It’s the end of the road for waste plastic. Using waste plastics to help improve our road networks in South Africa .
How were the products developed? On the journey to create the new products, MacRebur firstly had to understand the polymers which make up the plastics in the waste stream. The following criteria was used to select the polymers used to make the products: • The polymers have to come from a waste stream that would have otherwise gone to landfill or been incinerated • The polymers have to be able to melt into hot mix asphalt • The polymers have to be able to form part of the binder • The polymers have to be safe to use • MacRebur were then able to experiment with the performance of each polymer when mixed into both asphalt and bitumen. This information allowed the creation of what are now called the “MR products”. Gareth Nel – gareth@macreburSA.co.za
Our Products - MR6, , MR8 & MR10 • The ‘ MR ’ products are engineered from 100% waste plastic pellets used as an additive to replace or extend bitumen in any asphalt mix and are added in during the mixing process. Gareth Nel – gareth@macreburSA.co.za
Products All MR products are a blend of carefully selected polymers and are specifically designed to: • Be used as binder extenders to reduce the volume of bitumen required in an asphalt mix • Reduce waste plastics going to landfill or incineration • Reduce green-house gas emissions In addition to environmental benefits, each MR product is created to perform with specific tasks in mind. • MR6 was designed to reduce rutting and the associated failures of asphalt – some of which is caused by softening of bitumen in warm climates, trafficking of heavy loads or insufficient binder stiffness. • MR8 was designed as a binder extender. It does not influence the characteristics of the asphalt as much as Mr 6 or MR 10, but allows clients to maximise the reduction of fossil fuels, use waste plastics and reduce green house gas emissions, all while remaining cost neutral to the client. • MR10 was designed to reduce cracking failures of asphalt – some of which are caused by low temperatures or brittle binders. Gareth Nel – gareth@macreburSA.co.za
MR6 MR6 was the first product designed to be mixed into asphalt. It reduces the risk of asphalt deformation by rutting or shoving. The recommended dosage is 6% - 8% binder replacement. MR6 benefits • Increased stiffness • Increased resistance to deformation • Improves moisture resistance • Raises softening point • Improved fuel resistant properties • Reduces CO2e • Reduces fossil fuel requirements • Reduces waste plastics going to landfill or incineration Gareth Nel – gareth@macreburSA.co.za
MR6 – Where it has been used Above- Commercial Vehicle Car Park Right-Australia Right Top- A6, Carlisle Far Right Airport Runway
MR8 MR8 introduces a simple polymer into the mix, designed to deliver cost savings by replacing up to 10% of the bitumen. It does have increased performance results but not as great as MR6 or MR10 MR8 benefits • Maintains stiffness • Maintains resistance to deformation • Maintains resistance to crack propagation • Reduces CO2e • Reduces fossil fuel requirements • Reduces waste plastics going to landfill or incineration Gareth Nel – gareth@macreburSA.co.za
MR8 – Where it has been used Above- A689 Durham Right Top-Tesco Car Park Dumfries Right Bottom-Turkey Far Right-Bahrain
MR10 MR10 was designed to be mixed into asphalt to reduce the risk of cracking. It has been used on high stress pavements, roundabouts, road junctions, and trunk roads in all types of climates across the world. The recommended dosage is 4% -8% binder replacement MR10 benefits • Increases stiffness • Reduces risk of cracking at low temperatures • Improved fatigue resistance • Improved cohesion • Increased resistance to hardening • Increased resistance to deformation • Reduces CO2e • Reduces fossil fuel requirements • Reduces waste plastics going to landfill or incineration Gareth Nel – gareth@macreburSA.co.za
MR10 – Where it has been used Above- A709 Dumfries Right-Brisbane, Australia Right Top-Bahrain Right Bottom-Green Dragon Lane
