The present invention relates to a process of construction of artificial roads, walk ways, footpaths, etc. from unsorted waste plastics of various types and origin, resins and related polymers. More particularly the present invention relates to the process of laying the base and/or sub-base and/or a layer in construction of roads, footpaths and similar types of constructions or the construction wherein the frost free layer or medium required.

BACKGROUND OF THE INVENTION

Since last two decade, it has been realised that the issue related to protection of environment from all kind of pollutions must be addressed on priority. The use of plastic and related materials is increasing exponentially due to tremendous growth in population, urbanization and changed life style. This leads to widespread littering of plastic on the landscape. Disposal of waste plastic emerged to be a serious problem globally due to their non-biodegradability and hazardous nature. Land fill of waste plastic seems to be dangerous to the human health, since it's creates contaminate agricultural land and polluting the water near to the land filled areas by releasing the toxic chemicals. The disposal issue needs to be addressed in priority. The product developed will address these issued to a maximum extent by its application reads constructions. Construction of roads and buildings are also amongst the sources of environmental pollution. Therefore, the focus on sustainable and green design construction is the opportunity to use our resources more efficiently. This will also ensure lighter footprint on the environment through conservation of resources. Balancing energy-efficient, cost- effective, low-maintenance construction needs, the green products needs to be developed.

The great concern of disposal of waste plastic generated forced us to find alternatives ways to dispose or develop new uses for waste or recycled plastics. The efforts made in this direction across globe has also given incentives to introduce plastics from recycled sources into building or paving material, either to facilitate their disposal where it is hoped that their introduction does not degrade and does not increase its cost. It is also l hoped that their introduction will provide a cost effective improvement in the properties of the building or paving material. Research has been carried out to utilize waste plastic of selected and graded recycled plastic materials as an additive to the asphaltic binder component of asphaltic concrete paving material in an effort to improve the flexibility and reduce the propensity of the paving material to crack. However, these efforts got a very limited success due to limitation of the process.

Indian patent application no. 4631/CHE/2015 teaches a manufacturing process and method by using all types of waste plastics impregnated bituminous mix for road construction. Said method uses about 15% different type of plastic polymers collected from the solid waste, which is shredded, fine powdered and added to the VG30 or VG10 Bitumen of its weight recommended for the road engineering. As a process all types of plastics are shredded, fine powdered, sieved and heated to 200-220°C in a specially designed digester in-built with a high speed 5000 RPM propeller is agitated for one hour and further 5% of special binder grade tar pitch is added and again running the agitator for 30 minutes at the same temperature. Further to this 3% of combined form of polymerized, Pongamia Glabra - species oil and pyrolyzed rubber oil as a catalyst cum stabilizer is added and then one MT of pre-heated VG 30 or VG 10 grade Bitumen will be pumped to the digester and the agitation will be continued for further one hour, for availing excellent Bitumen and waste plastic compatibility and homogeneity, end in a mutant form of matrix impregnated waste plastic bitumen for high performance and new generation road construction engineering.

Indian patent IN246060 teaches a process for the preparation of waste plastic modified bitumen useful for rut resistant and water resistant bituminous mix for road construction. The said patent teaches a process for the preparation of waste plastic modified bitumen useful for rut resistant and water resistant bituminous mix for road construction. More particularly it relates to utilisation of waste plastic bags for modification of bitumen to obtain 'Polymer Modified Bitumen' used for construction of roads. The bituminous mixes prepared using waste plastic modified bitumen has higher resistant to rutting compared to other modified bitumen and conventional bitumen. In the process powdered plastic waste 2 to 8 wt% of bitumen are added in standard bitumen, mixture is stirred at 1000 to 3000 rpm for 25 to 40 minutes and further 0.15 to 0.25 % of hydrogenated tallow is added for better homogeneity of blend to obtain the desired product. However, the aforesaid methods involve mixing of the waste plastic material with the bituminous mixes at certain temperature which leads to the utilization of very limited amount of plastic waste. Further, plastic waste and bitumen do not get integrated together over the period of time which may leads to the damaged and cracked roads.

The present invention provides a solution to conventional construction or repairing work, as repairing of damaged roadways by conventional methods can be extremely expensive, time consuming. The route is also environmentally disruptive because the entire compacted gravel layer of the road must be replaced. Using the current methods a required shape can be tailored or existing shape can be well adjusted to the area to be repair.

