How Ferguson Waterworks helps contractors reduce costs, stabilize roads, and overcome tough subgrades.
“My subgrade is soft and unstable. Aggregate is expensive, and I need to reduce how much I use. I also want to avoid chemicals and create durable haul roads that won’t rut under heavy loads.” — Contractor
Unpaved haul and access roads are essential to most construction, industrial, and mining operations. These roads must be built quickly, handle constant heavy loads, and remain passable in all weather. But poor subgrades, rising material costs, and environmental concerns often make this difficult. Below, we outline the most common problems—and how Ferguson’s geosynthetic solutions solve them.
Challenge 1: My subgrade is soft or pumping, leading to instability.
Soft or saturated subgrades lead to rutting, pumping, and premature failure of the road surface—even with thick aggregate layers. Without proper reinforcement, these roads become maintenance burdens and site liabilities.
Available Solutions:
- Geogrids (Tensar InterAx®): Primary solution. Reinforces soft soils by distributing loads evenly, minimizing rutting and preventing subgrade pumping.
- Geotextiles (Mirafi® H2Ri): Provides separation between aggregate and subgrade, while also improving filtration and drainage to keep the road base dry and stable.
- Geocells (Presto GEOWEB®): Adds 3D confinement, stabilizing weak soils under heavy haul loads, especially in wet conditions.
Challenge 2: My aggregate is expensive, and I want to reduce base thickness.
Hauling and placing thick sections of high-quality aggregate is one of the costliest parts of road construction. In remote areas, aggregate can become the project’s single biggest expense.
Available Solutions:
- Geogrids (Tensar InterAx®) Spreads loads effectively, allowing a significant reduction in aggregate thickness without compromising performance.
- Geotextiles (Mirafi® H2Ri) Prevents mixing of the base and subgrade, preserving the structural integrity of thinner aggregate layers.
- Geocells (Presto GEOWEB®) Increases the bearing capacity of infill materials, reducing the quantity of imported aggregate required.
Challenge 3: I want to avoid using chemical stabilizers.
Lime, cement, and fly ash stabilization adds cost, time, and regulatory complexity. Many project owners are pushing for environmentally responsible alternatives.
Available Solutions:
- Geogrids (Tensar InterAx®) Provides mechanical stabilization without the need for lime, cement, or fly ash treatments.
- Geotextiles (Mirafi® H2Ri) Offers structural support and moisture control without chemicals.
- Geocells (Presto GEOWEB®) Confines and stabilizes the base mechanically, avoiding environmental and regulatory concerns tied to chemical use.
Challenge 4: My haul roads need to support heavy, repetitive loads without failing.
Heavy trucks, equipment, and frequent vehicle traffic cause unpaved roads to degrade quickly. Without reinforcement, these surfaces develop ruts and potholes that slow work, increase fuel usage, and pose safety risks.
Available Solutions:
- Geogrids (Tensar InterAx®) Enhances load distribution, preventing rutting and surface deformation even under constant heavy vehicle traffic.
- Geotextiles (Mirafi® H2Ri) Maintains separation and stability under cyclic loading.
- Geocells (Presto GEOWEB®) Reduces lateral movement of base material, preserving surface integrity and reducing maintenance needs.
Can geosynthetics also lower costs beyond reducing aggregate?
Yes. In addition to saving on base material, geosynthetics can help you:
- Use locally available, lower-cost fill instead of premium aggregate.
- Reduce hauling and installation time, lowering labor and equipment costs.
- Minimize long-term maintenance and downtime.
What environmental advantages do geosynthetics offer?
- Lower aggregate and fuel use, reducing carbon footprint.
- No chemical stabilizers, eliminating environmental and permitting concerns.
- Extended service life, resulting in fewer repairs and material replacements.
Where can I get design support or a materials consultation?
Ferguson Waterworks’s geosynthetics experts can assist with the design, material selection, and supply for your next haul or access road project—no matter the soil conditions or load requirements.
Contact your local Ferguson Waterworks expert to get started.
