Sustainable Road Maintenance: Evaluating Recycled Plastic-Coated Aggregates (PCA) for Enhanced Pothole Repair

The rapid deterioration of road infrastructure, exacerbated by monsoon-induced water ingress and heavy vehicular loading, remains a significant challenge for global economic progress and public safety. Simultaneously, the accumulation of non-biodegradable plastic waste (LDPE, HDPE, and PP) presents a severe environmental crisis. This research explores the technical, chemical, and economic integration of these two challenges by evaluating the use of Plastic-Coated Aggregates (PCA) for localized pothole repair. Utilizing a "Dry Process" where shredded plastic waste ( by weight of bitumen) is coated onto aggregates heated to , the study assesses mechanical strength, hydrophobic properties, and long-term durability. Laboratory results indicate a increase in Marshall Stability, a reduction in water absorption, and a significant improvement in the Interfacial Transition Zone (ITZ) compared to conventional VG-30 bitumen mixes. Field implementation over a 180-day cycle showed zero pothole reformation. The study concludes that the PCA method offers a technically superior, cost-effective ( savings), and environmentally sustainable alternative to traditional bitumen patching, effectively creating a circular economy for low-value plastics.