The present invention thus aims to obviate the drawbacks of the prior art and is extremely useful at any location including isolated locations or locations with difficult terrain. Because of exorbitant expense of removing and replacing or repairing the roads is difficult due to atmospheric or geographical conditions. This avoids reduce noise and air pollution at site, due to extended delays during repair. Conventional method of storing material for construction may degrade the stored materials due to delayed use of the same. The current method the product is ready to use at any time does not have any effect of storage on the quality.

Another advantage of the present invention is that the product can be prepared both off site and on site, transported by any rod, air and sea route to any location. It can be stored for long time without any damage.

In view of above the method of present invention offers advantages in a wide variety of road applications, from unpaved roads that will remain un-surfaced to the roads that will receive running surface treatments. The major advantage of the present invention is that the product laid has been formulated to be as gentle on the environment as they are effective on the roadways at very low cost. Another advantage is the process does not require costly base or aggregate materials to build subsequent paving or sealing. The inventive product in use is non-hazardous, non-flammable, non-corrosive, and nontoxic, use waste generated sustainable basis and keep the environment clean, will not harm vegetation or wildlife, and will not leach out of the surface so they are safe to use close to streams and bodies of water. The present invention provides a method of using a product prepared from waste to form mixed waste plastics of various types and origin, plastic type resins and related types of polymers and/or waste materials. A product, which is designed such that, that it is suitable for use in construction of roads and which has a relatively low thermal conductivity. The low thermal conductivity and relatively small thickness of the product enables it is to be used as an insulation barrier to protect the permafrost when a road is to be built in artic and/or subarctic regions also. However, the method of laying such product could also be used for other purposes than building roads, for example, as oil well drilling pads, airport runways, railways related construction or any construction wherein the frost free paths, roads, layers are required or insulation in buildings. The invention relates to a process for laying a foundation, comprising the excavation of a of ground where the road needs to be constructed, placing thereon a layer means for the basement subsequent introduction of setting material as appropriate, and the subsequent laying of the remaining foundation by product in the invention. The product laying can be altered also and layers of invented products can be single and/or multiple and alternate layering can also be done with the same product.

OBJECT OF THE INVENTION

The primary object of the present invention is to provide a method to lay road from the green product developed from mixed waste plastics of various types and origin, plastic type resins and related polymers for any or all source/s.

Another object of the present invention is to provide a ready to lay and pollution free method to construct, either partly or fully, roads, footpaths, rural roads or similar kind of construction.

Another objective of present invention is to provide a method of pavements using paving blocks developed using mixed waste plastics of various types and origin and/or recycled plastics, in pavements. More particularly, this invention relates to develop green methods pavements using green paving blocks and to provide a method of laying the blocks having unsorted, residual or other recycled or waste plastic as a component of the paving block or pavement.

Further object of the present invention is to provide a method of construction of roads, footpaths, rural roads or similar kind of constructions having high flexibility in shaping and tailoring the base or sub-base material. Further object of the present invention is to provide a method for quick repairing of damaged roadways and to provide alternative to conventional methods can as they are extremely expensive, time consuming, and environ mentally disruptive because the entire compacted gravel layer of the road needs to be replaced.

Yet further object of the present invention is to provide a method of avoiding the generation of waste from road repair as excavating the roadbed of a 1-km portion of road measuring 4 m in width produces about 2000 cubic meters (m ³ ) of earthy waste; in a conventional road bed repair project, which would require roughly 200 truckloads of waste to be removed from the worksite, with 200 truckloads of new gravel being shipped back the worksite to complete the project.

Further object of the present invention is to improve the properties of pavements and of paving materials, particularly asphaltic concrete materials, and most particularly, to improve the strength and useful life of the pavements made of the paving materials by insulating the material in product or blocks prepared from waste plastic, plastic type resins and related polymers.

Another object of the present invention is also to provide a new and improved method of laying the green blocks for constructing a road over frozen ground wherein the material is made from waste plastic, plastic type resins and related polymers and has a relatively low thermal conductivity.

Yet another object of the present invention is to improve the properties of paving materials in a cost effective manner thereby addressing the issue of waste plastic and /or municipal solid waste.

Yet another object of the present invention is to avoid the onsite preparation of mixture there by avoiding the C0 ₂ emissions in surrounding and to provide a process by which it is possible to lay foundations with ready to use green blocks with relatively little effort.

Yet another object of the present invention is to provide a method to lay the base and/or sub-base of road and related types of constructions with selective removal and replacement of piece of road where in the repair needs to be done. In another objective of the present invention is to mix the environmentally hazardous material with the asphalt road mix and fill in the product block for its safe disposal.

Another object of the present invention is to provide a process for making tough, highly elastic, wear- resistant, economical pavements without addition of any coating or additive.

