850420paverHenr.pdf

Project Manual

Version 4.13.26

Project Manual for

ITB No. 26-3010-10EAR

Paver Laid Full Depth Reclamation

Department of Public Works

County of Henrico, Virginia

October 6, 2026

Paver Laid Full Depth Reclamation

Department of Public Works, County of Henrico, Virginia

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TABLE OF CONTENTS

1 Table of Contents TOC

2 Invitation to Bid ITB

3 Scope of Work/Specification SOW

4 Extra Work, Force Account FA

5 Bid Form BF

6 County of Henrico Construction General Terms and Conditions GTC

7 County of Henrico Insurance Specifications INS

8 Sample Unit Price Contract UPC

AIA Documents

9 Contractor’s Qualification Statement: AIA Document A305, 2020 Electronic Edition

Contract Documents

10 County of Henrico, Virginia Bid Bond

11 County of Henrico, Virginia Standard Performance Bond

12 County of Henrico, Virginia Standard Labor and Material Payment Bond

Attachments

A Three-Year FDR Project Plan

- END OF TABLE OF CONTENTS -

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INVITATION TO BID

Annual Contract for Paver Laid Full Depth Reclamation

County of Henrico, Virginia

Sealed bids to furnish all labor, supervision, materials, supplies, equipment, etc. necessary for successful completion of various project assignments under an annual contract for Paver Laid Full Depth

Reclamation when needed and as requested by Department of Public Works, in accordance with the conditions, specifications, and instructions below and on the attached sheets hereto, will be received no later than 4:00 P.M., local prevailing time, October 21, 2026 and then publicly opened and read immediately thereafter through a Microsoft Teams meeting. Sealed bids shall be submitted through Henrico County’s

Electronic Documents Web Portal, ProcureWare, at https://henrico.procureware.com. Bidders interested in participating in the bid opening shall send a request to be added to the meeting invitation to Eric

Rosen via email atros074@henrico.gov.

Time is of the essence, and any bidder that attempts to submit a bid after the appointed hour for submission, will be unable to, as ProcureWare automatically closes the bid. The time of receipt shall be determined by the time clock in ProcureWare. Bidders are responsible for ensuring that their bid is submitted in ProcureWare by the deadline indicated.

Pursuant to Henrico County Code Section 16-43, the Board of Supervisors of Henrico County, Virginia, shall be the awarding authority when the contract amount is over $200,000. Otherwise, the award will be made by the Purchasing Director.

Bidding Documents consisting of Contract Drawings and Project Manual may be obtained by visiting the

Henrico County Electronic Document’s Web portal at https://henrico.procureware.com/home. Options are provided for downloading a complete set of documents or selected files from this web portal. The Contract

Drawings and Project Manuals are provided in PDF Format, which may be shared electronically with your subcontractors, employees, and suppliers. The failure or omission of any bidder to download, receive or examine any form, instrument, addendum or other documents, or to acquaint itself with conditions existing at the site(s), shall in no way relieve any bidder from any obligations with respect to its bid or to the contract.

Bids must be accompanied by either a cashier’s check or certified check or bid bond in the amount of 5% of the Total Bid Amount and made payable to the County of Henrico, Virginia.

A bid may not be modified, withdrawn or cancelled by the bidder after the time and date designated for the receipt of bids and for 90 days thereafter except as provided by Va. Code § 2.2-4330. The following is the procedure for withdrawal of a bid: Va. Code § 2.2-4330(B)(1), as may be amended from time to time.

Nothing herein is intended to exclude any responsible bidder, its product or service or in any way restrain or restrict competition. Comments as to how bid documents, specifications or drawings can be improved are welcome.

If a contract is awarded, a separate performance bond and payment bond, County of Henrico, Virginia

Standard Performance Bond and County of Henrico, Virginia Standard Labor and Material

Payment Bond, and as provided in the Project Manual, for 100% of each individual task ordered under the contract shall be provided by the Successful Bidder. The annual cap for the total work that may be https://henrico.procureware.com/ https://henrico.procureware.com/home

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authorized by the underlying contract is $5,000,000.00. Pursuant to Section 16-50 of the Henrico County

Code, the Purchasing Director has elected to allow the contractor awarded the contract to furnish a performance bond and a payment bond for each individual task identified in the underlying contract in amounts equal to the dollar amount of such individual tasks. Bidders must submit documentation verifying their ability to furnish performance and payment bonds for no less than $1 million apiece (or the annual cap for the total work that may be authorized by the underlying contract, if less than $1 million).

Bidders must register with Surety2000 by visiting www.surety2000.com. If you have already registered with Surety2000 previously you will not need to register again. If a contract is awarded, the Successful

Bidder must verify that its Surety Broker is registered with Surety2000. If the Surety Broker is not registered with Surety2000, the Successful Bidder must direct its Surety Broker to visit www.surety2000.com to register. After verifying that its Surety Broker is registered with Surety2000, the

Successful Bidder must provide its Surety Broker with the bond details for the awarded contract. After the

Surety Broker has confirmed execution of the electronic bond, the Successful Bidder must log into www.surety2000.com to digitally sign the bond and receive the Digital Staple and QR code.

