Final Road Level of FDR Base

Process to be followed for determination of the Final Road Level of FDR Roads:

First Determine the existing Road Level of the pavement with the help of Auto Level. Suppose that
the crust of the existing road is 20 cm & RL @ Center point is 101.20 & Width of the road is 3.75 m.
when we dismantle the pavement and spread the material in 5.65 m, the Compacted thickness is
calculated by the following Formula:

Existing Crust × Existing Width 0.20× 3.75

¿ = =0.132 m
Proposed Width 5.65

Then the level of the Road after spreading of Material will be = 101.20 – (0.20 – 0.132) = 101.13

101.13 m is the proposed RL of top of FDR Base (meter)

If we are doing 40 mm BC the final road Level of the pavement will be = 101.13 + 0.04 = 101.17

Then Mark the Levels on the Level Pillars. We can check the levels either by Auto Level or by directly
using Line Dori, Put Line Dori on both side at the level of layer.
 Profile Details of Existing Material of Carriageway

1. At every 100 m chainage interval note thickness(mm) & width (3.90 m or 5.65 m) of the
Proposed FDR Base.
2. Write % of Aggregate and Soil in JMF @ every 100 m chainage interval.
3. Determine Existing Carriageway Details (Existing Crust Thickness & Width)
4. Determine aggregate available for use in pulverization & Recycling (after spreading in
required width) In Thickness & Percentage

How to determine that sufficient aggregate is available or not for pulverization

Case-1 [ When the Existing Crust is more than the thickness of FDR base]

For an example suppose that the existing crust of the road is 350 mm & the depth of the FDR
Base is 250 mm. As per JMF the required %age of aggregate is 60% & Soil is 40%.

In this case the existing crust thickness (350 mm) is greater than thickness of the FDR Base.
When you Spread the aggregate in 5.65 m width, the compacted thickness will be

Existing Crust × Existing Width 0.35 ×3.75

¿ = =0.232 m=232 mm
Proposed Width 5.65

Aggregate available is 93% of 250 mm. When you pulverize with recycler @ depth of 250 mm
only Aggregate is pulverized, in this case you have to add soil in this situation to maintain the
Aggregate: Soil ratio.
The ratio of the aggregate: soil is 60: 40. So for 250 mm FDR thickness, 60 % of 250 mm = 150
mm thickness of aggregate will be required & 40 % of 250 mm = 100 mm thickness of soil
will be required.
When we construct the bed, we have to ensure the mix ratio of 60:40. So we take aggregate
of 150 mm from the existing crust after spreading & 100 mm thick layer of soil will be spread
over aggregate on top. In Pulverization 100 mm Thick Top Soil & 150 mm thickness of
Aggregate is used in pulverization.
Case-2 [ If the Existing Crust is less than the thickness of FDR base]

For an example suppose that the existing crust of the road is 80 mm & the depth of the FDR
Base is 250 mm. As per JMF the required %age of aggregate is 60% & Soil is 40%.

In this case the existing crust thickness (80 mm) is less than thickness of the FDR Base. When
you Spread the aggregate in 5.65 m width, the compacted thickness will be

Existing Crust × Existing Width 0.08 × 3.75

¿ = =0. 053 m=53 mm
Proposed Width 5.65

Aggregate available is 21% of 250 mm. When you pulverize with recycler @ depth of 250 mm
only Aggregate & Soil is pulverized, but the aggregate quantity is less than 60 %. In this case
you have to add fresh GSB of Grade 1 to maintain the Aggregate: Soil ratio. Additional
Aggregate thickness required to be added will be [ 150 mm i.e., 60 % of 250 mm – 53 mm =
100 mm].
100 mm thick Fresh GSB Grade 1 is to be added in the aggregate prior to pulverization. After
adding fresh GSB of Grade 1, the available aggregate will be 150 mm (i.e., 60% of 250 mm).
in this case you can use subgrade soil of 100 mm (i.e., 40 % of 250 mm) in pulverization. Or
you can add 100 mm thick layer of soil on the top of aggregate layer to maintain the Final
Road level.