08-25-2025, 12:51 AM
The Challenge of Rebuilding a Mountain Access Road
Repairing a steep, poorly constructed mountain road presents a unique set of challenges. In this case, the road in question was originally laid with loosely compacted aggregates like 411s and 304s, without a proper wearing course or drainage infrastructure. Over time, erosion, rutting, and water damage turned it into a hazardous goat trail, with grades exceeding 14%—well beyond the recommended maximum for gravel roads.
The site serves a cell tower, meaning it requires periodic access for maintenance and fuel delivery. However, the road’s condition has deteriorated to the point where even light-duty dump trucks cannot safely traverse it. The repair plan involves stabilizing the base, improving drainage, and reconstructing the surface using geosynthetics and stone—while navigating steep terrain and limited access.
Evaluating Equipment Options for the Job
The core question is whether to rent two specialized machines—a compact dozer and a tracked loader—or find a single machine with interchangeable attachments that can handle both grading and material transport. Each approach has trade-offs in terms of cost, efficiency, and maneuverability.
A compact track loader (CTL) with a high-horsepower rating (90+ HP) and a tooth bucket can handle material movement and light excavation. However, its grading capabilities are limited compared to a dozer equipped with an SU (semi-universal) blade, which excels at pushing and shaping material. While some CTLs offer blade attachments, they often lack the hydraulic power and blade geometry needed for precise grading on steep slopes.
In contrast, a small dozer—such as a Caterpillar D3 or Komatsu D39—offers superior control for cutting and shaping the roadbed. These machines are designed for slope work and can handle the push-pull dynamics required to flatten uneven terrain. Renting both machines may increase costs, but it ensures that each task is performed with the right tool.
Understanding Geogrid Stabilization
Geogrids are synthetic mesh materials used to reinforce soil and aggregate layers. Unlike geotextile cloth, which primarily separates materials, geogrids interlock with stone to distribute loads and resist lateral movement. In this project, a triaxial geogrid like Tensar TX190 was proposed to stabilize the road base and adjacent swale.
While geogrids are highly effective in soft or wet soils, their role in steep terrain is more nuanced. They do not prevent surface washout but can reduce subgrade deformation and extend the life of the road. In Ohio’s clay-rich soils, geogrids can help bind the base material and reduce the risk of rutting and collapse—especially when paired with proper drainage and a robust wearing course.
Drainage Design and Erosion Control
Water management is critical in mountain road construction. Without proper drainage, even the best materials will fail. The original road lacked culverts, swales, and water diversion features, leading to undercutting and collapse. The repair plan includes:
Material Selection and Cost Breakdown
The largest cost component in this project is stone, estimated at over $30,000. The plan calls for:
Lessons from the Field
In a similar case in southern Indiana, a communications company faced access issues to a remote tower site. Rather than investing in proper road construction, they opted for minimal grading and stone placement. Within two years, the road became impassable during wet seasons, requiring emergency repairs and helicopter access for technicians.
This highlights the false economy of underbuilding access roads. While initial savings may seem attractive, long-term costs—including safety risks and operational delays—can far exceed the investment in proper construction.
The Role of Ethics and Responsibility
One of the most compelling aspects of this project is the contractor’s refusal to cut corners. Despite pressure to minimize costs, they insisted on a design that prioritizes safety and longevity. In one incident, a culvert collapsed during inspection, nearly causing a vehicle rollover. This reinforced the need for thorough reconstruction and proper engineering.
The contractor’s stance reflects a broader industry shift toward accountability and risk management. In remote infrastructure projects, especially those involving public utilities or emergency services, road integrity is not just a logistical concern—it’s a matter of life and death.
Conclusion
Repairing a steep mountain road requires more than just machinery—it demands a strategic blend of engineering, equipment selection, and ethical decision-making. While a single multi-purpose machine may seem efficient, the complexity of the terrain and tasks often necessitates specialized tools. Geogrids offer valuable stabilization but must be paired with robust drainage and material layers. Ultimately, the success of such a project hinges on a commitment to doing the job right, not just cheaply. In an industry where shortcuts can have fatal consequences, that commitment makes all the difference.
