The sustainable infrastructure solution: the CCL-series

A circular and modular road

made from recycled plastic

The CCL series comprises various circular and modular elements made from recycled plastic. Its building blocks: a deck, substructure and a retaining profile. The rainwater is channelled via a spillway to an overflow, from where it drains into the underground elements. During heavy showers, these cavities in the substructure can efficiently store the excess water. This water then gradually infiltrates into the local subsoil, which promotes a healthy water cycle in the surrounding area. The retaining profile stops the road elements from drifting to the surface, while porous geotextile allows the water to drain into the substrate via natural infiltration.

As such, the CCL series is a truly future-proof solution. One that allows municipal authorities to effectively mitigate the consequences of climate change, in which we see more and more dry spells alternated by heavy rain – including in our crowded city centres.

Please note: Until early 2021, we undertook all our activities under the banner of PlasticRoad – which also served as the name of our product. In May 2021, we started referring to CCL elements (CCL = circular, climate adaptive en lightweight).

Deck with wearing course

The CCL products have a lightweight deck, which has been topped with a wearing course. This surface offers the required grip for cars and other road users. This wearing course consists of a thin aggregate layer, similar to the surfaces found on bridges and other structures. It is available in a range of colours and themes. This wearing course also prevents the structure from releasing microplastics, since the plastic is completely shielded from direct contact with road traffic. Consequently, it isn’t subject to wear. Moreover, the plastic element is protected from sunlight so it does not degrade due to UV exposure. This contributes to the product’s long useful service life.

The deck is fixed to the road with snap connectors, meaning it is very easy to replace at the end of its 30-year service life. With an estimated service life of 50 years, it takes a bit longer before the substructure is up for replacement.

Advantages

of PlasticRoad

Climate-adaptive

Mitigating the effects of flooding and dry spells

We are experiencing more and more long dry spells, alternated with heavy rainfall. This results in water shortages and soil subsidence in the public space, which in turn lead to numerous damages, high maintenance costs and other expenses. The CCL series can be used to collect rainwater, which gradually infiltrates into the local subsoil after the shower. The collected water can also be filtered during this process. This local infiltration contributes to a natural water cycle and counters aridification. And this reduces the risk of damage to road surfaces and other infrastructure, for example.

The integrated water storage cavity has a capacity of 300 litres per m². This means that extreme rainfall of up to 100 mm per hour can be accommodated – even in areas with high groundwater levels (up to 40 cm below grade).

Sustainable and circular design

From waste to added value, with lower emission levels

Municipal plastic waste – much of which is currently still incinerated or ends up in a landfill – is given a new life as a base material for our product. In a high-grade, fully circular application that is based on 100% recycled polypropylene. At the end of their useful service life, all plastic parts can be recycled as a base material for new CCL elements. Using CCL elements yields a substantial reduction in CO₂ emissions, both during production, installation and maintenance. This is a great added bonus when it comes to improving quality of life in urban environments.

Thanks to their longer service life and substantially fewer transport runs during installation, these low-maintenance elements can help you cut CO₂ emissions by up to 72% compared to conventional solutions. PlasticRoad has set an ambitious goal for itself: to cut CO₂, NO× and particulate emissions all the way back to zero.

Multi-purpose use of your available space

A total solution with predictive insight thanks to the inclusion of SMART sensors

We deal with a wide range of challenges in the public space. Space is scarce and comes at a mounting cost. The CCL elements present a multi-purpose solution, helping planners to arrange public space in new – and more efficient – ways. Our products present a comprehensive solution for paving, water storage and drainage, traffic monitoring and even underground cables.

As a rule, the cavity directly under the deck of the CCL series can be used for temporary water storage. Ideal for absorbing extreme precipitation, or when you are required to create adequate water storage in a new residential neighbourhood – where space often comes at a premium. In addition, the cavity has room to install sensors and other facilities like cables. Early identification of flooding, increasingly efficient planning of maintenance intervals, real-time insight into traffic flows: these are all examples of options that become available when you build with CCL elements. PlasticRoad enables users to install SMART applications for transport and predictive maintenance.

Simple to construct, manage and maintain

With an attractive Total Cost of Ownership

Thanks to the components’ long service life and modular format, our CCL solutions are considerably more appealing in terms of TCO (Total Cost of Ownership) than conventional programmes. The prefab CCL elements are virtually maintenance-free. Thanks to their modular structure, low weight and detachable connections, construction and maintenance are significantly simpler, more efficient and up to 70% faster than is the case with conventional road structures. The speedy installation process keeps nuisance for the surrounding area to a bare minimum. The elements’ snap connectors mean that they can be installed and replaced as easily as Lego bricks. Our products require up to 80% less transport and up to 75% less raw materials to produce.

Since the subsoil remains simple to access, locating cables and pipelines below the surface is a relatively straightforward affair. The elements can be positioned directly on the sand bed, so there is no need to construct a conventional subbase first. With a mass of approximately 40 kg per m², the CCL elements rank as the lightest paving structure in the world. This makes them eminently suited for developments in soft soil areas and minimises further subsidence after installation. What’s more: the elements can easily be detached and reinstalled afterwards.

*depending on which CCL variant you choose

Applications

SUITED TO A RANGE OF APPLICATIONS

Footpaths
Bike paths
Parking spaces
Pavements
Platforms
Schoolyards
Playing fields and sports infrastructure

MARKET SEGMENTS

The variants

The CCL series currently consists of two variants: CCL300 and CCL200.

CCL300 is a premium product, which was especially designed for clients that have climate adaption high on their agenda. It is a sustainable and circular paving alternative that comes complete with an integrated rainwater drainage system. As a result, clients can even dispense with a dedicated storm sewer – with the associated connections and storm drains – altogether, whether the project concerns a new area development or reconstruction.

CCL300 has an integrated water filter system that collects and purifies the rainwater, after which it can gradually infiltrate in the local subsoil. This filter system enables CCL300 to capture and collect all sorts of grime originating from passing vehicles before it ends up on the road verge. In addition, the inclusion of this filter system allows us to guarantee the infiltration functionality throughout the product’s useful service life, without the need for an overflow to an existing sewer system.

As a standard feature, CCL300 includes SMART sensors that simplify management and maintenance even further. The sensors allow you to digitally monitor the local status of your road surface and water drainage system. In effect, your road communicates with you, indicating when it is time to schedule new maintenance. This is CCL300, the new generation of sustainable infrastructure.

Studio product photo CCL300 plastic road element

CCL200 was designed for clients who are looking for a sustainable alternative to conventional paving, in which the structure furthermore complements an existing storm sewer. CCL200 allows you to collect excess water during rain showers and let a share of this water infiltrate in the local subsoil. The system is linked by means of an overflow to an existing storm sewer – providing you with paving that is both sustainable, modular and uniquely flexible.

Feel free to contact our sales consultant, so that we can jointly discuss which CCL variant and options would be best suited to your needs.

Studio photo CCL200 plastic road element