•  
  •  
 

Keywords

PET waste, Hot mix asphalt, Rutting resistance, sustainability, Plastic recycling, road construction

Document Type

Review Paper

Abstract

Plastic pollution has become a global environmental crisis, with millions of tons of polyethylene terephthalate (PET) waste accumulating in landfills and ecosystems. One promising solution is the integration of waste PET into hot-mix asphalt (HMA), offering the dual benefits of sustainable waste management and enhanced pavement performance. This review critically examines the mechanical, environmental, and economic impacts of PET-modified asphalt. Studies indicate that PET improves rutting resistance, durability, and flexibility, with optimal performance observed at moderate PET dosages (4– 6%). However, excessive PET content (> 6%) can lead to stiffening and premature cracking, while very high PET concentrations (> 20%) may reduce load-bearing capacity. Beyond mechanical benefits, the incorporation of PET significantly reduces carbon emissions and energy consumption, with Life Cycle Assessment (LCA) studies reporting a 47.4% reduction in Global Warming Potential (GWP). Economic analyses indicate that PET-modified asphalt can reduce bitumen consumption, resulting in potential cost savings; however, processing and collection costs remain significant barriers to the large-scale adoption of this technology. Despite promising laboratory results, long-term field trials remain limited, and concerns about phase separation, regulatory approval, and large-scale feasibility hinder widespread implementation. Future research should focus on long-term field evaluations, optimization of PET processing methods, and the development of standardized industry guidelines. Additionally, hybrid polymer modifications and multi-polymer blends should be explored to enhance performance and sustainability. With continued innovation and policy support, PET-modified asphalt presents a viable pathway toward greener and more durable road infrastructure.

