FULL DEPTH RECLAMATION

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FULL DEPTH RECLAMATION

• Highway 25
• Center-Hannover
• SS-1-025(009)028

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FDR Process

• Blend Roadway
• The contractor blended the roadway at an average
  depth of 9 inches (5 inches asphalt, 4 inches
  base) then returned to grade
• The cement was not added in this pass because
  material needed to be moved to the center of the
  road for slope correction
• The contractor used an offset stake to maintain
  centerline
• Cement Application
• The cement was distributed evenly across one lane
  of the roadway
• Once the cement was applied to the roadway it was
  blended in with the existing material.
• The roadway was compacted with a sheepsfoot
  roller following the cement application

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• Grading
• Once initial compaction was completed the roadway
  was finish graded
• The contractor was given 2 hours from the time of
  cement application to return the roadway to grade
• A rubber tire roller then finish-rolled the
  roadway
• After a portion of the FDR base had been
  compacted and finished the contractor had 10
  calendar days to place the initial pavement
  surface
• Sealing
• Prime was applied to the roadway to seal the road
  until it was paved. The roadway was then sanded
  but traffic could not return onto the completed
  section for 4 hours after initial mixing to allow
  time for the base to set up.
• Paving
• One 2.5 lift of Superpave FAA 40 was placed
• The pavement was not bonding well with the base
  so tack was applied to correct this problem.

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Advantages

• Provides new pavement structure
• Fast construction cycle
• No detours
• Traffic returns quickly
• Minimal change in elevation
• Conserves resources by recycling existing
  material
• Crown and slope corrections
• Eliminates existing reflective cracking and
  rutting

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Disadvantages

• May require additional effort to correct subgrade
  problems
• Some shrinkage cracks may reflect through
  bituminous surface
• Cement-treated materials will shrink naturally
  while curing
• Depth limitations
• Equipment can mill in excess of 18 but it is
  difficult to compact anything over 12
• NDDOT requires 50 asphalt 50 aggregate
• Cost

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Project Cost

• Project Length- 5.935 Miles
• Total Cost of FDR- 1,404,448.00
• Cost/Mile- 236,638.00
• Average cost/mile of thin lift overlay-
• 98,000.00

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Base Strengths

• Maximum- 400 PSI _at_ 28 days
• If strength was higher than 400 PSI the base
  would crack, causing pavement cracks
• Minimum- 200 PSI _at_ 28 days
• 300 PSI _at_ 28 days was the goal of Materials and
  Research

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Existing Roadway
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Blending Machine
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Blending Operation
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Loading Cement
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Cement Distributor
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Cement Application
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Dust
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Blending
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Material Sampling
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2nd Pass
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Initial Compaction
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Finish Blade
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Grading Operation
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Final Compaction
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Finished Base Surface
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Questions?