TYPICAL CROSS-SECTION

Conventional Flexible Pavement StabilRoad Stabilised Pavement

With Full Depth Recycling Technology
Bituminous Concrete (30 mm)
Dense Bituminous Macadam (60 mm)
Bituminous Concrete (40 mm)
Wet Mix Macadam (250 mm)
Existing Soil/Pavement + StabilRoad+ Cement
Granular Sub-Base (200 mm) (300 - 350 mm)

Compacted Soil Sub grade Compacted Soil Sub grade

Natural Soil Natural Soil

For Traffic < 20 MSA

The roads constructed by Full Depth Recycling Technology conforms to the latest Indian
Standards of IRC: 37- 2018 & IRC: SP- 89(Part-II) – 2018.
 TYPICAL CROSS-SECTION

Conventional Flexible Pavement StabilRoad Stabilised Pavement

With Full Depth Recycling Technology
Bituminous Concrete (50 mm)
Dense Bituminous Macadam (115 mm) Bituminous Concrete (40 mm)
Dense Bituminous Macadam (60 mm)
Wet Mix Macadam (250 mm)
Existing Soil/Pavement + StabilRoad+ Cement
Granular Sub-Base (200 mm) (300 - 350 mm)

Compacted Soil Sub grade Compacted Soil Sub grade

Natural Soil Natural Soil

For Traffic > 20 MSA

The roads constructed by Full Depth Recycling Technology conforms to the latest Indian
Standards of IRC: 37- 2018 & IRC: SP- 89(Part-II) – 2018.
PAVEMENT DESIGN CATALOGUE OF FDR TECHNOLOGY
AS PER IRC: 37- 2018
 IRC NORMS:
Ø IRC: SP 89 (PART II) – 2018 consists the “Guidelines for the Design of Stabilized
Pavements”. As per these guidelines,
• The Stabilised Base Layer is required to give a minimum compressive strength of 4.5 to 7
Mpa.(Mega pascals) or 450 to 700 MT/sqm
• Durability of the Stabilised base material to be tested by Wetting & Drying for 12 cycles. The
maximum permissible weight loss after this procedure is 14%. And the Residual Strength of
the specimen after this test shall not be less than 20% of 28 days UCS strength.

• The Commercial Chemical Stabiliser has to be tested for toxicity and leaching by CSIR-IITR.
Ø If the product passes the above tests with test reports from reputed institutes like
CRRI, IIT’s, NIT’s & Indian Institute of Toxicology Research, then it can be used at
the discretion of the user.
 STABILROAD (Commercial Chemical Stabiliser)

Ø Modern Civil Engineering has used cement as the main Stabilizer due to its excellent
bonding properties. But it does not work on clay, sandy, muddy soil.

Ø Only problem is cement-treated soils become very rigid and risk of cracking is very high.

Ø Addition of the product “StabilRoad” to cement during stabilization, significantly

increases the life of the pavement, strength of pavement & also eliminates the risks of
shrinkage cracks. This is due to its ability to change the parameters of the concrete’s
bending strength.

Ø It also helps in long lasting, durable, flexible, high load bearing pavements. The pavements
are also totally sealant to water, acids, oils and chemicals.
 STABILROAD (Commercial Chemical Stabiliser)

Ø The product StabilRoad is a commercial chemical stabiliser, manufactured by B&K

Industries UG & Co KG at Unterfohring, Germany and we have the exclusivity to use the
product in India.

Ø It is available in powder form, the texture is medium soft and the colour is Greyish-White.
It is made of 100% natural minerals with no synthetic chemicals.

Ø This product is already in use for nearly 20 years in several countries like Germany,
Estonia, Netherlands, United Kingdom, United States, Poland, Austria, Switzerland, Brazil,
Gabon, Guinea, Russia, South Korea etc.
 STONE AGGREGATE CONSERVATION

Ø Mining of Stone Aggregates involves extensive Quarrying & Stone Processing

Operations.

Ø It shall lead to:

§ Particulate emissions, causing Air Pollution in the mining & haulage Area.
§ Removal of natural vegetation on top causing deforestation.
§ Loss of Existing Wildlife.
§ Interruption of natural water recharge & reduced quantity & quality of drinking
water for residents & wildlife.