Another object of the present invention is to provide a construction of an environmental and water-permeable paving, which has substantially the same outer-appearance as general roadway, but has the function of draining away the water accumulated on the ground and kept the base safe from damage due to penetration of water.

Another object of the present invention is to develop a construction process for road base with a transition from the elastic base to the rigid base with marginal elasticity. For that purpose, a road surface construction is presented where the surface covers a rigid base, and the construction has been designed by taking into account the transition from the elastic base to the rigid base. The construction includes a rigid and marginal elastic base, so a net for receiving and diffusing shear stress, and a net for receiving and diffusing shear stress from the surface, a two-layer top surface can be taken care of.

SUMMARY OF THE INVENTION

The present invention relates to a process for construction of roads, walk ways, footpaths, pavements, etc. from unsorted and/or mixed waste plastics of various types and origin, plastic type resins and related polymers comprising:

laying at least one sub-base layer of hollow blocks such that the hollow blocks lie horizontally adjacent to each other;

- filling the said sub-base layer of hollow blocks with bituminous mixture or asphalt or road paving material;

- optionally covering the said filled hollow blocks with covers/lids;

- laying at least one base layer of hollow blocks over the sub-base layer such that the hollow blocks lie horizontally and vertically adjacent to each other;

- filling the said base layer of hollow blocks with bituminous mixture or asphalt or road paving material;

- optionally covering the said filled hollow blocks with covers/lids; laying the surface layer with road base materials or bituminous mixture or asphalt.

- Optionally the hollow block can also be filled off the field prior to laying and layed on the base or sub-base of the road.

The hollow blocks and covers/lids are prepared from unsorted waste plastics of various types and origin, plastic type resins and related polymers or combination thereof. Further, the hollow blocks of varying volume to weight ratio and different size and shape are chosen for road construction depending upon the requirement.

The base and sub-base layers are made by laying the blocks horizontally, in close contact with each other, in the area where the roads have to be constructed. There can be one or more layers of the blocks depending upon the requirement. The blocks are tailored to fill the potholes or as a medium for land levelling. The blocks are laid on any surface having soil at the bottom or old road or rock of on any type of earth surface suitable for road of or path or footpath construction.

The blocks are optionally joined/sealed with appropriate sealing agent/additive capable of sealing the gasps or cracks in the roads, plastic materials, concrete cracks but not limited to the same.

Further, the blocks are hollow shaped body with leak proof walls or porous wall having pores depending upon the requirement.

The arrangement of blocks is made in alternate in any direction and the gap are optionally bridged with pipes, cable trays or a solid or a hollow medium.

The roads have pre-determined length, width and thickness as per the requirement.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 A show the hollow container or blocks of product developed from Waste Plastic, Plastic Type Resins and Related Polymers or mixture thereof.

Figure 1 B show the cover of the product prepared from the similar material and process as that of Figure 1 A. Figure 1C depicts the container is filled with bituminous mixture or asphaltic mixture of any type which can be used for construction of roads or similar kind.

Figure ID show the product is covered and sealed. The seal can also protect the material filled there in from water and degradation.

Figure IE shows few illustrative design of the product in various geometrical shapes. The product can be shaped in all possible geometric shaped depends on application and need.

Figure 2A show the connection and alignment of blocks in various directions. Once the basic design finalised the connection and alignment of two or more blocks can be done depends on the need.

Figure 2B shows the layer block having basic block aligned and sealed in. The length, width and height can be tailored as per need. Once the alignment is done the solid block of a layer can be formed as shown in Figure 2 B.

Figure 2C show the illustrative layer structure of the road (reference: http://transportationenqineerinq2012onwards.bloqspot.in/2013 /02/function-of-arious- pavement-components.htmO, the solid block of as shown in Figure 2B can be laid in base course or in sub-base course or in both layers.

DESCRIPTION OF THE INVENTION

The present invention is directed to method of preparation of roads, pavement, base course and/or sub-base course, which utilizes an otherwise environmental polluting material. The pavement course composition contains ready to use block/s encapsulated with asphalt mix. The blocks so prepared are designed to suit the need of the construction.

According to preferred embodiment the methods of the present invention provides additional advantage in enhancement of life and strength of the construction as the bituminous mixture and/or appropriate mixture encapsulated in the block is safe from all types of atmospheric contamination and there by retain its original properties for long time or till the block gets naturally degrade. In another embodiment, when the individual blocks are laid nearby to for a road they will be adjacent to each other and integrate due to pressure and vibration from all the sides and appear as single layer. It should be understood that when the two layers are integrated through the vibration, the lower portion of the final product after installation is not visible to the eye. However, it is that lower portion of the paving block body that provides strength, load capacity and may interlocking capability.

