Description:TECHNICAL FIELD
[001] Embodiments disclosed herein relates to the process of manufacturing non-biodegradable polymeric-based construction material, and more particularly in construction purpose using non-biodegradable polymeric waste. Embodiments provides a cost-effective and durable construction technique.

BACKGROUND
[002] In conventional methods of construction purpose, bitumen is widely used as a binding material in flexible construction. Bitumen is derived from the fractional distillation of crude petroleum and is an essential component in asphalt. It acts as a cohesive agent, binding various construction materials to form a durable surface. However, the use of bitumen requires the extraction and processing of petroleum-based resources, contributing to the depletion of natural reserves. Additionally, bituminous material incorporates various natural materials, including asphalt, which primarily consists of hydrocarbons and other chemical compounds.
[003] Despite its extensive use, bituminous material has several drawbacks. Over time, exposure to environmental factors such as ultraviolet (UV) radiation, temperature fluctuations, and moisture leads to material degradation. Bituminous surfaces tend to soften in extreme heat, causing deformation and rutting, while in cold conditions, they may become brittle and prone to cracking. These vulnerabilities necessitate frequent maintenance and resurfacing, increasing overall costs. Furthermore, bituminous surfaces generate environmental concerns, as they contribute to the emission of volatile organic compounds (VOCs) and other pollutants during production and application.
[004] Concrete material used in construction purpose are widely used alternative, offering higher strength and longevity compared to bituminous material. However, the initial cost of constructing concrete in the construction purpose is significantly higher, particularly in areas where suitable construction materials are not readily available. Concrete materials require extensive supervision and skilled workmanship to ensure proper construction, making the process labor-intensive. Additionally, usage of concrete materials prone to cracking, warping, and twisting under fluctuating weather conditions. The rigid nature of concrete also makes it susceptible to stress fractures, leading to costly repairs. Another limitation is the extended curing period required before concrete can be opened for use, which causes delays in infrastructure development.
[005] Both bituminous and concrete materials rely heavily on natural construction materials such as crushed stone, gravel, and sand. The excessive extraction of these materials depletes natural resources and disrupts ecological balance. The large-scale consumption of such materials leads to habitat destruction, soil erosion, and water table depletion. Furthermore, the processing of these materials involves high energy consumption and generates significant carbon emissions.
[006] Another environmental concern associated with conventional construction is air pollution caused by the use of chemical additives and combustion-based production processes. The heating and mixing of bitumen and other materials release harmful fumes and greenhouse gases, contributing to air quality deterioration. Similarly, the production of cement, a primary component of concrete material, is a major source of carbon dioxide (CO₂) emissions. The cumulative environmental impact of traditional construction purpose which methods underscores the urgent need for sustainable alternatives.
[007] Given these challenges, there is a growing demand for innovative construction that minimize environmental impact while maintaining cost-effectiveness and durability. One such approach involves utilizing non-biodegradable polymeric waste as a substitute for conventional construction materials. By repurposing polymeric waste into a functional construction material, it is possible to reduce reliance on natural resources, lower production costs, and enhance longevity. The present disclosure addresses these concerns by introducing a process for manufacturing reconstituted polymeric-based materials, which can be used as a sustainable alternative in the construction purpose.
[008] Hence, there is a need in the art for solutions which will overcome the above-mentioned drawback(s), among others.

OBJECTS
[009] The primary objective of the embodiments herein is to disclose a process for utilizing non-biodegradable polymeric waste in the production of reconstituted polymeric-based materials that can be effectively used in asphalt-based construction, particularly roads.
[0010] Another objective of the embodiments herein is to develop a process for manufacturing polymeric-derived construction materials that enhance the durability and lifespan of the construction, ensuring superior performance in terms of strength, flexibility, and resilience under varying environmental conditions.
[0011] Further objective of the embodiments herein is to establish a sustainable construction process that integrates polymeric-based materials without emitting harmful fumes or posing any environmental hazards. The process aims to minimize air pollution and ensure a safer working environment during the construction.
[0012] Further objective of the embodiments is to incorporate polymeric-based materials in asphalt construction, wherein 10-15% of these materials can replace 30-40% of conventional construction materials. This substitution significantly reduces the consumption of natural resources, thereby contributing to environmental conservation and resource sustainability.
[0013] Another objective of the embodiments is to maximize the recycling of non-biodegradable polymeric waste, enabling the utilization up to 30% in construction applications. This process facilitates effective waste management and promotes circular economy principles by repurposing discarded polymeric materials.
[0014] Further objective of the embodiments is to enable the construction purpose using reconstituted polymeric materials, ensuring adaptability to extreme weather conditions while maintaining structural integrity.
[0015] Another objective of the embodiments is to enhance the resistance of the constructed surface to wear and deformation, providing long-term benefits in maintenance and improved quality.