Ø No Stone Aggregate Requirement in Full Depth Recycled layer.

STONE AGGREGATE MINING
 PRESERVATION OF ENVIRONMENT

Ø One Km of 2-Lane width Conventional Flexible Pavement requires 5,932 Cum

of Stone Aggregates, which is equivalent to 424 truck loads.

Ø One Km of 2-Lane width Full Depth Recycled Pavement requires 843 Cum of
Stone Aggregates (equivalent to 60 truck loads), if the traffic is > 20 MSA.

Ø Hence, adoption of Full Depth Recycling Technology instead of Conventional

Flexible Pavement can preserve upto 5089 Cum of Stone Aggregate per km of
2-Lane Width, which is equivalent to 364 truck loads.
 SAND CONSERVATION

Ø Construction of Rigid Pavements by conventional method requires raw materials like

River Sand & Stone Aggregates in huge quantities.

Ø Sand is Mined from Rivers causing:

§ Lowering of Stream Bottom, leading to bank erosion.
§ Deepening of Rivers & Enlargement of River Mouths.
§ Threat to Bridges, River Banks & Nearby Structures.
§ Effect on Adjoining groundwater System.
§ Loss of Fertile streamside land/ wildlife habitats in riparian areas.
§ Loss of Fisheries Productivity, Bio-diversity & Recreational Potential.
§ Extra Vehicle Traffic, leading to emission of Greenhouse gases.

Ø No Sand Requirement in Full Depth Recycled layer.

RIVER SAND MINING & IMPACTS
 PRESERVATION OF ENVIRONMENT

Ø One Km of 2-Lane width Rigid Pavement requires 5,719 Cum of Stone

Aggregates & 2035 Cum of Sand.

Ø One Km of 2-Lane width Full Depth Recycled Pavement requires 843 Cum of
Stone Aggregates (equivalent to 60 truck loads), if the traffic is > 20 MSA.

Ø Hence, adoption of Full Depth Recycling Technology instead of Conventional

Rigid Pavement can preserve upto 4876 Cum of Stone Aggregate & 2035
Cum of Sand, per km for a 2-Lane width road, equivalent to 494 Truck Loads.
 PRESERVATION OF ENVIRONMENT
Ø About 40,000 km of highways have been constructed in the past 5 years.

Ø And around 65,000 km of highways are planned in the next 3 years.

Ø Going by this pace, another 1,50,000 Km of Roads can be expected by 2028.

Ø Total Stone Aggregate Requirement would be approx. 1094 Million Cum.

Ø If atleast 10% of the above roads i.e. 21,500 km are executed with this technology, then
about 109 Million Cum of Stone Aggregate can be preserved, which is equivalent to
78,26,000 Truck Loads. This is based on the assumption of 2 –Lane Road.

Ø This is in a nut shell is a rough indicator of saving of Natural Resources in the Country.
State-of-Art German Technology Machines are used in Pavement Construction
 CONSTRUCTION PROCEDURE

STEP 1: Preparation of Surfaces:

Ø Secure traffic for construction equipment

Ø Pre-levelling/ pre-composition of rough

grade level

Ø Marking/ pegging of stabilization area

Ø Safeguarding of subterranean service pipes

Ø Excavation/Filling, if required
 CONSTRUCTION PROCEDURE

STEP 2: Spreading of Cement and StabilRoad:

Ø Spreading of controlled amount of cement using

Automatic Stru Master Machine Imported from
Germany

Ø Spreading of controlled amount of StabilRoad

using Stehr Spreader Imported from Germany
 CONSTRUCTION PROCEDURE

STEP 3: Recycling of Pavement:

Ø Recycling to mix the existing

soil/pavement, Cement &
StabilRoad using Cold Recycler
Machine Imported from Germany.

Ø Recycling upto depth of 30 cms to

40 cms depending on requirement.

Ø Maintaining optimum moisture

content by adding controlled
amount of water during recycling.
 CONSTRUCTION PROCEDURE

STEP 4: Compaction and levelling of the surface:

Ø Compaction using Sheepfoot Roller.

Ø Post-profiling to precise grade level with grader.