The Owner reserves the right to waive informalities and/or reject all bids. In accordance with Va. Code, Section

2.2-4319, the Owner shall not reject all bids solely to avoid awarding a contract to a particular responsive and responsible bidder.

The Bidder must be a registered contractor in the Commonwealth of Virginia in accordance with Title 54.1, Chapter 11 of the Code of Virginia, as amended, at the time of bid submission, and shall possess a Virginia

Contractor’s License Class A - H/H (Heavy/Highway). The Bidder shall have bid and completed projects of comparable nature, size, complexity and construction cost. The Bidder should submit with its bid a completed AIA Document A305, Contractor’s Qualifications Statement, which shall document how the applicable projects meet or exceeds the size, complexity, and nature of this project; and includes details of the management staff and self-performed activities associated with the referenced projects. Only those projects which the Bidder performed the work as the General Contractor should be included in the AIA

Document A305. Bidders are not required to submit AIA Document A305, Contractor’s Qualification

Statement if they have submitted one within the last twelve (12) months as of the date of this bid.

The County is no longer accepting sealed Bids physically and all Bidders must submit sealed Bids through ProcureWare.

- END OF INVITATION TO BID -

http://www.surety2000.com/

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SCOPE OF WORK/SPECIFICATIONS

A. The intent and purpose of this Invitation to Bid is to establish a term contract(s) with a qualified contractor(s) to furnish all tools, labor, materials, equipment, fees, and supervision necessary for Paver Laid Full Depth Reclamation when needed and requested by the Department of Department of Public Works, County of Henrico in accordance with the enclosed general terms, conditions and specifications.

It is the intent of the County to spend approximately $5,000,000 for paving for the first year of this contract. Remaining terms will be determined upon budget appropriation.

B. General Requirements:

1. Projects under this contract(s) will be assigned by Public Works.

2. Upon the Contractor’s failure to complete the work within the specified time, liquidated damages representing the estimated additional cost of administration, supervision, inspections, and other expenses may be assessed. The amount of liquidated damages assessed shall be $500.00 per calendar day.

To complete the various projects assigned to the contract within the allowed time, the

Contractor(s) may be required to work on more than one location simultaneously.

4. Utility Coordination and Site Investigation

The Contractor shall be responsible for conducting a thorough review and investigation of each project site prior to the commencement of construction. The Contractor shall identify and account for all known and reasonably identifiable utilities and utility facilities located within or adjacent to the project limits.

The Contractor shall coordinate with all applicable utility owners and utility providers and shall notify such parties of the upcoming construction activities as required. The

Contractor shall verify the location and status of utilities prior to commencing work and shall take all necessary measures to avoid damage, disruption, or interference with existing utility facilities.

The Contractor shall be solely responsible for ensuring that all required utility coordination and verification activities have been completed prior to the start of construction. Any damage to utilities resulting from the Contractor’s failure to properly coordinate, identify, or account for utilities shall be the responsibility of the Contractor.

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6. Pre-Construction Conference and Work Plan

The Contractor shall participate in any pre-construction conference requested by the

County. At such conference, the Contractor shall present and discuss a detailed work plan for the upcoming project, including, but not limited to, the proposed construction sequence, schedule, equipment, staffing, materials, quality control measures, and

Maintenance of Traffic (MOT) plan.

The Contractor shall coordinate with the designated County representative to ensure that the proposed construction work plan and MOT plan are consistent with the

Contract requirements and applicable County standards. The Contractor shall make any revisions to the work plan or MOT plan reasonably requested by the County prior to commencement of the applicable work.

7. Sweeper:

A sweeper shall be provided to sweep in front of the paving equipment.

8. Adjustment of Existing Utilities:

The Contractor shall adjust existing utility frame and covers.

9. Clean Up:

Before final acceptance of work on any assignment, the Contractor shall clean all ground and excess pavement material, debris, and rubbish. The work site shall be left in a neat and orderly condition. The Contractor shall provide for this purpose a vacuum sweeping truck to be on the site during the paving operations. The

Contractor shall remove, as frequently as necessary, all refuse, rubbish, scrap materials and debris from the site to the extent they are the result of the Contractor’s operations to the end that the site of the work shall present a neat, orderly, and workmanlike appearance at all times. At completion of the work, but before final acceptance the Contractor shall remove all surplus material, falsework, temporary structures including foundations thereof, and debris of every nature resulting from the Contractor’s operations or resulting from any activity on the site related to the

Contractor’s operations and put the site in a neat, orderly condition, and charge the cost to the Contractor. The County shall be entitled to offset such cost against any sums owed by the County to the Contractor under this Contract.

10. Contract Performance:

Public Works will notify Contractor of work orders and Contractor must respond within 48 hours after notification and commence work within 48 hours after

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notification. If the Contractor does not respond within 48 hours after notification than liquidated damages may occur, and the County reserves the right to award work to other contractors. The County reserves the right to inspect all operations under this contract and to withhold payment for any work performed which is considered not in accordance with specifications. Payments withheld for this reason will be released upon receipt of satisfactory evidence (site inspection by County inspector that the work has been corrected to the County’s satisfaction). Inspections shall occur within 48 hours of completion of work and correction shall be done within 24 hours of notice to contractor at no additional cost to the County. Failure to correct any deficiency in the 24-hour period shall result in cancellation of the

Contractor’s charge for that portion of the work found deficient. Repeated violations of this provision (more than four call-backs with any calendar month) may result in termination of the Contract for cause. Telephonic notice to the

Contractor shall be considered adequate and acceptable notice to enforce this provision with a follow up in writing.

