On the road to Viksit Bharat

India has completed over 17,000 km of roads and bridges under Bharatmala Phase I, with eco-friendly infrastructure now leading the way. The Ganga Expressway’s SMA stretch is just one example of how innovation is driving progress toward Vision 2047.

On a crisp January 2025 morning, the Ganga Expressway in Uttar Pradesh shone with a 50-km stretch freshly paved with stone matrix asphalt (SMA), infused with recycled plastic waste and marked with retroreflective, low-VOC paints that meet IS 164:2023 standards. This milestone, part of the Bharatmala Pariyojana’s ambitious 34,800-km highway network, was hailed by Union Minister Nitin Gadkari as “a blueprint for sustainable infrastructure, blending local ingenuity with environmental responsibility.” With 250 metric tonnes of plastic waste integrated into the asphalt and locally manufactured compactors ensuring precision, this stretch exemplifies India’s push toward durable, eco-friendly roads. Backed by the Ministry of Road Transport and Highways (MoRTH) INR 2.87 lakh crore budget for 2025, Bharatmala is redefining road and bridge construction, weaving cost-effective, sustainable solutions into the nation’s infrastructure fabric.

Bharatmala Pariyojana, launched in 2017, is transforming India’s landscape with a planned 34,800-km network of highways, comprising 26,000 km of economic corridors, 8,000 km of inter-corridors, and 7,500 km of feeder routes, with a target for Phase I completion by 2027–28. As of March 2024, 17,411 km have been completed, with contracts awarded for 26,425 km at an estimated value of INR 4.59 lakh crore. This cover story examines how local manufacturing, sustainable materials such as geosynthetics, coir, and recycled plastics, as well as eco-friendly road paints, are driving this transformation while addressing challenges and charting a path forward for procurement professionals.

The engine of efficiency
India’s construction equipment market, valued at USD 10 billion in 2025, is a linchpin of Bharatmala’s success, projected to reach USD 12 billion by 2027. Local manufacturers, such as CASE Construction Equipment and Powerbuild Private Limited, are reducing costs by 15–20 percent compared to imports, aligning with the ‘Make in India ‘ initiative. Shalabh Chaturvedi, Managing Director of CASE Construction Equipment – India & SAARC region, emphasises, “India’s rapid growth in road infrastructure has increased demand for advanced equipment. Our backhoe loaders, compactors, and excavators are tailored for Indian conditions, ensuring durability and fuel efficiency.” CASE’s 952 NX and 450 NX compactors, equipped with intelligent compaction technology, analyse amplitude, frequency, and Intelligent Compaction Value (ICV) to optimise soil density, reduce rework and extend road life.

Powerbuild’s R Haridoss, CEO, adds, “Our planetary gearboxes, developed under Make in India, deliver high torque and precision for bridge launching systems and concrete pumping units.” These locally produced solutions, used in projects such as the Delhi-Mumbai Expressway, reduce construction time by 20 percent and costs by 15 percent, supported by MoRTH’s National Highway Precast Concrete Policy (2022), which mandates a 25 percent precast concrete component from local factories. Kobelco’s SK80 excavator, launched in September 2024, further enhances efficiency with 10 percent better fuel economy, aiding geosynthetic installations on the Trans-Arunachal Highway.

Sustainable materials
The adoption of sustainable materials is redefining road durability and environmental responsibility. The geosynthetics market, valued at USD 1.41 billion in 2023, is growing at a 10 percent compound annual growth rate (CAGR), with geotextiles, geogrids, and geomembranes being used to stabilise soils in projects such as the Okhla flyover’s fly ash embankment. Coir geotextiles, used in Kerala’s rural roads under PMGSY, reduce aggregate use by 15 percent and extend road life by 3–4 years. Recycled plastics, integrated into asphalt per IRC: SP: 98-2013, have paved 703 km of national highways by 2023, with Uttarakhand’s 500-meter trial stretch in 2024 proving their resilience. The Green National Highway Corridors Project (GNHCP), spanning 781 km, uses coir and reclaimed asphalt pavement, funded by a USD 500 million World Bank loan.

Vikas Sharma, CEO of Genesis Infra Project Consultant, champions stone matrix asphalt (SMA) for its durability: “SMA, first tried on the Delhi-Mumbai Expressway, uses cellulose fibre to prevent bitumen drain-down, ensuring long-lasting roads.” Martinho Fernandes, Assistant Vice President at Ammann India, highlights the impact of recycling: “In Jaipur, we used 45 percent recycled material to overcome aggregate shortages, achieving a high-quality job mix formula.” Nasim Khan, Senior General Manager at Automark Industries, notes, “Polymer-modified bitumen and CRMB give roads strength to withstand India’s tropical conditions—heat, cold, and rain.” These materials, including fly ash and steel slag, reduce carbon emissions by 10–15 percent, as seen in the Eastern Peripheral Expressway.

Eco-friendly road paints
Road markings are the unsung heroes of highway safety, guiding drivers through India’s bustling corridors. The road marking paint market, valued at USD 500 million in 2025, is embracing low-VOC, retroreflective coatings that cut emissions by 30 percent and reduce accidents by 20 percent. Videyah Rao, General Manager of Kataline Infra-Products Pvt Ltd, explains, “Road markings act as silent guides. Our Traffix Range of thermoplastic paints, with luminance values exceeding 85 percent and reflectivity up to 800 mcd/sqm/lux, ensures visibility day and night.” Paired with SWARCO’s high refractive index glass beads and BORUM’s precision equipment, these coatings meet MoRTH and global standards, as demonstrated on the Ganga Expressway.

