John,
I want to reply to your message in depth, as I believe you may have misunderstood the function of this post, or perhaps missed some of the earlier content. Please don't take anything that I type as aggressive, that is anything but my intention. I am merely trying to keep things on track and avoid the typical forum snarkiness that tends to happen on the internet.
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As a Civil Engineer who designed and built roads and farm tracks there are many lessons for you to come..." Yes, for us all. The gravel roads I have built and maintained in the past were far closer to town, which meant I could haul material myself or it was a more reasonable ratio of haul bill to gravel. This has presented a new situation for us.
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Somebody has to remind you that 'cheap ' land is priced according to many factors, and you have discovered one." This is a massive assumption. I actually have not mentioned price here, and I am well aware of the budgetary requirements of building a road of this magnitude. This land was not cheap, and it was known from the beginning of our endeavors that the road would be one of the larger expenses of our time here.
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There are 2 real solutions, fiddle around with rock etc or do the job properly." I am unsure what you mean by this, as your solution is rock. Unless this is in comment to my thought of scattering rock thinly to provide the surface hardness that we are looking for.
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I can say that if you put a cost onto all the damage and repairs to the road and vehicles etc that may happen, you will be surprised." I can only assume you mean repairs in the sense of road rutting, aggregate replacement, and possible damage to vehicles as a result of sliding?
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Water and vehicle speed are the real cause of damage to roads assuming the ground is reasonable to start with." Water control is why we have what we have. Between water bars, proper drainage and prevention of elevated flow velocities, we have an extremely high compression strength subgrade on the majority of the length of the road. These good sections are what we are attempting to reinforce with good surface coverage.
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Now you have not given any detail about the location, soil types or rainfall. All these factors help plan a road " I actually have given some of that... Lower Appalachian mountains, two months of monsoon season. I can hire a soil engineer to analyze samples from the multiple different soil zones this passes through, but I can't be convinced to do so since the bare dirt holds up to travel in most areas with no deformation even when it's rained for a long time. The problem zones of the road will be dealt with in a more traditional way, but are not the topic of this thread.
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Draining the water to one side is a good start, but its important to ensure the water does not travel fast enough to cause erosion, about 3 feet a second." I have mentioned multiple places that we have water bars, which prevent high velocity travel.
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in soft patches big rock or geotextiles are the only way to start. Small rock will just keep sinking." This is not the topic of this particular thread. I actually have woven underlayment, 3+ base with a coat of crusher run in one of our softer zones, which has held up very well. We are ok with bringing in material for the problem areas, which are short and few, and we have a method that works for the soil there.
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Spreading 3/4 rock thinly will be of no use at all. " If it prevents droplet strike erosion, then it will be of great use to us
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I meant to add a note that you consider a separate mortgage to get the job done properly in the first place, over a 10 year period the weekly cost would be quite low and it may be worth taking that route. " It may be different in your region, but in my experience there are very few financing options for people who do not pursue bank loans. In our case, we saved extensively for a large down payment and are using owner financing. We are building off-grid and thus financing options are extremely limited.
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16 Tonne loads is the way to consider, so its a matter of finding a closer supply or a better transport cost. " I hope you realize from earlier posts that neither of these are options. We have done our due diligence, have found the nearest quarries, and the cost to haul has been cross-checked with multiple companies/individuals. The current price to haul right now is approximately 2x the price of the aggregate, only due to the fact that diesel prices are back down.
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Even consider getting a contractor to do the whole lot, making sure you have a written document detailing what outcomes are required, and the maximum estimated cost. " This is simply not in our budget, and against our DIY ways.
I am no civil engineer, but I do have degrees in ME/EE and do my fair share of planning, estimating and reading. One very interesting read I had was the Department of Transportation manual on construction of gravel roads, which gave a lot of insight into how roads are constructed by our government for steady flows of traffic with inconsistent maintenance.
I spoke with one civil engineer who told me that regardless of soil type, I would need underlayment, 4" of base rock and 4" of top material with fines. This works out to approximately $170,000 in materials and delivery alone, minus labor. A nearby neighbor is paying upward of $600,000 for a similar road. I simply cannot agree that a dirt road that holds up to a 15,000lb truck daily even during monsoon conditions needs underlayment and 8+" of gravel.
Conventional knowledge is available plentifully. This thread is a question of whether there might be a better way for a work-from-home couple who go off-property approximately twice per week to cover their stable road surface. I see no reason to sell our land to fund our gravel road