New material blends coal mine parting, fly ash and binder to tackle industrial waste and improve road durability
Researchers at the National Institute of Technology Rourkela (NIT Rourkela) have secured a patent for a high-strength composite material made from coal-mining waste and industrial waste. The innovation could support the construction of durable roads capable of handling heavy vehicle traffic, particularly in mining regions where haul trucks and transport vehicles place intense pressure on road infrastructure.
The patented technology addresses two major challenges facing India: the need to manage large quantities of mining and industrial waste, and the demand for stronger roads that can withstand repeated heavy loads. The patent has been granted under Patent No. 597749, based on Application No. 202331070306.
The research team includes Prof. K. Umamaheshwar Rao, Professor and Director, NIT Rourkela; Dr. Manoj Kumar Mishra, Professor; and research scholar Dr. Subhasrita Choudhury from the Department of Mining Engineering.
Turning waste into road material
India’s expanding coal industry generates significant volumes of waste during extraction and processing. According to the Ministry of Coal, India produced approximately 1,047.523 million tonnes of coal in 2024–25, crossing the one-billion-tonne mark. Around 94% of coal production comes from surface mining, which creates large quantities of overburden and coal parting material.
Coal mine parting contains rocks and non-coal materials separated during mining. It is often disposed of through conventional dumping methods, which can occupy large areas of land and create environmental pressures. The material may also contribute to dust, water contamination and long-term land degradation if not properly managed.
The NIT Rourkela researchers identified that coal mine partings contain silica, alumina and clay minerals with useful engineering characteristics. These minerals can provide stiffness and compressive strength when combined with suitable industrial additives.
A circular economy solution
The team developed a composite by combining coal mine parting, fly ash and a binder. The mixture was carefully evaluated to determine the optimum formulation for strength, load-bearing capacity and durability.
Fly ash, a major by-product of coal-based power generation, is already being studied for use in road bases and sub-bases. Research has shown that fly ash-stabilised mine spoil and coal partings can improve strength and stiffness for haul-road construction.
By combining two high-volume waste materials into a single construction product, the patented NIT Rourkela technology follows the principles of a circular economy. Instead of treating coal waste and fly ash as disposal problems, the system converts them into an engineering resource.
Designed for heavy vehicle corridors
Mining roads are exposed to repeated loads from trucks transporting coal, minerals and other materials. Frequent traffic can lead to rutting, cracking, potholes and surface deformation. Repairing such roads requires significant time, money and material.
Prof. K. Umamaheshwar Rao said the innovation was particularly relevant to coal-mining regions, where roads routinely carry heavy vehicles and deteriorate under repeated loading. A stronger composite road material could help extend service life, reduce repair frequency and improve transport efficiency.
The technology may be suitable for haul roads, industrial access roads, road sub-bases, embankments and other infrastructure projects where high load-bearing capacity is required.
Benefits for infrastructure and environment
Prof. Manoj Kumar Mishra described the composite as an example of converting industrial waste into a resource with engineering and economic value.
The technology could offer several benefits:
- Reduced dependence on natural construction materials.
- Lower volumes of coal waste and fly ash sent for disposal.
- Stronger roads for heavy industrial traffic.
- Potential reduction in maintenance and repair costs.
- Support for sustainable infrastructure development.
- Better utilisation of locally available waste materials.
The researchers’ next step is to conduct pilot-scale field trials to assess the material’s long-term strength, durability and performance under real-world traffic and weather conditions.
If field testing confirms its laboratory potential, the NIT Rourkela patent could provide mining regions with a practical, indigenous and sustainable solution for both waste management and durable road construction.
Conclusion
NIT Rourkela’s patented coal-waste composite offers a promising approach to addressing two major infrastructure challenges: industrial waste management and the need for stronger roads in heavy-traffic regions. By combining coal mine parting, fly ash and a suitable binder, the researchers have developed a material designed to deliver improved strength, load-bearing capacity and durability.
The technology could be particularly useful in mining and industrial areas where roads face continuous stress from heavy vehicles. At the same time, productive utilisation of coal-mining waste and fly ash could reduce pressure on landfills and dependence on conventional construction materials.
With pilot-scale field trials planned, the next phase will determine how effectively the composite performs under actual traffic, weather and operating conditions. Successful field validation could pave the way for wider adoption of the patented material in haul roads, industrial corridors, road sub-bases and other infrastructure projects while supporting India’s circular-economy and sustainable-development goals.
FAQs
1. What has NIT Rourkela patented for road construction?
NIT Rourkela researchers have patented a high-strength composite material made using coal mine parting, fly ash and a binder. The material is intended for durable road construction, particularly on routes exposed to repeated heavy-vehicle traffic.
2. What is the patent number of NIT Rourkela’s coal-waste composite?
The technology has been granted Patent No. 597749 based on Application No. 202331070306.
3. Who developed the patented coal-waste road material?
The research team includes Prof. K. Umamaheshwar Rao, Professor and Director of NIT Rourkela; Dr. Manoj Kumar Mishra, Professor; and Dr. Subhasrita Choudhury, research scholar from the Department of Mining Engineering.
4. What are the potential applications of the composite material?
The material could potentially be used for mine haul roads, industrial access roads, road sub-bases, embankments and other infrastructure projects requiring high load-bearing capacity.
5. How does the technology support sustainable development?
The innovation converts coal mine parting and fly ash—two major waste materials—into a useful construction resource. This could reduce waste disposal requirements, decrease dependence on natural construction materials and support circular-economy practices in the infrastructure sector.