A06_Flexible_Paving.pdf

Rehabilitate the Old El Portal Debris Basin, Gabion, and Service Road Specifications 5/2025

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FLEXIBLE PAVING

SECTION 32 12 00

PART 1 GENERAL

1.1 WORK SUMMARY

A. This section covers the requirements to perform work including but not limited to furnishing, placing, spreading and compacting asphalt materials and hot mix asphalt (HMA) to produce a finished flexible paving section as shown on the Drawings, conforming to the Specifications, and as otherwise directed by NPS Representative.

B. Provide all labor, materials, tools, equipment, services, and incidentals as necessary to perform the work as described in this section and in accordance with the Contract Documents and Drawings and to the satisfaction of NPS. Aggregate subbase to be placed by others prior to the commencement of paving operations. Contractor to coordinate their operations with NPS Representative to ensure that paving operations closely follow placement of aggregate base and are completed ahead of project deadlines.

1.2 RELATED WORK

A. Attention is directed to the General Requirements and related work specified in other sections includes, but is not limited to:

1. Section 32 11 00, Base Courses

1.3 DEFINITIONS

A. HMA – Hot Mix Asphalt

B. JMF – Job Mix Formula

C. RAP - Reclaimed Asphalt Pavement

D. Substitution Rate – amount of RAP aggregate substituted for virgin aggregate in (%)

1.4 SUBMITTALS

A. Submittals shall be in conformance with Contracting Requirements, Specifications, and Division 1 - General Requirements.

B. Comply with the submittal requirements and provide certifications, testing and samples as specified herein and per the applicable FP-14 Standard Specifications for materials to be used in the work.

C. Asphalt binder suppliers must comply with the Caltrans Certification Program for Suppliers of Asphalt. For a copy of the certification program, go to the METS website.

http://www.dot.ca.gov/hq/esc/Translab/index.htm http://www.dot.ca.gov/hq/esc/Translab/index.htm

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D. Certificates of Compliance for asphaltic emulsions must include:

1. Shipment number and shipment date

2. Source refinery, consignee, and destination

3. Type and description of material with specific gravity and quantity

4. Contract or purchase order number

5. Signature by the manufacturer of the material and a statement that the material complies with the Contract.

E. Contractor Mix Design Proposal

1. The Contractor shall submit for NPS’s review and acceptance, a proposed HMA mix design (JMF) for each HMA and Slurry Seal mixture to be used in the work before production of that HMA and Slurry Seal mixture.

2. Allow NPS up to 10 business days from a complete JMF submittal for document review.

3. The HMA mix design including aggregate quality and HMA mix requirement test results shall be no more than 12 months old when production of the HMA starts.

4. The Contractor may only start production if NPS has reviewed and accepted the proposed

JMF for compliance with the specifications.

5. Submit a new JMF if you change any of the following:

a. Target asphalt binder percentage greater than ±0.2 percent.

b. Asphalt binder supplier.

c. Combined aggregate gradation.

d. Aggregate sources.

e. Antistrip additive producer or dosage.

f. Average binder content in a new processed RAP stockpile by more than ±2.00 percent from the average RAP binder content reported on page 4 of your Contractor Hot Mix Asphalt Design Data form.

F. Contractor Quality Control Plan

1. The Contractor shall establish, implement, and maintain a quality control (QC) plan for asphalt paving work. Submit a QC Plan according to the provisions of Section 153, Contractor Quality Control of the FP-14 Standard Specifications.

2. The QC plan must describe the organization and procedures you will use to:

a. Control the quality characteristics for aggregate, asphalt binder, additives, HMA or

Slurry Seal production, and paving operations.

b. Identify sampling locations.

c. Determine when corrective actions are needed, and action limits.

d. Procedures to implement corrective actions.

3. Include a Work Plan based on the Contractor’s proposed work schedule and construction sequence to accommodate construction loads and protection of improvements throughout the sequence of construction including underground facilities (pipes and culverts), sub-grade deterioration and rutting, aggregate base structural section deterioration and rutting, and final pavements.

