Beneath the Build: Millions Saved with Smarter Soil Stabilization Solution

On Nebraska’s NDOT US-385—an important north–south highway route designated as the Gold Rush Scenic Byway—construction teams faced a major challenge near Angora, NE. Known for its rolling plains, historic landmarks, and scenic views, this corridor demanded a durable, cost-effective solution when crews encountered saturated silty clays, standing water, and a California Bearing Ratio (CBR) of less than 0.5 percent.


The original stabilization design called for over 42 inches of imported aggregate layered with geosynthetics—an expensive approach complicated by long haul distances and material sourcing limitations.  Tensar was brought in by the general contractor to explore a more efficient solution. Using Tensar’s NX850™ geogrid - part of the company’s InterAx® family of geogrid - and Tensar+™ design software, engineers developed a plan that reduced the section to just 35 inches of clean sand placed over a single layer of NX850.


The key? Leveraging on-site borrow material. This locally sourced sand replaced the need for distant aggregate, saving the contractor both time and millions of dollars in hauling costs. To validate the design, Tensar conducted field testing using tools like the dynamic cone penetrometer (DCP) and lightweight deflectometer (LWD). These tests confirmed the system’s ability to meet performance requirements without costly imports, giving both the contractor and the DOT confidence in the outcome.



This solution didn't just cut costs, it accelerated the construction timeline and allowed the road to open sooner.
The NDOT’s US-385 project in Angora, Nebraska, is a clear example of how Tensar’s performance-based designs using geogrid stabilization can unlock hidden value in even the most challenging conditions.

For questions or site evaluations, contact your local Tensar expert 

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About Beneath the Build:
Beneath the Build is a new video series that helps contractors and other construction pros maximize profitability and performance on their job sites. What happens beneath the surface determines the success of every project. Discover insights using geogrid and other technologies to win more bids, improve efficiencey and more.