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Council approves $2.73M Brewster Road rehab; officials cite deeper‑than‑expected asphalt during milling
Summary
Rochester Hills authorized a $150,000 contract increase and $100,000 contingency for the Brewster Road rehabilitation after field milling revealed an average asphalt depth of about 6.5 inches (design assumed 5 inches), a change that will increase project longevity but raised council questions about contingency and future bidding practices.
Rochester Hills City Council on Sept. 8 approved an increase to the Brewster Road rehabilitation contract with Proline Asphalt Paving Corp., authorizing a $150,000 increase and a $100,000 additional contingency for a new not‑to‑exceed project total of $2,734,503.29.
DPS and consultant staff described the change as an unforeseen circumstance uncovered during milling. Senior project manager Mark Lock of OHM said soil borings showed variable pavement depths across the two‑mile project—ranging from about 4.5 inches to as much as 10 inches in isolated spots—and that the milling operation removed more material than the design assumption to clear pavement fully. "We were assuming more like 5 and a half, and it came out to be 6 and a half," Lock said, explaining the additional 1.5 inches of full‑width HMA accounts for a large portion of the cost increase. He added the thicker section should improve the road's long‑term durability and reduce the need for full removals on future maintenance cycles.
Council members pressed for better predictability in future bids and questioned the size of the contingency after the increased costs. Staff and the consultant noted the city had performed numerous borings (many cited), but subsurface variability can still produce outliers that exceed contingency levels; staff suggested refining contingencies for specific line items in future projects. Despite the debate, council approved the contract increase unanimously.
The council record includes discussion of alternatives for the south mile (e.g., thinner mill to reduce costs) but staff advised those options carried tradeoffs in longevity and risk.
