ADOPTING GREEN & NEW TECHNOLOGIES

IN PMGSY

MaY, 2022
Contents

Introduction........................................................................................................................................................................ 1

New Technologies in PMGSY......................................................................................................................................... 2

Green and New Technologies commonly being used under PMGSY are as under: -............................... 3

Full Depth Reclamation Technology (Fdr)........................................................................................................ 3

Waste Plastic................................................................................................................................................................. 4

Cold Mix.......................................................................................................................................................................... 4

Cement Stabilization................................................................................................................................................. 5

Cc Block.......................................................................................................................................................................... 6

Paneled Cement Concrete....................................................................................................................................... 7

Cell Filled Concrete..................................................................................................................................................... 8

Surface Dressing.......................................................................................................................................................... 8

Terrazyme...................................................................................................................................................................... 9
 ADOPTING GREEN and NEW TECHNOLOGIES
IN PMGSY

Introduction
India has the second largest road network in the world. We have over 6.2 million km of roads. The
administrative control of roads in India is divided as per the type of road and its geographical locations.
The rural road is a state subject and within the state too, it is governed by several agencies such as Rural
Development (RD), Panchayati Raj (PR), Rural Works Department (RWD), State Rural Road Development
Agency (SRRDA), Public Works Department (PWD), Zilla Panchayat, Block Panchayat, Village Panchayat
etc. The roads are primarily divided into following forms comprising different proportion:-

Category of Road Network Percentage

National Highways 2..19%
State Highways 3.0%
Major District Roads 10.17%
Rural Roads 72.97%

Urban Roads & other Project Roads 11.67%

India is adopting new technologies day by day on a larger scale in construction of roads. Old technologies
are used in construction involving certain specified construction materials which primarily involve
usage of good quality soil and aggregate. The only reason that conventional technology holds good
on to its users is its awareness among all. Thus, for the induction of new technology, its awareness
and engineering advantages must be disseminated among various stake holders. The conventional
technology has shown various drawbacks such as excessive use of natural resources, rapid depletion of
aggregate, in–sufficient durability, poor riding quality, long hauls of construction material and excessive
pollution, to mention a few.

In order to redress these challenges, it is need of the hour to adopt new/ innovative technologies in road
sector in a big way. National Rural Infrastructure Development Agency (NRIDA) under Ministry of Rural
Development (MoRD) has effectively initiated for promoting different newly developed technologies
and in the process of achieving optimal use of such technology in building sustainable roads in cost
effective manner while implementing construction/ upgradation of rural roads under PMGSY.

Adopting Green and New Technologies in PMGSY 1

 New Technologies in PMGSY
zz The roads in India are classified, based on construction technology/ material used as Flexible
pavement, Rigid Pavement. The designs of different categories of roads are done as per specifications
provided by prevailing Indian Roads Congress (IRC) Codes.
zz The age long technologies involving certain specified construction material are used in construction.
This method primarily involves good quality soil and aggregate. The only reason that conventional
technology holds on to its users is mainly due to ease of understanding the conventional approach
and awareness among all.
zz Green, environment friendly and economically cheaper technologies are available which can create a
permanent impact on our environment, as well as end the depletion of good quality conventional material
which would ultimately minimize the damage to the environment due to emission of gasses like carbon
dioxide and heavy suspended particles in the air and a way forward to Sustainable Development.
zz A total length of 69278.06 km has been constructed till March 2022 using New Technologies under
PMGSY.
zz Under PMGSY-III, the States have been asked to propose at least 15% of the length of annual proposals
under new and green technologies. In order to promote cost-effective and fast construction
technologies and to achieve optimal use of non- conventional materials and cost- effective
environment friendly “Green Technologies” in the construction of PMGSY-III roads, the prominent
new technologies like use of waste plastic, cold mix technology, cell filled concrete, stabilization
using cement and lime, nano technology, full depth reclamation (FDR) are in use. Using of new &
green technologies has resulted not only in reduction of carbon footprint but also in savings of fuel
and natural resources.

New Technology adopted under PMGSY

Terrazyme
1%

CELL Filled Concrete

Others
3%
12%

Panelled Cement
Concrete
4%

Nano Technology for

Water proffing
4% Waste Plastics
37%
CC BLOCK
5%

Cement Stabilization
9%

Cold Mix Technology

25%

Waste Plastics Cold Mix Technology Cement Stabilization CC BLOCK Terrazyme

Nano Technology for Water proffing Panelled Cement Concrete CELL Filled Concrete Others

2 Adopting Green and New Technologies in PMGSY

Green and New Technologies commonly being used under
PMGSY are as under: -
FULL DEPTH RECLAMATION TECHNOLOGY (FDR)
Full-depth reclamation of asphalt pavement is a rehabilitation method that involves recycling of the
existing distressed bituminous layers of an existing asphalt pavement along with a predetermined
thickness of the underlying granular (WBM, WMM and GSB) layer(s) into a new base layer. The FDR
process begins with using a road reclaimer to pulverize an existing asphalt pavement layer and a portion
of the underlying base, sub-base, and/or subgrade. Usually, the pulverized material is uniformly blended
with an additional stabilizing material such as Portland cement or bituminous emulsion/foamed asphalt
or other Commercial Chemical Stabilizers (CCS), to provide an upgraded, homogeneous material.

