With 1 million cyclists, the PlasticRoad is ready for market launch

The millionth bike pass was measured yesterday on the world's first PlasticRoad in Zwolle, the Netherlands. The first road based on recycled plastic was a world first in 2018. After more than 1.5 years of testing, learning and further development into industrial design, the PlasticRoad is now ready for its market launch. Starting in the first quarter of 2021, the PlasticRoad will be industrially produced. The results of the two bike path pilots in Zwolle and Giethoorn are so positive that this big next step is now possible. The PlasticRoad can withstand heavy loads, provides a solution for water problems during heavy rainfall and drought and holds up well under all conditions.

The initiators of the PlasticRoad are extremely satisfied with the pilot results and are looking forward to the moment when the first PlasticRoad element rolls off the production line. Marcel Jager and Anne Koudstaal of the PlasticRoad team say, "Together with our clients, we have demonstrated that our pioneering circular concept - a prefabricated road based on recycled plastic with rainwater storage - is feasible. What started in 2018 with two pilots is already ready for industrial production, we are incredibly proud of that."

A circular bike path

The two 30-meter bike lane pilots provide proof that the road based on recycled plastic is possible. Each pilot contains about 1,000 kilograms of recycled plastic, which is as much as 218,000 plastic cups. This pilot version of the PlasticRoad already saved about 50 to 70% CO₂ emissions compared to a traditional bike path made of asphalt or concrete tiles. With the industrial production of the final design next year, this percentage increases. Also, the circularity of the final product has been optimized by further development of the construction, which is underlined by an independent circular audit.

Strong and robust

Upon installation, both pilots in Zwolle and Giethoorn were equipped with sensors that measure the use and "behavior" of the product 24/7. The main finding from the bike path pilots is that the PlasticRoad can also withstand heavy traffic. For example, field tests and data show that the PlasticRoad also holds up extremely well to heavy traffic such as garbage trucks and maintenance vehicles. By further improving the product, the final version will soon be more robust and 2.5 times stronger than the version in Zwolle and Giethoorn. This makes the PlasticRoad ready for application as parking lots; the team is working toward the first pilot for this application. It also means that a road for vehicular traffic made from the PlasticRoad is becoming increasingly realistic.

Climate adaptive infrastructure

Extreme rainfall and heavy showers are becoming more common due to climate change. The current infrastructure often cannot handle this well, resulting in flooded streets. The hollow space of the PlasticRoad is intended to quickly collect that water and then gradually allow it to infiltrate into the subsoil. This climate-adaptive solution is proving to work extremely well in practice. Both pilot sites previously had water problems. Even with the heaviest showers, the impact on storage capacity was minimal. The highest measured water level in the PlasticRoad was only 48% of the available storage at the Zwolle location. The water then gradually infiltrated into the ground within two days, exactly as expected.

The province of Overijssel and municipality of Zwolle were the launching customers of the PlasticRoad. Together they took the initiative for the two cycle path pilots of the PlasticRoad. The data are positive, but the users of the bike paths are also enthusiastic. "Sustainable infrastructure for our residents and smart use of space, that's what it's all about for us. To take steps, it is necessary to stick your neck out and dare to innovate. It is great to work together with innovative parties from the region as municipality and province," said Deputy Bert Boerman (province of Overijssel) and Alderman William Dogger (municipality of Zwolle).

Follow-up steps

Based on the convincing results of the pilots, work is currently underway to launch the production line. As of now, the PlasticRoad can be ordered and will be available from the first quarter in 2021. Much interest has already been shown from the market. Together with clients and contractors, the PlasticRoad will make cities climate-adaptive and carbon-neutral in the form of various applications. For example, bike paths, parking lots, sidewalks and schoolyards are planned. The focus is initially on sales in the Netherlands and surrounding countries, after which scaling up to other markets around the world is expected.