In this industry, there is significant pressure to just “get the road smooth.” Whether you are a city, county, or state engineer, the public wants the bumps gone, and they want them gone yesterday.
Because of that pressure, we see field projects fail that were initially completed without any understanding of the subgrade. A transportation agency will propose a solution to address the smooth ride, and the contractors will do what the client wants. But when that approach fails six months later — or goes massively over budget due to change orders — everyone loses.
At Onsite Improvement, we believe you have two choices: You can get the bad news now (identifying the real problem upfront), or you can get the really bad news later (costly change orders or even total failure of the repair).
Here is why skipping proper scoping is costing our industry millions, and an option to stop bandaiding the problem.
The “Smooth Road” Trap: 2D vs. 3D Thinking
The biggest mistake we see is treating a three-dimensional problem like it’s two-dimensional.
When a road or a bridge approach settles, the temptation is to look at the surface and say, “We need to lift this two inches.” That is “2D” or surface reasoning.
But the road isn’t floating in space; it’s sitting on soil. If you don’t understand why the soil gave way in the first place, you are just putting a band-aid on a broken bone.
We were recently asked for our opinion on a project in which contractors injected a High-Density Polyurethane Foam (HDPF) in a unique, client-directed scenario that was bound to fail. In addition to the agency’s inappropriate specification of the polymer, there was no consideration of the existing subgrade issues.
Unfortunately, the contractor executed on their design. The result? Failed project, wasted taxpayer dollars, and a black eye for the industry.
HDPF is a Tool, Not a Magic Wand
HDPF is an incredible technology. It expands to fill voids. It binds soil particles together. It can be used in highly saturated areas. And it can stabilize massive loads. But it is not a magic wand that you can blindly inject into the ground.
Appropriate use requires understanding the unique situation of each job:
- Site Conditions: What is the history of the site? How was it constructed, and what changes have been made along the way? What is the drainage situation? Etc.
- Subgrade Conditions: You can’t just “foam everywhere.” You need to know where the weak material is, how deep it goes, or whether the problem is actually the subgrade at all.
- The Goal: What is the lifecycle of this asset? If you are ripping the road out in two years for a total reconstruction, sure, a quick foam injection might be the right thing. But if you need that road to last ten years, you need to fix the subgrade first.
The 3-Week Investment That Saves Millions
We hear the pushback all the time: “We don’t have time to test. It can take months to get us a report.”
We get it. Traditional project development can be slow. But that is exactly why Onsite Improvement exists. We bridge the gap between “guessing” and “waiting forever.”
Using tools like our signature GeoCone Profiler™, we can test 10x deeper than traditional handheld units and get you data immediately. We don’t need three months; we can often tell you what’s happening underground in a matter of days.
Taking just three weeks to scope a project correctly — reviewing as-builts, testing the soil, and understanding the asset’s history — minimizes change orders and maximizes dollars. It ensures that when the contractor arrives, they are using the right polymer in the right place.
Let’s Solve It, Not Just Smooth It
Commercial and industrial clients already take this approach. They scope projects thoroughly up front because they can’t afford to shut down a facility. They need it fixed right the first time. More roadway authorities should adopt the same mindset — and given the vast distances road networks cover and the variability in subgrade conditions, you could argue that even more rigorous scoping is warranted.
If you’re tired of explaining why a repair didn’t hold up, give us a call. We’ll help you scope the site properly, using tools like GeoCone™ testing when appropriate, so you can address the root cause and get a long-lasting fix. To learn more about Onsite Improvement and its services, explore OnsiteImprovement.com.
About the Author: Kevin Stumpff is the Co-Owner of Onsite Improvement. With over 20 years of experience helping government and private organizations preserve infrastructure, Kevin focuses on connecting owners with innovative no-dig technologies that are faster, better, and less expensive. Onsite Improvement specializes in practical solutions that extend the life of your critical assets without the disruption and expense of full replacement.