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Potholes are one of the most irritating and dangerous challenges on Indian roads. They cause vehicle damage, traffic congestion, and play an important role in causing accidents. In urban villages and semi-urban roads, the problem is even worse because the roads are constructed from inferior materials and only receive temporary efforts to repair these roads. Therefore, no matter how many repairs are conducted, we can expect to see potholes return with every monsoon season. Beyond daily inconvenience, potholes also delay ambulances and emergency services, where every second lost can mean the difference between life and death
Why Do Potholes occur frequently even after taking measures?
Poor drainage → rainwater finds its way into cracks and breaks down the base.
Weak materials → thin layers of tar/bitumen and sub-base break down very quickly.
Heavy traffic load → continuous weight and stress from buses and trucks exacerbate cracks.
Temporary fixes → loose tar and gravel used do not bond and wash away quickly.
My idea: Interlocking Modular Smart Tiles
Instead of filling potholes with tar, I suggest hexagonal 3D-printed tiles that are created using recycled plastic polymers.
Here’s How It Works:
Tiles fit into and inside potholes and connect like a puzzle and lock into place.
Damaged tiles are separate, and single tiles can be replaced without road excavation.
Protective tiles can have low-cost vibration sensors that indicate very early signs of loosening or cracking.
One major concern is drainage,
Since blocked water often worsens road damage. For this, each tile can be designed with micro-grooves on its surface, guiding rainwater toward the side drains instead of letting it pool. The sensors themselves would be waterproof-coated and installed only in selected tiles, so even during heavy rains, their risk of damage is minimal.
Another concern raised by the public is the issue of confusion over manholes being misidentified as potholes, particularly in flooding conditions, such as occurred in coastal locations. However, manholes will have a fixed metal cover on top; in addition, HexaRoad would only be utilized for small to medium potholes—not to identify drainage—so it is unlikely to be confused..
Advantages :
Durable – Unlike tar patches that collapse easily, these interlocking tiles form a stable and water-resistant layer. Their modular nature ensures they can withstand heavy vehicle loads without quickly displacing.
Eco-Friendly – The tiles are made from recycled plastic waste, turning an environmental hazard into a valuable road material, helping reduce landfill and pollution at the same time.
Quick Repairs – Because they don’t require heavy machinery, small crews can repair potholes within minutes, minimizing road closures and saving both time and labor costs.
Safety First – By providing smoother and more reliable surfaces, HexaRoad prevents sudden tyre bursts, skids, and accidents caused by water-filled potholes, improving safety for all road users.
Smart Monitoring – The sensor-enabled tiles bring predictive maintenance into road design, detecting problems before they become dangerous and helping authorities plan more efficient repairs.
Why This Matters
HexaRoad is more than a patch — it is a different way of managing potholes. By creating modular tiles from plastic waste, improving drainage, and adding smart monitoring, we could make roads safer, longer-lasting, and cheaper to maintain.
For me, this idea demonstrates how small and practical improvements can make a substantial difference to people’s lives. Improvements to roads benefit everyone — personal vehicles and public transportation, and emergency services.