In another embodiment, the advantage of present method of construction provides the stability to the block against excessive strain due to traffic load as the asphalt and/or bituminous mixture encapsulated there in support material against deformation.

In another embodiment the blocks design is such that it demonstrate the elasticity against the pressure and regain the shape back there by keeping the base intact.

In another embodiment the road construction can be done with the conventional method and on levelling the ground the alignment of ready to use blocks can be laid.

In another embodiment advantage of present method is that the damage to the block layer can be arrested to the selective region and its spreading can be avoided thereby keeping the strength of the road intact.

In another embodiment the layers of different thickness of blocks can also be uses as per the need. The adjacent blocks can be of different size, shape and thickness or can be tailored to match the need of the construction.

In another embodiment the advantage of present method is to construct an anti-crack base. As the blocks are individual units joined together, any major impact by heavy traffic movement or by earth quake, the blocks may distance itself for a while and regain its position again so cracking will be arrested.

In another embodiment as the blocks are made of plastic type material, the percolation of water or moisture can be entered in the road mixture thereby preventing the water movement to the road surface by capillary effect.

According to one of the embodiment of the invention, the sub-base layer and the base layers are laid in the ground by horizontally laying the blocks in the ground such that the blocks cover the entire area where the road has to be made. The empty blocks are then filled with the road base materials or road paving material or asphalt mixture or bituminous mixture. Thus there is no requirement of adding any additive in the road base materials or road paving material or asphalt mixture or bituminous mixture or the waste plastic to mix with each other. Said filled blocks may then be optionally covered with the cover/lid. The cover/lid is also prepared from the waste plastic similar to the hollow blocks. The base layer of filled blocks are then optionally covered with sand, fine stone crust, any kind of solid powder, asphalt mix used for road construction or to cover the base or sub-base.

In another embodiment of the present invention, methods for covering road base materials, sand, fine stone crust, any kind of solid powder, is used broadly to describe the top layer of the earth's surface, consisting of rock and mineral particles mixed with organic matter (also known as, by non-limiting reference, earth or dirt); Whether originally located at the road construction site ("local soil" or "in situ soil") or transported to the road construction site.

In another embodiment of present patent application, the phrase "road base materials" is broadly used to describe any substance from which a road surface, base, or sub-base could be constructed, however, this including, but not limited to rock, broken rock, gravel (whether pebble, granule, or other size or mixture), sand, cobble, slag, or other construction aggregate or fill material.

An embodiment of the invention is directed to layers comprising a first layer of block and a second layer of block contacting the first layer. The first and second layers of block may be the same or different, in composition, thickness, orientation, etc. The invention contemplates a layer having any number (greater than one) of layers of blocks.

In another embodiment the blocks so prepared with different size shape and thickness can be laid manually, semi manually or by machine also. Similarly, if needed, the blocks with different size shape and thickness can be rearranged, replaced, removed for their fit to suit the need of the path, road, footpaths or related construction can be done manually, semi manually or by machine also.

In another embodiment, to seal the gasp of two blocks after laid, the composition application can include any method chosen for sealing with sound engineering judgment, but in most instances, application of the chemical agent to the block seal or soil is accomplished by the use of conventional spray equipment (spray trucks). The agent is gravity fed or pumped through hoses, spray nozzles, or fixed sprayers and evenly applied to the soil or material to be treated.

In another embodiment, the treated soil or road base materials are graded and compacted as per conventional process used to construct roads; using any methods chosen with engineering judgment, and a top coat of the composition is applied as usual before or after laying the current product. Motor-graders, asphalt grinders, mixers, pug mills, compactors, rollers, and other conventional construction equipment may be utilized to blend, set grade, and compact stabilized base, if necessary, can be used with current product.

In another embodiment the present invention does not required any curing agent and allows the road or road base to be open to traffic or use in a matter of hours rather than days.

In another embodiment the blocks can be paved with arrangement such that there is a gap with specific dimensions. The space of gas can be used to lay the pipes or cable trays or any such object which required protecting the object pass through it such as cables.

In another embodiment the after laying the blocks and formation of roads, footpaths or walkways or paths, if there is a need to remove the blocks for some or the other reason, these blocks can be used to construction at other locations.

