FULL DEPTH RECLAMATION FOR

REHABILITATION OF LOW
VOLUME RURAL ROADS

PRESENTED BY

ARNAB BISWAS
SE, P&RD Deptt. and DIRECTOR RCTRC
Introduction:

• The rural roads often suffer with distress like rutting, raveling,
cracking and in general loss of riding quality. These problems not
always successfully solved by replacing the surface layer by
another thin bituminous layer and not effective at all to reduce
life cycle cost with lower carbon footprint.

• Full depth reclamation also known as full depth recycling

(FDR) of the existing pavement layers offers a significant cost
effective and sustainable rehabilitation process.

• Apart from rehabilitation of distress pavement structure FDR

can be adopted for up gradation and widening of existing roads
without overlaying any structural base layer for higher level of
traffic category.
• The FDR process also widely applied on existing
Bituminous/Asphaltic layers also. Here the existing bituminous
pavement along with a portion of underlying base, sub-base and
even sub grade needs to be reclaim and pulverized to required
grading. The pulverized material then uniformly blended with
additional stabilized materials like Portland cement, bituminous
emulsion or Commercial Chemical Stabilizer (CCS) to provide a
upgraded homogeneous stabilized base.

• With FDR layer strong cement treated stabilized base layer

(CTB) prepared which provides a strong resilience modulus and
only a bituminous layer like BM/BC will be sufficient over CTB
to carry traffic for low volume rural roads. It is recommended to
provide Stress Absorbing Membrane Interlayer (SAMI) over
CTB before laying Bituminous layers for traffic more than T6
category.
TYPES OF FULL DEPTH RECLAMINATION:

The different types of stabilization associated with FDR

• Mechanical Stabilization (addition of aggregates)

• Chemical stabilization (Addition of cement and stabilizing
agent)
• Bituminous Stabilization (addition of asphalt binder)

Mechanical Stabilization:

In this process granular material is added with reclaimed

pulverized material and compacted to specified density to provide
adequate structural support. The stabilization of the layer depends
upon interlocking between pulverized material, granular material and
sub-surface layers.
Chemical Stabilization:

In this process chemical stabilizers mixed with pulverized

asphalt pavement materials with sub-surface layers and finally
compacted to desired resilience modulus. The standard chemicals
used as

• Portland Cement

• Lime

• Fly Ash

• Cement kiln dust (CKD)

• Lime kiln dust (LKD)

• Commercial Chemicals
Bituminous Stabilization:

In this process pulverized asphalt pavement and sub-surface

material mixed with emulsified asphalt. In this process Portland
cement may also be added for better performance.

Preparation steps for implementation of FDR:

• At first the details of existing pavement to be collected for at

least 1 pit sample from each km.

• Additional sample required to be collected if variation in

pavement layers noticed.

• Finalization of the mix design based on available material

and required gradation.
• Determination of either cement or stabilizing agent percentage
(%) based on trial mix and laboratories test results.
• Obtaining final 7 days soaked UCS values of different cubes.
• Calculation of resilience modulus of CTB by using empirical
formula.
• Performed pavement design using IITPAVE.
• Selection of appropriate machinery with facilities of
microprocessors and GPS.
• Evaluation of pavement strength using directly either by
FWD or by obtaining core sample. Application of bituminous
layers as required.
• Quality control during execution.
Mix design of FDR:

The following steps are involved in the mix design of FDR process

• Obtain the field samples in each km to understand the

material grading and proportioning the mixed design.

• Determination of the gradation of the reclaimed sample.

• If necessary only then additional material may be necessary

to satisfy the grading requirement.

• For mix design three different cement contents (i.e 3%, 5%

and 7%) needs to be selected.
• Determination of OMC and MDD for each mix of different
cement/CCS content.
• For each cement content 150 mm cube to be prepared at OMC
and MDD for 28 days UCS testing.
• Cylindrical specimen for 100 mm diameter and 200 mm height
may also be prepared. The result of cylindrical specimen should
be multiplied by 1.25 to obtain 150 mm cube strength.
• 12 cycles of wet dry durability test of each specimen at the
estimated cement content to be conducted.
• Plot UCS and wet dry durability test result on a graph for
different cement content.
• Select the desired cement content from the graph based on
UCS and In situ Modulus data required for pavement design
using IITPAVE.
Gradation of Mix:
In FDR process gradation is one of the most important things
to obtain correct stabilization strength. In most of the cases the
reclaimed machines not always break down the pavement materials
small enough with correct grade. Thus if required the additional
mixing may be required.

Grading limits of reclaimed material:

Is Sieve Percent by weight passing in range

53.0 mm 100
37.5 mm 95-100
19.0 mm 45-100
9.5 mm 35-100
4.75 mm 25-100
600 micron 8-65
300 micron 5-40
75 micron 0-10
Optimum Moisture Content and Maximum Dry Density:
The determination of OMC and MDD is very essential for the
trial mix. The cement stabilized pulverized material gives best
strength when they compacted at OMC and MDD. Accordingly the
water percentage of FDR mixes to be determined.

Unconfined Compressive Strength (UCS):

• At first OMC and MDD of the trial mix to be determined.

• Specimen to be prepared for estimated cement content of 3%,

5% and 7%.

• A minimum of two specimens to be prepared for each cement

content.
• The specimen cubes or cylinder to be prepared as per IRC: SP-
89-2018.

• 7 days curing of specimens in moist curing room.

