Full Depth Reclamation (FDR) is an advanced pavement rehabilitation method where all existing asphalt layers and a portion of the underlying base are pulverized and blended on-site.
This process creates a homogeneous, stabilized base layer, which is then overlaid with new asphalt — forming a stronger and more durable pavement structure.
FDR is gaining popularity because it is cost-effective, environmentally sustainable, and minimizes traffic disruption compared to full reconstruction. Instead of removing and replacing existing material, FDR reuses it — reducing waste and the need for virgin aggregates.
When to Choose FDR
FDR is ideal when:
- The existing pavement shows base failures, cracking, or rutting.
- Increased load-bearing capacity is required.
- A project demands minimal traffic disturbance or reduced environmental impact.
It is most suitable for roads, parking lots, and industrial surfaces where structural issues exist below the surface.
The Full Depth Reclamation Process
1. Pre-Project Evaluation
Before FDR begins, engineers conduct site evaluations including:
- Coring and sampling to assess material thickness and uniformity
- Moisture content and density tests to determine stabilization needs
- Subgrade evaluation to identify any deep instability
Proper testing ensures the treatment is applied to the right depth and that materials are suitable for reuse.
2. Pulverization
Using a reclaimer or recycler, the asphalt surface and base are pulverized into a consistent material.
If the pavement includes curbs or fixed elevations, pre-milling may be necessary to maintain height requirements.
The pulverized material is then compacted to form a uniform foundation.
3. Stabilization
Stabilization is the most critical step in FDR and determines the long-term performance of the pavement. It strengthens the recycled base through one of three methods:
- Mechanical stabilization – blending granular materials to improve strength
- Chemical stabilization – using agents such as cement, lime, or fly ash to increase stiffness and moisture resistance
- Bituminous stabilization – incorporating asphalt emulsion or foamed asphalt for flexibility and improved fatigue resistance
Over 90% of modern FDR projects use a chemical or bituminous stabilizing agent for better durability.
4. Moisture Control and Compaction
Moisture levels are closely monitored to achieve Optimum Moisture Content (OMC) for compaction.
- Too little moisture prevents density.
- Too much moisture delays curing and reduces strength.
Contractors adjust moisture on-site using calibrated equipment to ensure uniformity.
Proper compaction using pneumatic or vibratory rollers creates a dense, stable base ready for surfacing.
5. Curing and Surface Application
After stabilization and compaction, the base must cure before applying the surface course.
Curing times vary depending on temperature, binder type, and moisture. Premature traffic can damage the surface, so proof-rolling is used to confirm readiness.
Once cured, the surface can be finished with:
- Hot mix or cold mix asphalt overlay
- Chip seal
- Slurry seal or micro surface
This final step seals and strengthens the pavement, ensuring a long service life — often 15 to 25 years.
Key Benefits of Full Depth Reclamation
- Cost Savings: Uses existing materials, reducing hauling and disposal costs.
- Structural Strength: Creates a unified base layer capable of handling higher loads.
- Environmental Efficiency: Recycles 100% of the old pavement in place.
- Minimal Traffic Disruption: Faster turnaround than full reconstruction.
- Longevity: Provides a durable foundation resistant to rutting, cracking, and moisture damage.
Best Practices Summary
- Conduct a detailed engineering analysis before starting.
- Maintain consistent pulverization depth and gradation.
- Apply the correct stabilizing agent and dosage through lab mix design.
- Monitor moisture content and compaction density on-site.
- Allow adequate curing time before surface paving.
- Use proof rolling and quality control testing to ensure base strength.
Conclusion
Full Depth Reclamation is one of the most effective and sustainable methods for restoring deteriorated pavements. It combines engineering precision, cost savings, and environmental benefits — creating a stronger and longer-lasting roadway foundation.
At AMR New York, we specialize in asphalt paving and rehabilitation solutions, including FDR and base stabilization, tailored to the specific needs of your project. Our focus is on quality, efficiency, and long-term performance.
Contact us today to discuss your pavement rehabilitation project or request a site evaluation.
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