Most rural counties construct unpaved roads because they’re far cheaper to build than paved roads. Contractors estimate that a two-lane, 24-foot wide gravel road costs from $64,000 to $150,000 per mile, whereas similar paved roads cost $2-3 million per mile.
Of course, if your county is like most, you’re working on a tight budget where even $150,000 a mile can feel like a stretch. Hey, we get it—and we’re here to help. We’ve been working with counties to build low-cost, dirt and gravel roads for over 50 years. Now, we’re sharing our top seven tips to help you build the roads you need without breaking the bank:
Maybe your county is considering building brand-new roads because a manufacturer moved in, a developer converted farmland into housing, or residents need more direct routes to the interstate. But, what if you could rebuild and improve existing roads to meet those demands?
Existing roads have distinct advantages because the land is already clear, and the roadbed is already in place. So, two of the largest initial roadbuilding costs are off the table. (Whew!) You may also save on material hauling if the road already has some acceptable dirt and gravel.
You already have information about how the road has worn over time, so you can confidently mitigate issues when you rebuild it. With brand-new roads, you can only predict what their flaws will be, and the margin of error could leave you vulnerable to unnecessary spending for potential problems or higher maintenance costs later if you miss something.
So, before starting from scratch, evaluate your existing roads. Can they meet the county’s demands with some modifications? For example, lane widening or surface repairs to improve safety and travel times may be sufficient.
There’s a saying that, “Time is money.” And that’s true—just not in the way most people think. You’re likely building a road because you have a pressing need, and you may save some money upfront by rushing the construction. But, moving too fast costs more in maintenance and penalties later.
So, when you’re planning your project, give yourself plenty of time for design, contractor bids, and permits. During that time, you can spot potential issues and determine how to address them before you start building your road. You can also consider ways to save money on maintenance later. Here’s what we mean:
The planning phase is meant to unearth potential problems so you can prevent or mitigate them. That makes building a road faster (fewer delays for unforeseen problems) and cheaper (less expensive rework).
When you build a road, you’re not looking for the cheapest thing right now. You’re looking for the best value long-term. Think of it like this:
You can buy gravel from Quarry A for $20 per ton or from Quarry B for $30 per ton. Most people would say, “Quarry A is cheaper, so let’s place the order.” But, you’re too savvy for that. You do some research, and you learn the gravel from Quarry B offers a better ride quality that residents will prefer. It’s less dusty, so you’ll need fewer dust suppressants. And it’s slightly coarser, so it doesn’t wash away or work into the soil as easily.
When you factor in resident complaints, dust control, and lost material, suddenly the cheaper gravel from Quarry A doesn’t look so good. The gravel from Quarry B may cost more upfront, but it’s better for your budget long-term.
The same goes for renting or buying equipment. One equipment dealer might charge more than another, but that dealer might also take the time to train your crew on how to use the equipment properly. Or, they might have a better maintenance warranty. It’s important to consider all factors that add value—not just the sticker price.
Part of getting the best value is getting the right people on your team. These people may or may not charge the cheapest rate, but they’re certainly knowledgeable and helpful.
A contractor can make or break your project, so choosing the best person for the job is critical. Get bids from multiple contractors, and ask questions about their experience and their plans for your project. A good contractor will have good answers, revealing who’s really here to construct high-quality roads and who’s just out to make a quick buck. Another wise idea? Get insight from people in neighboring counties who have similar roads or have used the same contractor.
Most importantly, ask this question when vetting any contractor, supplier, or even new hires for your crew: “Are they a good, honest person to do business with?” At the end of the day, you’re not looking for bells and whistles. You’re looking for a person of integrity who will offer you a good product with excellent service.
When you hire a contractor, you’re trusting them to hire and train the right people for the job. To make sure you’re aligned, ask about their foreman’s experience and how they train their employees on unpaved road construction.
When your own crew builds the county’s roads, that’s another ball of wax. There’s a big difference between performing routine maintenance and building a brand-new road… and a lot of county road crew members know more about maintenance than full-blown construction. So, teach them how to do construction!
Your whole crew can benefit from training:
In fact, the Construction Industry Institute released a massive research project that suggests investing just 1% of your labor budget into training increases productivity by 11% while dropping injuries and rework by 26% and 23%, respectively. (It also decreases turnover and absenteeism—which are noteworthy benefits in today’s age of labor shortages!)1
So, training may cost you money to spend time doing toolbox talks or bring in an expert for a training session in the shop instead of having your crews out in the field working. But, it’ll save you money by helping your crew do the job better, faster, and safer. Plus, training can turn Average Joes into great crew members who want to stick around for the long haul.