Ø Compaction of precise grade level using smooth

drum roller.
 CONSTRUCTION PROCEDURE
STEP 5: Curing the surface:
Ø Water tanker is used to spread
the water for curing for 48 hours.
STEP 6: Applying Prime Coat:
Ø A layer of prime coat is applied on the surface of the
stabilised soil for better adhesion of the stabilised road with
the wearing coat.
STEP 7: Bitumen Concrete Layer:
Ø 40 mm thick bitumen concrete
layer is laid on it, to the desired
camber, which acts as a wearing
coat.
 FAST ROAD LAYING TECHNOLOGY
Ø Conventional Method of Road Construction involves formation of several layers like GSB,
WMM, DBM etc one after another. Therefore, the road construction requires atleast 15 days
to complete one lane km of 3.75 m width carriageway.
Ø During which, traffic must be diverted or restricted causing huge inconvenience to the daily
commuting life of common public.
Ø With Full Depth Recycling Technology,
one lane km of 3.75 m width carriageway
can be laid in a single day.

Ø The stabilised surface is ready for traffic

after 12 hrs of completion of work.

Ø Hence, the inconvenience can be avoided.

 TRADITIONAL ROAD VS STABILISED ROAD

DESCRIPTION TRADITIONAL ROAD STABILISED ROAD

AGGREGATES 424 RIDES (Flexible) 60 RIDES

SAND 145 RIDES (Rigid) 0

FUEL CONSUMPTION 7000 LITRES 1000 LITRES

15 DAYS (Flexible)
DURATION 3 DAYS
21 DAYS (Rigid)
CO2 POLLUTION 3225 CO2/KM 645 CO2/KM
Very Less due to use of
MANPOWER Significant
High-End Machinery
 LIST OF PROJECTS EXECUTED BY VSE WITH
STABILROAD STABILISATION TECHNOLOGY
S Description of Work Client Project Specifics Year of
No. Completion
Development of Truck Terminal in Krishnapatnam Krishnapatnam Port Road Length: 2.54 km;
1 Aug - 2017
Port Limits- Nellore, A.P. Company Limited Width: 8 m
Construction of Roads using Soil Stabilization
GHMC, Govt. of Road Length: 1.1 km;  
2 Technology from Indira Gandhi statue to Telugu Talli
Telangana Width: 9.5 m Feb – 2018
Statue, Hyderabad, Telangana
Road Length: 0.285 km;
Construction of Roads using Soil Stabilization
GHMC, Govt. of Width: 7.3 m
3 Technology from Unani Hospital, Moulali to NCL March - 2018
Telangana Road Length: 0.27 km;
Apartments, Moulali, Hyderabad, Telangana
Width: 9.0 m
Construction of Recycled Bituminous Concrete
Krishnapatnam Port Road Length: 0.5 km;
4 Stabilizer Road from Berth No – 3 to 4 at May - 2018
Company Limited Width: 15.5 m
Krishnapatnam Port, Nellore, A.P.
Panchayat Raj & Rural Road Length: 1.605 km;
Rehabilitation of MV road to Poranki H/W via
Development Width: 3.75 m
5 Salipeta using StabilRoad Asphalt Recycling in July - 2018
Department, Govt. of Road Length: 0.66 km;
Poranki(V) of Penamaluru Mandal.
Andhra Pradesh Width: 7.0 m
 LIST OF PROJECTS EXECUTED BY VSE WITH
STABILROAD STABILISATION TECHNOLOGY
S Description of Work Client Project Specifics Year of
No. Completion
Improvements to Anayadi-Pazhakulam-Kurampala-
Keerukuzhi-Chandanappally-Koodal Road in Kerala Infrastructure Road Length: 5.9 km
6 Oct - 2018
Pathanamthitta District – Full Depth Reclamation Investment Fund Board Width: 6 m
(FDR) Technology
Construction of approach road at Kothapatnam (V), Nekkanti Mega Food Road Length: 1.97 km
7 Jan - 2019
Kota (M), SPSR Nellore District Park Private Limited Width: 7.8 m
Construction of Recycled Bituminous Concrete Krishnapatnam Port Road Length: 0.5 km
8 Jan - 2019
Stabiliser BC-4 Road (0.5 Km) Company Limited Width: 10 m
Construction of Recycled Bituminous Concrete Krishnapatnam Port Road Length: 0.22 km
9 Jan - 2019
Stabiliser BC-4 Road (0.22 Km) Company Limited Width: 10 m
Construction of Recycled Bituminous Concrete Krishnapatnam Port Road Length: 0.75 km
10 Jan - 2019
Stabiliser Road from Berth-6 to LC-10A Company Limited Width: 10 m
Strengthening of Lalru-Handesra-Khelan Mallan road Public Works
Road Length: 15 km
11 from Km 0.00 to 15.00 by way of Cold in-Situ Department, Govt. of April - 2019
Width: 5.5 m
Stabilization Technology as PILOT PROJECT Punjab
 LIST OF PROJECTS EXECUTED BY VSE WITH
STABILROAD STABILISATION TECHNOLOGY
S Description of Work Client Project Specifics Year of
No. Completion
Formation of B.T. Road with Soil Stabilization
The Andhra Sugars Road Length: 0.56 km
12 Technology in the 3 MW Power Plant, Saggonda, West April - 2019
Limited Width: 8 m
Godavari District, A.P.