References

UNEP, From pollution to solution: A global assessment of marine litter and plastic pollution, United Nations Environment Programme, 2021. Earnest, M. D., Performance characteristics of polyethylene terephthalate (PET)- modified asphalt, Thesis M.Sc., Georgia Southern University, 2015. F. M. Nejad, A. Azarhoosh, G.H. Hamedi, Effect of high density polyethylene on the fatigue and rutting performance of hot mix asphalt–a laboratory study, Road Mater. Pavement Des., 15 (2014) 746–756. https://doi.org/10.1080/14680629.2013.876443 Kaza, S., Yao, L. Bhada-Tata, Van Woerden, F., What a Waste 2.0: A Global Snapshot of Solid Waste Management to 2050, World Bank, 2018. https://doi.org/10.1596/978-1-4648-1329-0. D. C. Wilson, C. Velis, C. Cheeseman, Role of informal sector recycling in waste management in developing countries, Habitat Int., 30 (2006) 797–808. https://doi.org/10.1016/j.habitatint.2005.09.005 J. R. Jambeck, R. Geyer, C. Wilcox, T. R. Siegler, M. Perryman, et al., Plastic waste inputs from land into the ocean, Science, 347 (2015) 768–771. https://doi.org/10.1126/science.1260352 J. Hopewell, R. Dvorak, E. Kosior, Plastics recycling: challenges and opportunities, Philos. Trans. R. Soc., B 364 (2009) 2115–2126. https://doi.org/10.1098/rstb.2008.0311 R. Geyer, J. R. Jambeck, K. L. Law, Production, use, and fate of all plastics ever made., Sci. Adv., 3 (2017) e1700782. https://doi.org/10.1126/sciadv.1700782. UN-Habitat,Waste Wise Cities: Global Assessment Report, United Nations Human Settlements Programme, 2023. S. Yadav, S. R. Samadder, A critical review of the life cycle assessment studies on plastic waste-based road construction: challenges and future prospects, Rev. Environ. Health, 33 (2018) 159–172. https://doi.org/10.1515/reveh-2017-0035. I. M. Khan, S. Kabir, M. A. Alhussain, F. F. Almansoor, Asphalt design using recycled plastic and crumb-rubber waste for sustainable pavement construction, Procedia Eng., 145 )2016( 1557–1564. https://doi.org/10.1016/j.proeng.2016.04.196. O. Maadani, M. Shafiee, I. Egorov, Climate change challenges for flexible pavement in Canada: an overview, J. Cold Reg. Eng., 35 (2021) 03121002. https://doi.org/10.1061/(ASCE)CR.1943-5495.0000262 P. Kumar, S. Shukla, Flexible pavement construction using different waste materials: A review, Mater. Today Proc., 65 (2022) 1697–1702. https://doi.org/10.1016/j.matpr.2022.04.713 S. Bhandari, X. Luo, F. Wang, Understanding the effects of structural factors and traffic loading on flexible pavement performance, Int. J. Transp. Sci. Technol., 12 (2023) 258–272. https://doi.org/10.1016/j.ijtst.2022.02.004 A. Raut, S. W. Dhengare, AL, Dandge, H. R. Nikhade, Utilization of waste plastic materials in road construction, J. Adv. Res. Mech. Civ. Eng., 3 (2016) 1–12. https://doi.org/10.53555/nnmce.v3i3.321. A. I. Al-Hadidy, T. Yi-Qiu, Effect of polyethylene on life of flexible pavements, Constr. Build. Mater., 23 (2009) 1456–1464. https://doi.org/10.1016/j.conbuildmat.2008.07.001. A. Modarres, H. Hamedi, Effect of waste plastic bottles on the stiffness and fatigue properties of modified asphalt mixes, Mater. Des., 61 (2014) 73–83. https://doi.org/10.1016/j.matdes.2014.04.046 T. Ren, H. Zhan, H. Xu, L. Chen, W. Shen, Y. Xu, D. Zhao, Y. Shao, Y. Wang, Recycling and high-value utilization of polyethylene terephthalate wastes: A review, Environ. Res., 249 (2024) 118428. https://doi.org/10.1016/j.envres.2024.118428 M. Saleh, N. Ahmed, T. B. Moghaddam, L. Hashemian, Towards a high-performance asphalt concrete for extreme climatic conditions using asphaltenes and polyethylene terephthalate fibres, Constr. Build. Mater., 420 (2024) 135573. https://doi.org/10.1016/j.conbuildmat.2024.135573 E. Ahmadinia, M. Zargar, M.R. Karim, M. Abdelaziz, P. Shafigh, Using waste plastic bottles as additive for stone mastic asphalt, Mater. Des., 32 (2011) 4844–4849. https://doi.org/10.1016/j.matdes.2011.06.016. Z. N. Kalantar, M. R. Karim, A. Mahrez, A review of using waste and virgin polymer in pavement, Constr. Build. Mater., 33 (2012) 55–62. https://doi.org/10.1016/j.conbuildmat.2012.01.009 