Conversion of Unsegregated Dump Yard Plastic Waste into Structural Grass Blocks for Sustainable Road Infrastructure.

Abstract Plastic waste accumulation in municipal dump yards represents one of the most critical environmental challenges in developing countries. A major barrier to efficient plastic recycling is the requirement of waste segregation prior to processing, which increases operational cost and reduces recycling efficiency. Large quantities of mixed plastic waste are therefore disposed of in landfills or openly burned, causing severe environmental pollution. This study proposes an innovative approach for the direct conversion of unsegregated dump yard plastic waste into structural grass blocks suitable for landscaping and road infrastructure applications. The developed blocks are manufactured using processed mixed thermoplastic waste and molded into a grid structure that allows soil filling and vegetation growth. The developed grass blocks have dimensions of 400 mm × 400 mm with a prototype thickness of 80 mm. Mechanical testing conducted on the blocks shows a compressive strength of 10.37 N/mm², indicating suitability for applications such as pedestrian walkways, parking areas, landscaping surfaces, and as a structural base layer beneath concrete pavement. The technology also demonstrates large-scale waste utilization potential, where the construction of a 1-kilometer road with a width of 3 meter can consume approximately 150 tons of waste plastic material. This approach provides a sustainable solution for plastic waste management while supporting environmentally friendly infrastructure development. The proposed solution provides a sustainable method for recycling mixed plastic waste without segregation while generating durable construction materials. The technology significantly reduces landfill waste, lowers environmental pollution, and contributes to circular economy practices in infrastructure development.