4. Submit QC plan when submitting mix designs (JMF) for review and acceptance.

5. Do not start production of HMA until NPS has authorized the QC plan.

1.5 REFERENCES

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A. The Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects (FP-14), dated 2014; and published revisions thereto.

https://flh.fhwa.dot.gov/resources/specs/

1. Payment descriptions in the FP-14 Standard Specifications shall not apply.

2. In case of conflict with the FP-14 Standard Specifications, the most stringent specification shall apply.

3. “Contracting Officer” as stated in the FP-14 Standard Specifications shall generally be defined as the CEO and General Manager of NPS or the authorized representative for the purposes of these Specifications.

4. References to Transportation Acquisition Regulations (TAR), and references to Federal Acquisition Regulations (FAR) shall not apply.

B. Applicable ASTM and AASHTO standards.

C. A reference within parentheses to a law or regulation is included in the Contract for convenience only and is not a comprehensive listing of related laws and regulations. Lack of a reference does not indicate no related laws or regulations exist.

D. Where the version of a referenced document is not specified, use the most recent version in effect on the date of the Notice to Bidders.

E. A code not specified as a federal code is a California code.

F. An agency or a department not specified as a federal or local agency or department is a California agency or department.

1.6 QUALITY ASSURANCE

A. Conform to the Contract Documents including but not limited to Permits, Technical Conditions, Drawings, and Standard Specifications.

B. Testing Agency: NPS may engage a qualified independent geotechnical engineering and/or material testing agency/consultant to perform material acceptance testing.

C. Inspection: The Contractor shall coordinate with the NPS Representative during all HMA and Slurry Seal paving operations to allow for access to the site as often as necessary for the performance of any special inspections and material testing for verification that the specifications are being met for the installation of materials. Frequency of material testing shall conform to the applicable Specifications, Standards, and Test Methods.

D. NPS may assure conformance to contract specifications by inspection of the Contractor's procedures, by oversight of the Contractor's quality control inspection and records, and by independent verification sampling and testing during HMA and Slurry Seal production and construction. Acceptance tests will be performed using similar test methods used for quality control testing.

E. Acceptance criteria for HMA and Slurry Seal produced and finished product constructed shall conform to applicable provisions of FP-14 Standard Specifications and the Caltrans “Revised” Standard Specifications for the materials to be used in the work.

https://flh.fhwa.dot.gov/resources/specs/

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1.7 CONTRACTOR QUALITY CONTROL

A. Contractor quality control process and documentation shall conform to Section 153, Contractor Quality Control of the FP-14 Standard Specifications and the Contract Documents.

B. Contractor, at their expense, shall provide quality control sampling, testing, and inspection during HMA paving work at specified rates sufficient to ensure materials and work conform to the Specifications. The Contractor shall submit all test results to NPS.

C. The Contractor may witness acceptance sampling and testing performed by NPS. However, NPS is not required to formally notify the Contractor of anticipated sampling schedules or locations and will not delay sampling or testing if the Contractor is unable to attend. The Contractor shall not use samples taken by NPS for acceptance testing, for any testing and submittal as a quality control test result unless NPS authorizes split samples.

1.8 PROJECT CONDITIONS AND REQUIREMENTS

A. Hold a pre-paving conference to discuss the methods of performing the paving work and quality control procedures, including the Contractor’s QC Plan.

B. The JMF mix design shall be prepared by a laboratory (or laboratories) whose proficiency has been reviewed and qualified in conformance with the California Department of Transportation's Independent Assurance Program, has been AASHTO accredited, or is otherwise approved by

NPS.

1.9 TOLERANCES

A. The lower specification limit for HMA compaction is 92 percent of the theoretical maximum specific gravity (density) determined according to AASHTO T166 and AASHTO T209.

