SPECIFICATION 509

POLYMER MODIFIED BITUMINOUS

SURFACING
Copyright MAIN ROADS Western Australia
Specification 509 Polymer Modified Bituminous Surfacing – 06/2852 Issued 05/02/2018

REVISION REGISTER
Clause Authorised
Description of Revision Issue Date
Number By
509.01(1) Deleted exclusion of rubber binder BPC
509.01(2a) Added primed basecourse, seal and asphalt
509.01(1d) Added new treatment “enhanced aggregate
retention seal”
509.02 Deleted AP-T09, WA 0.1, AGPT/T130, various
WA test methods
509.02 Added AP-G41/15, AP-T262-14, AGPT/T101,
AGPT/T530-535, Main Roads 71/05/1396
509.03 Amended where relevant to be consistent with AS
1348.1 definitions. Added enhanced aggregate
retention seal. New definition for high stress seal
509.03(2) Moved from (1) to (2)
509.12(2) Deleted clause on precoating
509.16.5 Extra text on submission of ALD results
509.17 Moved to 509.24.02
509.20(1) Next wording consistent with Specification 503
509.21(2 & 3) Added bridge deck, ERN15 and guideline on
bridge deck sealing
509.21(4) deleted AS 1141.20.1 as incorrect
Table 509.1 SAM, HSS and SAMI design information deleted
as now in ERN15. Included rates for bridge
decks.
509.24.01 Amended to be consistent with Specification 503
509.26.01(5) Clause deleted on mercury thermometer
Table 509.2 Precoating rates same as Specification 503
509.26.02(1) Hold point removed and clause reworded
509.27.01(1) Management plan required for stockpile sites
509.27.01(3) Hold point includes management plan
509.27 Precoating moved to 509.37
509.30.03 Moved to 509.37.01
509.32.01 Moved to 509.41.03
509.33.01 New clause consistent with Specification 503
509.33.02(1) Updated references
509.33.02(2) New text on calibration requirements
Table 509.02 New table on nozzle set up
Table 509.3 New table on nozzles to be used
509.33.02 Amended wording
(4, 5, 6 & 7)
509.33.02 Old clause on sealed shoulders deleted
509.33.03 New requirements for rollers
509.33.05 Extra text on aim of using drag broom
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509.36.01(1 & 3) New text on primed basecourse requirements

509.36.01(4) Hold point reworded
509.36.01(5) Requirement for repairing holes
509.36.02 Now includes concrete surfaces
509.36.03 New clause
509.37 New clause on precoating including heated
aggregate
509.39.4 Requires signs to be weighted down
509.41.01(2) New words relocated from 509.41.01(4)
509.41.01(4) New wording plus Table 509.5 on spray
temperatures
509.41.02 & .03 New clause on spraying viscosity
509.42.01(1) New requirement on weather
509.42.04 New or amended text
509.43.01(1a) Text deleted and moved to 509.43.01(1c)
509.43.01(1b) Hold point deleted
509.43.01(3) New clause on double seals consistent with
Specification 503
509.43.02(1) Adopted coverages in accordance with
Specification 503. Table 509.9 now nominates
roller size
509.43.03(3) Stones to be sept clear of guide posts
509.49(1) Moved to 509.91
509.55(1) New clause on testing
509.91 New clause on records
Table 509C1 New to align with Specification 503
Table 509C2 Reorganised layout and seal types
509C.3(1) Line spotting same as Specification 503
Guidance Note 1 References added
Guidance Note Included 7mm and 20mm aggregate
3.1.3
Guidance Note 3.3 New on aggregate sizes
Guidance note 4 New on responsibility for seal design
Guidance note 5.2 Notes on selection of roller sizes
Whole document Reformatted SCO 23/05/2017

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Specification 509 Polymer Modified Bituminous Surfacing – 06/2852 Issued 05/02/2018

Table of Contents
GENERAL....................................................................................................................................... 5
509.01 SCOPE 5
509.02 REFERENCES 5
509.03 DEFINITIONS 6
509.04 – 509.05 NOT USED 7

PRODUCTS AND MATERIALS.......................................................................................................7

509.06 POLYMER MODIFIED BINDER 7
509.07 BITUMEN EMULSION 7
509.08 PROTECTIVE PAPER 7
509.09 NOT USED 7
509.10 MEDIUM CURING CUTTING OIL 7
509.11 SLOW CURING CUTTING OIL 7
509.12 PRECOATING AGENT 8
509.13 ADHESION AGENT 8
509.14 – 509.15 NOT USED 8
509.16 AGGREGATES 8
509.17 - 509.19 NOT USED 8

DESIGN OF SPRAYED SEALS......................................................................................................9

509.20 GENERAL 9
509.21 DESIGN METHODS 9
509.22 DESIGN BY PRINCIPAL 9
509.23 DESIGN BY CONTRACTOR 10
509.23.01 GENERAL 10
509.23.02 PRELIMINARY DESIGN 10
509.23.03 FINAL DESIGN 10

TRANSPORT AND HANDLING OF BINDER...............................................................................10

509.24 TRANSPORT AND SAMPLING 11
509.24.01 GENERAL 11
509.24.02 SAMPLING OF BINDER AT DELIVERY 11
509.25 NOT USED 12

PREPARATORY OPERATIONS...................................................................................................12
509.26 BINDER STORAGE AND DISPOSAL FACILITIES 12
509.26.01 BINDER STORAGE SITES 12
509.26.02 DISPOSAL SITES 12
509.27 AGGREGATE DUMP SITES 12
509.27.01 GENERAL 12

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509.27.02 SITE PREPARATION 13

APPLICATION OF SEAL.............................................................................................................. 13
509.28 GENERAL 13
509.29 - 32 NOT USED 13
509.33 PLANT AND EQUIPMENT 13
509.33.01 ROAD TANKER 13
509.33.02 MECHANICAL SPRAYER 13
509.33.03 ROLLERS 15
509.33.04 ROAD BROOM 15
509.33.05 DRAG BROOM 16
509.33.06 PRECOATER 16
509.33.07 SURFACE DAMAGE 16
509.34 - 509.35 NOT USED 16
509.36 SURFACE PREPARATION 16
509.36.01 EXISTING BITUMINOUS SURFACE 16
509.36.02 BRIDGE DECKS OR OTHER CONCRETE SURFACES 17
509.36.03 COLD PLANED SURFACE 17
509.37 AGGREGATE PREPARATION 18
509.37.01 PRECOATING 18
509.37.02 HEATED AGGREGATE 18
509.38 NOT USED 19
509.39 PROVISION FOR TRAFFIC 19
509.40 NOT USED 19
509.41 PREPARATION OF POLYMER MODIFIED BINDER 19
509.41.01 general 19
509.41.02 spraying viscosity – SAMI and Bridge decks 20
509.41.03 spraying viscosity – SAM and high stress seals 20
509.42 APPLICATION OF BINDER 22
509.42.01 GENERAL 22
509.42.02 APPLICATION RATE 22
509.42.03 VOLUME CONVERSION 22
509.42.04 SPRAYING 23
509.42.05 EXISTING GUIDEPOSTS 24
509.43 APPLICATION OF COVER MATERIAL 24
509.43.01 APPLICATION 24
509.43.02 ROLLING AND DRAG BROOMING 26
509.43.03 SURFACE SWEEPING 26
509.44 - 509.51 NOT USED 27
509.52 NONCONFORMING TEST RESULTS 27
509.53 NON-CONFORMANCE IN BINDER APPLICATION 27
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509.54 CRUSHED AGGREGATE 28