Some of the advantages of Full Depth Reclamation are as under:

zz Most pavement distress can be treated satisfactorily.
zz Cost effectiveness
zz Early opening to traffic (Within 7-8 hours) of compaction
zz Eliminates material disposal problem
zz Results in conservation of natural resources
zz Minimal air quality problem.
zz Reduce carbon footprint

With the use of FDR technology, a strong cemented stabilized layer is produced, which behaves like a
semi rigid pavement. Such pavements will behave in a satisfactory manner if they are laid on a uniformly
compacted and structurally sound underneath layers. States such as Uttar Pradesh, Andhra Pradesh has
used this technology on large scale for upgradation of Rural Roads.

Adopting Green and New Technologies in PMGSY 3

 WASTE PLASTIC
Waste plastic is shredded & coated over aggregate & mixed with hot bitumen and the resulted mix is
used for pavement construction. 

Some of the advantages of Waste Plastic are as under:

zz Increased road strength (Increased Marshall Stability Value)
zz Better resistance to water and water stagnation
zz No stripping and have no potholes
zz Increased binding and better bonding of the mix
zz Increased load withstanding property
zz Overall consumption of bitumen decreases
zz Reduction in pores in aggregate and hence less rutting and ravelling
zz Better soundness property
zz Maintenance cost of the road is almost nil
zz The Road life period is substantially increased

IRC code: IRC: SP:98-2013“ Guidelines for the use of waste plastic in Hot Bituminous mixes (dry process)
in wearing courses”

Till date under PMGSY 25899.04 km of road length has been constructed using Waste Plastic all over
the country, Madhya Pradesh has completed 8783.74 km which is the highest among all the States and
UTs followed by Rajasthan and Chhattisgarh with the length 4646.29 km and 3090.67 km respectively
completed using Waste Plastic.

COLD MIX
Cold Mix technology is field application of bituminous surfacing course using cold mix binders with the
available IRC Specifications. In this technology heating of bitumen is not required resulting in saving in
fuel and thereby saving of environment. By this process the construction activity will be faster. Cold mix
technology is an impressive option to solve the problem of road connectivity in the states as various
factors like rainfall, often delay in construction and maintenance of roads.

Some of the advantages of Cold Mix Technology are as under:

zz 2-3 times faster progress using existing facilities at site without any extra investment in capacity
building or equipment’s.

4 Adopting Green and New Technologies in PMGSY

 zz Green Technology: Non-polluting process, no heating, saves fuel and 90% energy efficient.
zz Highly durable - contains anti-stripping properties, performing better than Hot Mix roads.
zz All weather construction- during monsoons and cold winters on dry days.
zz Local & semiskilled labour can execute the work.
zz No chance of accident of labour

IRC code:IRC: SP:100-2014“Use of cold mix technology in construction and Maintenance of roads using
bitumen emulsion”.

Till date under PMGSY 16987.84 km of road length has been constructed using Cold Mix all over the
country, Odisha has completed 3933.20 km which is the highest among all the States and UTs followed
by Uttarakhand and Assam with the length 1839.94 km and 1762.54 km respectively completed using
Cold Mix Technology.

CEMENT STABILIZATION
zz Construction of subbase/base course using locally available sub grade material adopting
mechanical stabilization using cement as stabilizer.
zz Cement stabilised base / subbase improves the strength, reduces the thickness of pavement
ultimately proving to be economic.
zz The hydrated products of cement bind the soil particles; the strength of the stabilised subbase/
base course depends upon the concentration of cement and the intimacy with which the soil
particles are mixed with cement.

Advantages of CTSB/CTB in Road Construction:

zz The use of CTB/CTSB saves the material required for the construction of flexible pavement.
zz The transportation charge, fuel consumption, machineries required is less for CTB/CTSB method
than the traditional method. Hence the initial cost of construction is less for CTB/CTSB method.
zz The CTB/CTSB is having more strength as compare to the traditional material. So, the maintenance
work required for CTB/CTSB will be less. It will save the maintenance cost and affects the life
cycle cost of the project.

