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Flexible Pavement Design for North Texas Soils

Site investigations you can build on.

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Irving sits squarely on the Eagle Ford Shale formation, which weathers into highly plastic, expansive clays. Anyone who has driven Loop 12 after a wet winter knows what volume change does to asphalt: longitudinal cracking, alligator patterns, and rutting that reappears two seasons after a mill-and-overlay. A CBR road subgrade assessment run on undisturbed Shelby tube samples tells us whether the native subgrade can carry traffic loads or whether we need chemical stabilization before placing the asphalt. When the plasticity index pushes past 25 — not uncommon near the Trinity River floodplain — we pair standard Proctor curves with triaxial resilient modulus data to calibrate the AASHTO 1993 structural number so the pavement section actually matches Irving's moisture regime. Our lab runs ASTM D1883 soaked CBR on every project because a dry-weather number is meaningless here; the clay swells, loses strength, and that is exactly when the pavement fails.

Soaked CBR values in Irving's Eagle Ford clay routinely drop below 3 percent — designing with dry-weather numbers guarantees a premature failure.

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Process and scope

The City of Irving references AASHTO 1993 pavement design methodology, and most TXDOT projects in Dallas County default to the same framework. What makes Irving different from, say, Fort Worth is the depth of the moisture active zone — we routinely see seasonal suction changes down to 12 feet in the Eagle Ford, which means the subgrade modulus is a moving target. We run plate load tests in the field at the top of the prepared subgrade and compare the measured k-value against the lab-derived resilient modulus; the ratio tells us whether the compaction spec actually delivered the stiffness the design assumed. Our technicians cast three-point bending beams for asphalt modulus and run repeated load triaxial on the base course so the mechanistic-empirical analysis uses layer-specific inputs, not textbook defaults. That level of granularity matters when you are paving a distribution center off Belt Line Road that will see 800 truck passes a day.
Flexible Pavement Design for North Texas Soils
Technical reference — Irving

Site-specific factors

Irving recorded over 40 inches of rain in 2024, and the swelling potential of the Eagle Ford clay is among the highest in the Metroplex — volume changes of 8 percent or more between dry summer and wet spring conditions. A pavement section designed without accounting for this moisture sensitivity will pump fines up through the base course within three to five years, creating the classic 'mud wave' failure at the joints. The bigger financial risk is not the asphalt itself; it is the aggregate base that gets contaminated with clay and loses drainage capacity, forcing a full-depth reconstruction that costs four to six times the price of a mill-and-overlay. We quantify that risk upfront with suction-controlled resilient modulus testing so the structural number has a built-in moisture reduction factor, not a generic one pulled from a table that was never validated on Irving subgrades.

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Reference standards

ASTM D1883 (CBR of Laboratory-Compacted Soils), AASHTO T307 (Resilient Modulus of Subgrade Soils), ASTM D4123 / AASHTO TP31 (Indirect Tensile Resilient Modulus of Asphalt), AASHTO 1993 Guide for Design of Pavement Structures, ASTM D1557 (Modified Proctor — moisture-density relationship)

Technical parameters

ParameterTypical value
Design methodologyAASHTO 1993 & MEPDG (mechanistic-empirical)
Subgrade testSoaked CBR (ASTM D1883), resilient modulus (AASHTO T307)
Asphalt modulusIndirect tensile or 3-point bending beam at 20°C and 40°C
Base course characterizationRepeated load triaxial, permeability, gradation
Moisture considerationSuction-controlled resilient modulus at optimum + 2% moisture
Structural number verificationFWD backcalculation on test sections
Typical design ESALs0.5 to 10 million (residential to arterial)

Common questions

How much does a flexible pavement design cost for a project in Irving?

For a typical commercial or light industrial project in Irving, the pavement design package — including subgrade sampling, soaked CBR testing, resilient modulus determination, and the stamped structural section — runs between US$1,520 and US$4,810 depending on the number of borings, the depth of investigation, and whether FWD verification testing is required by the owner.

Why can't I just use the TXDOT standard pavement section for Irving?

TXDOT standard sections are a reasonable starting point, but they are calibrated for statewide average conditions. Irving's Eagle Ford clay has a higher plasticity index and a deeper moisture active zone than most of the state, so the standard section often underestimates the required base thickness. We adjust the structural number based on project-specific soaked CBR and resilient modulus values, which typically adds 2 to 4 inches of aggregate base compared to the default — a small upfront cost that avoids a full-depth failure five years later.

How long does the pavement design process take?

From the day we mobilize the drill rig to the day you receive the stamped report, plan on two to three weeks. The critical path is the soaked CBR test, which requires a 96-hour soak period per ASTM D1883. Resilient modulus testing adds another three to four days. If the project is on a tight timeline, we can issue preliminary base thickness recommendations based on index properties within one week and follow up with the final design once the modulus data is complete.

Do you test the asphalt mix as part of the pavement design?

Yes — we run indirect tensile resilient modulus on compacted asphalt specimens at both 20°C and 40°C to capture the temperature sensitivity of the mix. For high-traffic projects we also cast three-point bending beams for flexural modulus and fatigue life prediction. The asphalt layer modulus is a direct input into the mechanistic-empirical analysis, and using a default value instead of a lab-measured one can shift the predicted rutting life by 30 percent or more.

Location and service area

We serve projects in Irving and surrounding areas.

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