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PRS Geo-Technologies — Stabilizing an unstable world!

Neoloy Pavement Designer

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PRS Geo-Technologies — Stabilizing an unstable world!

Neoloy Pavement Designer

Neoloy Pavement Designer

Advanced pavement design, optimization, and performance analysis using Neoloy Tough Cells®.

Design flexible, rigid, industrial, and working-platform pavements with confidence. Evaluate subgrade improvement, layer equivalency, reinforcement benefits, and lifecycle performance using Neoloy Tough Cells technology.

1

Start new project

Create a project with a name and owner, then save your calculator work for later.

2

Resume project

Choose from saved projects in the connected project workspace.

PRS Geo-Technologies — Stabilizing an unstable world!

Road & Pavement Design

Neoloy Pavement Designer

EV2 pavement structures and unpaved road design.

Current Project Unsaved calculator

Scenario Manager

Build one or more pavement design cases, then compare them side by side.

Design suite link Pick the pair that feeds the Carbon and Unpaved tabs.

Active Scenario

Rename it and set the global inputs here; layers and subgrade CBR are edited in the tables on the right.

Project Materials The materials this project offers in each layer's dropdown. Seeded from the country / standard; rename, set a default CBR, add or remove. Changes apply on Apply.
Material nameDefault CBR %

Layer Design & Results

One editable table per scenario — surface at the top, subgrade (with its CBR) at the base. Inputs are on the left; computed EV2 updates on the right. Every scenario marked Compare gets its own table plus a side-by-side summary.

Layer Design

Drag the handle to reorder layers. Reinforced types reveal cell height / overfill / grid controls below the row. Click a scenario title to make it active.

Pavement Structure

Thickness profile with EV2 labels.

EV2 vs Depth

Step profile from subgrade to pavement surface.

Calculation Notes

    Neoloy Tough-Cells MIF

    Standalone MIF lookup — no full pavement design needed. Enter the infill material CBR and the support it sits on; the chart shows the 40 / 80 / 120 MPa support curves, the interpolated curve for your support, and the resulting MIF.

    MIF is interpolated between the 40, 80 and 120 MPa support curves and floored at 1.0. Support is clamped into the 40–120 MPa fit domain: below 40 MPa the MIF is taken from the 40 MPa curve, above 120 MPa from the 120 MPa curve. The SIF vs support view compares the SIF cap (support modulus × SIF factor, ramping between the calibrated factors across support CBR 3–4.6) with MIF × Emax — the lower of the two governs the layer modulus.

    Find my pavement

    Suggest the thinnest Neoloy Tough-Cells structure — either from a few quick questions, or by matching an existing unreinforced pavement.

    1 What are you building?
    2 What is the ground like?
    3 Which materials can you get on site?
    Advanced options

    These are filled in automatically from your answers above. Change them only if you know the exact figures.

    Material design CBR (%)

    Before You Start

    • Use this mode only for granular pavement layers.
    • Do not use asphalt or concrete as the top layer in this quick tool.
    • Enter layers from top to bottom; the last row sits on the subgrade.

    Unreinforced Input Structure

    Choose the granular material and thickness for each layer. The tool applies the standard CBR automatically.

    Optimizer Results

    The optimizer returns the thinnest structure plus one or two alternatives that satisfy the target EV2.

    Pavement Sketch

    Load a structure from the calculator or optimizer as an independent snapshot, then edit it freely. Changes here never affect the calculator.

    Drawing title block

    Shown in the CAD sheet's bottom title block. Leave a field blank to fall back to the project defaults.

    Sketch Layers

    Thickness, material, hatch, density, and description are all editable.

    # Thickness (mm) Material Hatch Density Description Remove

    Sketch Output

    Switch between the 2D cross-section and the 3D view. Both export to JPG.

    Style
    0 / 250
    Drag to rotate · Scroll to zoom · Right-drag to pan

    Legend

    Tender-ready road CO₂ model

    Carbon Comparison

    Enter road geometry and layer thicknesses. Emission assumptions use defaults unless changed in the Data & Defaults sub-tab. This tab is independent of the structural calculator.

    Estimated reduction 0% 0 t CO₂ saved

    Project Geometry

    Enter only the road geometry. Results update automatically.

    Define each scenario's layers (type + thickness). Emission assumptions live in the Data & Defaults sub-tab. Add or remove layers and scenarios freely.

