Full Depth Reclamation

Full-Depth Reclaimation (FDR)

“FDR” is a pavement rehabilitation and up-gradation technique where in bituminous and underlying pavement layers of predetermined thickness are excavated, pulverised and blended with a binder and compacted to act as a bound or hardened base course of the new pavement . Different types of additives, such as asphalt emulsions, and chemical agents, such as calcium-chloride, Portland cement, fly ash, and lime, are added to obtain an improved base. It is a cold-mix recycling process in which different types of additives are added, mostly in-situ, and compacted to obtain a strong base. Full Depth Recycling (FDR) is employed for constructing economical and long lasting new pavements by recycling existing distressed flexible pavements. “KABA Infratech” specifically uses a highly researched Dutch additive “Geocrete”  of which they are the exclusive license holders. This product has been extensively used in FDR by KABA Infratech in all of its projects across different landscapes and have successfully delivered roads with unmatched strength and longevity.

Before discussing the FDR process, a brief introduction of sub base stabilization and base stabilization is as follows:

Soil Stabilization

Soil stabilization is the process of blending and mixing materials with soil to improve certain properties of the soil. The process may include blending of soils to achieve a desired gradation or mixing of commercially available additives that may alter the gradation, texture or plasticity, or act as a binder for cementation of the soil. Additive stabilization is achieved by the addition of proper percentage of cement, lime, fly ash, or combinations of these materials to the soil

Mechanical Stabilization

Mechanical stabilization is a process in which materials are proportioned to obtain desired gradation and plasticity of the mix. This type of stabilization adds selected aggregate sizes or RAP to the pulverized existing materials to create a stronger sub-base. Mechanical stabilization can be used in combination with asphalt or chemical modification.

Cement Stabilization

Generally granular soils are suitable for cement stabilization.
Lime Stabilization – Clayey soils including heavy clays, Mourn and other soils met with in alluvial plains can be effectively treated with lime. In case of highly plastic soils, two stage stabilization is adapted Soil is first treated. with a small quantity of lime. Later on the soil may be treated with remaining quantity of lime or with cement to achieve the desired strength.

Sub base stabilization

A stabilized and therefore stiffer, sub base provides greater load spreading ability and hence reduces stresses imposed on the subgrade. When stabilized the sub base provides much of the structural rigidity in the pavement, and also assists during the compaction of the upper granular layers and hence increases their ability to withstand deformation.

FDR PROCEDURE

➣ Analysing existing materials
➣ Pulverization
➣ Monitor Depth of Cut
➣ Monitor Gradation
➣ Addition of stabilizer
➣ Initial Compaction (Sheep/ Pad foot)
➣ Shape material (Grater)
➣ Final Compaction
➣ Wearing surface

ADVANTAGES OF FDR

➣ Significantly improve the structure of pavement without altering the geometry and shoulder
➣ Restore old pavement to the desired profile, eliminate existing wheel ruts, restore crown andslope, and eliminate potholes, irregularities, and rough areas
➣ Eliminate alligator, transverse, longitudinal, and reflection cracking. Ride quality can be improved
➣ Frost susceptibility may be reduced.
➣ Production cost is low, and only a thin overlay or chip seal surfacing is required on most projects.
➣ Engineering costs are low.
➣ Materials and energy are conserved, and air quality problems resulting from dust, fumes, and smoke are eliminated. The process is environmentally desirable, since the disposal problem is avoided.

MACHINERY FOR FDR

➣ Cement spreader
➣ Road reclaimer
➣ Water truck
➣ Motor grader
➣ Various types of road rollers
➣ Machineries for construction of bituminous layer- Hot mix plant, roller, trucks, etc.

MACHINERY FOR FDR

APPLICABILITY OF FDR

➣ FDR is very much suitable for rehabilitation of roads, when existing road pavement is to be upgraded after completion of its design life to increase its structural strength, with or without additional widening so as to cater for increased number of load repetitions (higher MSA).
➣ When the existing bituminous pavement has excessive distress (distress in more than 50 per cent of the paved area in various form like excessive cracking,\ deformation like deep rutting or shoving, slippage, extensive potholes and patching, raveling, base or sub-base failure which require pavement reconstruction
➣ When the existing road pavement comprises of low grade materials like brickbats, soft aggregates, marginal materials, etc., which need to be replaced with new pavement layers like GSB, WBM/ WMM, etc., for reconstruction of such roads

RECOMMENDED FOR

➣ Damaged pavement that is beyond resurfacing
➣ Pavements with deep rutting, load- associated cracks, non load- associated thermal cracks, reflection cracks and maintenance patches such as spray, skin, pothole, and deep hot mix
➣ Problems with subbase/ subgrade
➣ Flexural distress in wheel lanes
➣ Increase structural design of roadway
➣ Widening of existing roadway

FDR SUMMARY

➣ Eliminates most of the pavement distress
➣ Turns a deficient pavement structure into a new homogeneous section with increased structural capacity
➣ 25 to 50% cost savings compared to other rehabilitation methods
➣ Same day returns to light traffic
➣ Sustainable: Reuses 100% of existing materials, conserving non- renewable resources and reducing trucking

ABSTRACT

Good practice dictates that pavements be maintained and preserved so that major rehabilitation is not needed. For a variety of reasons, this does not always happen. Sometimes it is not practical to fully rehabilitate a badly deteriorated asphalt pavement. Cracking or other distresses may have progressed to the point that a more: aggressive approach is needed. Complete removal and replacement is not necessary; the in-place materials of the old pavement have value and can be reused. Full depth reclamation (FDR) acts as the answer to these problems and is an efficient means of rehabilitating these pavements.