Ø More 2 Lakh SQM of Area is executed in India with Full Depth Recycling Technology,
which is Equivalent to approx. 60 Lane-Km.

Ø More than 10 Million SQM of Area is executed world wide using this Technology.
(Brief List is Enclosed)
SAALIPETA-PORANKI ROAD, VIJAYAWADA
SAALIPETA-PORANKI ROAD, VIJAYAWADA
SAALIPETA-PORANKI ROAD, VIJAYAWADA
CORE SAMPLES OF SAALIPETA-PORANKI ROAD, VIJAYAWADA
PANCHAYAT RAJ, AP – QC TEAM – UCS TEST RESULTS
 UCS TEST REPORT BY NIT WARANGAL
ON CORE SAMPLES FROM PORANKI, VIJAYAWADA
 UCS TEST REPORT BY KDM ENGINEERS
ON CORE SAMPLES FROM PORANKI, VIJAYAWADA
CONDITION OF ROAD BEFORE TAKING-UP WORK, KERALA
STABILROAD SPREADING
RECYCLING CEMENT, STABILROAD & EXISTING PAVEMENT
PAVEMENT AFTER RECYCLING, KERALA
COMPACTION & GRADING
CURING, ROAD AFTER STABILISATION
CLEANING AND APPLYING BITUMEN EMULSION
LAYING OF WEARING COAT
FINISHED ROAD, KERALA
CORE SAMPLES
NIT WARANGAL – CORE SAMPLES TEST REPORT- KERALA

KDM ENGINEERS– CORE SAMPLES TEST REPORT- KERALA

CONDITION OF ROAD BEFORE TAKING-UP WORK, LALRU, PUNJAB
CEMENT & STABILROAD SPREADING, LALRU, PUNJAB
RECYCLING, LALRU, PUNJAB
COMPACTION & ROLLING, LALRU, PUNJAB
STABILISED SURFACE, LALRU, PUNJAB
CURING, LALRU, PUNJAB
CORE SAMPLES, LALRU,
PUNJAB
 DURABILITY TEST REPORT BY NITTTR
ON CORE SAMPLES FROM LALRU, PUNJAB
 UCS TEST REPORT BY NITTTR
ON CORE SAMPLES FROM LALRU, PUNJAB
CURRENT STATUS OF COMMISSIONED ROAD, NTR MARG
CURRENT STATUS OF COMMISSIONED ROAD, NTR MARG
CURRENT STATUS OF COMMISSIONED ROAD, KRISHNAPATNAM PORT
CURRENT STATUS OF COMMISSIONED ROAD, KRISHNAPATNAM PORT
 LABORATORY TEST REPORTS

Ø CSIR- Central Road Research Institute (CRRI), New Delhi:

• Has conducted the Strength & Durability tests on StabilRoad Stabiliser in the lab and
the report is Enclosed.
• Has also collected core samples from the three roads constructed in Krishnapatnam
Port, Saalipeta - Poranki Road & NTR Marg, Hyderabad & conducted the following
Tests:
§ Unconfined Compressive Strength Test (Report is Enclosed) &
§ Durability & Water Absorption Test (Report is Enclosed)
Ø Results obtained from the Unconfined Compressive Strength, Durability & Water
Absorption tests are much better than the norms in IRC: 37- 2018 & IRC: SP-
89(Part-II) – 2018. Hence, the technology is approved by CRRI.
CORE SAMPLES COLLECTED BY CRRI
UCS TEST RESULTS ON STABILROAD
DURABILITY TEST RESULTS ON STABILROAD
 UCS TEST RESULTS ON CORE SAMPLES