B. Determine HMA pavement roughness / smoothness using a 10-foot straightedge to meet the requirements per Section 403.11, Pavement Straightedge Measurement of the FP-14 Standard Specifications.

C. Correct defective areas per the applicable provisions of FP-14 Standard Specifications. Obtain approval for the method of correction. Any pay reductions will conform to the Standard Specifications and Contract Documents.

PART 2 PRODUCTS

2.1 HOT MIX ASPHALT

A. HMA shall conform to Type I of the provisions in Section 403, Asphalt Concrete of the FP-14 Standard Specifications.

1. The composition of mix (JMF) shall conform to Section 39-2.07, Minor Hot Mix Asphalt of the Caltrans “Revised” Standard Specifications, including the following:

a. The grade of asphalt binder for Type A HMA must be PG 64-16 conforming to the provisions in Section 92, Asphalt Binders of the Caltrans “Revised” Standard Specifications.

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b. The aggregate gradations for Type A HMA shall conform to Section 39- 2.02B(4)(b), Aggregate Gradations of the Caltrans “Revised” Standard Specifications.

c. Antistrip additives is required for all asphalt concrete.

d. You must obtain written approval from NPS for use of RAP.

e. You must obtain written approval from NPS for use of WMA.

B. Changes from one mix design to another shall not be made during the progress of the work unless permitted by NPS. However, changes in proportions to conform to the approved job formula mix design shall not be considered changes in mix design.

2.2 TACK COAT

A. Tack coat shall conform to Section 412, Asphalt Tack Coat of the FP-14 Standard Specifications.

2.3 SLURRY SEAL

A. Slurry seal shall conform to Section 410, Slurry Seal of the FP-14 Standard Specifications.

PART 3 EXECUTION

3.1 GENERAL

A. Materials and construction of asphalt concrete pavement using HMA shall conform to Section 401, Asphalt Concrete Pavement by Gyratory Mix Design Method of the FP-14 Standard Specifications.

B. All existing facilities to remain shall be located and protected from damage during paving operations. Additional requirements are specified in Section 02 01 00, Maintenance of Existing Conditions.

C. Existing facilities, to be preserved, may be lowered and protected and restored upon completion of the work.

D. The Contractor shall be responsible for adjusting (raising or lowering) all frames for manhole covers, valve box covers, utility vault boxes, pull boxes, hand holes, monument covers, environmental test well covers, etc., to an elevation of no less than one-eighth (1/8) inch and no greater than one-quarter (1/4) inch below the finished grade of the adjacent paved surface to protect the device from interference with future snow plow, sweeping and/or maintenance operations.

3.2 PRODUCTION & MIXING PLANT

A. The mixing plant and production of HMA shall conform to applicable provisions of the FP-14 Standard Specifications and the Caltrans “Revised” Standard Specifications for the materials to be used in the work.

B. Storage or stockpiling of completed HMA mixtures in any manner other than through the use of a batch plant pugmill or storage silo discharging directly into a haul vehicle, and discharging of the haul vehicle directly into the paving operation shall not be allowed unless approved by NPS.

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Any request to store or handle the HMA mixture in an alternate manner not specifically allowed for in these Specifications or the Standard Specifications shall address temperature control, mechanical and thermal segregation control, and contamination control for any proposed change.

3.3 SUBGRADE AND TACK COAT

A. The subgrade to receive HMA shall comply with the compaction and elevation tolerance specifications for the material involved and approved by NPS prior to starting paving operations.

B. HMA shall not be placed when the underlying layer or surface is frozen, wet, saturated or pumping, or when weather conditions will prevent proper handling, finishing or compaction of the mixture.

C. Subgrade (prepared or existing) must be free of loose and extraneous material. Remove loose particles, dirt, organic matter, and other extraneous material by sweeping, blowers or other appropriate means which shall not damage the subgrade.