509.55 TESTING FREQUENCY 28
509.56 – 509.80 NOT USED 28

AS BUILT AND HANDOVER REQUIREMENTS...........................................................................28

509.81 – 509.90 NOT USED 28

CONTRACT SPECIFIC REQUIREMENTS....................................................................................28

509.91 WORKS RECORDS 28
509.92 – 509.99 NOT USED 28

ANNEXURE 509A......................................................................................................................... 29
SCHEDULE OF WORKS 29

ANNEXURE 509B......................................................................................................................... 30
COVER MATERIALS - PRINCIPAL SUPPLY 30

ANNEXURE 509C......................................................................................................................... 31
509C.1 RESPONSIBILITY FOR SEAL DESIGN 31
509C.2 BINDER AND AGGREGATE APPLICATION RATES 31
509C.3 LINE SPOTTING 32
509C.4 RECORD FORMS 32

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SPECIFICATION 509

POLYMER MODIFIED BITUMINOUS SURFACING

GENERAL
509.01 SCOPE

2. The work under this specification consists of the supply and application of Types of
the following types of sprayed polymer modified bituminous treatments : Treatment

b. Strain Alleviating Membrane (SAM)

d. Strain Alleviating Membrane Interlayer (SAMI)

f. High Stress Seal (HSS)

h. Waterproof Bridge Deck Membranes (including prime)

4. The sprayed polymer modified bituminous treatment must provide a Intent

durable surface that:

b. bonds to the underlying surface (whether a primed basecourse or

concrete surface, a seal or asphalt;

d. provides a safe wearing surface for traffic; and

f. waterproofs the pavement or bridge deck.

6. Where applicable, a separate Schedule of Works is included at Annexure Schedule of

509A, which provides details of specific surfacing treatments. Works

509.02 REFERENCES

2. Australian Standards and MAIN ROADS Western Australia Test Methods

are referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA
123). For convenience, the full titles are given below:

Australian Standards
AS 1141.20.1 Methods for Sampling and Testing Aggregates -
Average least dimension - Direct measurement (nominal
size 10 mm and greater)
AS 2809.5 Road tank vehicles for dangerous goods – Part 5:
Tankers for bitumen-based products

Other Standards and Publications

AP-G41-15 Austroads Bitumen Sealing Safety Guide
AP-T262-14 Performance Requirements for Bitumen Sprayers

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AGPT/T101 Method of sampling polymer modified binders, polymers

and crumb rubber
AG:PT/T530 Calibration of Bitumen Sprayers – General Introduction
and List of Methods
AG:PT/T531 – Volumetric Calibration of Bitumen Pumps
AG:PT/T532 – Transverse Distribution by Fixed Pit Facility
AG:PT/T533 – Transverse Distribution by Field Mat
AG:PT/T534 – Transverse Distribution by Portable Trough
AG:PT/T535 – Road Speed Calibration
Engineering Road Note No 15 – Design of Sprayed Seals
Main Roads 71/05/1396 Guidelines for the Application of
Waterproof Membranes to Bridge Decks
WA Government Dangerous Goods Safety (Road and Rail
Transport of Non-explosives) Regulations 2007

MAIN ROADS Test Methods

WA 200.1 Sampling Procedures for Aggregates
WA 210.1 Particle Size Distribution of Aggregate
WA 215.1 Average Least Dimension
WA 310.1 Pavement Skid Resistance: British Pendulum Method
WA 311.1 Texture Depth
WA 312.1 Ball Embedment
WA 340.1 Sprayed Binder Application Rate: Carpet Tile Method

MAIN ROADS Specifications

Specification 201 QUALITY SYSTEMS
Specification 202 TRAFFIC
Specification 203 OCCUPATIONAL SAFETY AND HEALTH
Specification 301 CLEARING
Specification 302 EARTHWORKS
Specification 503 BITUMINOUS SURFACING
Specification 511 MATERIALS FOR BITUMINOUS TREATMENTS

509.03 DEFINITIONS

2. The term “polymer modified binder” is a binder consisting of polymeric PMB

materials dispersed in bitumen with enhanced binder performance for
particular applications.

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4. The terms “polymer modified binder” and “polymer modified bitumen” and Terms
“binder” have the same meaning except where the context of any particular
passage indicates otherwise.

6. The term “batch” shall mean any quantity of material all of which has been Batch
produced at the same time by the same process and which is subject only
to random variation and can therefore be accepted as being of
homogeneous quality.

8. The terms “seal”, “sprayed seal” and “reseal” have the same meaning Seal/Reseal
except where the context of any particular passage indicates otherwise.

High Stress
10. A “high stress seal (HSS)” is a bituminous seal, or reseal, treatment that is
Seal
subject to heavier than normal traffic loading due to braking, accelerating
and turning vehicles. HSS can also include a seal applied at a low binder
application rate requiring an S45R binder to achieve improved aggregate
adhesion.

509.04 – 509.05 NOT USED

PRODUCTS AND MATERIALS

509.06 POLYMER MODIFIED BINDER

2. The polymer modified binder shall meet the requirements of Specification

511 MATERIALS FOR BITUMINOUS TREATMENTS.

4. Prior to the use of polymer modified binder, the Contractor shall HOLD POINT
demonstrate compliance with the properties of the polymer modified
binder for each batch used on the Contract.

509.07 BITUMEN EMULSION

2. The bitumen emulsion shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

509.08 PROTECTIVE PAPER

2. Protective paper shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

509.09 NOT USED

509.10 MEDIUM CURING CUTTING OIL

2. The cutting oil shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

509.11 SLOW CURING CUTTING OIL

2. The cutting oil shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

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509.12 PRECOATING AGENT

2. Aggregate shall be precoated with a bitumen based precoating fluid

meeting the requirements of Specification 511 MATERIALS FOR
BITUMINOUS TREATMENTS. Where the weather is hot and the
aggregate is clean and dry the Superintendent may approve the use of a
distillate precoating fluid.

509.13 ADHESION AGENT

2. The adhesion agent shall meet the requirements of Specification 511 Approved
MATERIALS FOR BITUMINOUS TREATMENTS. Adhesion
Agents
509.14 – 509.15 NOT USED

509.16 AGGREGATES

2. Crushed aggregate, including its source rock, shall meet the requirements
of Specification 511 MATERIALS FOR BITUMINOUS TREATMENTS.

4. Where Principal supplied aggregate cover material is made available to the Principal
Contractor, the Contractor shall use all such aggregate cover material Supplied
before using Contractor supplied aggregate cover material. Details of Aggregate
Principal supplied aggregate are given in Annexure 509B.

6. The source of aggregate supplied by the Contractor shall be nominated

with the Tender.

8. The Contractor shall make all necessary arrangements with the nominated
supplier concerning load size, rate for supply, timing of the delivery,
payment and documentation.

