Full depth reclamation (FDR) is a pavement rehabilitation process that pulverizes the existing asphalt surface and base material together, recompacts it as a new stabilized base, and applies a fresh asphalt surface on top. It’s used when the pavement structure has failed too deeply for resurfacing to fix but full removal and replacement is unnecessary.
How It Works
A reclaimer machine grinds the existing asphalt and aggregate base to a specified depth — typically eight to twelve inches — mixing the materials in place. The pulverized material is regraded, compacted, and often treated with a stabilizing agent. A new asphalt surface is then applied on top. The existing material becomes the base, eliminating the cost and waste of hauling it away.
When Full Depth Reclamation Is the Right Choice
- Base failure, not just surface failure. When alligator cracking, rutting, or settlement indicate the base has failed, resurfacing won’t solve the problem. FDR rebuilds from the foundation up.
- Large areas of widespread failure. FDR becomes cost-effective relative to full reconstruction when the failed area is large enough that the equipment mobilization cost is justified.
- When existing base material can be reused. FDR recycles the existing pavement structure rather than removing and replacing it, reducing material and hauling costs significantly.
Full Depth Reclamation vs. Mill and Overlay
Mill and overlay addresses surface deterioration when the base is still structurally sound. FDR addresses base failure. Applying a mill and overlay over a failed base produces a new surface that fails for the same reasons the old one did. FDR corrects the root cause.
Freequently Asked Questions
How much does full depth reclamation cost compared to full reconstruction?
FDR typically costs significantly less than full reconstruction because the existing base material is reused rather than hauled away and replaced with new aggregate. The equipment and process are also faster than full excavation and reconstruction.
How long does a full depth reclamation project take?
Most commercial FDR projects are completed in two to four days depending on the size of the area, followed by the new asphalt surface application. The lot can typically be reopened to traffic within 24 to 48 hours of paving.
Does full depth reclamation work in cold weather?
FDR requires appropriate temperatures for proper compaction and asphalt application. In New England, FDR projects are typically scheduled within the paving season from late spring through fall.
How do I know if my parking lot needs FDR versus resurfacing?
A site evaluation by a qualified contractor will determine whether the failure is surface-level or structural. Signs that suggest FDR may be needed include widespread alligator cracking, areas that have sunk or shifted, and sections that continue to fail after repeated resurfacing.
US Asphalt performs full depth reclamation for commercial and industrial clients across the Boston metro. Call (855) 246-8867 to discuss your project.
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