D. All existing asphalt concrete or concrete structures that will adjoin new asphalt concrete surfaces shall be neat, clean flat surfaces. Existing asphalt concrete at driveways, transition paving, or other joint locations shall be neatly saw cut. If saw cut pavement is damaged prior to paving, the Contractor shall re-cut any damaged portions prior to paving.

E. In advance of spreading HMA over an existing base, surfacing or bridge deck, if there is a Contract item for leveling or if ordered by the NPS Representative, HMA shall be spread by mechanical means that will produce a uniform smoothness and texture. HMA (leveling) shall include, but not be limited to, the filling and leveling of irregularities and ruts and changing the cross slope or profile of an existing surface.

F. Apply an asphalt tack coat to contact surfaces of pavements, curbs, gutters, manholes, and other structures in conformance with Section 412, Asphalt Tack Coat of the FP-14 Standard Specifications.

G. Tack coat shall be applied in advance of placing the HMA only as far as that day’s scheduled work or as otherwise directed by the NPS Representative. When asphaltic emulsion is used as tack coat, the HMA shall not be placed until the applied asphaltic emulsion has cured (completely changed color from brown to black).

3.4 EQUIPMENT

A. Paving equipment shall conform to Section 401.05, Equipment of the FP-14 Standard Specifications.

1. When paving contiguously with previously placed mats, the end of the screed adjacent to the previously placed mat shall be controlled by a sensor that responds to the grade of the previously placed mat and will reproduce the grade in the new mat within a 0.01 foot tolerance. The end of the screed farthest from the previously placed mat shall be controlled in the same manner the screed was controlled when placing the initial mat.

2. If the automatic screed controls fail to operate properly during a day's work, the Contractor may use manual control of the spreading equipment for the remainder of that

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day. However, the equipment shall be corrected or replaced with alternative automatically controlled equipment conforming to the requirements in this section before starting another day's work.

B. Hauling vehicles shall conform to Section 401.11, Hauling of the FP-14 Standard Specifications. Material transfer vehicle (MTV) is not required for the work.

C. Compacting equipment shall conform to Section 401.14, Compacting of the FP-14 Standard Specifications.

1. A sufficient number of rollers shall be provided to obtain the specified compaction and surface finish; consistent with Contractor’s submitted and accepted QC Plan. Rollers shall be sized to achieve the required results.

2. Pneumatic-tired rollers may be used depending on the compatibility of the mix.

Pneumatic-tired rollers shall be skirted to retain heat in the pneumatic tires, use of a release agent and other accepted methods to minimize their tendency to pick up fine aggregate from the surface.

D. The use of equipment that leaves ridges, indentations, or other objectionable marks in the HMA shall be discontinued.

E. If the methods and equipment furnished by the Contractor fail to produce a layer of asphalt concrete conforming to the specifications and tolerances, the paving operations shall be discontinued and the Contractor shall modify the equipment or methods, or furnish substitute equipment.

3.5 TRANSPORTING, SPREADING AND COMPACTING

A. Paving operations shall conform to Section 401, Asphalt Concrete Pavement by Gyratory Mix Design Method of the FP-14 Standard Specifications.

B. Do not use mixes produced from different plants.

C. Comply with the weather limitations specified in Section 401.07, Weather Limitations of the FP-14 Standard Specifications.

D. HMA shall be placed and compacted in such a manner that cracking, shoving, and/or displacement will be avoided. HMA must be free of segregation, coarse or fine aggregate pockets, or hardened lumps.

E. HMA shall be deposited on the roadbed at a uniform quantity per linear yard, as necessary to provide the required compacted thickness without resorting to spotting, picking-up or otherwise shifting the mixture.

F. During transporting, spreading, and compacting, petroleum products such as diesel fuel or kerosene shall not be used as a release agent on trucks, spreaders or compactors in contact with the HMA mixture.

