plastic, India moves closer to a cleaner, more resilient future.
As the world seeks scalable solutions to plastic waste, India’s plastic roads could soon serve as a model for sustainable infrastructure globally. By turning discarded waste into durable foundations, the CRRI-BPCL partnership has proven that innovation truly begins where challenges lie.
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