11. Mobilization:

All costs for mobilization shall be included by the Contractor as part of the contract price.

12. Maintenance of Traffic:

a. The Contractor shall conduct its operation in a manner that will ensure that traffic will be uninterrupted except as approved by the County. At the close of each work day, the area of work shall be confined to the smallest area possible so that the maximum use of the street will be restored and the hazard to traffic reduced to the minimum. No excavation shall remain open within the roadway without the approval of the County except when the excavation can be safely bridged with the use of steel plates or other materials acceptable to the County. When areas of excavation outside of the roadway do remain open, the area shall be barricaded, and warning signs shall be posted.

b. At all times the Contractor shall use the men and traffic control signs and devices necessary to comply with the Part VI of the “National Manual on Uniform Traffic

Control Devices”. During the progress of the work when the street may be obstructed to any extent by construction equipment or construction operations, in addition to the signs and barricades, special workers equipped with red flags shall be designated by the Contractor to direct traffic. Those workers so designated shall not be assigned to any other duties while engaged in directing traffic. The

Contractor has sole responsibility for ensuring that is operations are conducted in a safe manner and not withstanding any other provision to the contrary, shall fully indemnify Henrico County, its officers, agents and employees for any damage or

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injury related to traffic operations which is caused by negligent or otherwise improper or deficient performance under the contract or nonperformance of the terms of the contract. All personnel, signs, barricades, and any other items necessary for the maintenance of traffic and safety shall be provided by the

Contractor. No separate payment shall be made by the County for this work. All costs of this work are included by the Contractor as part of the contract price.

c. The plan for the maintenance of traffic during any assignment under this project shall be in accordance with the above and as directed by the County Project Officer.

13. Construction of Public Streets and Roads:

a. All work shall be in accordance with latest (Department of Public Works and/or

Public Utilities) Henrico County Standards and Specifications and with the County or State Permit issued for the project.

b. The County will obtain and pay for all construction permits in County and/or State rights-of-ways and any environmental permits required.

c. The Contractor shall be responsible for the preservation of all property corners and monuments. If an existing property corner or monument is destroyed, the

Contractor shall have same replaced by a certified land surveyor at no extra expense to the County.

d. The construction in all respects shall be kept complete and approved except for testing, to a point not more than 500 feet behind the foremost progress of the work.

In addition, construction shall not be started at a new location until all back work is approved, unless authorized otherwise by Public Works. In the event the above two requirements are not fulfilled, the Contractor shall automatically be shut down in forward progress until the back work is completed and approved.

e. Contractor shall include in applicable unit prices the cost of normal safety requirements of the Traffic Engineering Division and Virginia Department of

Transportation (VDOT). This shall include barricades, signs, blinker lights, and other required construction safety equipment.

14. Warranty:

a. All material provided to the County shall be fully guaranteed by the Contractor against factory defects. Any defects which may occur as the result of either faulty material or workmanship by the manufacturer within the period of the manufacturer’s standard warranty shall be corrected by the Contractor at no expense to Henrico County. The Contractor shall make evidence of all

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manufacturers’ warranties available at the completion of the assigned work. All work is guaranteed by the Contractor against defects resulting from the use of inferior or faulty materials or workmanship for one year from the date of final acceptance of the work by the County in addition to and irrespective of any manufacturer’s or supplier’s warranty. No date other than the date of final acceptance may be established to govern the effective date of this Guaranty unless that date is agreed upon by the County and the Contractor in a signed writing.

b. The County, at its sole discretion, may require a warranty for any FDR project based on the project scope, site conditions, or other factors deemed appropriate by the County Representative.

c. When a warranty is required, the Contractor shall warrant all FDR work, including the reclaimed and stabilized roadway and asphalt pavement placed as part of the

FDR process, for a period of thirty-six (36) months from the date of final acceptance.

d. The Contractor shall be responsible, at no additional cost to the County, for correcting deficiencies or premature failures determined by the County

Representative to be caused by defective materials, improper mix design, inadequate stabilization, improper construction methods, insufficient compaction, or other deficiencies in the Contractor's FDR operations. Such deficiencies may include, but are not limited to, excessive rutting, cracking, potholes, raveling, delamination, settlement, or loss of structural integrity.

e. Upon written notification of a potential warranty deficiency, the Contractor shall investigate the affected area and, when determined to be the Contractor's responsibility, perform the necessary corrective work as directed by the County

Representative and at no additional cost to the County. The County may require appropriate testing, including material testing, density testing, or coring, to determine the cause and extent of the deficiency. Costs associated with investigation and corrective work shall be borne by the Contractor when the deficiency is determined to be the Contractor's responsibility.

f. The warranty shall not apply to failures caused solely by utility work or repairs performed by others, third-party damage, extraordinary traffic loading, flooding, or other conditions beyond the Contractor's control.

g. When the County elects to require a warranty, the Contractor shall be entitled to a warranty fee equal to three percent (3%) of the final completed project cost. The warranty fee shall be paid only for projects on which the County has elected to require the warranty.

h. The Contractor's warranty obligations shall be in addition to any other requirements or remedies provided under the Contract Documents.