• Perform UCS test in designated machines.

• A graph of 7 days UCS with varying cement content to be

prepared.

• Determine the optimum cement content / CCS content from

target UCS values required for designed resilience modulus of
CTB layer.
Approximate equation of straight line obtained
Y = 0.95x – 0.1667
Avg Slope Φ = tan-1(0.9738)
With Target value of Y the cement content x to be obtained.
Durability Test:
• In addition to unconfined compressive test the mix design should also pass
the wet dry durability test.
• This test consists of 12 cycles of wetting, drying and brushing of sample as
per ASTM D 559.
• Wet-Dry cycle results in carbonation of exposed surface of stabilized
specimen and brushing cause loss of weight. The weight loss should be within
permissible limit.
• Before preparation of mix and after finalization of gradation ASTM
classification of sample to be made.

ASTM Soil Classification Maximum allowable wt loss %

GW, GM, SW, SP, SM 14
GM,GP,SM,SP 14
GM,GC,SM,SC 14
SP 14
CL, ML 10
ML, MH, CH 7
CL, CH 7
OH, MH, CH 7
Mix Design Report as part of DPR:
The mix design report to be prepared which consist of the
following.
• Gradation of combined mixture.
• LL, PL and PI of combined material (If applicable)
• MDD and OMC of combined mixture of FDR
• UCS test report of each trial sample
• Wet density of test specimen before and immediate after
curing.
• % weight loss in Wet-dry 12 cycle test
• Final recommendation of cement content / CCS content.
Rate analysis for the technology layer (taking Daily average output of 625 cum
for 0.25 m depth
Sl. Rate Amount
Description Unit Quantity
No. (Rs.) (Rs.)

A Labour (Mazdoor) Day 20 335.00 6700.00

Machinery
B

1. Recycler Machine hour 8 30277.00 242216.00

2. Cement Spreader hour 8 7408.50 59268.00

3. Additive Spreader hour 8 1750.00 14000.00

Vibratory Pad Foot

4. hour 8 4200.00 33600.00
Roller (20 tonne)

5. Vibratory Roller Smooth Drum hour 8 1687.00 13496.00

6. Motor Grade 150 HP hour 8 1800.00 14400.00

7. Pneumatic Tyre Roller (PTR) hour 8 2236.50 17892.00

Rate analysis for the technology layer (taking Daily average output of 625 cum
for 0.25 m depth
Sl. Rate Amount
Description Unit Quantity
No. (Rs.) (Rs.)

8. Front end/back oe loader 2.1 cum capacity hour 8 1513.00 12104.00

Bulker for cement handling for uploading to cement

9. hour 48 1370.00 65760.00
spreader, 6 units daily for 8 hours/bulker
Water tanker 24KL Capacity4 number for 10
10. hour 40 440.00 17600.00
hours/each
Materials
C

1. Cement at site @ 5% by weight of soil treated tonne 62.50 5717.00 357312.50

2. Additive per square meter@ Rs 450 per square meter sq.m 2500.00 450.00 1125000.00

3. Cost of water KL 180.00 50.00 9000.00

D TOTAL = Rs. 1988348.50

E Overhead & C P @ 15.00% over 'D' Rs. 298252.28

F Cost for 625 cum (D+E) = Rs. 2286600.78

Rate per cum = Rs. 3658.56

Comparative Rate for the technology layer
(taking Daily average output of 625 cum for
0.25 m depth)

Uttar Pradesh Bihar West Bengal

Rs. 3706.81 /Cum Rs. 3625.86 /Cum Rs. 3658.56 /Cum

Pulverization:
This step is very important in FDR construction. The adequate
strength of cementious base is not possible without proper grading.
The pulverization of existing material improved by

• Slower forward speed of mixing machine.

• Additional passes if using multiple pass machines.

• Replacing worn mixture teeth.

• Premixing of water at OMC before beginning of the process

• Checking of OMC with rapid moister meter.

Evaluation of strength for stabilized base:
The pavement design under FDR done based on the strength
factor achieved in stabilized base. The base strength evaluated as
follows

• Based on UCS value obtained at lab and using Sullicon et al

(208) for cement treated base. The empirical relation given by

MR = 3032 x (UCS)1/2

Where MR is the resilience modulus of CTB in MPa

• The value of modulus use in IITPAVE for calculating strains
under bituminous layers and just above sub-grade.

• The traffic and CBR data to be given as input in IITPAVE.

• The strain values to be checked with 80% reliability.

• During construction either 150 mm cube to be prepared and

to be tested after 7 days moist curing. Also result after 28 days
to be recorded.

• The result of FWD may also be recorded and in situ modulus

to be calculated based on FWD data.
Acceptance Criteria:
• Tolerance up to 5% in intermediate sieves except first and last
sieve for gradation.
• As per mix design average UCS value should be more than 4.5
MPa after 7 days curing and individual value should not be less than
4.0 MPa.
• Average stiffness modulus of CTB layer should not be less than
5000 MPa subjected to a minimum of 4500 MPa after 28 days
curing.
• Average stiffness modulus of CTB layer should not be less than
3500 MPa subjected to a minimum of 3000 MPa after 7 days curing.
• 100% of MDD to be achieved by heavy compaction.
• Tolerance in surface level (+ /-) 10%
• Opening to traffic after 7 days moist curing
• with DCP penetration < 10mm/ blow acceptable for construction
of subsequent layer after 3 days.
Construction
Techniques:
THANK YOU