On site test for Full Depth Reclamation (FDR) during site execution.

 

On site Test of FDR

Gradation of FDR base layer:

The gradation of the in-situ pulverized materials should meet the criteria given in MoRD specifications as presented in Table 1. However, if the gradation obtained is different, then additional material of desired sizes shall be mixed and mix design can be done subjected to meet the desired gradation, strength, and durability criteria. . A well graded mixture is critical to ensure the FDR layer will be strong and durable with the minimum amount of cement.

Before pulverization:

The gradation of existing base is done before pulverization, if the gradation obtained is different, then additional material of desired sizes shall be mixed to obtain aggregate soil ratio as per mix design/Job Mix Formula (JMF). Test format of before gradation is given below:

PROJECT:
Client:
Contractor:
Sieve Analysis (FDR Mix)
Package No./ Road Name:
Chainage/Location			Date of Sampling:
Sample By:			Date of Testing:
Tested By:			Description of material:		Before pulverization
Weight of material taken (gm)
IS Sieve Size (mm)	Weight Retained on Sieve (gm)	Cumulative Weight Retained (gm)	Cumulative Percentage Weight Retained (gm)	Percentage Passing		Specified Limit
						Lower	Upper
53.00						100	100
37.50						95	100
19.00						45	100
9.50						35	100
475						25	100
0.600						8	65
0.300						5	40
0.075						0	10
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

After Gradation:

Gradation after pulverization is done to check aggregate soil ratio pulverization FDR based layer as per mix design or Job Mix Formula (JMF). Test format of after gradation is given below:

PROJECT:
Client:
Contractor:
Sieve Analysis (FDR Mix)
Package No./ Road Name:
Chainage/Location			Date of Sampling:
Sample By:			Date of Testing:
Tested By:			Description of material:		After Pulverization
Weight of material taken (gm)
IS Sieve Size (mm)	Weight Retained on Sieve (gm)	Cumulative Weight Retained (gm)	Cumulative Percentage Weight Retained (gm)	Percentage Passing		Specified Limit
						Lower	Upper
53.00						100	100
37.50						95	100
19.00						45	100
9.50						35	100
475						25	100
0.600						8	65
0.300						5	40
0.075						0	10
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

Moisture content:

Moisture Content or Natural Moisture content is amount of moisture content present in FDR layer before pulverization. To obtained optimum moisture it is crucial to determine natural moisture content, because it tell as require water content to obtain optimum moisture content.

Controlling the moisture content of the reclaimed material is crucial for proper compaction and achieving the desired strength. Water is added to the mix as needed to optimize the moisture content for compaction.

PROJECT:
Client:
Contractor:
Moisture Content Test
Package No./ Road Name:
Sample By:				Date of Testing:
Tested By:				Description of material:
Description	Trail-1	Trail-2		Trail-3	Trail4			Trail-5
Location/ Chainage:
Side:
Weight of Container/Trey (gms), W1
Weight of Container + Wet Material (gms), W2
Weight of Container + Dry Material (gms), W3
Weight of Water(gms), W4 = W3 - W2
Weight Dry Material (gms), W5 = W3 - W1
Moisture Content (%)= (W4/W5)x100
Average (%)
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

Cement Spreading Rate:

It is amount of cement required for per square unit for pulverization as per mix design. Spreading rate of cement depends on the percentage, depth, and maximum dry density of FDR mix.

PROJECT:
Client:
Contractor:
Spreading rate test for cement
Package No./ Road Name:
Chainage/Location			Date of Sampling:
Sample By:			Date of Testing:
Tested By:			Description of material:
S. NO.	Trail-1	Trail-2	Trail-3	Trail4		Trail-5
Location/ Chainage:
Side:
Area of tray in (m2): (A)
Wt of Empty Tray (kg) (B)
Wt of Tray + Material (kg) ©
Wt. of Material (kg) (D= C-B)
Rate of Spray (kg/m2) (E=D/A)
Average Rate of Cement Spreading (Kg/m2) :
Required Limit of Cement Spreading (Kg/m2) :
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

 

Mixing uniformity:

For to check mixing uniformity Visual inspection is done at regular interval. It depends on the experience of technical staff present at site for execution work.

For cement content commonly used chemical to determine the presence of calcium in cement-stabilized materials is phenolphthalein.