Your county’s residents can be your greatest champions or your worst nightmares. And you get to help them decide!
Sometimes, community members object to a county’s roadbuilding plans for practical or sentimental reasons. It’s easy to get frustrated when that happens. But, remember that these roads are for them, and you both share the goal of making the community its best (even if you differ on how to do it). Ignoring the community’s input now could cost you later in the form of complaints or—in extreme cases—lawsuits.
To encourage positive community engagement, keep residents up-to-date throughout the planning process. Clearly explain the pros and cons of the new road, and ask for input from those whom the road will impact most. You’ll stand a better chance of finding common ground when you hear their perspective. Plus, they may have good insight or valid concerns that you should consider.
You can even communicate more often and more transparently than the law requires, like this county road commissioner did when she rebuilt a road.
Realistically, some people will still object. You may have to make compromises that add to the construction timeline and price. But overall, you’ll win more support if you help the community understand why the construction project is genuinely best for them. You may even find that they’re more likely to put some of their own skin into the game when they know why they’re doing it.
Even well-built dirt roads are prone to erosion that requires constant grading—sometimes weekly. Gravel roads are a little more durable, but they’re prone to material loss that requires frequent reapplications.
This maintenance may not technically be part of the cost to build a road, but it will affect your budget for decades to come. The best time to consider how you’ll maintain the road (and how much it’ll cost) is during construction.
Soil stabilization strengthens soil to reduce erosion, material loss, and maintenance. There are several types of soil stabilizers, each with its own pros and cons. The main trouble for counties is that many traditional options are too expensive for unpaved roads (cement, lime, and polymers) while others are short-lived (chlorides and gravel).
So, let’s take a look at a long-lasting, cost-effective soil stabilizer.
Perma-Zyme contains special proteins called enzymes that chemically react with clay and limestone particles to bind soil together into a hard, concrete-like surface that resists water and erosion for over 10 years. This significantly reduces maintenance, allowing most customers to grade their roads just once or twice per year (instead of once or twice per month)! You can also use Perma-Zyme to lock in a gravel topcoat, preventing material loss, and to control dust.
Customers who use Perma-Zyme report saving an average of 60% on road construction compared to traditional methods and spending as little as $0 per year on maintenance. And you won’t just be saving money; you’ll be saving the environment, too! Eco-friendly Perma-Zyme is 100% organic, non-toxic, non-corrosive, and biodegradable.
Atlas Township, Michigan, had problems with Walker Road. This gravel road had two low, swampy spots that developed massive frost boils in early spring. The frost boils were so bad that residents who lived nearby parked their cars in another location and walked home.
And conditions weren’t much better the rest of the year. Every time it rained—which was often in Michigan—Walker Road became muddy and difficult to drive on. The county was constantly expending time and fuel to regrade the road.
The Genesee County Road Commission, which oversees Atlas Township, decided to try Perma-Zyme. They notified residents about the treatment and generated public support. Within a week of treating the road with Perma-Zyme, the residents and county were both happy. The road no longer has frost boils, rarely needs maintenance, and sees much less dust. Road Commission Vice Chair Shirley Kautman Jones called the project a "huge success."
Reconstructing Walker Road went so well that Genesee County has since used Perma-Zyme on over 10 roads, and they’re all going strong. You can enjoy these same fantastic results!
Last but not least, we mention soil testing! It’s tempting to do the bare minimum when it comes to soil testing and surveying. After all, these pricey services drive up the cost of building a road—even a dirt or gravel one. It’s cheaper to make educated guesses based on past experience, right?
Not quite! The truth is that, while your best guess may be close, it’s impossible to identify soil’s exact composition without testing it. And remember, close only counts in horse shoes. If you don’t know what the soil’s made of, you could also miss crucial details about how it will behave during or after construction. Over time, roads built on untested soil are more likely to erode or collapse.
Paying for adequate testing and planning accordingly costs less in the long run than repeatedly fixing a road. And hey, there is one way to get your soil tested for free: use Perma-Zyme. We perform complimentary soil evaluations for U.S. counties and parishes to make sure your soil is compatible with Perma-Zyme, and we’ll even give you tailored recommendations to help you build the best possible road with enzyme soil stabilization.
The key to build a low-cost county road isn’t to just find the cheapest way to get the job done right now. It’s to build a road that will last with as little maintenance as possible, so you can save money for years once construction is complete. So, to sum it all up, some of the best ways to do that are:
Perma-Zyme is a great option that has helped road departments across the U.S. and the rest of the world build high-quality unpaved roads. But don’t just take our word for it!