15. Work Site Damages:

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i. Any damage to property, whether owned by the County or others, resulting from work performed under this Contract shall be repaired or replaced to the County’s satisfaction at the Contractor’s expense.

16. Communication:

a. The Contractor shall have at least one (1) individual on the worksite that communicates in English (both orally and in writing) and comprehends the English

Language. This individual shall communicate instructions to the others working under this contract or coordinate this communication. Henrico County personnel must be able to understand the English used by this person. Any individual that is working as a flagger shall comprehend and speak only in English while performing this job duty as required by the Virginia Work Area Protection Manual.

b. Contractor shall also inform all resident on work being done on their road at least 5 days prior to the work being commenced.

17. Normal working hours shall be between 8:00 a.m. and 4:30 p.m. Monday through

Friday except where required by the individual contract documents or authorized by the County. No work shall be done on Saturdays, Sundays, and/or legal holidays unless authorized by the County. Legal holidays shall be defined as those holidays annually observed by the Owner. These are: Labor Day, Veterans Day, Thanksgiving (2 days), Christmas (2 days), New Year’s Day, Martin Luther King

Day, President’s Day, Memorial Day, Juneteenth, and Independence Day (a total of 12 days).

18. Paver Laid Full Depth Reclamation:

a. Paver-Laid Full Depth Reclamation is defined as those processes in which all of the asphalt pavement layers and some portions of the underlying bound and unbound layers are pulverized, stabilized, compacted, and paved in place. The depth of this is 10”-12”. Paver-Laid Full Depth Reclamation is performed using hydraulic cement, lime, lime kiln dust (LKD), or liquified cement as the primary stabilizing additives.

b. The pavement layers may be milled, stabilized, and repaved using the same machine or machine train.

c. The Contractor shall select the final mix design (job mix formula- JMF) and construction methods to meet the performance requirements specified in this

Project Manual.

d. The Contractor shall submit a Quality Control Plan (QCP) as defined herein to the

Henrico County Representative at least 10 working days prior to the

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commencement of the Work for review and approval by the Henrico County

Representative. The Contractor shall not commence work until the QCP is approved by the Henrico County Representative.

e. The Contractor shall mix the top 10-12 inches of Material form the road surface down.

19. Disposal of FDR Millings

a. All reclaimed materials and millings generated from FDR operations, including asphalt millings and profile millings, shall remain the property of the County unless otherwise directed in writing by the County.

b. At the County’s request, the Contractor shall transport and deliver such millings to a County-designated disposal, storage, or stockpile site. The Contractor shall be responsible for loading, hauling, and placement of the millings at the designated site in accordance with the Contract requirements and as directed by the County representative.

20. Price Adjustment:

a. The prices for asphalt mix used in the performance of the contract shall be adjust-ed throughout the contract term in the following manner.

b. The Contractor shall use the following information to provide monthly pricing information to Public Works.

c. Price adjustments will be computed using the Virginia Department of

Transportation (VDOT) Index PG 64-S-22 using the short ton. Price increases/decreases shall be made monthly for asphalt orders used on the construction project for re-pavement of roads in Henrico County. If the VDOT

Index is not available for the month of pickup of asphalt than use the latest index available in computing the adjusted price. The adjustment will always be based on the unit price at the time of the bid and the base price for September 2026 for asphalt only. Invoices submitted prior to the VDOT Index release date will be calculated on the prior month release date.

d. The VDOT Index web site is www.virginiadot.org/business/const/indices-asphalt.asp.

e. Release date for computing your adjusted price shall be base price index for

September 2026. VDOT Index will be used for calculating the price for the number http://www.virginiadot.org/business/const/indices-asphalt.asp http://www.virginiadot.org/business/const/indices-asphalt.asp

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of tons used for the referenced month by applying the Contractor’s state ap-proved job mix formula to the quantity and types of asphalt covered by the invoice.

f. The Contractor may adjust the invoice to indicate the change in price from the

“base” index month (September 2026) to the VDOT-published “current” index for the month. The price change shall equal the number of tons of job mix per-centage contents times the dollar, difference in the base and current indices. The Contractor shall submit with the adjusted invoice published indices used for that calculation.

g. The monthly-adjusted increase (or decrease) shall then be added to or subtracted from the base price unit measure offered in response to this bid. The price in-crease/decrease per unit of measure shall be calculated using the formula in

Attachment A.

h. The Contractor is required to submit Attachment A or Bidder(s) Asphalt

Adjustment Form (if approved by Public Works) with the invoice for payment of asphalt. The County has the right to correct incorrect calculations on the asphalt form, or incorrect use of the VDOT Index. If the Contractor fails to submit required documentation with the asphalt adjustment factor than no asphalt adjustment factor will be considered. The documentation to support the Asphalt Adjustment Form will be the latest VDOT Index for Asphalt.

i. The Job Mix Percentage of Asphalt Contents must be entered on the bid form for calculation using the VDOT Index for September 2026.

j. The Contractor shall provide a price adjustment to the County for any materials included in the original estimate that are not actually used in the performance of the work. This requirement shall apply specifically to, but not be limited to, instances where the specified or estimated twelve-inch (12") Full-Depth Reclamation (FDR) depth is not achieved.

k. Prior to submission of any invoice to the County, the Contractor shall review and reconcile all quantities, material usage, and associated charges with the designated

County representative. The Contractor shall provide supporting documentation, as requested by the County, verifying the actual quantities and materials incorporated into the work. Any necessary adjustments to the invoice shall be made prior to submission to the County for payment.