Application into the mix • Products can be stored outside in the original packaging, however it is recommended that it is stored away from any source of ignition of temperatures above 60°C. • MR products are specifically designed for the use in hot-mix asphalts. The low melt point and easy flow characteristics allow for easy mixing within an asphalt mix, in which the products form a homogeneous binder. Correctly mixed products give outstanding long term wearing protection and have excellent plucking and fretting (loss of material from the road surface) resistance. • MR products are supplied in 3 Kg low melt bags designed to be manually fed into an asphalt plant. They can also be supplied in 500 kg bulk bags designed to be automatically fed into an asphalt plant through the existing asphalt hopper system • Products are designed to be used in either continuous drum or batch asphalt mixing plants. If you are using a drum mixing asphalt plant then you add the product into the plant at the same time as the bitumen and aggregates are added. If you are using a continual mixing asphalt plant then the pellets get added to aggregate straight after they have been heated, they cannot go before the aggregate is heated as they will burn. Gareth Nel – gareth@macreburSA.co.za
Application into the mix cont.. .. • Due to the easy flow nature of MR products, asphalt plants do not need to alter their existing infrastructure. • MR products can be used by replacing between 5% and 10% by weight of bitumen within any standard asphalt mix. However, we recommend for best structural results that 6% (3 Kg) by weight of bitumen is replaced. • MR products can be used in the production of asphalt in any weather conditions, however the finished asphalt must still be laid in accordance with local regulations and standards. • Asphalt made using MR products do not compromise nor restrict laying capabilities. Gareth Nel – gareth@macreburSA.co.za
CO 2 e CO MR products can be used in any type of Hot Mixed Asphalt being manufactured. 90% of the asphalt market uses standard bitumen in their asphalt and 10% uses polymer modified bitumen. MR8 is best suited to be used as a replacement for standard bitumen and MR6 & MR10 are designed to be used as an alternative to polymer modified bitumen. The below table demonstrates the potential CO2e savings of using MR products across the world. For this example a conservative 6% MR products replacing bitumen has been used, however MR8 could be used to replace up to 10% standard bitumen. PRODUCT CO2e saving Potential UK Potential UK Potential Potential Potential Potential Potential Potential per product market by CO2e saving European European North North Worldwide Worldwide product per annum market by CO2e saving America America market by CO2e saving product per annum market by CO2e saving product per annum Tonnes Tonnes product per annum Tonnes Tonnes Tonnes Tonnes Tonnes Tonnes MR6 -3.06 3,000 -9,180 65,250 -199,665 82,500 -252,450 240,000 -734,400 MR8 -1.22 54,000 -65,880 1,174,000 -1,432,280 1,485,000 -1,811,700 4,320,000 -5,270,400 MR10 -2.8 3,000 -8,400 65,250 -182,700 82,500 -231,000 240,000 -672,000 South Africa – 5 Million tons of Asphalt manufactured annually equates to – 20,865 tons CO2e saving Gareth Nel – gareth@macreburSA.co.za
Global Presence Internationally to date, MacRebur have already completed laid roads in the following countries: United Kingdom, Bahrain, Australia, Turkey, New Zealand, Canada, USA, Russia and Saudi Arabia. Due to large media coverage recently, the product is now being sampled in many more countries with the potential for them to all come on board before the end of 2019. The idea is to set up a manufacturing plant here in South Africa, that can produce enough product to export into Sub-Sahara Africa. This will highlight South Africa’s commitment to saving the environment while continuing to show itself as a leader in new innovative products and keeping its status as the ‘gate way into Africa’. Gareth Nel – gareth@macreburSA.co.za
Benefits of f our products • Made with 100% recycled materials • Uses unwanted plastics destined for landfill • Reduction in landfill Tax costs • Reduction in fossil fuel usage • Reduction in carbon footprint • Helps foster a circular economy • Can be used in the production of hot mix asphalts • Increases lifespan of roads • Reduces maintenance costs • Cheaper alternative to polymer modified bitumen • No additional infrastructure costs for asphalt plants • Job Creation in the unskilled sector Gareth Nel – gareth@macreburSA.co.za
Contact Details Gareth Nel +27 (0) 60 550 3789 gareth@macreburSA.co.za www.macrebur.com
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