Adopting Green and New Technologies in PMGSY 5

 IRC code: IRC: SP:89-2010 “Guidelines for Soil and Granular Material Stabilization using Cement, Lime & Fly
Ash”

Till date under PMGSY 5887.09 km of road length has been constructed using Cement Stabilization
all over the country, Jharkhand has completed 2959.39 km which is the highest among all the States
and UTs followed by Odisha and Telangana with the length 1404.45 km and 459.86 km respectively
completed using Cement Stabilization Technology.

CC BLOCK
Interlocking Concrete Block Pavement (ICBP) is an environment-friendly and labour intensive paving
technology which is widely applied in many countries to solve special-purpose paving problems. The
block-paved surface consists of interlocking flat concrete blocks on coarse bedding sand, with fine
sand between the blocks. Compared with asphalt pavements, ICBP has less good initial riding quality,
skidding resistance usually at least as good and lower noise. Four main approaches have been adopted
for designing ICBP worldwide. ICBP has a life of about 40 years, with repairs needed after 20 years.

Advantages of CC BLOCK Pavements

zz Concrete paver blocks can be used at habitation areas on rural roads without diversion of the
Traffic as the construction process is relatively faster.
zz It gives a good aesthetic view as compared to cast in situ concrete roads.
zz As regard of maintenance point is concern the damaged blocks can be easily replaced whereas
in case of concrete roads the replacement of damaged concrete is difficult.

IRC code: IRC SP 063: “Guidelines for the Use of Interlocking Concrete Block Pavement”

6 Adopting Green and New Technologies in PMGSY

Till date under PMGSY 3309.98 km of road length has been constructed using CC BLOCK pavement all
over the country, Assam being the leader with 3027.59 km length completed.

PANELED CEMENT CONCRETE

zz Concrete pavement appears to be the obvious solution for such locations where Bitumen
pavements are subjected to adverse moisture conditions due to inadequate and clogged
drainage resulting in heavy damage during every monsoon.
zz Since the initial cost of the conventional concrete pavement is quite high because of higher
thickness. A new type of thinner concrete pavement with shorter panel size similar to the white
topping over bituminous pavements as per IRC:SP:76-2008(1) can be used in the construction
of concrete pavements for village roads and city streets because of low flexural stresses caused
by shorter panel sizes.
zz Panels of size 0.5mx0.5m to 1.5mx1.5m with thickness from 50mmto 150mm.

Advantages of Panelled Cement Concrete Pavements

zz Panelled concrete pavements can be a good alternative for reducing the cost of concrete
pavements for built up areas, rural roads, bus bays etc.
zz Stresses are reduced drastically in concrete pavements with panels of size1.0 m x 1.0 m.
zz If alternative route can be arranged, this type of pavement is very easy to construct with much
higher durability than Mastic Asphalt surfaced bituminous pavement and serviceability expected
to be same as conventional rigid pavement at much lower cost.
zz This technology can be emerged to be a good and long-term solution to the perpetual
maintenance problem of the roads with poor drainage

Till date under PMGSY 2513.39 km of road length has been constructed using Panelled Cement Concrete
all over the country, Bihar has completed 768.64 km which is the highest among all the States and UTs
followed by Odisha and West Bengal with the length 761.92 km and 518.20 km respectively completed
using Panelled Cement Concrete.

Adopting Green and New Technologies in PMGSY 7

 CELL FILLED CONCRETE
zz Cell-filled concrete pavement is the technology developed by IIT Kharagpur, which has proved
to be a very promising solution for overloaded vehicles, inadequate drainage facilities, and
waterlogging problems.
zz Cell-filled concrete pavement consists of formwork of plastic cells over the compacted subgrade /
sub-base, filled with concrete or stones.

Advantages of Cell Filled Concrete Pavements

zz Use of recycled plastic.
zz As the expansion or contraction joints are not required, and hence maintenance of joints is
eliminated.
zz The cost of construction is considerably reduced when compared to conventional cement
concrete pavement.
zz The consumption of aggregates is almost reduced to 50% when compared to normal CC
pavements.
zz If the individual block fails, it can be easily replaced without much effort and with the least cost.

Till date under PMGSY 2218.32 km of road length has been constructed using CELL Filled Concrete all
over the country, Assam has completed 565.97 km which is the highest among all the States and UTs
followed by Bihar and Rajasthan with the length 522.01 km and 327.53 km respectively completed using
CELL Filled Concrete.

SURFACE DRESSING
Surface dressing is a simple, highly effective, and inexpensive road surface treatment if adequate care is
taken in the planning and execution of the work. The process is used throughout the world for surfacing
both medium and light traffic roads, and as a maintenance treatment for roads of all kinds.

8 Adopting Green and New Technologies in PMGSY

Surface dressing comprises a thin film of binder, generally bitumen or tar, which is sprayed onto the road
surface and then covered with a layer of stone chippings. The thin film of binder acts as a waterproofing
seal preventing the entry of surface water into the road structure. The stone chippings protect this film of
binder from damage by vehicle tyres, and form a durable, skid-resistant, and dust-free wearing surface.
In some circumstances the process may be repeated to provide double or triple layers of chippings.