10. Prior to the on-site delivery of crushed aggregate, the Contractor shall HOLD POINT
provide test results to the Superintendent showing that the aggregate
conforms to specified requirements. Results for the Average Least
Dimension (ALD) of each stockpile shall be provided before the
aggregate is applied. The Superintendent is to be advised of a
change in stockpile source and the ALD of that aggregate before it is
applied.

12. The Contractor shall organise all cover material supplied under this Stockpiles
Contract into clearly identifiable stockpiles either at source or on site in
order that they may be tested as required by the Quality Plan.

14. The maximum size of a lot shall be no more than one day’s production, or, Lot Size
no more than approximately 2000m3, whichever is the lesser.

16. Any contamination of aggregate after acceptance by the Superintendent Contamination

shall be corrected at no cost to the Principal.

509.17 - 509.19 NOT USED

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DESIGN OF SPRAYED SEALS

509.20 GENERAL

1. Unless otherwise specified in Table 509C1 the sprayed seal shall be Design
designed by the Principal. Where Table 509C1 specifies design by the Responsibility
Contractor, then the Contractor shall be responsible for and shall carry out
the design for binder application rate and aggregate spread rate for each
type of treatment specified except for a bridge deck waterproof membrane.

509.21 DESIGN METHODS Design Method

1. The design of sprayed seals shall include selection of binder class and
design of binder and aggregate application rates unless otherwise
specified.

2. Selection of binder class, except for a bridge deck waterproof membrane, Binder Class
shall be in accordance with Engineering Road Note No. 15. Selection of
binder class for a bridge deck waterproof membrane shall be in accordance
with Main Roads Guidelines for the Application of Waterproof Membranes
to Bridge Decks, document 71/05/1396.

3. Design of binder application rates and aggregate spread rates, except for a Application
bridge deck waterproof membrane, shall be in accordance with Engineering Rates
Road Note No. 15. Rates for a bridge deck waterproof membrane are
shown in Table 509.1.

4. Testing for Average Least Dimension (ALD) shall be carried out in Test Methods
accordance with AS 1141.20.1 or WA 215.1. Sampling for testing of ALD
shall be in accordance with WA 200.1.

5. Testing for surface texture shall be in accordance with WA 311.1. Testing

for ball embedment the test shall be in accordance with WA 312.1.

TABLE 509.1 APPLICATION RATES FOR BRIDGE DECK WATERPROOF MEMBRANE

Binder Class Binder Application Rate at Aggregate Size and

15°C Application Rate
S45R 1.6 L/m2 5mm at 250 m2/m3
S25E 1.6 L/m2 7mm at 200 m2/m3

509.22 DESIGN BY PRINCIPAL

1. Where Binder Application Rate(s) and other aspects of the sprayed seal
have been provided by the Principal, the Superintendent will as necessary,
issue to the Contractor any variations to such design.

2. Such amended details may include, but not necessarily be limited to: Design
Variables
a. Average Least Dimension (ALD) of the aggregate
b. Aggregate precoating rate

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c. Binder Application Rate (BAR)

d. Binder type and composition
e. Aggregate spread rate
f. Rolling and sweeping requirements

509.23 DESIGN BY CONTRACTOR

509.23.01 GENERAL

1. Where the Contractor is responsible for the design of the sprayed seal, the Design
design shall be in accordance with the procedures described in 509.21. Practices

509.23.02 PRELIMINARY DESIGN

1. The Contractor shall carry out a preliminary design based on the following
as applicable:

a. The type of treatment and nominal aggregate size specified by the

Principal.
b. Measurement of the Average Least Dimension of the aggregate
proposed for use, or if not available, an estimate based on past test
results from the same aggregate source, or an estimate based on
typical results for aggregate of the size proposed for use.
c. Measurement of the surface texture and/or ball embedment of the
surface upon which the treatment is to be applied.
d. Traffic volume and composition data provided by the Principal on
request.
e. A visual assessment of the condition of the surface on which the
seal is to be applied and the defects present.
f. Historic data provided by the Principal on request on similar
treatments in similar circumstances where available.
g. Climatic data relevant to the Site.
509.23.03 FINAL DESIGN

1. The Contractor shall carry out a final design based on the measurement of
the Average Least Dimension of the aggregate supplied under this Contract
and for other factors listed in 509.23.02.

2. Prior to the application of any sprayed seal, the Contractor shall HOLD POINT
provide the Superintendent with evidence of the application of
appropriate design methods as outlined in 509.21.

3. During application of a seal the Contractor may vary the design to allow for
changes to any of the design factors, site conditions or observed
performance. Details of the design variations shall be documented and
submitted to the Superintendent within 7 days of implementation of the
variations.

TRANSPORT AND HANDLING OF BINDER

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509.24 TRANSPORT AND SAMPLING

509.24.01 GENERAL

1. The handling, transport and heating of polymer modified binder shall

comply with the requirements of Specification 511 MATERIALS FOR
BITUMINOUS TREATMENTS.

2. The Contractor shall make all necessary arrangements with its supplier
concerning load sizes, rates of supply, loading temperatures, payment of
opening fees where applicable and all documentation.

3. In order to avoid the danger of mixing incompatible bituminous products in Dangerous

any cartage vehicles provided by the Contractor for the purpose of Mixes
transporting polymer modified binder, the Contractor shall ensure that the
binder supplier’s loading procedures are understood and the Binder
Loading Docket is fully completed by the Contractor’s driver PRIOR TO
LOADING, including the signing of any certification concerning the nature
of the previous load carried by the cartage vehicle.

509.24.02 SAMPLING OF BINDER AT DELIVERY

1. Prior to application or blending with any cutters or adhesion

agent, the Contractor shall sample a minimum of one (1) load in every
five (5), or part thereof. Two samples shall be taken from each load to
be sampled, immediately following one another in accordance with
Austroads AG:PT/T101 such that each is similar and represents the
polymer modified binder in the load.

2. Each of the sample containers in which the samples are

taken from a load shall be labelled to identify the supplier, the supplier’s
batch number, the date of sampling, the road and the SLKs of the
section on which the polymer modified binder is applied so that
traceability between samples and corresponding road sections is
maintained.

3. The Contractor shall provide the Superintendent with, one of

each set of samples at no cost to the Principal.

4. In addition to samples provided to the Superintendent by the

Contractor, the Superintendent may take audit samples at any stage
during production, storage, delivery or application process.

5. The frequency and timing of sampling will be at the

Superintendent’s discretion. The Contractor shall provide the
Superintendent with ready access for sampling at all times within the
hours of work of the Contractor or its Sub-contractors.

6. The cost of material taken, cleaning of the sampling facility

and any delays to road tankers or site operations as a result of the
sampling shall be considered to have been included in the Schedule of
Rates item for binder application. Sampling may be carried out by the
Contractor on behalf of the Superintendent but a representative of the
Superintendent shall be present at the time of the sampling.

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509.25 NOT USED

PREPARATORY OPERATIONS
509.26 BINDER STORAGE AND DISPOSAL FACILITIES

509.26.01 BINDER STORAGE SITES

1. The Contractor shall select suitable sites for bulk storage of binder HOLD POINT
and notify the Superintendent in writing at least five (5) days prior to
establishing the sites.

