Even a well-built AASHTO flexible pavement design Excel spreadsheet can fail. Here are typical mistakes:
The spreadsheet automatically calculates the required structural number. (If using iterative solving, enable Excel iterations: File → Options → Formulas → Enable iterative calculation.)
Instead of static aᵢ values, use AASHTO’s correlations:
Update your spreadsheet to auto-calculate aᵢ when E_BS changes.