N. Agha, A. Hussain, A. S. Ali, Y. Qiu, Performance evaluation of hot mix asphalt (HMA) containing polyethylene terephthalate (PET) using wet and dry mixing techniques, Polymers, 15 (2023) 1211. https://doi.org/10.3390/polym15051211. T. W. Mahdi, S. Senadheera, T. Ghebrab, Effect of PET size, content and mixing process on the rheological characteristics of flexible pavement, Materials, 15 (2022) 3565. https://doi.org/10.3390/ma15103565. A. F. Ahmad, A. R. Razali, I. S. Razelan, Utilization of polyethylene terephthalate (PET) in asphalt pavement: A review, IOP. Conf. Ser.: Mater. Sci. Eng., 203 (2017) 012004. https://doi.org/10.1088/1757-899X/203/1/012004 A. O. Sojobi, S. E. Nwobodo, O. J. Aladegboye, Recycling of polyethylene terephthalate (PET) plastic bottle wastes in bituminous asphaltic concrete, Cogent Eng., 3 (2016) 1133480. https://doi.org/10.1080/23311916.2015.1133480. N. Mashaan, A. Chegenizadeh, H. Nikraz, Performance of PET and nano-silica modified stone mastic asphalt mixtures, Case Stud. Constr. Mater., 16 (2022) e01044. https://doi.org/10.1016/j.cscm.2022.e01044. L. You, Z. Long, Z. You, D. Ge, X. Yang, F. Xu, M. Hashemi, A. Diab, Review of recycling waste plastics in asphalt paving materials, J. Traffic Transp. Eng., 9 (2022) 742-64. http://dx.doi.org/10.1016/j.jtte.2022.07.002 T. Ren, H. Zhan, H. Xu, L. Chen, W. Shen, Y. Xu, D. Zhao, Y. Shao, Y. Wang, Recycling and high-value utilization of polyethylene terephthalate wastes: A review, Environ. Res., 249 (2024) 118428. https://doi.org/10.1016/j.envres.2024.118428 J. Cardoso, A. Ferreira, A. Almeida, J. Santos, Incorporation of plastic waste into road pavements: A systematic literature review on the fatigue and rutting performances, Constr. Build. Mater., 407 (2023) 133441. https://doi.org/10.1016/j.conbuildmat.2023.133441 R. Choudhary, A. Kumar, K. Murkute, Properties of Waste Polyethylene Terephthalate (PET) Modified Asphalt Mixes: Dependence on PET Size, PET Content, and Mixing Process, Periodica Polytech. Civ. Eng., 62 (2018) 685–693. https://doi.org/10.3311/PPci.10797. G. White, F. Hall, Laboratory Comparison of Wet-Mixing and Dry-Mixing of Recycled Waste Plastic for Binder and Asphalt Modification, Proc. 100th Transportation Research Board Annual Meeting, Washington DC, (2021). G. García-Travé, R. Tauste, M. Sol-Sánchez, et al., A Comparative Study of the Effect of Moisture Susceptibility on PET-Modified Asphalt Mixes under Different Regulatory Procedures, Sustainability, 15 (2023) 14519. https://doi.org/10.3390/su151914519. K. Chen, Z. Mraiza, Y. Pu, J. Li, Z. Liu, A. J. Ragauskas, F. Zhou, and J. S. Yuan, A Multi-Streamline Approach for Upcycling PET into a Biodiesel and Asphalt Modifier, Polymers, 16 (2024) 796. https://doi.org/10.3390/polym16060796. F. Xu, Y. Zho, K. Ii, Using Waste Plastics as Asphalt Modifier: A Review, Materials, 15 (2021) 110. https://doi.org/10.3390/ma15010110 Indian Roads Congress, IRC SP:98-2013 – Guidelines for the Use of Waste Plastic in Hot Bituminous Mixes (Dry Process) in Wearing Courses, Indian Roads Congress, New Delhi, 2013. Ministry of Road Transport & Highways (MoRTH), Circular RW/NH-33044/2015/S&R (R) – Mandatory Use of Waste Plastic in Hot Mix Asphalt for National Highways, Government of India, New Delhi, 2015. Austroads, Technical Guide TG-TP21: Use of Recycled Plastics in Asphalt. Austroads Ltd., Sydney, 2019. Federal Highway Administration, Use of Recycled Plastics in Asphalt Pavements – TechBrief FHWA-HIF-21-042, U.S. DOT, FHWA, Washington, DC, 2021. PIARC., Innovative Use of Plastic Waste in Road Construction – State of Practice Report. World Road Association (PIARC Technical Committee D.2), Paris, 2022. R. Choudhary, A. Kumar, K. Murkute, Properties of waste polyethylene terephthalate (PET) modified asphalt mixes: dependence on PET size, PET content, and mixing process, Period. Polytech. Civ. Eng., 62 (2018) 685–693.  