Repairing a steep, poorly constructed mountain road presents a unique set of challenges. In this case, the road in question was originally laid with loosely compacted aggregates like 411s and 304s, without a proper wearing course or drainage infrastructure. Over time, erosion, rutting, and water damage turned it into a hazardous goat trail, with grades exceeding 14%—well beyond the recommended maximum for gravel roads.
The site serves a cell tower, meaning it requires periodic access for maintenance and fuel delivery. However, the road’s condition has deteriorated to the point where even light-duty dump trucks cannot safely traverse it. The repair plan involves stabilizing the base, improving drainage, and reconstructing the surface using geosynthetics and stone—while navigating steep terrain and limited access.
Evaluating Equipment Options for the Job
The core question is whether to rent two specialized machines—a compact dozer and a tracked loader—or find a single machine with interchangeable attachments that can handle both grading and material transport. Each approach has trade-offs in terms of cost, efficiency, and maneuverability.
A compact track loader (CTL) with a high-horsepower rating (90+ HP) and a tooth bucket can handle material movement and light excavation. However, its grading capabilities are limited compared to a dozer equipped with an SU (semi-universal) blade, which excels at pushing and shaping material. While some CTLs offer blade attachments, they often lack the hydraulic power and blade geometry needed for precise grading on steep slopes.
In contrast, a small dozer—such as a Caterpillar D3 or Komatsu D39—offers superior control for cutting and shaping the roadbed. These machines are designed for slope work and can handle the push-pull dynamics required to flatten uneven terrain. Renting both machines may increase costs, but it ensures that each task is performed with the right tool.
Understanding Geogrid Stabilization
Geogrids are synthetic mesh materials used to reinforce soil and aggregate layers. Unlike geotextile cloth, which primarily separates materials, geogrids interlock with stone to distribute loads and resist lateral movement. In this project, a triaxial geogrid like Tensar TX190 was proposed to stabilize the road base and adjacent swale.
While geogrids are highly effective in soft or wet soils, their role in steep terrain is more nuanced. They do not prevent surface washout but can reduce subgrade deformation and extend the life of the road. In Ohio’s clay-rich soils, geogrids can help bind the base material and reduce the risk of rutting and collapse—especially when paired with proper drainage and a robust wearing course.
Drainage Design and Erosion Control
Water management is critical in mountain road construction. Without proper drainage, even the best materials will fail. The original road lacked culverts, swales, and water diversion features, leading to undercutting and collapse. The repair plan includes:
- Excavating and backfilling the uphill swale with rip-rap to redirect runoff
- Installing culverts at key low points to prevent pooling
- Adding “waterbars” or “wooboys”—angled berms that divert water off the road surface
- Using inverted crowns every 50–100 feet to steer water into drainage paths
Material Selection and Cost Breakdown
The largest cost component in this project is stone, estimated at over $30,000. The plan calls for:
- A base layer of 2"–4" rock for structural support
- A middle layer of 1¼" minus aggregate for compaction
- A wearing course of #4 or #57 limestone for surface durability
Lessons from the Field
In a similar case in southern Indiana, a communications company faced access issues to a remote tower site. Rather than investing in proper road construction, they opted for minimal grading and stone placement. Within two years, the road became impassable during wet seasons, requiring emergency repairs and helicopter access for technicians.
This highlights the false economy of underbuilding access roads. While initial savings may seem attractive, long-term costs—including safety risks and operational delays—can far exceed the investment in proper construction.
The Role of Ethics and Responsibility
One of the most compelling aspects of this project is the contractor’s refusal to cut corners. Despite pressure to minimize costs, they insisted on a design that prioritizes safety and longevity. In one incident, a culvert collapsed during inspection, nearly causing a vehicle rollover. This reinforced the need for thorough reconstruction and proper engineering.
The contractor’s stance reflects a broader industry shift toward accountability and risk management. In remote infrastructure projects, especially those involving public utilities or emergency services, road integrity is not just a logistical concern—it’s a matter of life and death.
Conclusion
Repairing a steep mountain road requires more than just machinery—it demands a strategic blend of engineering, equipment selection, and ethical decision-making. While a single multi-purpose machine may seem efficient, the complexity of the terrain and tasks often necessitates specialized tools. Geogrids offer valuable stabilization but must be paired with robust drainage and material layers. Ultimately, the success of such a project hinges on a commitment to doing the job right, not just cheaply. In an industry where shortcuts can have fatal consequences, that commitment makes all the difference.