2. The Contractor shall ensure that site layout and safe handling procedures
conform to requirements detailed in Austroads "Bitumen Sealing Safety
Guide" AP-G41-05.

3. The Contractor shall provide and maintain adequate equipment to receive, Equipment
store, heat, circulate, handle and protect bulk binder from the time of
receipt to prevent misuse, damage, deterioration or loss.

4. Binder heating and storage tanks shall be fitted with dipsticks for volume
measurement and suitable thermometers for temperature reading of the
bitumen.

5. Suitable equipment shall be supplied by the Contractor to facilitate removal

of liquid used to flush pumps and lines to approved disposal sites.

6. Storage tanks for slow curing cutting oil and medium curing cutting oil shall
be fitted with dipsticks or flow meters for volume measurement and suitable
thermometers for monitoring temperature control.

7. The accuracy of volume and temperature measurement facilities shall be Required

sufficient to ensure that the binder constituents (adhesion agent excepted) Accuracy
and proportions (expressed as percentages) are those ordered  0.5%.

509.26.02 DISPOSAL SITES

1. The Contractor shall dispose of bituminous products or other disposable

items such as protective paper at an authorised waste disposal site.

2. Any area so used without the approval of the Superintendent shall be made
good immediately at no cost to the Principal.

509.27 AGGREGATE DUMP SITES

509.27.01 GENERAL

1. The aggregate stockpile sites shall be constructed and maintained in a tidy

condition and the Contractor's operations shall not contaminate aggregate
in the stockpiles. Surplus aggregate shall be removed from temporary
stockpiles and the aggregate stockpile sites shall be fully cleaned and
rehabilitated. The Contractor shall prepare a management plan for the
stockpile sites detailing how contamination from precoating work is to be
managed and cleaned after completion of work.

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2. Where aggregate is supplied in stockpiles by the Principal, the locations of

the stockpile sites are as detailed in Annexure 509B. Where aggregate is
supplied by the Contractor, temporary stockpile sites shall be prepared and
maintained in good condition by the Contractor.

3. Prior to the stockpiling of aggregate, the Contractor shall nominate to HOLD POINT
the Superintendent the proposed location of the stockpile sites and
provide a management plan for the sites.

509.27.02 SITE PREPARATION

1. The Contractor shall prepare aggregate stockpile sites such that they Site
incorporate a firm, smooth, level, well-drained surface. Stockpile areas Requirements
shall be of sufficient size to allow a 4m clear margin around each stockpile.

2. Clearing of sites shall be in accordance with Specification 301 CLEARING, Clearing and
and compaction shall be in accordance with EMBANKMENT Compaction
FOUNDATION COMPACTION: PRINCIPAL’S METHOD SPECIFICATION
as detailed in Specification 302 EARTHWORKS.

APPLICATION OF SEAL
509.28 GENERAL

1. The application of a seal shall include preparation of the surface, and the
supply and application of various treatments over the widths, lengths and
areas either as shown in the Drawings and/or as specified in Annexure
509A and 509C.

509.29 - 32 NOT USED

509.33 PLANT AND EQUIPMENT

509.33.01 ROAD TANKER

1. Road tankers shall comply with AS 2809.5 and the Australian Dangerous
Goods Code. Road tankers shall have lagging and shall have calibrated
thermometers located at the top, middle and bottom thirds of the product
tank. The tanker shall be provided with heating tubes and pipework to
allow circulation of the binder during heating. Road tankers shall have a
permanent sampling cock that is safe and easy to use to obtain samples of
the polymer modified binder.

509.33.02 MECHANICAL SPRAYER

1. Binder shall be applied using a bitumen sprayer with a minimum capacity of

5 000 litres complying with AS 2809.5 and the Australian Dangerous Goods
Code. The sprayer shall comply with the requirements of Austroads
document AP-T262-14. In addition to the above requirements, the sprayer
dipstick shall be calibrated in 50 litre increments, and unless the sprayer is
of the air pressure type, the spray bar shall be fully circulating.

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2. The sprayer shall have been calibrated at a facility accredited by NATA for Sprayer
the calibration of bitumen sprayers to the Austroads test methods AG:PT/T Calibration
530, T531, T532 or T533 or T534, and T535. The tests shall have been
performed within the past twelve (12) months and the sprayer shall have
passed the Pump Output and Transverse Distribution tests for the
maximum allowable width of the bar. A sprayer shall have been tested to
method AG:PT/T 531 for each type of nozzle to be used by the sprayer.
The sprayer shall be tested at the nozzle output and width of the bar up to
the maximum as shown in Table 509.2. A NATA endorsed calibration
certificate shall be issued for the sprayer which clearly indicates the
Austroads methods used in the calibration and the pass/fail status of the
sprayer to each of the Austroads calibration test methods.

TABLE 509.2 NOZZLE SETUP

Austroads Previous Nozzle Output of Nozzle Maximum Width of

Nozzle Type Naming (L/min.) Spraybar (m)

AN 18 A4 18 NA

AN 27 B6 27 5.0

AN 36 B8 36 4.0

3. Prior to the use of the sprayer on the Works, the Contractor shall HOLD POINT
make available to the Superintendent the calibration certificate for the
sprayer. The Superintendent may require the sprayer to be made
available at the Main Roads’ Calibration Facility at Welshpool, Perth,
for inspection and testing prior to or during execution of the work.

4. The Superintendent may request prior to the commencement of Works, or

at any time during the Works, that the sprayer be tested for uniformity of
spray bar output, particularly transverse application, in accordance with WA
340.1. The test will be conducted for the maximum spray bar width to be
used under this Contract. The requirements for the spraybar output and
distribution are shown below:

a. The mean binder application rate of the width tested shall not
exceed ± 10% of the binder application rate at 15°C specified for
the Works;

b. Every tile used in the test which was fully coated shall have a binder
application rate within 15% of the mean binder application rate for
the width tested;

c. Not more than two consecutive tiles that have been fully coated
shall have a binder application rate exceeding ± 10% of the mean
binder application rate for the width tested.

5. If the sprayer does not conform to the requirements shown above it shall Sprayer
not be used on the Works. Subsequent tests to confirm conformity will be Conformity
at the Contractor’s cost. Any delays to site operations because of
conducting these tests are not claimable as separate costs.

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6. The Contractor shall use Copley EAN18 (W) End Nozzles for use in Spray Nozzles
spraying edges with all binders. Copley intermediate nozzles shall be fitted
to the remainder of the spray bar as shown in Table 509.3. Nozzles shall
not be used for more than two years of service and shall be used within 4
years of the date stamp on a nozzle.

TABLE 509.3 NOZZLE TYPES

Binder Class S10E S35E S20E S45R

Single Coat Seal (including AN 18 or AN 18 or

AN 27 AN 36
those with a scatter coat) AN 27 AN 27

Bridge Deck Waterproof AN 36 or

AN 27
Membrane AN 27

Single Coat Seal with

AN 36 or
BAR < 1.5 L/m2
AN 27
(S45R only)

AN 18 or AN 18 or
Double Double Seal AN 27
AN 27 AN 27

8. The sprayer shall be capable of passing over protective paper doing a

running start without damaging or moving the paper. Where curtains are
fitted to the spraybar they shall be fitted with sufficient height off the ground
such that build-up of binder does not interfere with the paper.