    Automatic Comparison

    CO₂ totals, savings, percentage reduction, and lane-km intensity.

    Total CO₂ savings0 kg0.00 t CO₂
    Reduction0%Neoloy Tough-Cells vs conventional
    Conventional CO₂0 kg0 kg/m2
    Neoloy Tough-Cells CO₂0 kg0 kg/m2
    CO₂ per km road0 t/kmSavings normalized by length
    CO₂ per lane-km0 t/lane-kmUseful for tender benchmarking

    Total CO₂ by Scenario

    kg CO₂, including materials, transport, equipment, excavation, and binders.

    Conventional Breakdown

    Contribution by work item.

    ScenarioTotal CO₂kg/m2t/km roadt/lane-kmTruckloadsTransport CO₂

    Transport Defaults

    Most users can leave these unchanged. Edit them when you have fleet or project-specific data.

    Approximate Values Guide

    Starting points when project-specific data is unavailable. Not a substitute for local EPDs, supplier data, or measured fuel records.

    InputTypical valuePractical rangeUse for
    Soil density1.8 t/m31.6-2.0 t/m3Excavation/removal mass and transport
    Locally available material density1.8 t/m31.6-1.9 t/m3In-situ / local fill mass
    Sand density1.7 t/m31.6-1.8 t/m3Granular sand layers
    Type A Base Course density2.0 t/m31.9-2.2 t/m3Crushed base aggregate mass
    Asphalt density2.35 t/m32.3-2.4 t/m3Asphalt mass and production CO₂
    Truck CO₂ factor0.18 kg/t-km0.16-0.20 kg/t-kmLoaded and return haul emissions
    Empty return factor0.50-10 = ignore, 1 = full empty return
    Excavation CO₂0.5 kg/m30.3-0.8 kg/m3Soil excavation and replacement works
    Aggregate CO₂10 kg/t5-20 kg/tCrushing and aggregate production
    Asphalt CO₂35 kg/t30-40 kg/tAsphalt production
    Layer equipment CO₂1 kg/m20.5-2.0 kg/m2Water truck, grader, and compactor
    Lime binder CO₂ / dosage800 kg/t / 3%750-900 kg/t / 2-8%Lime stabilization
    Cement binder CO₂ / dosage900 kg/t / 2.5%~900 kg/t / 2-3%Cement stabilization

    Calculation Background

    Formulas, default values, and literature sources used by the carbon calculator.

    1. Geometry and Quantity Takeoff

    Area = road length x road widthLayer volume = area x layer thicknessLayer mass = volume x density

    Density converts volume in m3 to mass in tons for material and transport emissions.

    2. Truck Transport

    Truck capacity, tons = capacity, m3 x densityTruckloads = roundup(mass / capacity)Transport CO₂ = mass x distance x (1 + return) x truck factor

    Default truck body 16 m3, emission factor 0.18 kg CO₂/t-km (range 0.16-0.20). The return factor scales empty return travel.

    3. Material Production

    Material CO₂ = layer mass x material CO₂ factor

    Aggregate defaults to 10 kg CO₂/t (range 5-20). Asphalt defaults to 35 kg CO₂/t (range 30-40).

    4. Excavation and Equipment

    Excavation CO₂ = layer volume x excavation factorEquipment CO₂ = road area x equipment factor

    Excavation defaults to 0.5 kg CO₂/m3. Layer equipment defaults to 1 kg CO₂/m2 for watering, grading, and compaction.

    5. Lime and Cement Stabilization

    Binder mass = layer mass x binder dosageBinder CO₂ = binder mass x binder CO₂ factor

    Lime defaults to 3% dosage and 800 kg CO₂/t. Cement defaults to 2.5% and 900 kg CO₂/t.

    6. Results and Savings

    Total CO₂ = material + transport + excavation + equipment + binderCO₂ savings = conventional total - Neoloy Tough-Cells totalReduction % = savings / conventional total x 100CO₂ per lane-km = total / (length in km x lanes)

    The dashboard compares total emissions and intensities per m2, per km, and per lane-km.

    Literature Basis for Default Values

    References used to build the default ranges and calculation logic.

    Excavation and Diesel Emissions

    Diesel is ~2.68 kg CO₂/L. Medium excavator fuel use supports ~0.3-0.8 kg CO₂/m3, with 0.5 used as default.