In another embodiment the material filled there in blocks, asphalt mixture or bituminous mixture or any mixture or concrete used for road and like constructions, can be removed and reprocessed, refilled and reused. In another embodiment if the block or part of blocks removed from the place of construction, the block can be made free from the material filled therein and can be reprocessed as a raw material for preparation of new block.

In another embodiment the solid blocks prepared can also be used to form above type of constructions. The solid blocks dose not required any mixture to be filled in. In the embodiments described hereinabove, the person of ordinary skills in the art may incorporate changes and modifications without departing from the general scope of current invention. It also include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. Though, the description above contains much specificity, this should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently pre referred embodiments of this invention.

EXAMPLE 1

A patch with 16 meter in length and 4 meter in width was excavated till 500 mm depth. All the necessary process followed as per standard procedure such as cleaning of area, levelling water bound macadam rolling the area with 10 ton road roller and patch was prepared. The first set of work was carried out for the sub-base course of the road. A one inch layer of bituminous concrete was layered over a hot bitumen tack coat on the sub-base and rolled till consistency in level achieved for the area excavated. On completion of this, area of 2 meter in width and 14 meter in length was marked for laying the module by leaving 1 meter from each side of the excavated area. Modules of size 20 inch width, 20 inch length and 5 inch wall height, top open, were layered adjacent to each other. In one row of 2 meter width 4 modules were layered adjacent to each other and similar way 16 modules layered in 8 meter length. In total 16 m ² area 64 modules of 20 inch width, 20 inch length and 5 inch wall height were layered. Adjacent to the last line of 20 inch width, 20 inch length and 5 inch wall height module a modules with size 10 inch width, 40 inch width and 5 inch wall height was placed. A total 32 numbers of modules with 10 inch width, 40 inch width and 5 inch wall height were layered on both the sides.

Next to the last line of 20 inch width, 20 inch length and 5 inch wall height, 9 numbers of modules with 32 inch width, 32 inch length and 5 inch wall height were layered. Adjacent to 32 inch width, 32 inch length and 5 inch wall height modules the modules with 32 inch width, 42 inch length and 5 inch wall height were layered. All the modules were layered such that outer side walls of module touches face to face. On completion of laying of modules, a hot bituminous concrete prepared with 4% 80/100 pen was filled in these modules till the all modules gets completely filled and levelled manually.

Once the levelling was over, the compaction of bituminous concrete was done by rolling the surface with a road roller having weight of 10 tons. The rolling was continued till a good compaction achieved. The top-up was done by filling bituminous concrete and rolling done till desired level of thickness of base course achieved.

The same sub-base was used to lay a base course with the modules with a wall height 2.5 inches, keeping all other dimensions width and length same as that of above modules. Once the appropriate thickness for sub-base is achieved, the work for second layer for base course was carried out. Modules of size 20 inch width, 20 inch length and 2.5 inch wall height with top open were layered adjacent to each other above the rolled sub-base. In one row of 2 meter length area 4 modules were layered and 16 modules layered in 8 meter length. In total 16 m ² area 64 modules of 20 inch width, 20 inch length and 2.5 inch wall height were layered. Adjacent to the last line of 20 inch width, 20 inch length and 2.5 inch wall height module a modules with size 10 inch width, 40 inch width and 2.5 inch wall height was layered. A total 32 numbers of modules with 10 inch width, 40 inch width and 2.5 inch wall height were layered on both the sides. Next to the last line of 20 inch width, 20 inch length and 2.5 inch wall height, 9 numbers of modules with 32 inch width, 32 inch length and 2.5 inch wall height were layered. Adjacent to 32 inch width, 32 inch length and 2.5 inch wall height modules the modules with 32 inch width, 42 inch length and 2.5 inch wall height were layered. All the modules were layered such that the walls touch face to face. On completion of laying a hot bituminous concrete was filled in these modules and levelled manually. Once the levelling is complete, the compaction of bituminous concrete was done by rolling the surface with a road roller having weight of 10 tons.

The rolling was continued till a good compaction achieved. The top-up was done by filling bituminous concrete and rolling done till desired level of height achieved. On completion of base course a surface course was completed by mixing appropriate quantity and size of stone dist and bitumen. The mixture was layered on the road and rolled till uniform distribution and desired thickness achieved. A total quantity of 895 kilograms of waste plastic was used in a road stretch with 16 meter in length and 4 meter in width.

It will be understood by a person skilled in the art that although the paving block disclosed herein may be used in a variety of applications including but not limited to roads, footpaths only. It will further be understood by a person skilled in the art that the method disclosed herein may be used to manufacture objects other than paving blocks, for example, artificial ready to lay rode module and other articles.