Khan underscores the superiority of thermoplastics: “Thermoplastic road marking materials, with intermix and drop-on glass beads, provide initial and long-term reflectivity, making them cost-effective and durable.” However, he notes challenges with advanced materials like cold plastics: “Cold plastics last longer, but their high cost—four to five times that of thermoplastics—deters adoption.” Kerala’s eight roads, revamped in January 2025 using full-depth reclamation (FDR) and eco-friendly paints, have showcased a 20 percent reduction in maintenance costs, setting a model for Bharatmala projects.

Precision in bridge construction
Bridges, critical to Bharatmala’s connectivity goals, demand precision and durability. V. Senthil Kumar, Managing Director of Propel Industries, highlights the role of technology: “LiDAR and GPS-based sensors enable continuous machine tracking and real-time performance assessment, ensuring accurate alignment and structural integrity.” These tools, used in batching plants and concrete pumping units, reduce wear and tear, enhancing equipment life. Sujit Mule, Managing Director of Rachana Construction Limited, emphasises material choices: “Concrete roads last longer for highways with heavy loads. “

Challenges on the horizon
Despite these advancements, hurdles persist. Local manufacturing faces technology gaps, with 30 percent of advanced components still being imported, which inflates costs. Sustainable materials struggle with scalability; plastic waste availability is limited to 100–200 kg per household per year, and coir geotextiles are constrained outside Kerala. “Contractors resist change, sticking to traditional methods to save costs,” Sharma warns, noting Genesis’s training efforts. Eco-friendly paints, while durable, cost 20 percent more upfront, deterring adoption. Education gaps further complicate progress. “Education is a problem,” Fernandes says. “Lab designs overlook production processes. Our Ammann Academy addresses this.” Khan adds, “India is yet to fully adopt smart sensor-enabled marking due to policy gaps prioritising road completion over marking readiness.”

Charting the path forward
Solutions are taking shape. Public-private partnerships with firms like CASE and Maccaferri bridge technology gaps, while MoRTH’s USD 1.3 billion PLI scheme for technical textiles boosts geosynthetic production. Partnerships with urban local bodies, as seen in Uttarakhand, ensure a steady supply of plastic waste. MoRTH’s 2025 training program for 50,000 workers targets skills in geosynthetics and paint application. Policy incentives, including a 15 percent price preference for local equipment and mandates for plastic waste on roads near cities, streamline adoption. “Innovation is at the core of sustainability,” says Soumitra Wagholikar, Product Manager at Dynapac India. “Integrating digital tools and machine capabilities builds a self-reliant ecosystem.” Fernandes envisions a fossil fuel-free future: “We’re testing hydrogen burners to reduce carbon footprints, a technology we’re ready to adapt once green hydrogen is available in India.”

A Roadmap to Viksit Bharat
With 50percent of Bharatmala Phase I completed by March 2024, India is on track to achieve its Vision 2047 goal of universal access to high-speed corridors. The program’s synergy with PM Gati Shakti, backed by INR 13 trillion in bank lending and a 2.8percent gross NPA ratio, reflects financial confidence. Innovations such as warm mix asphalt (WMA) and self-repairing asphalt with steel fibres promise lower emissions and reduced maintenance costs. “Recycling is critical,” Fernandes asserts. “Without it, we’re lost in carbon footprints and resource depletion.” For procurement professionals, the directive is clear: source equipment from CASE or Powerbuild, geotextiles from Strata Geosystems, coir from Kerala, and paints from Kataline. Align with MoRTH’s mandates and GNHCP guidelines to deliver projects that are cost-effective, sustainable, and future-ready. As India forges its roads and bridges, it’s not just connecting cities but weaving a resilient, green future for Viksit Bharat 2047.

======

Quote

“Bharatmala’s scale demands equipment that’s both robust and cost-effective. Our locally manufactured compactors, like the 952 NX, use intelligent compaction technology to ensure durable roads while cutting project timelines by 10 percent.”
–        Shalabh Chaturvedi, Managing Director, CASE Construction Equipment – India & SAARC region

“Road markings are critical for safety. Our Traffix Range thermoplastics, with reflectivity exceeding 800 mcd/sqm/lux, ensure clear guidance day and night, aligning with MoRTH’s sustainability goals.”
–        Videyah Rao, General Manager, Kataline Infra-Products Pvt Ltd

“Our Make in India planetary gearboxes power bridge construction with high torque and precision, reducing energy consumption and supporting India’s net-zero goals.”
–        R Haridoss, CEO, Powerbuild Private Limited

“Precision is key in bridge construction. Our LiDAR and GPS-enabled equipment optimises feed rates, ensuring structural integrity and extending machine life for Bharatmala projects.”
–        V Senthil Kumar, Managing Director, Propel Industries

“Sustainable road construction requires integrated digital tools. Our compactors create a self-reliant ecosystem, ensuring durability and efficiency across Bharatmala’s diverse terrains.”
–        Soumitra Wagholikar, Product Marketing Manager, Dynapac India

“Recycling is non-negotiable for sustainable roads. Our asphalt plants, using 15–20 percent recycled materials, deliver durable highways while reducing carbon footprints, as seen in the Jaipur Road project.”
–        Martinho Fernandes, Assistant Vice President & Product Head – Asphalt Plants, Ammann India Private Ltd

“Automated road marking machines can complete 40-km stretches in 25 days, but policies must ensure roads are fully prepared to maximise efficiency and safety.”
–        Nasim Khan, Senior General Manager, Automark Industries (India) Pvt. Ltd

“Stone Matrix Asphalt enhances highway durability, but proper mix design is critical. We train contractors to adopt sustainable technologies like SMA for long-lasting roads.”
–        Vikas Sharma, CEO & Founder, Genesis Infra Project Consultant