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Dr. Sahadat Hossain [Photo: UTA]<\/p>\n
A University of Texas at Arlington civil engineering researcher is testing a new type of asphalt made with recycled plastic that could help roads last longer, resist cracking in extreme heat, and reduce plastic waste.<\/p>\n
UTA professor Sahadat Hossain developed a method that replaces part of the petroleum-based binder used in asphalt with recycled plastic from everyday items such as plastic bags and bottles.<\/p>\n
The technology is already being tested in North Texas. A one-mile section of roadway in Rockwall was built using the plastic-infused material, and additional test sections have been installed in UTA parking lots.<\/p>\n
\u201cMy goal is to take one problem\u2014plastic pollution\u2014and use it to fix another: deteriorating roads,\u201d Hossain wrote in an article<\/a> published by The Conversation.<\/p>\n Photo: UTA<\/p>\n A North Texas pilot puts the material to the test<\/p>\n The Rockwall project used about 4.5 tons of recycled plastic to construct nearly a mile of one-lane pavement.<\/p>\n The pilot allows researchers to evaluate how the material performs under real-world conditions, including traffic loads and extreme summer temperatures.<\/p>\n That durability could be especially important in states like Texas, where prolonged heat can soften asphalt and contribute to cracks, potholes, and costly maintenance.<\/p>\n Hossain said pavement made with the plastic mixture has remained intact on days when temperatures exceeded 100 degrees at the UTA and Rockwall test sites.<\/p>\n A different way to strengthen asphalt<\/p>\n Traditional asphalt is made from aggregates such as stone and sand combined with a petroleum-based binder called bitumen that holds the material together.<\/p>\n In Hossain\u2019s process, about 8% to 10% of that bitumen is replaced with melted recycled plastic.<\/p>\n The plastic is first cleaned and shredded into flakes before being mixed into asphalt at high temperatures so it melts and bonds within the material.<\/p>\n The result, according to Hossain, is a pavement mixture that adds flexibility and strength, helping roads withstand heavy traffic and extreme temperature swings.<\/p>\n Testing in Bangladesh has also shown promising results. During one extreme heat wave, roads built with the plastic mixture showed no visible cracks while many traditional roads experienced distress.<\/p>\n Lower maintenance and less plastic waste<\/p>\n Beyond durability, the approach could reduce demand for petroleum-based bitumen while giving discarded plastic a new use.<\/p>\n More than 400 million tons of plastic are produced each year worldwide, with less than 10% recycled.<\/p>\n Because plastic-infused pavement is designed to resist cracking and deterioration, cities may also reduce long-term maintenance costs. Early estimates from the Rockwall test suggest the roads could extend pavement life by several years.<\/p>\n Researchers are still studying questions related to scaling the technology, including the need for consistent supplies of clean plastic and whether the material could release microplastics as it wears down.<\/p>\n Early research suggests that risk is low because the plastic becomes bound within the asphalt mixture. Hossain said his lab has observed minimal microplastic release, and a 2024 study estimated recycled plastic asphalt releases about 1,000 times fewer microplastics than particles produced by worn vehicle tires.<\/p>\n The university has filed a patent for the process, and Hossain\u2019s team plans to expand testing to additional cities as it works toward commercializing the technology.<\/p>\n Don\u2019t miss what\u2019s next. Subscribe\u00a0to\u00a0Dallas\u00a0Innovates.<\/p>\n Track Dallas-Fort Worth\u2019s business and innovation landscape with our curated news in your inbox Tuesday-Thursday.<\/p>\n \u00a0<\/p>\n \tR E A D\u00a0\u00a0 N E X T\t<\/p>\n \t The grant supports development of reusable, impact-resistant materials designed to withstand frequent landings and collision events in next-generation aircraft\u2014everything from air taxis to the flying cars of the future.<\/p>\n \t The investment strengthens UTA\u2019s pipeline for high-demand engineering talent and supports research on AI-enabled safety systems for nuclear plants.<\/p>\n \t The brain-inspired design could lower the energy and compute costs behind AI training requirements, an increasingly urgent challenge for enterprises.<\/p>\n![\"\"](\"https:\/\/www.newsbeep.com\/us-tx\/wp-content\/uploads\/2026\/03\/UTA_PlasticPavement_hossain-970.jpg\")
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