https://doi.org/10.3311/PPci.10797 V. S. Punith, A. Veeraragavan, Behavior of reclaimed polyethylene modified asphalt cement for paving purposes, J. Mater. Civ. Eng., 23 (2011) 833–845. https://doi.org/10.1061/(ASCE)MT.1943-5533.0000235 M. R. R. Osorto, M. D.T. Casagrande, Environmental impact comparison analysis between a traditional hot mixed asphalt (HMA) and with the addition of recycled post-consumer polyethylene terephthalate (RPET) through the life cycle assessment (LCA) methodology, Sustainability, 15 (2023) 1102. https://doi.org/10.3390/su15021102. D. Movilla-Quesada, A. C. Raposeiras, J. Olavarría, Effects of recycled polyethylene terephthalate (PET) on stiffness of hot asphalt mixtures, Adv. Civ. Eng., 2019 (2019) 6969826. https://doi.org/10.1155/2019/6969826 S. Moghimi, G. Shafabakhsh, H. Divandari, Evaluation of rutting, fatigue, and moisture resistance of low-energy asphalt mixtures modified by crumb rubber, Adv. Civ. Eng., 2023 (2023) 6668963. https://doi.org/10.1155/2023/6668963 T. B. Moghaddam, M. R. Karim, T. Syammaun, Dynamic properties of stone mastic asphalt mixtures containing waste plastic bottles, Constr. Build. Mater., 34 (2012) 236–242. https://doi.org/10.1016/j.conbuildmat.2012.02.054 H. Taherkhani, M. R. Arshadi, Investigating the mechanical properties of asphalt concrete containing waste polyethylene terephthalate, Road Mater. Pavement Des., 20 (2019) 381–398. https://doi.org/10.1080/14680629.2017.1395354 W. M. N. W. A. Rahman, A. F. A. Wahab, Green pavement using recycled polyethylene terephthalate (PET) as partial fine aggregate replacement in modified asphalt, Procedia Eng., 53 (2013) 124–128. https://doi.org/10.1016/j.proeng.2013.02.018. Z. Dehghan, A. Modarres, Evaluating the fatigue properties of hot mix asphalt reinforced by recycled PET fibers using 4-point bending test, Constr. Build. Mater., 139 (2017) 384–393. https://doi.org/10.1016/j.conbuildmat.2017.02.082 S. L. Hake, R. M. Damgir, P. R. Awsarmal, Utilization of plastic waste in bitumen mixes for flexible pavement, Transp. Res. Procedia, 48 (2020) 3779–3785. https://doi.org/10.1016/j.trpro.2020.08.041. A. Modarres, H. Hamedi, Developing laboratory fatigue and resilient modulus models for modified asphalt mixes with waste plastic bottles (PET), Constr. Build. Mater., 68 (2014) 259–267. https://doi.org/10.1016/j.conbuildmat.2014.06.054 M. Ali, B. Al-Bayati, Dynamic creep response of hot-mix asphalt containing waste PET flakes, Arab. J. Sci. Eng., 48 (2023) 12279–12290. http://dx.doi.org/10.30880/ijie.2022.14.05.005 V. Sinha, M.R. Patel, J.V. Patel, Pet waste management by chemical recycling: A review, J. Polym. Environ., 18 (2010) 8–25. https://doi.org/10.1007/s10924-008-0106-7. M. I. Khan, S. Tayabji, Field rutting performance of PET-modified bituminous layers under heavy traffic, Transp. Res. Rec., 2678 (2024) 145–156. https://doi.org/10.1177/03611981231223647. R. Li, Z. Leng, J. Yang, G. Lu, H. Zhu, Innovative application of waste polyethylene terephthalate (PET)-derived additive as an anti-stripping agent for asphalt mixture: Experimental investigation and molecular dynamics simulation, Fuel, 300 (2021) 121015. https://doi.org/10.1016/j.fuel.2021.121015 R. Vasudevan, A. R. Chandra Sekar, B. Sundarakannan, R. Velkennedy, A technique to dispose waste plastics in an eco-friendly way – application in construction of flexible pavements, Constr. Build. Mater., 28 (2012) 311–320. https://doi.org/10.1016/j.conbuildmat.2011.08.031 A. Biswas, A. Goel, S. Potnis, Performance comparison of waste plastic-modified versus conventional bituminous roads in Pune city: A case study, Case Stud. Constr. Mater., 13 (2020) e00411. http://dx.doi.org/10.1016/j.cscm.2020.e00411 WSP., Cumbria Live Lab: Plastic additives in asphalt—Final report. Cumbria County Council, Project 70066681-REP2 (2021). F. Giustozzi, M. Enfrin, D.L. Xuan, et al. Use of road-grade recycled plastics for sustainable asphalt pavements: Final performance and environmental assessment, Austroads Res. Rep. AP-R669-22, (2022). Virginia Transportation Research Council. Evaluation of recycled-plastic-modified asphalt mixtures and pavements: Phase I—A case study in Virginia, Report 25-R11, (2025). G. Hao, S.M. Lim, M. He, G.P. Ong, A. Zulkati, S. Kapilan, J. H. Tan, Long-term