C. MATERIALS

1. Stabilizing Agent(s) – Agents used for stabilizing shall be limited to any of the following or any combination of the following: Portland cement (type I, II, or 1L), quicklime, and lime kiln dust. The amount of stabilizing agents to be used shall be determined by the Contractor by means of a mixture design process. Hydraulic

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cement shall conform to Section 214 of the latest VDOT Road and Bridge

Standards. Lime shall conform to Section 240 of the latest VDOT Road and Bridge

Standards.

2. Water – Any water used for mixing shall meet the requirements of Section 216 of the latest VDOT Road and Bridge Standards.

3. Full Depth Reclamation – The full depth reclamation material shall have 100% of all particles passing the 2.5-inch sieve size and 55% of all particles passing the 3/8 inch sieve size prior to the addition of any stabilizing agents. The full depth reclamation material shall be uniformly distributed and graded throughout the total depth of full depth reclamation placed.

4. Other Additives – If necessary, additional additives may be used by the Contractor to meet the requirements in TABLE 4. In the case where an additional additive is used, the type and dosage must be described in the JMF’s submitted to the Henrico

Representative. For full depth reclamation using asphalt emulsion, hydrated lime shall be added according to Section 211.02(i) of the latest VDOT Road and Bridge

Standards.

5. Addition of Crushed Reclaimed Asphalt Pavement (RAP) Material – RAP material may be added by the Contractor and shall meet the requirements of Section

211.02(j) of the latest VDOT Road and Bridge Standards and TABLE 1.

TABLE 1 – ADDITIONAL CRUSHED RAP

Tests Method Limit

Deleterious Materials: Clay Lumps and

Friable Particles in Aggregate

AASHTO T

0.2% maximum

Maximum Sieve size, 2.5 in. (63 mm) AASHTO T

100% passing

6. Additional aggregate – Based on the results of the mixture design or other requirements, the Contractor shall determine if additional aggregate is required. If the Contractor determines additional aggregate is required any additional aggregate shall meet Section 203 of the latest VDOT Road and Bridge Standards and TABLE

2, and it shall produce a product which meets the mixture requirements given in

TABLE 4 and final mix gradation specified in Section IV-1.

7.

TABLE 2 – ADDITIONAL AGGREGATE

Tests Method Limit

Los Angeles Abrasion Value AASHTO T

45% maximum loss

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Sand Equivalent AASHTO T

45% minimum

Maximum size, 100% Passing, Sieve Size

AASHTO T

2.5 in. (63 mm)

Water absorption AASHTO T

3% maximum

8. Handling and Storage – Cement shall be handled and stored in such a manner to prevent moisture degradation and partial hydration. No cement that has become hard, caked or lumpy shall be used. The Contractor shall store aggregates and RAP so that segregation and inclusion of foreign materials are prevented. The Contractor shall not use the bottom six (6) inches of aggregate or RAP piles in contact with the ground.

D. QUALITY CONTROL PLAN

1. The Contractor shall also be responsible for developing and implementing a Quality

Control Plan to ensure that operational techniques and activities provide integral and finished material of acceptable quality. Contractor sampling and testing shall be performed to control the processes and ensure material compliance with the requirements of the Contract. The Contractor shall provide their Quality Control Plan and Job Mix Formula(s) to Henrico County Representative(s) for approval no less than

30 calendar days prior to the start of Paver-Laid Full Depth Reclamation operations.

2. For each Paver-Laid Full Depth Reclamation project, the Contractor shall furnish a project specific Quality Control Plan that shall include, at a minimum, the following information:

c. A description of the Contractor’s Quality Control organization, including the number of full-time equivalent employees or Sub-Contractors with specific

Quality Control responsibilities, including an organizational chart showing lines of authority and reporting responsibilities

d. A listing by discipline with the name, qualifications, duties, responsibilities, and authorities for all persons proposed to be responsible for Construction Quality

Control

e. A Quality Control Sampling, Testing and Analysis Plan with methods that include a description of how random locations for testing and sampling are determine.

f. Identification and description of qualifications of the laboratory(s) to be used for each type of testing.

g. Specific listing of documentation for Quality Control activities

h. Procedures to meet contract requirements for corrective action when Quality

Control criteria are not met

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i. Procedures to protect stabilized material from receiving excessive moisture from weather events (i.e. rain, fog, etc.) and corrective actions when criteria are not met

j. Contingency Plan including but not limited to:

i. Inclement weather

ii. Equipment breakdowns

iii. Materials shortages

iv. Excessive fluff - (greater than 10%). Fluff is defined as the increase in material thickness of the recycled layer over the specified recycling depth due to remixing in place.

v. Deficient density of installed Full Depth Reclamation

vi. Material doesn’t break or cure in timely manner

vii. Gradation is outside tolerance(s)

viii. Production modifications based on changes in ambient and/or material temperature.