    AIP: Estimating GHG emissions from construction equipment

    Truck Transport

    Heavy truck transport default 0.18 kg CO₂/t-km (range 0.16-0.20), applied to loaded haul and optional empty return.

    EDF: Green freight math for truck moves

    Quarry Aggregate / Base

    Aggregate production is lower carbon than cement or asphalt. Default 10 kg CO₂/t within the 5-20 range.

    NSSGA: Greenhouse gas emissions report

    Asphalt

    Asphalt production defaults to 35 kg CO₂/t (range 30-40). Density 2.35 t/m3.

    Ecochain: Asphalt carbon footprint

    Lime and Cement Stabilization

    Lime ~2-8% dosage; production is carbon intensive due to calcination. Cement ~900 kg CO₂/t and 2-3% dosage.

    OSTI: Lime production and calcination emissions

    Bill-of-quantities cost comparison

    Cost-Benefit Analysis

    Compare the unreinforced design against the Neoloy-reinforced design. Pull both from the EV2 calculator, set the project sections and unit rates, and the bill of quantities is taken off automatically.

    Initial cost saving 0% 0 saved
    Life-cycle saving 0% 0 saved

    Project sections

    Add a row per paved area (carriageway, shoulders, hardstand). The footprint is the sum; layer volumes come from each design's thicknesses.

    SectionLength (m)Width (m)QtyArea (m²)
    Footprint area0 m²
    Unreinforced excavation depth0 mm
    Reinforced excavation depth0 mm
    Excavated spoil avoided0 m³

    Unit rates

    Edit any cell to reprice, or load a saved rate sheet. Granular rates are per m³, reinforcement per m².

    Custom line items

    Optional extras the structural design doesn't carry — surfacing, kerbs, drainage, markings. Apply to one design or both.

    DescriptionApplies toBasisThickness (mm)Rate

    Maintenance & life-cycle

    Recurring maintenance events, priced per m² per occurrence (in the tab currency) with separate values per design. Life-cycle cost = initial (CAPEX) + NPV of the maintenance stream over the analysis period. Real terms — no inflation, no residual value.

    Maintenance eventUnreinforcedReinforced
    Cost / m²Every (yrs)Cost / m²Every (yrs)

    An interval of 0 (or blank) on a side means the event does not apply to that design. Events recur at t = interval, 2×interval, … strictly before the end of the analysis period. Fuel and CO₂ impacts are quantified separately in the Carbon (CO₂) tab and are not monetised here.

    Comparison

    Initial (CAPEX), maintenance NPV, and life-cycle cost over the analysis period, in real terms.

    Unreinforced — initial00 / m²
    Reinforced — initial00 / m²
    Initial saving00% lower
    Initial saving / m²0before margin
    Unreinforced — life-cycle00 / m²
    Reinforced — life-cycle00 / m²
    Life-cycle saving00% lower
    Maintenance saving0NPV
    TierUnreinforcedReinforcedBalance%
    CategoryUnreinforcedReinforcedBalance%

    Not monetised here: the reinforced design removes excavation & haul-away, cuts imported granular, and shortens the build — surface these as supporting benefits. Life-cycle figures are in real terms at the stated discount rate, with no inflation/indexing and no residual value.

    Reports

    Every export from every tool, gathered in one place. Each report downloads in its own format; the in-tab export buttons still work as before.

    Report Source Status Format Generated Action

    Ready EV2 design changed — out of date No data yet — open that tool first

    Neoloy Pavement Designer

    Administration

    Manage user accounts and per-country material & pricing profiles.

    Users Country profiles

    Create User

    New users must change their temporary password the first time they sign in.

    Existing Users

    Reset passwords, change roles, toggle access, or remove accounts.

    Country Profiles

    Standard material palette and currency per country. Calculation formulas are defined in code per country code; this screen never edits formulas.

    Material name CBR % Price / ton Density (t/m³)
    CBA unit rates (optional)

    Seeds the CBA tab's rate card for projects tagged with this country, in the profile currency. Leave a field blank for no seed. Granular per-m³ rates are derived automatically from the materials above (price/ton × density).

    Existing Country Profiles

    Edit currency/materials, or deactivate. The Generic profile is built in and cannot be removed.