Road infrastructure development plays a crucial role in enhancing regional connectivity and supporting agricultural distribution in rural areas such as Karo Regency. This study aims to analyze and design flexible pavement for the Kutabangun–Kutakendit road section at STA 0+000 to STA 2+000 by comparing two widely used methods, namely the AASHTO 1993 method and the 2017 Revised Highways Pavement Design Manual. The analysis focuses on determining the optimal pavement layer thickness based on traffic load and subgrade conditions to achieve durable and efficient road performance. The results show that the 2017 Revised Highways method produces a thicker base layer and embankment, while the AASHTO 1993 method distributes thickness across surface, base, and subbase layers with different proportions. These differences highlight the variation in design approaches, where each method offers specific advantages in terms of structural strength and material efficiency. Therefore, the selection of an appropriate pavement design method should consider local conditions, construction feasibility, and long-term performance to ensure sustainable road infrastructure development.
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