3. The Contractor shall have a technical representative at the project site during the mixing and placement operations for the trial section and first day of production.

At a minimum, this person must:

c. Have 2 years minimum experience with the Paver-Laid Full Depth Reclamation process

d. Have personally supervised a minimum of 5 successful Full Depth Reclamation projects.

e. Have personal experience in developing Full Depth Reclamation mix designs

f. Have the experience to perform and supervise field process control testing

g. Submit a list of references, with current telephone numbers, who are able to verify the experience required herein

4. The Contractor may use consultants or manufacturers’ representatives to satisfy the requirements of this section provided they meet the requirements above and are on-site or available for contact while construction operations are

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being performed.

E. Job Mix Formula (JMF)

1. Mixture Designs – Full Depth Reclamation mix designs in the form of a job-mix formula (JMF) shall be submitted to the Henrico Representative for the Department’s approval no less than 30 calendar days prior to the start of Full Depth Reclamation operations. More than one JMF may be required. The gradation of each JMF shall fall within the bands shown below.

TABLE 3 - DESIGN RANGE

Sieve Size Percentage by Weight Passing Square Mesh Sieves (in)

Lower Upper

2.5” 100 100

3/8” -- 55

2. The Contractor shall obtain sufficient samples of the material to be reclaimed directly from each roadway within the project for laboratory testing and mix design analysis. Samples shall be obtained from every 2500 linear feet, within each lane and to the proposed total recycling depth, with a minimum of six locations for each mix design. Sample locations from each lane may be offset or adjacent from each other. Additional locations may also be selected based on pavement conditions and variability.

3. Mixture Designs Submittal – The design shall be performed by the Contractor according to these specifications and submitted to Henrico County Representative for approval (30) working days prior to the planned start of the work. The mix design submittal shall include, at a minimum, the following information:

a. Target field density

b. Percent by weight of all stabilizing agents to be added to the recycled mix

c. Percent water content (at room temperature) required

d. Expansion ratio and half-life characteristics and temperature of asphalt binder at the time of injection into foaming chamber (for mixtures using foamed asphalt)

e. Minimum curing time/set time for the asphalt emulsion

f. Target gradation (including any aggregate to be added)

TABLE 4 – FULL-DEPTH RECLAMATION MIX DESIGN REQUIREMENTS

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* Three specimens shall be produced using either 75 blows per side (per VTM-57) or

30 gyrations (per AASHTO T 312) compacted at or below Optimum Moisture

Content and cured as follows: 4 inch (100 mm) diameter specimens, oven dry at 104ºF

(40°C) for 72 hrs and cool to ambient air temperature for 24 hrs; 6 inch (150 mm) diameter specimens, air dried for 24 hours, then an additional 48 hours at 104ºF

(40ºC) in sealed plastic bag, cool to ambient air temperature for 24 hrs.

** Three specimens shall be produced at 75 blows per side (or 30 gyrations per

AASHTO T 312) and cured at 140ºF (60°C) to constant mass, hold specimens at 104ºF

(40°C) for 2 hours in a forced draft oven immediately prior to testing.

If a change in source materials is made during construction, a new JMF’s shall be created and approved by the Henrico Representative prior to use on the project. The

JMF’s shall meet the above criteria at the approved stabilizing agents content.

F. EQUIPMENT

1. Pulverizing – The equipment used to reclaim existing pavements shall be capable of pulverizing existing pavement, as well as any additional materials, to meet the gradation provided in the approved job mix design, for the widths provided in the Plans, to the depth specified in the approved pavement design.

Test Test Method Criteria

Liquid Limit, Plastic Limit, and

Plasticity Index of Soil

VTM-7 Report

Dry Preparation and Mechanical

Analysis of Soils, Select Material, Subbase and Aggregate Bases

VTM-25 Report

Classification of Soils AASHTO M 145 Report

Moisture-Density Relations of

Soil- Cement Mixtures

AASHTO T 134 Report

Compressive Strength of Soil-

Cement Cylinders

ASTM D 1633 Min. 250 psi (Max. 450 psi) at seven (7) days

Determining the Strength of Soil-

Lime Mixtures

VTM-11 Min. 150 psi

Dry Indirect Tensile Strength

(ITS) for Foamed Asphalt

Stabilizing Agent

AASHTO T 283

Section 11*

45 psi minimum

Marshall Stability Test for

Asphalt Emulsion Stabilizing

Agent

ASTM 5581 (6

inch specimens), AASHTO T 245 (4 inch specimens)**

2500 lbs minimum (6 inch (150mm) diameter specimen), or 1250 lbs

(4 inch (100mm) diameter specimen)

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2. The paver-laid Full Depth Reclamation work shall be completed with a self-propelled machine with a down cutting milling head that is capable of pulverizing and recycling the existing asphalt concrete pavement, as well as any other additional materials, to a maximum depth of 12 inches, uniformly incorporating the stabilizing agent(s) and water and mixing the materials to produce a homogeneous product throughout the entire depth of reclamation. The machine shall be capable of pulverizing and recycling the full lane width of 10.5 to 12 feet in one pass. The machine shall have the ability to meter dosage rates for stabilizing agent(s) and water relative to the machine’s ground speed. Individual valves on the spray bar shall be capable of being turned off as necessary to minimize stabilizing agent(s) and water overlap on subsequent passes. The equipment shall be operated according to the manufacturers’ recommendations. All homogeneous materials from the pulverizing machine should be delivered directly to the paving operation.