509.33.03 ROLLERS

2. The size of multityred rollers to be used is specified in Table 509.9 and Rubber Tyred
where not specified then the requirements of this clause are the minimum Rollers
requirements. Where an 18T roller is specified then a minimum of two 18T
rollers shall be used. Where an 11T roller is specified it shall be used
along with a combination roller with a vibrating rubber coated drum OR a
vibrating multi tyred roller. The wheels shall have smooth pneumatic tyres
inflated to pressures of at least 700kPa.

509.33.04 ROAD BROOM

2. The units shall be a mechanically or power driven roller broom, capable of

removing excess cover material and/or other loose material from the
pavement surface without damage to the existing primerseal or seal
surface.

4. The broom, or its prime mover, shall be equipped with an amber flashing Flashing Lamp
lamp visible from all directions in accordance with Specification 203
OCCUPATIONAL SAFETY AND HEALTH.

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509.33.05 DRAG BROOM

2. The units shall consist of fixed brushes fitted to a frame and shall be
capable of distributing loose cover material laterally and longitudinally to fill
empty void spaces. The drag broom shall not dislodge particles embedded
in the binder or damage the surface in any way. Brooms shall be angled,
height adjustable and suspended under rubber tyred rollers.

509.33.06 PRECOATER

2. The precoater shall be capable of applying a uniform film of precoating

agent to cover all of the surface area of the aggregate particles at a
controlled and variable rate. The precoater shall have sufficient output
capacity to maintain an adequate supply to the spraying operations.

4. The precoater shall also be capable of screening dirt/foreign matter (both Screening
oversize and undersize materials) from the aggregate during its operation.

6. Prior to the use of the precoater on the Works, the Contractor shall HOLD POINT
notify the Superintendent of such intention.

509.33.07 SURFACE DAMAGE

2. In the event of any fuel or oil leaks or spillages onto the newly sealed Care of Works
surface, the Contractor shall reinstate the surface to its pre-damage
condition at no cost to the Principal.

509.34 - 509.35 NOT USED

509.36 SURFACE PREPARATION

509.36.01 EXISTING BITUMINOUS SURFACE

2. Where the pavement to be sealed is a seal, microsurfacing, asphalt or a

primed basecourse the surface shall be swept clean of all loose sand,
stones, dust and other foreign matter before the new surfacing is applied.
Adherent patches of foreign matter shall be removed by using hand
brooming and steel scrapers or similar methods. For a primed basecourse
the surface shall be dark in colour uniformity with primer on the entire
surface area. Where the colour of the basecourse is showing on more than
25% of the surface area the modified binder shall not be applied.

4. Loose material shall be swept a sufficient distance off the pavement to

permit execution of the bituminous surfacing.

6. On a primed basecourse the Contractor shall set out and mark the edge of Line Spotting
the binder at a position to achieve the specified tolerances and to suit the
method of work employed. The interval of spotting of any line is given in
Annexure 509C. The Contractor shall provide such additional markers as
are necessary to achieve the specified tolerances.

8. Prior to the application of bituminous binder the Contractor shall HOLD POINT
certify to the Superintendent that any required sweeping and/or
necessary repairs to the existing surface have been carried out, and
that the surface is suitable to receive the sprayed seal.

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10. Where encountered, the Contractor shall remove and dispose off site Raised
existing raised pavement markers, both permanent and temporary, prior to Pavement
spraying. The pavement markers shall only be removed at the Markers
commencement of works for the day, and shall be removed only from the
section to be resealed on that day. Any depression left by the removal of a
raised pavement marker shall be repaired with coldmix to a level flush with
the existing seal.

509.36.02 BRIDGE DECKS OR OTHER CONCRETE SURFACES

2. Bridge deck or concrete surfaces shall be swept clean of all loose sand,
stones, dust and other foreign matter before sealing. Adherent patches of
foreign matter shall be removed by hand brooming, or by using steel
scrapers, or similar methods.

4. The surface shall be primed with a cationic slow setting emulsion (Grade Emulsion
CSS/170-60 or CRS/170-60), diluted with water in the ratio of one (1) part Grade
emulsion to one (1) part water. The emulsion shall be compatible with the
water used for dilution. The rate of application of the dilute bitumen
emulsion primer shall be 0.6L/m². No polymer modified binder shall be
applied on the prime until the emulsion has broken and all water has
evaporated.

6. All traffic shall be kept off the bridge deck or concrete structure until
application of the binder is complete and conforms to the Specification.

509.36.03 COLD PLANED SURFACE

1. Where the pavement surface to be sealed has been produced by cold

planning, the surface shall be swept clean of all loose sand, stones, dust
and other foreign matter before surfacing. Adherent patches of foreign
matter shall be removed by using hand brooming and steel scrapers or
similar methods

2. Loose material shall be swept a sufficient distance off the pavement to

permit execution of the bitumen surfacing.

3. At the completion of the cold planning surface being swept and prior HOLD POINT
to the application of the bituminous binder, the Contractor shall
certify to the Superintendent that the cold planed surface complies
with the surface finish requirements as described in Specification 508
COLD PLANING and that the surface is suitable to receive the
bituminous binder. The Contractor shall request the release of this
Hold Point in writing after the sweeping of the cold planed surface is
completed and at least one (1) hour prior to the application of the
bituminous binder.

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509.37 AGGREGATE PREPARATION

509.37.01 PRECOATING

2. All aggregate precoated with a bitumen based precoating agent shall be Timing
precoated a minimum of four (4) days but not more than twenty eight (28)
days prior to its intended use. Aggregate must not be left uncovered for
more than 14 days. Where approved, aggregate precoated with a distillate
precoating agent shall be precoated at least 24 hours but not more than
seven (7) days prior to its intended use.

4. The rate of application of precoating agent for clean, surface dry aggregate Rate of
shall be as stated in Table 509.4. The rate shall be varied to provide a Application
complete, light, uniform, effective cover to all aggregate particles at the
time of spreading in accordance with the type and condition of the
aggregate. At the time of spreading the precoated aggregate shall not be
covered with excess precoat such that it sticks together or picks up on
vehicle tyres or causes a delay in adhesion to the polymer modified binder.

6. Care shall be taken to minimise aggregate losses and to ensure dust does
not blow back onto precoated aggregate.

TABLE 509.4 APPLICATION RATE FOR PRECOATING

Nominal Size Application Rate Application Rate

Aggregate (litres/m³ loose) (litres/m³ loose)
(mm) Bitumen based agent Distillate only

7 12 6

10 10 5

14 8 5

16 6 4

20 5 4

509.37.02 HEATED AGGREGATE

2. The aggregate shall be clean 7 or 10mm sealing aggregate that has not Aggregate
been precoated. Where used in a seal other than a SAMI seal or bridge
deck membrane the aggregate shall be from the same quarry as any
aggregate applied in an adjacent seal with precoated aggregate. Heated
aggregate shall not be used for a geotextile reinforced seal.