Advantages of Surface dressing Pavements

zz One of the Cheapest Surfacing Technique
zz One - third the cost of premix carpet
zz Precoat stone chips with bitumen if black surface desired; marginal cost increase of Rs. 0.34
lakhs totalling Rs. 2.96 lakhs per km
zz Highly effective in waterproofing the road
zz Used successfully worldwide for low to medium traffic roads (US, Europe & Australia)

IRC code: IRC 110-2005“Standard Specifications and Code of Practice for Design and Construction of
Surface Dressing”

Till date under PMGSY 948.70km of road length has been constructed using Surface dressing all over the
country, Odisha has completed 457.23km which is the highest among all the States and UTs followed by
Jharkhand with the length 385.16km completed using Surface dressing.

TERRAZYME
TerraZyme is an environmentally friendly soil stabilizer used in the construction of road infrastructure.
The product provides a tool for engineers to reduce the construction costs, while increasing the overall
quality of road structures. TerraZyme is easy to use, not harmful to the environment or its users and
guarantees a better and longer lasting road that has been accepted and appreciated WORLDWIDE.

Adopting Green and New Technologies in PMGSY 9

 The use of TerraZyme in the construction of base and sub-base structures removes the need for the use
of a sand/gravel mix; soling or water bound macadam in the construction of road structures. The base
and sub-base constructed with TerraZyme are built up immediately from the sub-grade level. Between
the sub-grade and the asphalt or concrete layers, TerraZyme constructed structures have a much greater
flexural strength and a higher CBR % than the conventional structures.

Advantages of Terrazyme
zz Liquid Enzyme, making it very easy to use and apply
zz Cuts construction cost by 10%-20%, approximately Rs. 2 Lakhs to Rs 10 Lakhs per km
zz Up to 70% GSB and Aggregate material in roads constructed is reduced.
zz Reduction in Carbon dioxide emissions attributable to 1Km of Road construction using
TerraZymeis approx. 5.0 Tonnes
zz Higher CBR and Modulus / higher road strength
zz Lowers the maintenance cost by 30-50%
zz Saves construction time by 50%
zz Pavement thickness is reduced by 5-10% in phase of trials
zz Environment friendly and bio-degradable product
zz The product has been accredited by IRC

IRC Accreditation: Soil stabilizing material used in construction of roads

Date of Issuance of Accreditation Certificate: 03-Jul-2013 (re renewed on29-Oct-2016, 29-Oct-2018

and16-Apr-2021).

Till date under PMGSY 997.90km of road length has been constructed using Terrazymeall over the
country, Andhra Pradesh has completed 257.51 km which is the highest among all the States followed
by Chhattisgarh with the length 251.74 km completed using Terrazyme.

10 Adopting Green and New Technologies in PMGSY

The following Publications has been issued by IRC for Low Volume roads:-
Sl. No. Publication
1 IRC: SP-72-2015 “Guidelines for The Design of Flexible Pavements for Low Volume Rural Roads”
2 IRC: SP- 62 2014.” Construction of Cement Concrete Roads for Low Volume Roads”.
IRC: SP:98-2013 “Guidelines for the use of waste plastic in Hot Bituminous mixes (dry process) in
3
wearing courses”
4 IRC SP 063: “Guidelines for the Use of Interlocking Concrete Block Pavement”
IRC: SP:100-2014 “Use of cold mix technology in construction and maintenance of roads using bitumen
5
emulsion”.
IRC 110-2005 “Standard Specifications and Code of Practice for Design and Construction of Surface
6
Dressing”
7 IRC:44-2008 “Guidelines for Cement Concrete Mix Design for Pavement”

8 IRC: SP:89-2010 “Guidelines for Soil and Granular Material Stabilization using Cement, Lime & Fly Ash”

9 List of IRC Accredited New Materials (as on 31.01.2022)

The following Guidelines/ Manuals/Formats/template have been issued by NRIDA/ MORD for PMGSY
roads:

1 Programme Guidelines for PMGSY I

2 Programme Guidelines for PMGSY II
3 Programme Guidelines for PMGSY III
4 Operations Manual “Pradhan Mantri Gram SadakYojana”
5 Standard Bidding Document
6 Model Bidding Document (WB)under Pradhan Mantri Gram SadakYojana (PMGSY)
7 Guide on Managing Maintenance of Rural Roads in India
8 Manual on Procurement and Contract Management for PMGSY Rural Road Projects
9 NQM and SQM Inspection formats
10 DPR template for PMGSY-III
11 Proforma C for scrutiny of DPRs of Road works
12 Online Management, Monitoring and Accounting System (OMMAS)

Adopting Green and New Technologies in PMGSY 11

Notes