3. The self-propelled machine shall also have a screed attached to the milling and mixing unit. The screed shall be 10 feet wide at a minimum and be capable of extending up to

16 feet in width. The screed shall have slope control and the ability to convey material out to the side of the screed if there is a surge of material between the mixing chamber and the screed. The mixing unit and screed combination must have electronic grade controls. In lieu of a screed attachment, the material may be placed into an asphalt-type paver that meets the requirements of Section 315.03(b) of the latest VDOT Road and

Bridge Standardsby means of a material transfer device.

4. Any additives such as water, cement slurry, asphalt emulsion etc. added by the equipment at the milling head or mixing unit shall be controlled through liquid metering devices capable of automatically adjusting for the variation of material going into the mixing unit, by means of weighing device or proportional control systems.

5. The metering devices shall be capable of delivering the amount of additive to within

+/- 5% of the total amount specified.

6. A material distributor truck shall be used if dry stabilizing agent(s) is(are) applied directly to the asphalt concrete pavement prior to recycling operations. The material distributor truck shall have the ability to uniformly apply the stabilizing agent(s) at the specified rate.

7. Stabilizing – The equipment used to stabilize the pulverized materials shall be capable of incorporating the stabilizing agents at the rate provided in the approved job mix design, automatically metering dosage and mixing the full depth and width of pulverized material to a homogenous mixture.

8. Grading – The equipment used to grade the stabilized material shall be capable of working within the constraints of the excavation and grading the full width of stabilized material in conformity with the lines and grades provided in the Plans.

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9. Compacting – The equipment used to compact the stabilized material shall be capable of working within the constraints of the excavation and compacting the stabilized material in conformity with the lines and grades provided in the Plans, as well as in conformity with the density requirements provided in the approved job mix design.

G. TRIAL SECTION

1. Start date of full production, the Contractor shall stabilize a 2,500-foot-long trial section, one-lane wide, at the designated thickness and designed optimal stabilizing agents content provided in the approved job mix design. Construct the trial section on the Project at a location approved by Henrico County Representative.

2. Construct the trial section using construction procedures intended for the entire project. Cease production after construction of the trial section until the trial section is evaluated and accepted by Henrico County Representative. The Henrico County

Representative may require immediate termination of trial section construction prior to completion if it is apparent that the requirements of this provision are not being met. If the trial section conforms to the requirements of this provision, it will be considered a lot and payment will follow the payment tables established in this specification. If the results of the trial section are not in conformity with this provision, the Henrico County Representative may require reconstruction or further trial sections until such time that results satisfactory to the Henrico County

Representative obtained.

H. CONSTRUCTION METHODS

1. Grass and Other Vegetation – All grass and other vegetation shall be removed from the edge of the existing pavement by the Contractor to prevent contamination of the pulverized bituminous material during the milling operation or the material can be delivered directly to a high density paver.

2. Full Depth Reclamation – Recycling shall be performed to the depth provided in the plans, while incorporating stabilizing agents, mineral filler, additional aggregate and water. Mixing shall continue until, and the speed of the recycling unit adjusted to ensure, a homogenous mixture of the above materials and pulverized materials is achieved uniformly throughout the entire depth and width of the final product. All material must be delivered to the paver to insure a homogenous blend of materials.

c. The application rate of all stabilizing agents shall be continuously monitored using calibrated, automatic meters. The application rate shall be within ± 5% of the total amount of the optimal stabilizing agents content provided in the approved job mix design. If the measured application rate falls outside the above tolerance, then the recycling operations shall be stopped and corrected before proceeding.

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d. The moisture content of the Full Depth Reclamation mixture shall be monitored closely to ensure conformance with the approved JMF to within ± 2% of optimum moisture content.

e. Longitudinal joints between adjacent stabilization passes shall be overlapped at least

4 inches. Transverse construction joints created by the recycling process shall be saw-cut when instructed by the Henrico Representative to provide a vertical, clean face to ensure proper compaction around the transverse joint.

3. Final Grading and Compacting – The final grading and compacting shall be performed within the constraints of the excavation and the stabilized material shall be compacted in conformity with the lines and grades provided in the Plans. Compaction shall progress across the full width of the stabilized area until maximum density is achieved.

Once the entire working width (full lane width plus affected shoulder width) has been stabilized, and only after primary compaction has been completed, the entire working width shall be graded to the required profile and cross-slope. Disturbance to the stabilized and primarily compacted material shall be kept to a minimum during this grading and shaping operation.

4. Surfacing – For materials stabilized with Portland cement, the surface of the compacted material shall be kept moist until covered with a 2 inch riding surface asphalt concrete course or placement of a curing membrane. Subsequent asphalt concrete courses may be placed any time after finishing as long as the Full Depth

Reclamation is able to support subsequent paving operations without marring or distortion of the surface.