4. The aggregate shall be heated, dried and coated with Class 170 or 320 Heating and
bitumen in a batch type asphalt plant. The aggregate shall be heated to a Mixing
dry condition and then mixed with 0.3-0.4% by mass of bitumen for an
extended wet mixing time to ensure an even coating of the bitumen over all
stones. The temperature of the coated aggregate shall be 170°C to 180°C
at discharge from the plant.

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6. The heated aggregate shall be transported to site covered with a heavy

tarpaulin or covered tray.

8. Heated aggregate shall be applied to a sprayed binder immediately and

rolled immediately.

509.38 NOT USED

509.39 PROVISION FOR TRAFFIC

2. The Contractor shall minimise delays and inconvenience to road users

during the course of the work. Traffic shall not be allowed on the new work
until sufficient rolling has taken place to prevent damage to the freshly
applied bituminous mat.

4. The Contractor shall supply signs, lights, plus any other necessary
equipment, and erect and maintain same in good condition in accordance
with Specification 202 TRAFFIC.

6. Signs inscribed "ROADWORKS IN PROGRESS FOR NEXT ... KM" shall Signing
be erected at each end of unswept work where the length of the work,
intermittent or continuous, exceeds 1 kilometre.

8. Signs shall remain in position until after the seal has been swept with no
loose stones remaining on the surface. No item of plant will be permitted to
operate outside the appropriate warning signs. All signs shall be free
standing and weighted to hold the signs down.

10. The Contractor shall provide at least two persons on a full time basis as Traffic
traffic controllers. Warning signs shall always be erected in conjunction Controllers
with the use of traffic controllers. Each traffic controller shall be equipped
with a portable two-way radio, plus a spare and wear a high visibility vest.

12. Prior to implementing traffic control measures for the Works, HOLD POINT
particularly temporary speed restrictions, the Contractor shall notify
the Superintendent of such proposed measures.

509.40 NOT USED

509.41 PREPARATION OF POLYMER MODIFIED BINDER

509.41.01 general

1. Polymer modified binder and other constituents shall be mixed by Mixing

circulation in the mechanical sprayer for not less than fifteen minutes
immediately prior to application or such longer periods as may be
necessary to ensure a uniform and homogeneous mixture.

2. Adhesion agent as specified in clause 509.8 shall be dissolved in the hot Adhesion
binder and thoroughly mixed prior to the binder being sprayed on the road. Agent
The binder shall be sprayed within twelve (12) hours of adding the
adhesion agent to the binder. Where the binder has not been sprayed
within twelve (12) hours, further adhesion agent shall be added to the
remaining binder. Adhesion agent shall be added at a rate of 0.5% by
volume of the binder.

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3. Adhesion agent shall be added at least to the minimum level specified or Mix Tolerance
ordered. All other binder constituent proportions (expressed as
percentages) shall be those specified or ordered + 0.5%.

4. The binder spraying temperature shall be as specified in Table 509.5 Spraying

unless otherwise specified by the binder manufacturer. The manufacturer’s Temperature
instructions shall take precedence over Table 509.5. Where cutting oil is
added refer to the manufacturer’s instructions for spraying temperature.

TABLE 509.5 SPRAYING TEMPERATURE

Binder Type Temperature C

S10E S35E S20E 180 to 190

S45R 190 to 200

509.41.02 spraying viscosity – SAMI and Bridge decks

1. Medium curing cutting oil shall not be added to S20E or S45R binders Mix Tolerance
where they are being used in a SAMI seal or waterproof bridge deck
membrane. The sprayer shall apply these seal types in accordance with
Clause 509.42.04(2).

509.41.03 spraying viscosity – SAM and high stress seals

1. To achieve the initial wetting of aggregate modification of the binder Mix Tolerance
viscosity is required. Depending upon the anticipated pavement
temperature medium curing cutting oil shall be added to the binder.

a. For a single/single seal add medium curing cutting oil in accordance

with Table 509.6 and accompanying notes;

b. For a double/double seal where both coats are applied on the same
day using S10E and S35E binders do not add cutter to the binder
used in the first coat. For the second coat add medium curing
cutting oil in accordance with Table 509.6 and accompanying notes;

c. For a double double seal where both coats are applied on the same
day using S45R binder add only 2% medium curing cutting oil to the
binder used for the first coat. For the second coat add medium
curing cutting oil in accordance with Table 509.6 and accompanying
notes.

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TABLE 509.6 PERCENTAGE OF CUTTING OIL TO BE ADDED

Pavement Traffic Class of Polymer

Temperature (vehicle/lane/day Modified Binder
(C) based on AADT)
S10E and S45R
S35E (Note e)

20 to 25 Less than 1000 6 9

1000 or more 4 7 to 8

26 to 32 Less than 1000 4 6 to 8

1000 or more 2 6

33 to 38 Less than 1000 2 6

1000 or more 2 4 to 6

39 to 45 Less than 1000 0 to 2 Min 4

1000 or more 0 to 2

Above 45 All 0 Min 4

NOTES to Table 509.6

a. Cutter amount is percentage by volume of total binder.

b. Assessment of pavement temperature shall take into account the

presence of shaded areas. Areas with a significant portion of
shading shall be treated separately to adjacent areas that are not
shaded. Ambient weather conditions in the days and week
following must be considered in deciding on adding cutting oil.

c. Where manufacturer’s instructions vary from Table 509.6, the

manufacturer’s instructions shall be followed.

d. Where the proportion of heavy vehicles is greater than 20% of the

total traffic reduce the cutter content by 2%.

e. Where AN36 nozzles are being used for a single coat seal with a
BAR of ≥ 1.5 L/m2 no cutter is required above a pavement
temperature of 45 C and the cutter content below 45 C is reduced
by 2 C.

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509.42 APPLICATION OF BINDER

509.42.01 GENERAL

1. The surface to be sealed shall be dry and no binder shall be applied during Weather
wet or rainy conditions, or when adverse weather conditions may prevail at Minimum
any time during such work. When binder is applied and rain is forecast Pavement
during the 24 hour period after application of the seal the Contractor shall Temperature
be responsible for any damage to or defects in the seal and action and cost
to maintain or repair the seal. No binder shall be applied whilst the
pavement surface temperature is less than 20C.

2. The Contractor shall provide the Superintendent with safe and convenient
access to the sprayer at all times for checking the volume before and after
spraying by means of the dipstick.

509.42.02 APPLICATION RATE

1. The binder application rate (BAR) for tender purposes shall be as detailed
in Annexure 509C. Where adjustments to the binder application rates in
excess of 7.5 percent of the rates detailed in Annexure 509C are directed
by the Superintendent, then changes to the Contractor's rates for sealing
shall be made as follows:

URN = URC + ( ARO - ARC)L

Where :

URN = New Rate for polymer modified binder treatment ($ per m2)

URC = Contracted rate for polymer modified binder treatment as

applicable ($ per m2)

ARO = Ordered binder application rate (Litres per m2)

ARC = Contracted binder application rate in Annexure (Litres per m2)

L = Rate per litre for variation in the Schedule of Rates ($ per litre)

Adjustments made under this clause shall be made prior to any

adjustments that are due to conditional acceptance.

2. The actual BAR at 15°C shall be calculated from the quantity of binder
sprayed and the actual area covered as measured on the ground.

