By Abbas Nazil
India has embarked on its first-ever road trial using plastic waste-based Geocells, a breakthrough innovation developed by the Central Road Research Institute (CRRI) in collaboration with Bharat Petroleum Corporation Limited (BPCL).
This initiative aims to tackle the growing problem of end-of-life plastic waste while improving road construction, particularly in difficult terrains.
The new construction method, which incorporates a 3D block-shaped textile called Geocell, will soon undergo full-scale testing by the Military Engineering Services beginning in August 2025.
Geocells are designed to be filled with soil, construction debris, or other granular materials to provide structural stability for roads.
The Geocells are produced entirely from 100% waste plastic, particularly mixed and multi-layered plastic, which has been notoriously difficult to recycle through conventional methods.
Developed through a mechanical recycling process, the modules range from 4 mm to 8 mm in thickness and represent a significant leap in both plastic waste management and civil engineering.
According to Ankita Behl, principal scientist at CSIR-CRRI, the new plastic-based Geocell technology addresses two pressing concerns: improving the structural performance of roads and providing an environmentally responsible solution to plastic disposal.
A patent has already been filed jointly by CRRI and BPCL, with support from Tata Projects and the National Highways Authority of India (NHAI) for trial implementation.
A 160-meter-long road section near the elevated part of the DND-Faridabad-KMP Expressway has been successfully laid using this technique.
Approximately 20 to 25 tonnes of plastic waste were repurposed in the demonstration.
CRRI stated that the Geocell modules remained structurally sound throughout the laboratory and plant trials, with no signs of cracking or deformation observed before, during, or after load-bearing tests.
What sets this initiative apart is its alignment with sustainable infrastructure goals. By effectively using multi-layered and mixed plastics—materials not currently covered in Indian Roads Congress (IRC) guidelines—the method provides a pathway to integrate difficult-to-recycle plastics into mainstream infrastructure development.
CRRI emphasized that compared to conventional road-building practices, this technique significantly enhances the utilization of problematic plastics while improving pavement durability.
The CRRI-BPCL Geocell innovation marks a significant step forward for India’s waste-to-wealth strategy, potentially transforming how the country manages its plastic waste and builds resilient roads in complex landscapes.
With military and NHAI-backed trials now underway, the success of this project could pave the way for nationwide adoption of plastic-based road infrastructure.