S. No. Road Location Avg. UCS (MPa)

1 Krishnapatnam Port, A.P. 10.52

2 Saalipeta – Poranki Road, A.P. 10.04

3 NTR Marg to Telugu Thali Flyover, Hyderabad 10.06

DURABILITY TEST RESULTS ON CORE SAMPLES
DURABILITY & WATER ABSORPTION TEST
RESULTS ON CORE SAMPLES
 HIGHLIGHTS OF CRRI REPORTS
STABILROAD - CORE SAMPLES-
DESCRIPTION IRC SP 89 -2018
CRRI CRRI

UCS after 28 days 4.5 – 7 MPa 5.88 MPa 10.20 MPa

CBR 6% >100 %
(California Bearing Ratio)
Durability Test
(12 Cycles of 48 hours each)
Weight Loss after Durability test 14 % Permissible Max 0.63% Max 1.16%
Residual UCS after Durability Test Not less than 20  
14.23 Mpa
% after 28 days
 LABORATORY TEST REPORTS

Ø National Institute of Technology (NIT), Warangal has also conducted UCS tests on
the core samples from the different roads. Reports are Enclosed.

Ø Indian Institute of Toxicology Research (IITR) has done:

• Acute Immobilization Test of Stabil Road in Daphia Magna. Report is Enclosed.

• Acute Toxicity Test of Stabil Road in Earthworm. Report is Enclosed.

• Acute Toxicity Test of Stabil Road in Zebrafish. Report is Enclosed.

Ø 0 % Immobilisation was observed at the end of 48 hours in Control & Daphnids &
also no mortality, abnormal behaviour or toxic signs are observed in Earthworm or
in Zebra fish.
 FALLING WEIGHT DEFLECTOMETER (FWD)

Ø Structural Condition of the pavement can be evaluated using FWD and subsequent analysis be
carried out to ascertain the performance of the pavement in accordance with the IRC 115:2014.
Ø The FWD is designed to impart a load pulse to the pavement surface which simulates the load
produced by a rolling vehicle wheel.
Ø When subjected to a load, the pavement will bend and a deflection bowl is created. The
deflections at various distances from the loading centre are recorded by the sensors (geophones).
Ø The deflections were then back calculated using the KGP-BACK application to obtain Elastic
Modulus values of different Layers.
Ø From on the Deflection data, Elastic Modulus values & design traffic in MSA, the pavement
performance is calculated by IITPAVE Application to find the actual Remaining Life retained at
present in terms of Fatigue and Rutting performances for Flexible Pavements.
 LABORATORY TEST REPORTS

Ø KDM Engineers (India) Pvt. Ltd., accredited laboratory by NABL, has evaluated the
Structural Condition of the Pavement using FWD for the roads constructed by us at:
• Saalipeta – Poranki Road, Vijayawada (Report Enclosed) &
• Adoor Town, Kerala (Report is Enclosed)

Ø Indian Road Survey & Management Pvt. Ltd. (IRSM), has also studied the Structural
Condition of the pavement using FWD for the roads constructed by us at:

• NTR Marg, Hyderabad (Report is Enclosed)

• KPCL, Nellore (Report is Enclosed)

 RESULTS OF FWD TESTS

Residual Life of
S. No. Road Location Design Traffic Pavement from FWD
analysis
1 Saalipeta – Poranki Road, Vijayawada 8 MSA 320 MSA

2 Ayandi Section, Kerala 10 MSA 580 MSA

3 NTR Marg, Hyderabad 50 MSA 3624 MSA

4 KPCL, Nellore 241 MSA 4615 MSA

 FULL DEPTH RECYCLING WITH
STABILROAD
www.stabilroad.in
ü Eco-Friendly.

ü Fast Road Laying. DISCUSSION

ü Highly Durable.

ü More Strength.

ü Less Manpower involved.