Comprehensive Cost and Material Performance Analysis of Road Construction Using Cement Concrete, Geopolymer Concrete, and Bitumen

This study conducts a comprehensive cost and material performance analysis for constructing a 1 km road using cement concrete, geopolymer concrete, and bitumen. The analysis includes various road types, such as standard roads and expressways, and evaluates the impact of incorporating nylon crystals (1%-5% by weight) into geopolymer concrete. Material quantities were calculated following Indian standards, considering a road width of 15 meters and a thickness of 0.3 meters. The cost components included materials, labour, machinery, and ancillary infrastructure. For the cement concrete road, the total material cost was calculated based on the mix ratio of 1:2:4 (cement: sand), with an estimated total cost of ₹35,582,856.7. For geopolymer concrete, replacing 30% of cement with fly ash/slag and adding alkaline activators resulted in a total cost of ₹32,605,714.2. The bitumen road, considering 5% bitumen by volume, had a total cost of ₹39,240,000.2.. Technical analysis revealed that while geopolymer concrete offers cost savings and environmental benefits due to reduced cement usage, potentially offsetting these benefits. The bitumen road, despite being the most expensive, is noted for its flexibility and shorter construction time. The expressway configuration adds complexity and cost, with additional expenses for drainage, safety barriers, signage, lighting, land acquisition, and contingencies.This study provides a detailed comparison, highlighting the cost-efficiency and material performance of each method. It aims to guide engineers and policymakers in selecting the most suitable and sustainable materials for road construction projects. Future research should explore the long-term performance a environmental impact of these materials to ensure sustainable infrastructure development.