Standard operating procedure for FDR:

Stage 1: Preparation of FDR Bed:

Machineries used: Loader-backhoe, Reclaimer/recycler/excavator, motor grader,
vibratory roller. Machineries used can be changed (added or eliminated) depending on
methodology given in DPR of particular road.
Step-1: Earth filling in extra widening and shoulder. Make sure all embankment prepared are fully
compacted before handing the further procedures.

Step-2 Find out the trench width (one sided or both sided) deducting the existing width from FDR
formation width (given in DPR).

Step-3 Find the depth of trench comparing and equivalent of the crust thickness available at
particular stretch.

Step-4 Dismantle the existing crust up to depth of equivalent to thickness required of finer soil.
Always prefer the Reclaimer machine for dismantling work. In different circumstances and
availability excavator or grader with ripper can be used.

Step-5 Once the dismantling work completes at stretch grade out the bed using motor grader in
required levels and camber/tolerance.

Step-6 Compact the surface using the roller to meet the design proportion of depth to cement and
additive mix. C

Step-7 Check NMC (Natural moisture content) of bed which should be nearest %age of OMC for
doing FDR. If NMC is greater than OMC, then do efforts to allow to bed dry.

In trials perform the step-7 before step-1. Treat this as most important.

Stage 2: FDR using cement and CCS:

Machineries used: Cement spreader, Water tanker, Reclaimer/recycler, vibratory pad-
foot roller (20 T), Motor grader 150 HP, Vibratory roller smooth drum (14-20T),
Pnematic Tyre roller (PTR). Machineries used can be changed (added or eliminated)
depending on methodology given in DPR of particular road.

Step-1 Perform the NMC (Natural moisture content) test (1set of 3 tests) of bed of up to a depth of
FDR thickness. Sample taken should be properly mixed in finer and coarser proportion. Find the
moisture content per cent.

Step-2 Perform the GSA of soil of retaining and passing percentage of 4.75mm sieve.

Step-3 Assume the water %age required (AMC) to add in FDR process considering the step-1 and
step-2 to meet the OMC (optimum moisture content).
Generally, percentage of water can be obtained deducting the NMC from OMC. Extra percentage of
water up to 1.5 % can be added considering the weather and temperature of the day. Practically it
varies from 2.5% to 4%.

Step-4 Set out the road width and length to be reclaimed. Highlight the stretch using lime powder.

Step-5 Cement spreading/mixing process:

Make sure the cement spreading rate is as per given JMF (job mix formula). Treat this step as most
important.

Step-6 Mixing of ANT stabilizer with water to make ANT-water aqueous solution.

(A) Find the quantity of water (Qwater) by given expression:

Road volume*MDD(kg/cum) *AMC
(B) Mix the ANT stabilizer to Qwater as per JMF per cum.
(C) Make sure and allow it to minimum 15 minutes for mole reaction before applying it to the
soil and cement mix.

Step-7 Mixing of ANT-water aqueous solution to the soil and cement mix using Reclaimer/recycler:
Make sure the maximum depth of reclaiming is +10 mm of FDR thickness. Reclaiming machine speed
varies from 7-9 m/min. Observe and control water penetration at overlapped stretches of road
width to prevent bulging (over-moisture).

Step-8 Initial compaction process using pad-foot roller: Pad-foot rolling can be performed as soon
as soil cement mixing started by reclaimer/recycler. Speed limit of pad foot varies from 5-7 kmph.
One third of every pass must be overlapped with next pass. Operation of every pass should be done
from lower to upper side sequences in a manner of 1:6:1 ratio.

Step-9 Grading process using motor grader: Grading process is performed as soon as the initial
compaction process ends. This is performed to setting the required levels and camber (longitudinal
and transversal). Check the camber and longitudinal gradient while grading operation. If okay, then
proceed for step 10.

Step-10 Final compaction process using smooth drum vibratory roller: As soon as the grading
process ends final compaction must start Operation of every pass should be done from lower to
upper side sequences in a manner of 1:6:1 ratio. Check the surface for no marks of drum of roller.
Passes can be increased or decreased depending on the visually observation of compaction process.
Observe the voids formed on top of surface while grading process and fill those voids/ segregation
with FDR mixed soil.

Step-11 Kneading and smoothening using PTR: 10-12 passes with PTR should be rolled for kneading
and smoothening of bed.
Note:

1. Step 6-11 from stage 2 must be performed and completed within +8 hours from timing of step 6
of stage 2.

2. Click photographs of each and every step with Notecam or equivalent Geotag camera.

Step-12 Grade and compact the shoulder of road in desired camber to support and rain-off the
surface water from main carriage way.