5. Curing – When Portland cement is used as a stabilizing agent, the compacted and finished Full Depth Reclamation pavement layer shall be cured with the approved curing agents as soon as possible, but in no case later than two (2) hours after completion of the finishing operations.

c. Curing material(s) shall meet the requirements in Paragraph 304-2.7 of the latest

VDOT Road and Bridge Standards. The layer shall be kept moist using a moisture-retaining cover or a light application of water until the curing material is applied.

d. When asphalt emulsion is used as the curing agent, the entire surface of the Full

Depth Reclamation layer shall be uniformly sprayed with an asphalt emulsion at a rate of between 0.15 and 0.30 gallons per square yard; the exact temperature and rate of application being that required to achieve complete and uniform coverage without runoff. Apply sand to treated surfaces requiring protection from traffic.

e. When liquid membrane-forming curing compound is used as the curing agent, the surface of the Full Depth Reclamation layer shall be uniformly sprayed with a liquid membrane-forming curing compound at the rate of one (1) gallon to not more than

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100 square feet to obtain a uniform cover over the surface. The compound shall be thoroughly mixed with the pigment uniformly dispersed throughout the storage tank. During application, the compound shall be stirred continuously by effective mechanical means. Hand spraying of odd widths or shapes is permitted.

f. The curing seal shall be maintained and protected until additional courses of pavement are placed. If the surface of the finished Full Depth Reclamation and/or the curing seal becomes damaged, additional curing material shall be applied at the time it is damaged or when the damage is first observed.

6. Protection – The Contractor shall protect the finished Full Depth Reclamation against traffic and freezing temperatures. Completed portions of the Full Depth Reclamation layer may be opened immediately to low-speed traffic and to construction equipment provided the curing material is not damaged and the Full Depth Reclamation is sufficiently stable to resist marring or permanent deformation. Should the Full Depth

Reclamation be damaged by the Contractor, it shall be replaced or repaired and re-sprayed with the selected curing compound as described above at no cost to the County.

I. ACCEPTANCE TESTING

1. Field Compaction – Density shall be determined with a nuclear gauge operating in direct transmission mode conforming to VTM-10 to the full depth of the Full Depth

Reclamation layer. The Contractor shall have had the gauge calibrated within the previous 12 months by an approved calibration service. In addition, the Contractor shall maintain documentation of such calibration service for the 12-month period from the date of the calibration service.

The project will be divided into lots by the Henrico Representative for the purpose of defining areas represented by each series of tests.

2. Lot

c. For the purposes of acceptance, each day’s production shall be considered a lot unless the paving length is less than 3,000 linear feet or greater than 7,500 linear feet. When paving is less than 3,000 feet, it shall be combined with the previous day’s production or added to the next day’s production to create a lot as described below.

d. For the purposes of acceptance, the standard size of a lot shall be 5,000 linear feet, with 1,000-foot sublots, the full width of the lane (including any affected shoulder width). If the Henrico County Representative approves, the lot size may be increased to 7,500 linear foot lots with five 1,500-foot sublots when the

Contractor’s normal daily production exceeds 7,500 feet. When a partial lot occurs at the end of a day’s production or upon completion of the project, the lot shall be either added to the previous lot if the partial lot contains one or two complete

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sublots, or redefined to be an entire lot if the partial lot contains three or four complete sublots.

e. Each lot shall be tested for density by taking a nuclear density reading from two stratified- random test sites selected by the Henrico Representative within each sublot. Test sites shall not be located within 18 inches of any longitudinal joint.

f. The average of the sublot density measurements will be compared to the maximum density from the approved mix design to determine the acceptability of the lot. Once the average density of the lot has been determined, the Contractor will not be permitted to provide additional compaction to raise the average. If two consecutive sublots produce density results less than 97.0 percent of the target density, the

Contractor shall immediately notify the Engineer and institute corrective action. By the end of the day’s operations, the Contractor shall furnish the test data developed during the day’s production to the Engineer.

3. Payment will be made according to TABLE 5.

TABLE 5 - PAYMENT SCHEDULE FOR LOT DENSITIES

% of Density from Approved Mix

Design

% of Payment

97.0 or greater 100

96.0 to less than 97.0 95

95.0 to less than 96.0 90

Less than 95.0 75

Less than 93.0 No payment or remove and replace at the discretion of the

Engineer

4. Depth Check – Depth checks shall be performed by the Contractor twice per lot after compaction and prior to the placement of the next pavement layer. The depth checks shall be performed twice per lot following VTM-38, Method B.

c. Acceptance testing of Full Depth Reclamation for depth will be based on the mean result of measurements of samples taken from each lot of material placed.

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d. A lot will be considered acceptable for depth if the mean result of the tests is within the tolerance of the plan depth for the number of tests taken as shown in TABLE

6.

TABLE 6 – PROCESS TOLERANCE FOR DEPTH CHECKS

Plan Depth, inches

Tolerance, inches (Minus)

1 test 2 tests 3 tests 4 tests

>8 ≤

1 0.9 0.7 0.5

>12 1.2 1 0.8…