3. On sections where the actual binder application rate differs from the
ordered application rate and the work is deemed to be non-conforming,
refer to Clause 509.53 (“Non Conformance in Binder Application”).

509.42.03 VOLUME CONVERSION

1. Table 509.7 gives factors to be used when converting binder volumes or

spray rates at temperatures other than 15°C to volumes or spray rates at
15°C or vice versa. Adjustment shall be made using the following
formulae:

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a. Volume or spray rate at 15°C equals the Volume or spray rate at T

°C multiplied by the Factor for T °C

b. Volume or spray rate at T °C equals the Volume or spray rate at

15°C divided by the Factor for T °C

TABLE 509.7 CONVERSION FACTORS

Observed Factor For Observed Factor for Observed Factor

Temp T °C T °C Temp T °C T °C Temp T °C For T °C

15 1.000 80 0.9597 145 0.9207

20 0.9969 85 0.9567 150 0.9177

25 0.9937 90 0.9536 155 0.9148

30 0.9906 95 0.9506 160 0.9118

35 0.9875 100 0.9476 165 0.9089

40 0.9844 105 0.9446 170 0.9060

45 0.9813 110 0.9416 175 0.9031

50 0.9782 115 0.9385 180 0.9002

55 0.9751 120 0.9356 185 0.8973

60 0.9720 125 0.9326 190 0.8944

65 0.9689 130 0.9296 195 0.8915

70 0.9658 135 0.9266 200 0.8886

75 0.9628 140 0.9236

Note: Factors for intermediate temperatures in Table 509.7 may be obtained by direct interpolation.

509.42.04 SPRAYING

1. S45R binder shall be sprayed at a width no more than 4.0m regardless of

nozzle type being used. Other binder types being sprayed with AN 27
nozzles shall be sprayed at a width no more than 5.0m. For binders
sprayed with AN 18 nozzles the maximum width is as specified in the
calibration certificate for the sprayer.

2. Binder shall not be applied until the Contractor has sufficient HOLD POINT
spreader trucks to comply with 509.43.01(1c) at the location of the
area to be sprayed. In addition all rollers shall be at the location of the
area to be sprayed at the time of spraying.

3. The binder shall be bar circulated for a minimum of three (3) minutes
immediately prior to spraying.

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4. The spraying of the binder for each run of the sprayer shall start and finish Protective
on protective paper. All tapers and fillets shall be sprayed after masking Paper
with protective paper. The paper so used and any spilt binder shall be
removed and disposed of in a suitable manner.

5. The sprayer shall cross the protective paper at its correct spraying speed at Sprayer Speed
the start of each run. The sprayer shall maintain its correct spraying speed
over the full length of each run and shall cross the finish paper at this
speed.

6. All outside edges of the seal, parallel to the road centreline shall be End Spray
sprayed using Copley EAN18 (W) end nozzles. Nozzles

7. Where the direct use of the mechanical sprayer is impracticable, the binder
may be applied by using a hand lance fed from the mechanical sprayer.
Caution should be taken with this operation due to the higher viscosity of
the polymer modified binder.

8. The binder shall be sprayed onto areas as detailed in the Drawings, or as Spraying
otherwise specified between two lines as defined by the line markers and Tolerances
the surfacing widths given in Annexure 509A. The sprayed binder edge
shall conform to the following requirements:

a. the sprayed edge shall not deviate from the specified edge by more
than 50mm;

b. the rate of deviation of the sprayed edge from the specified edge
lines shall not exceed one in four hundred (1: 400);

c. tapers to accommodate variations in specified width shall be at one

in one (1:1), except at floodway exits, where the tapers shall be at
one in twenty (1:20).

9. The Contractor shall take all necessary precautions to prevent binder from Damage
adhering to any existing structure. Any damage or defacement shall be
made good by the Contractor at no cost to the Principal immediately
surfacing work on a section has been completed.

509.42.05 EXISTING GUIDEPOSTS

1. Where necessary, existing guideposts shall be removed and stored safely Guidepost
by the Contractor to allow bituminous surfacing operations to proceed. Removal

2. The Contractor shall reinstate removed guideposts to their original Guidepost

locations at the completion of bituminous surfacing operations. Any Reinstatement
guideposts damaged during their removal or reinstatement shall be
replaced by the Contractor at no cost to the Principal.

509.43 APPLICATION OF COVER MATERIAL

509.43.01 APPLICATION

1. General

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a. The aggregate shall be dry (containing no water) at the time of

application and shall be uniformly spread over the sprayed area by
use of a suitable mechanical spreader. The mechanical spreader
shall be fitted with removable cut-off attachments to allow the
aggregate spread width to match the required width on the
pavement.

b. The aggregate shall be placed to form a uniform stone mosaic of

single particle thickness, in almost continuous interlocked contact,
generally orientated with their least dimension vertical. Specified
aggregate application rates given in Table 509C2 are nominal and
should be adjusted to suite the aggregate used to give the correct
stone mosaic. Where the aggregate is supplied by the Principal,
approval shall be obtained from the Superintendent for any change
in the ordered rate.

c. The sprayed binder shall be totally covered with the exception of Timing of
approved lapping strips with aggregate within 5 minutes of the Application
application of the binder. The length of spray runs shall be limited to
comply with this requirement.

2. Additional Aggregate

a. Additional aggregate shall be applied to any bare or insufficiently

covered areas as necessary to provide a uniform and complete
cover. Where the area to be covered with additional aggregate is
not of uniform width the additional aggregate shall be spread by
hand.

b. Additional aggregate shall be applied before the completion of four Timing

passes of rubber tyred rolling.

c. If there are surplus loose particles on any portion of the sealed area,
such portion shall be swept lightly to remove the loose particles but
not disturb the aggregate embedded in the binder.

3. Double/Double Seals

a. the first coat of a double/double seal shall be applied using a larger

sized aggregate than the aggregate used in the second coat;

b. the application rate of aggregate for the first coat shall result in more
gaps between the aggregate particles than would occur if the same
sized aggregate was applied in a single coat seal.

4. Principal Supplied Aggregate

a. Where the actual aggregate spread rate is less than 0.925 times the Spread Rate
ordered or approved aggregate spread rate, the cost of any
additional aggregate used supplied by the Principal (calculated as
below) shall be deducted from payments due to the Contractor.

 1 1  Aggregate Cost
A  R  
Cost of additional aggregate =
 Sa 0.925So 

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where: A = actual area (m²) covered at rate S a

R = rate (in $/m³) stated in Annexure 509B

S o = ordered aggregate spread rate in m²/m³

S a = actual aggregate spread rate in m²/m³

b. The cost of aggregate spread outside the specified area (with due
allowance for tolerances) shall be deducted from money due to the
Contractor at the rate stated in Annexure 509B.

509.43.02 ROLLING AND DRAG BROOMING

1. Immediately after application of the cover material, the surface shall be Rolling
rolled to the number of complete coverages as stated in Table 509.9 over Sequence
the whole area. Where the roller size is not specified then 11 tonne rollers
shall be used. A complete coverage is one pass of a roller over the entire
area, ie. the total length and width of a spray run being rolled. For the first
four complete coverages, rollers shall be operated at speeds less than 7km
per hour. Drag brooming shall be carried out after every second pass of
rolling.