SUMMARY
[0016] The embodiments disclose a process for manufacturing a non-biodegradable polymeric-based construction material for construction purpose, comprising: receiving, by a segregation unit, non-biodegradable polymeric waste; segregating, by the segregation unit, received polymeric waste using air to remove contaminants; blending, by a blending unit, segregated polymeric waste wherein blending occurs at a controlled temperature between 70°C and 80°C using rotating screws operating at 60 –70 rpm to achieve uniform mixing and melting; applying controlled pressure, by a pressing unit, on blended polymeric material using a cap-like steel structure to ensure compactness and prevent premature extrusion; cutting, by a cutting unit, wherein compacted polymeric material is divided into standardized pieces; granulating, by a granulating unit, wherein cut polymeric material is broken down into granules of specific sizes through a blade-cutting and mesh-filtration unit.
[0017] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the scope thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF FIGURES
[0018] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the following illustratory drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, and in which:
[0019] FIG. 1 is an example diagram representing the process of producing reconstituted polymeric-based materials from non-bio degradable polymeric waste, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0020] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0021] For the purposes of interpreting this specification, the definitions (as defined herein) will apply and whenever appropriate the terms used in singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.
[0022] The words/phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,” , “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein using the words/phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0023] Embodiments herein may be described and illustrated in terms of blocks which carry out a described function or functions. These blocks, which may be referred to herein as managers, units, modules, hardware components or the like, are physically implemented by analog and/or digital circuits such as logic gates, integrated circuits, microprocessors, microcontrollers, memory circuits, passive electronic components, active electronic components, optical components, hardwired circuits and the like, and may optionally be driven by a firmware. The circuits may, for example, be embodied in one or more semiconductor chips, or on substrate supports such as printed circuit boards and the like. The circuits constituting a block may be implemented by dedicated hardware, or by a processor (e.g., one or more programmed microprocessors and associated circuitry), or by a combination of dedicated hardware to perform some functions of the block and a processor to perform other functions of the block. Each block of the embodiments may be physically separated into two or more interacting and discrete blocks without departing from the scope of the disclosure. Likewise, the blocks of the embodiments may be physically combined into more complex blocks without departing from the scope of the disclosure.
[0024] It should be noted that elements in the drawings are illustrated for the purposes of this description and ease of understanding and may not have necessarily been drawn to scale. For example, the flowcharts/sequence diagrams illustrate the method in terms of the steps required for understanding of aspects of the embodiments as disclosed herein. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Furthermore, in terms of the system, one or more components/modules which comprise the system may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0025] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any modifications, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings and the corresponding description. Usage of words such as first, second, third etc., to describe components/elements/steps is for the purposes of this description and should not be construed as sequential ordering/placement/occurrence unless specified otherwise.
[0026] FIG. 1 is an example diagram representing the process of producing reconstituted polymeric-based materials from non-bio degradable polymeric waste, according to embodiments as disclosed herein. As illustrated, FIG. 1 is an example diagram representing the process of converting non-biodegradable polymeric waste 100 into a reconstituted polymeric-based material 112 for use in construction applications, which may include, but not limited to, construction of road, pavement, pathway, sidewalk, pedestrian way, paved path, footpath, walkway constructions, and so on.
[0027] The non-biodegradable polymeric waste may include, but is not limited to, synthetic material, resin-based, polymers, synthetic compound, and so on. The process 100A comprises multiple stages, such as segregating, blending, pressing, cutting, and granulating. Each step ensures the transformation of non-biodegradable polymeric waste 100 into a viable construction material while maintaining environmental sustainability.
[0028] As illustrated in FIG. 1, the segregating process is performed in the segregation unit 102. The process begins with collecting and segregating of polymeric waste 100. The non-biodegradable polymeric waste 100, sourced from various locations such as households, commercial establishments, and industries, is fed into a specialized segregation unit 102. The air in the segregation unit 102 effectively separates dust, vegetable waste, kitchen waste, and food residues from the polymeric waste 100. The segregation unit consists of a rotating rod equipped with 4–5 fans, operating at a speed of 200 rpm, which causes only polymeric waste/ materials 100 to remain in the process while non- polymeric waste is discarded. The process is capable of handling various types of polymeric materials, including high-molecular weight polyethylene (HM), high-density polyethylene (HDPE), polypropylene (PP), low-density polyethylene (LDPE), aluminum-coated polymeric, and multi-layered polymeric materials.
[0029] As illustrated in FIG. 1, the next process, blending, is performed in the blending unit 104. The segregated polymeric waste from the segregation unit 102 is transferred into the blending unit 104. In the blending unit 104, the segregated polymeric waste undergoes mechanical blending to break down and soften the polymeric material for further processing. The blending is performed using two screws that rotate at a controlled speed of 60–70 rpm while maintaining a temperature between 70–80°C. The process ensures that the polymeric is uniformly mixed and transformed into a malleable form, which facilitates the subsequent processing steps.
[0030] As illustrated in FIG. 1, pressing is performed in the pressing unit 106. In the unit 106, due to the continuous rotation of screws during blending, the softened polymeric material tends to move outward. To maintain proper processing, a cap-like steel structure applies pressure on the blending polymeric material, forcing the polymeric back into the blender. This ensures consistent blending and prevents premature extrusion of the polymeric material, thereby achieving a uniform consistency in the material.
[0031] As illustrated in FIG. 1, upon completion of the blending process, the blended polymeric material is provided as the input to the cutting unit 108. The material is cut into manageable pieces to facilitate further refinement in the next stage of the process.
[0032] As illustrated in FIG. 1, the cut pieces of the polymeric material are provided as input to the granulating unit 110. The cut polymeric pieces are processed through a granulating mechanism, where the cut pieces are broken down into smaller, uniform particles. The granulating process involves blade cutting, followed by passage through a mesh-based filtration system. The mesh ensures that the granulated material meets the required size specifications as per user requirements. Once granulated to the desired size, the processed material is packaged for further use.
[0033] As illustrated in FIG. 1, at the end of process 100A, the granulated polymeric material is converted into reconstituted polymeric-based construction material, which can be mixed with asphalt or other binders for construction purpose. This innovative process not only provides an effective alternative to conventional construction materials but also contributes to waste recycling, environmental sustainability, and reduced dependency on natural resources.
[0034] The process of manufacturing non-biodegradable polymeric-based construction material for the construction begins with the systematic collection and sorting of various polymeric waste materials. These materials undergo an advanced scrubbing process that eliminates contaminants such as dust, food residues, and organic matter, ensuring the purity of the raw material. Following scrubbing, the waste polymeric material is blended using high-precision rotating screws at controlled temperatures, ensuring uniform melting and homogenization.
[0035] The blending process converts the polymeric material into a semi-fluid, malleable state, which is essential for achieving the required consistency. A specialized pressing mechanism applies controlled pressure on the blended polymeric material, ensuring its compactness and preventing premature extrusion. The compacted material is then directed to a precision cutting unit, where it is divided into standardized pieces.
[0036] The cut polymeric pieces are then subjected to granulation, where they are finely processed into granules of specific sizes through a blade-cutting and mesh-filtration system. The granulated material is then packaged, and stored for use in construction purpose.
[0037] The final polymeric-based construction material offers superior durability, flexibility, and resistance to environmental degradation. When combined with asphalt or other binders, it enhances material strength, prolongs service life, and reduces maintenance costs. This method also significantly minimizes the consumption of natural resources by substituting conventional construction materials with a sustainable alternative. The integration of polymeric-based construction material in construction applications thus represents a major advancement in sustainable infrastructure development, addressing both environmental and economic challenges.
[0038] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.
, Claims:I/We claim:

1. A process (100A) for producing reconstituted polymeric based construction material, comprising:
receiving, by a segregation unit (102), the non-biodegradable polymeric waste from various sources;
segregating, by a segregation unit (102), the received polymeric waste using air to remove contaminants comprising at least one of dust, food residues, and organic matter;
blending, by a blending unit (104), the segregated polymeric waste wherein the blending occurs at a controlled temperature between 70°C and 80°C using rotating screws operating at 60–70 rpm to achieve uniform mixing and melting;
applying controlled pressure, by a pressing unit (106), on the blended polymeric material using a cap-like steel structure to ensure compactness and prevent premature extrusion;
cutting, by a cutting unit (108), wherein the compacted polymeric material is divided into standardized pieces;
granulating, by a granulating unit (110), wherein the cut polymeric material is broken down into granules of specific sizes through a blade-cutting and mesh-filtration unit; and
packaging, the granulated polymeric material for storage and further use in construction purpose.

2. The process (100A) as claimed in claim 1, wherein the polymeric waste material (100) comprises at least one of a synthetic material, a resin-based polymer, a synthetic compound, a high-molecular weight polyethylene (HM), a high-density polyethylene (HDPE), a polypropylene (PP), a low-density polyethylene (LDPE), an aluminum-coated polymeric materials, and a multi-layered polymeric material.

3. The process (100A) as claimed in claim 1, wherein the segregation unit (102) comprises a rotating rod equipped with 4–5 fans operating at a speed of 200 rpm, allowing only polymeric waste to remain in the process while discarding non-polymeric contaminants.

4. The process (100A) as claimed in claim 1, wherein the blending unit (104) utilizes two screws rotating at controlled speeds to ensure even distribution and transformation of the polymeric waste into a semi-fluid state suitable for further processing.

5. The process (100A) as claimed in claim 1, wherein the pressing unit (106) applies pressure on the blended polymeric material to ensure consistent compactness and prevent premature extrusion.

6. The process (100A) as claimed in claim 1, wherein the granulating unit (110) involves blade cutting, followed by mesh-based filtration to achieve uniform particle sizes based on user requirements.