G. Unless otherwise designated on the Drawings or allowed by NPS, HMA shall be spread and compacted in the layers and thicknesses indicated in the following table:

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Hot Mix Asphalt Layers and Thickness

Total Thickness Shown on the

Plans

Minimum Number of

Layers

Top Layer Thickness (Inches)

Next Lower Layer

Thickness (Inches)

Other Lower Layers

Thickness (Inches)

Min. Max. Min. Max. Min. Max.

3" or less 1 ---- ----- ---- ---- ---- ---- 3.1" through 3.5" 2 1.5 2 1.5 2 ---- ---- 3.51" through 5.3" 2 2 2.5 2 3 ---- ---- 5.31" or more * 2 2.5 2 3 2 5

* At least three (3) layers if total thickness is more than 5.31 inches and less than 10 inches. At least four (4) layers if total thickness is 10 inches or more.

H. Layers shall be spread with an asphalt paver, unless otherwise specified or approved by the NPS Representative. Asphalt pavers shall be operated in such a manner as to ensure continuous and uniform movement of the paver.

I. Unless otherwise shown in the Drawings or directed by the NPS Representative, additional HMA surfacing material shall be placed along the edge of the surfacing at road connections, private drives or other highway and non-highway facilities, tapered or feathered if necessary, and compacted to form smooth tapered conforms.

J. At locations where HMA is to be placed over areas inaccessible to standard mechanical spreading and rolling equipment, the HMA shall be spread by practical means to obtain specified results and shall be compacted thoroughly to the required lines, grades, and cross sections by means of a plate compactor, pneumatic tamper or equivalent to produce thorough compaction of the layer. Reduce layer thickness as necessary to achieve compaction. Care shall be taken to ensure adequate temperature for compaction of the HMA is maintained until compaction is complete.

K. Compacting shall conform to Section 401.14, Compacting of the FP-14 Standard Specifications.

L. Rolling patterns must progress from the lower edge and progress toward the highest part.

M. If using a vibratory roller as a finish roller, turn vibrator off for finishing.

N. Rolling must leave the completed surface compacted and smooth without tearing, cracking or shoving. The completed HMA surfacing shall be thoroughly compacted, smooth, and free from ruts, humps, depressions, or irregularities. Ridges, indentations or other objectionable marks left in the surface of the HMA by blading or other equipment shall be eliminated by rolling or other suitable means.

3.6 JOINTS, EDGES AND CLEANUP

A. Conform to Section 401.15, Joints, Trimming Edges, and Cleanup of the FP-14 Standard Specifications.

B. Tack coat and heat all vertical edge cold joints when paving is resumed.

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C. Use a step taper for longitudinal joints. Offset the longitudinal joint of one layer at least 6 inches from the joint in the layer immediately below. Make the longitudinal joint in the top layer along the striped centerline of two-lane roadways or at the lane lines of roadways with more than two lanes.

1. Compacting longitudinal joints should be accomplished by rolling from the hot side of the asphalt. The steel wheel roller is placed with the majority of the drum on the hot, newly placed asphalt, with approximately 6" of the drum extending over the cold asphalt.

D. The end of the paving mat should be cut off vertically for transverse joints to allow the subsequent full lift thickness to be placed against it. Lumber may be used as bulkhead or use a papered transverse joint.

E. NPS may, at their discretion, test the density of longitudinal or transverse joints with a calibrated nuclear density gauge or through the use of 6-inch diameter cores obtained directly on the longitudinal joint.

F. The Contractor shall be responsible for the cleanup of all asphalt spoils generated from the project. Cleaning out of any paving equipment by spreading of asphalt concrete spoils on unpaved surfaces is not allowed. Fuel or other hazardous material spills shall be documented and cleaned up immediately.

3.7 SLURRY SEAL

A. Materials and construction of asphalt slurry seal shall conform to Section 410, Slurry Seal of the FP-14 Standard Specifications.

B. Slurry seal will only be applied for rehab of existing roadways where directed and authorized by

NPS.

C. Sampling, testing and acceptance shall conform to applicable provisions of the FP-14 Standard Specifications for the materials to be used.

END OF SECTION