performance of porous asphalt pavement incorporating recycled plastics, Resour. Conserv. Recycl., 212 (2025) 107979. https://doi.org/10.1016/j.resconrec.2024.107979 S. Q. Aziz, S. O. Ismael, I. A. Omar, Recyclable solid waste materials management in Erbil City–Iraq, Int. J. Eng. Inventions, 8 (2019) 57–62. S. Q. Aziz, S. O. Ismael, I. A. Omar, New approaches in solid waste recycling and management in Erbil City, Environ. Prot. Res., 3 (2023) 1–13. https://doi.org/10.37256/epr.3120231758 A. A. Mohsin, A. Mustafa, Management of municipal solid waste in Baghdad, Iraq, Int. Scholarly Sci. Res. Innovation, 11 (2017) 700- 704. http://dx.doi.org/10.5281/zenodo.1316235 M. Abdulredha, P. Kot, R. Al Khaddar, D. Jordan, Investigating municipal solid waste management performance during the Arba’een event in Kerbala, Iraq, Environ. Dev. Sustain., 22 (2020) 1431–1454. https://doi.org/10.1007/s10668-018-0256-2 A. S. Ashoor, M. M. Kareem, M. N. Al-Baiati, Improved asphalt binder using recycled polyethylene terephthalate polymer, IOP Conf. Ser. Mater. Sci. Eng., 571 (2019) 012094. https://doi.org/10.1088/1757-899X/571/1/012094 M. Tariq I. Alyaseri, Using recycled PET waste bottle as clasp of ring strips in hollow concrete blocks in Iraq, Muthanna J. Eng. Technol., 12 (2024) 22–30. https://www.muthuni-ojs.org/index.php/mjet/article/view/234 A. V. Tiwari, Y.R. Rao, Study of plastic waste mixed bituminous concrete using dry process for road construction, Sel. Sci. Pap. J. Civ. Eng., 13 (2018) 105–112. https://doi.org/10.1515/sspjce-2018-0024. E. A. Fahmy, A. M.Youssef, E. E. Ali, A. Algabry, O. El-Bagalati, Evaluation of asphalt mixtures modified with polyethylene terephthalate (PET), Innov. Infrastruct. Solut., 9 (2024) 434. https://doi.org/10.1007/s41062-024-01734-9 UNECE., Circular economy benefits of plastic-modified pavements: LCA synthesis report, United Nations Economic Commission for Europe, 2023. S. M. Lim, M. He, G. Hao, T. C. A. Ng, G. P. Ong, Recyclability potential of waste plastic-modified asphalt concrete with consideration to its environmental impact, Constr. Build. Mater., 439 (2024) 137299. https://doi.org/10.1016/j.conbuildmat.2024.137299 L. Yao, Z. Leng, J. Lan, R. Chen, J. Jiang, Environmental and economic assessment of collective recycling waste plastic and reclaimed asphalt pavement into pavement construction: a case study in Hong Kong, J. Clean. Prod., 336 (2022) 130405. https://doi.org/10.1016/j.jclepro.2022.130405 A. M. Al-Sabagh, F. Z. Yehia, G. Eshaq, A. M. Rabie, A. E. ElMetwally, Greener routes for recycling of polyethylene terephthalate, Egypt. J. Pet., 25 (2016) 53–64. https://doi.org/10.1016/j.ejpe.2015.03.001. M. Enfrin, R. Myszka, F. Giustozzi, Paving roads with recycled plastics: microplastic pollution or eco-friendly solution? J. Hazard. Mater., 437 (2022) 129334. https://doi.org/10.1016/j.jhazmat.2022.129334 Y. J. Boom, M. Enfrin, S. Grist, F. Giustozzi, Recycled plastic-modified bitumen: evaluation of VOCs and PAHs from laboratory-generated fumes, Sci. Total Environ., 832 (2022) 155037. https://doi.org/10.1016/j.scitotenv.2022.155037 S. M. Lim, T. C. A. Ng, M. He, B. E. C. Amio, G. Hao,et al., Refining leaching protocols of waste-plastic incorporated asphalt mixes for environmental impact assessment, J. Clean. Prod., 487 (2025) 144610. https://doi.org/10.1016/j.jclepro.2024.144610 SusPAN Consortium, Environmental Impact of Plastic Roads – Final Report, EU H2020 SusPAN Project, Brussels, (2022).

Highlights

PET-modified asphalt enhances rutting resistance, stability, and fatigue life at a dosage of 4–6% Wet and dry mixing techniques have a significant influence on mechanical performance and moisture resistance A Life Cycle Assessment (LCA) reveals a potential reduction of up to 47.4% in Global Warming Potential using PET Fine particle PET enhances dispersion and interfacial bonding while reducing permanent deformation Economic feasibility improves when PET replaces bitumen, resulting in lower material and maintenance costs

DOI

10.30684/etj.2025.159983.1956

First Page

879

Last Page

890

Download

Share

COinS