Partnership Brings Accelerated Construction Success

The Smithville Loop 230 Downtown Pavement Projet

When a pavement needs to move from concept to completion in a matter of days, success depends on trust, experience, and a willingness to collaborate under pressure. That was the case in downtown Smithville, where an accelerated asphalt pavement construction project demonstrated how strong partnerships and sound engineering judgment can deliver outstanding results for a community.

A Project Defined by Urgency

The project began as a planned maintenance effort intended to extend the service life of an aging roadway through downtown Smithville, a small but active community with local businesses, pedestrian traffic, and upcoming community events. The original approach included a scrub seal application designed to preserve the roadway temporarily before a future overlay.

However, conditions in the field indicated the pavement was not performing as intended and the citizens of Smithville were eager for a resolution. With an important downtown event approaching, the timeline quickly accelerated. What had initially been planned as a near-term maintenance response became a full-scale, fast-tracked paving operation.

Rather than allowing the situation to escalate, representatives from TxDOT’s Austin District and Lone Star Paving came together immediately to determine the most effective path forward.

Collaboration at Every Level

According to Miguel Arellano, Deputy District Engineer for TxDOT’s Austin District, the outcome hinged on open communication and long-standing professional relationships.

Within hours of identifying the need for action, teams from TxDOT and Lone Star Paving coordinated design recommendations, construction logistics, materials availability, and staffing. Multiple evening calls took place among district leadership, maintenance staff, project managers, and operations teams to align resources and expectations.

Engineering he Right Solution

Given the compressed schedule and existing surface conditions, the team selected a dense-graded Type D mix (D64) with 20 percent reclaimed asphalt pavement (RAP). The mix was engineered specifically for the roadway’s characteristics: low-speed traffic, downtown access points, and the need for thickness flexibility over an irregular underlying surface.

The binder selection also reflected practical considerations. A PG 64 binder provided sufficient performance while allowing extended workability during overnight paving in November, when conditions would have been more challenging with a stiffer binder.

Importantly, the mix design aligned with TxDOT Austin District standards and lifecycle performance goals, delivering an engineered solution optimized for both cost and durability.

Construction Completed in 32 Hours

Once mobilized, the operation moved quickly. What did not exist as a construction project earlier in the week became a fully paved roadway by Friday afternoon.

The project included

• Approximately 2.25 miles of roadway
• 6,000 tons of asphalt
• Continuous paving over 32 hours
• Two rotating paving crews
• Around-the-clock plant operations
• Approximately 25–30 belly dump trucks cycling throughout the operation

To ensure proper surface transitions through downtown curb-and-gutter sections, the team incorporated targeted edge milling during overnight shifts, preventing excessive buildup at intersections and parking areas.

Throughout the operation, TxDOT maintenance crews worked in advance of paving to sweep loose material and prepare the surface, allowing Lone Star Paving to begin work immediately upon arrival.

De Leon, who was on site during paving, noted the sense of pride among crews. “You could feel it out there,” he said. “Spirits were high, and everyone took pride in working together to get the job done.”

Safety without Compromise

Despite the intensity of the schedule and scale of operations, the project was completed with zero safety incidents; a point of pride for everyone involved.

“Hundreds of people were involved when you consider plant crews, truck drivers, paving crews, and support staff,” noted Chuck Fuller of TXAPA. “To run continuously for more than 30 hours without an incident speaks volumes about the planning and professionalism of the teams.”