For aggregate Mixing uniformity of FDR layer is check by collecting FDR base material after Pulverization at 30m to 40m interval to check gradation for aggregate soil ratio and mixing uniformity is checked by visual inspection if larger size aggregate settled at lower than reclaimer RPM higher and speed of reclaimer is higher, it should range from 4m/min to 6m/min for best result.

Visual inspection for Aggregate 

Phenolphthalein Test for cement before compaction

Thickness of Stabilized Layer:

Depth of FDR layer is checked by Phenolphthalein Test indication by making the pit/hole on compacted FDR layer.

PROJECT:
Client:
Contractor:
Test for Depth of Pulverization
Package No./ Road Name:
Chainage/Location				Date of Testing:
Tested By:				Description of material:
Sr. No.	Depth of Pit/Hole (mm)		Depth of FDR Base Layer (mm)		Phenolphthalein Test Result (satisfactory/unsatisfactory)
Remark:
Contractor                                                      PMU                                             PIU’s  (Representative)                                      (Representative)                            (Representative)

                   

Compaction:

Immediately after final rolling is completed, in-place density tests should be performed at several locations on the first few sections completed. A density gauge can be used to determine the degree of compaction obtained in the field to avoid disturbance in the stabilized layer. It should be noted that density gauges should be properly calibrated, operated, and maintained to ensure that results are accurate. In the absence of density gauge, Sand replacement method or determination of density of extracted core by wax coating method may be used. The density of the layer should not be less than 100% of the maximum density of the cement-treated mix as determined in the laboratory. Test format for sand replacement method is given below:

PROJECT:
Client:
Contractor:
Field Density test by Sand Replacement Method
Package No./ Road Name:
Source of material:			Date of Test:
Chainage:			Bulk density of sand (Ys)
OMC of material (%) :			MDD of material (gm/cc) :
Pouring cylinder, no :			Weight of sand in cone (gm) :
Description	Unit	Trail-2	Trail-3	Trail4	Trail-5
Test Pit Location (Chainage)
Offset	m
Wt. of Wet material from hole (Ww)	gm
Wt. of sand + cylinder before pouring, (W1)	gm
Wt. of sand + cylinder after pouring, (W2)	gm
Wt. of sand in hole & cone, (W3) gm	gm
Wt. of sand in hole, W4 = (W1-W2-W3)	gm
Volume of the hole, Vh = W4/Ys	cc
Bulk Density of material Yb = {(Ww/Vh}	gm/cc
Moisture Content
Wt. of Wet Soil (W1)	gm
Wt. of Dry Soil (W2)	gm
Moisture Content (w)= (W1-W2/W2)*100	%
Result
Field max. dry density Yd = {Yb/(1+(w/100))}	gm/cc
Compaction obtained, ((Yd / Yd (Max))*100)	%
Average Compaction obtained	%
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

 

Camber/Superelevation:

Camber of base should be provided as per the guidelines of project. Camber is checked by auto level or by the camber plate whichever available on the site.

UCS Test (from cubes):

Cubes are casted from the pulverized material on site on daily basis and should be checked at the interval of 7 Days and 28 Days at the site laboratory. Testing should be done in the presence of Govt./client representative. Format for FDR cube test is as given below:

PROJECT:
Client:
Contractor:
Unconfined Compressive Strength
Package No./ Road Name:
Chainage/Location					Date Of Casting
Name Of Structure					Grade Of Concrete
Part Of Structure					Grade Of Cement
Side					Area Of Cubes
Sr. No.	Wt. of cube (gm)	Density (gm/cc)	Date of Testing	Age of Specimen		Load (KN)	Compressive Strength		Average Compressive Strength (N/mm2)
Remark:
Contractor                                                      PMU                                                    PIU’s (Representative)                                      (Representative)                               (Representative)

 

Test Frequency:

It is prudent to conduct periodic testing during construction to confirm that the properties of materials being used are within the range of value anticipated during the design. Quality control tests and their minimum desirable frequency are as given in Table-1 for tests to be conducted during construction . Tests indicated here are minimum number of tests to be conducted in any project. However, PIU or Contractor may carry out a greater number of tests if they so desire. Tests to be conducted by State Quality Monitors (SQMs) and National Quality Monitors (NQMs), departmental senior officers during their inspections will be in addition to these tests. All these quality tests/checks are to be considered incidental to works, and no separate payment shall be made. Contractor’s laboratory must be well equipped to carry out these tests.