TABLE 509.9 ROLLER SIZE AND COVERAGES

Minimum Mass of Multityred Minimum Number of

Rollers Complete Coverages

18 tonne 10

11 tonne 10

2. The Superintendent may order additional rolling and drag brooming and
such additional work shall be paid at Daywork rates.

3. For double double seals, the rolling shall comply with the requirements of Double Double
this clause for each coat of the seal. Any aggregate not incorporated in the Seals
first coat of the seal shall be removed in such a manner as to prevent
removal of aggregate embedded in the first coat. Any damage to the first
coat shall be repaired by the Contractor at no cost to the Principal prior to
spraying the binder for the second coat.

509.43.03 SURFACE SWEEPING

1. Any loose cover material not incorporated in the seal after the completion of
rolling shall be swept off the sealed surface to beyond the outer edge of
each shoulder without damage to the seal, shoulder or guideposts, and
shall then be dispersed such that no windrows of swept material remain.

2. Where the roadway to be sealed is kerbed, the excess cover material may Excess Cover
be swept hard against the kerb during interim sweeping operations but shall Material
be picked up and removed during the final sweeping.

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3. The initial sweeping shall be carried out prior to the completion of the day’s Repeated
work. A second sweeping shall be carried out at the commencement of the Sweeping
following day’s work. The Contractor shall carry out subsequent sweepings
as necessary for the following seven (7) days to ensure that no loose
stones remain on the road surface. All loose aggregate shall be swept clear
of the sealed surface, off the shoulder and past the line of the guide posts.

4. The Contractor shall install “LOOSE STONE” signs and other temporary Signing
traffic management signs in accordance with Specification 202 TRAFFIC.
The signs shall remain in place on each section of the Works for the
following seven (7) days after completion of sealing.

509.44 - 509.51 NOT USED

509.52 NONCONFORMING TEST RESULTS

1. If defects occur in the surfacing in any way, either in part or in full,

attributable to binder for which test results are non-conforming, then within
60 days of completion of the works on which that binder was used, the
Superintendent may direct the Contractor to take remedial action to repair
or replace any defective sections of work. Any remedial action so directed
will be at no cost to the Principal.

2. The Superintendent may consider not making payment to the Contractor for
the Schedule of Rates item for binder supply and delivery related to that
delivery for 60 days after the work has been completed, plus any
subsequent time thereafter if remedial work is outstanding.

3. The Superintendent may initiate testing of other samples retained but not
previously tested.

509.53 NON-CONFORMANCE IN BINDER APPLICATION

1. The actual binder application rate at 15°C on a spray run shall be deemed
to be conforming to the ordered binder application rate if it falls within the
tolerances given in Table 509.10 for Polymer Modified Bituminous
Surfacings.

2. Where the actual binder application rate at 15°C on a spray run differs from Application
the ordered rate, the Quality Level shall be deemed to be either a
non-conformance or one of a range of conditional conformance levels,
depending on the difference between the actual binder application rate and
the ordered binder application rate. The tolerances applicable to conditional
conformance are given in Table 509.10, and a Pay Factor shall be applied
for work at the corresponding conformance levels. The Pay Factor applied
will reflect the lower level of serviceability of conditionally conforming
sprayed bituminous work.

3. Where sprayed work is deemed non-conforming, the Contractor shall apply

corrective action subject to the procedures contained in the Quality System
Specification.

4. No payment shall be made for binder sprayed outside the 50mm margin
specified in Clause 509.42.04.

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TABLE 509.10 PAY FACTORS FOR POLYMER MODIFIED BITUMINOUS

SURFACINGS

Actual Binder Application Rate Quality Level Pay Factor

(BAR) L/m² @ 15° (Converted) (PF)

(OAR - 0.16) or less Non-Conformance N/A

(OAR - 0.15) to (OAR - 0.11) Conditional Conformance Level 2 0.90

(OAR - 0.10) to (OAR + 0.10) Conformance 1.00

(OAR + 0.11) to (OAR + 0.15) Conditional Conformance Level 1 0.90

(OAR + 0.16) to (OAR + 0.20) Conditional Conformance Level 3 0.70

(OAR +0.21) or more Non-Conformance N/A

(OAR = Ordered Binder Application Rate at 15ºC)

509.54 CRUSHED AGGREGATE

1. Conformance of the aggregate at its source shall be construed only as

authorising the Contractor to deliver the material. Contamination of the
aggregate during cartage, or failure to cart and stockpile the aggregate as
specified shall render the material non-conforming. The Contractor shall
not be paid for non-conforming material or its cartage.

509.55 TESTING FREQUENCY

1. The minimum testing frequency to determine the conformance of product

and work processes with specified characteristics shall be in accordance
with Specification 201 QUALITY SYSTEMS.

509.56 – 509.80 NOT USED

AS BUILT AND HANDOVER REQUIREMENTS

509.81 – 509.90 NOT USED

CONTRACT SPECIFIC REQUIREMENTS

509.91 WORKS RECORDS

1. The Contractor shall accurately record the information required on Record

Forms similar to those shown in Annexure 509C, in respect of each
application of binder. The forms shall be supplied by the Contractor and
one copy of the completed form for each item of work shall be submitted to
the Superintendent at the completion of each day's surfacing work.

509.92 – 509.99 NOT USED

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ANNEXURE 509A
SCHEDULE OF WORKS

Works Item From ¹ To ¹ Length Width Side ² Area Type of Treatment Comments
(Section Nos) (SLK) (SLK) (km) (m) (L,C,R) (m²)

Road Name 1
1
2
Etc. etc.

Road Name 2
1
2
Etc. etc.

Road Name 3
1
2
Etc. etc.

Note 1: SLK denotes Straight Line Kilometre distance values for “From” and “To”. Alternatively, section limits may be described using chainages.
Note 2: “L, C, R” denotes “Left”, “Centre”, or “Right”. Leave “Side” column blank if width value in previous column is entire seal width.

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ANNEXURE 509B
COVER MATERIALS - PRINCIPAL SUPPLY

1. AGGREGATE DUMPSITE LOCATIONS

1.1 Details of aggregate supplied by the Principal are shown in Table 509B1.

TABLE 509B1 DUMPSITE DETAILS

Location Offset Quantity Size Type

(SLK) (M) Available (Mm)
(M³)

2. RATE OF DEDUCTION

2.1 The rates for deduction for over-spreading the Principal’s aggregate are as shown in
Table 509B2.

TABLE 509B2 RATES FOR DEDUCTION

Nominal Size of Rate for Deduction

Aggregate ($/m³)
(mm)

10

14

16

20

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ANNEXURE 509C
509C.1 RESPONSIBILITY FOR SEAL DESIGN

TABLE 509C1 DESIGN RESPONSIBILITY

Seal Type Location Design

Responsibility

Strain Alleviating All Works Principal

Membrane

Strain Alleviating All Works Principal

Membrane Interlayer

High Stress Seal All Works Principal

509C.2 BINDER AND AGGREGATE APPLICATION RATES

The aggregate size, spread rate, class of binder and binder application rates for Tender purposes
shall be as detailed in Table 509C2. Final binder application rate and aggregate spread rate to be
designed in accordance with 509.20.

TABLE 509C2 BINDER, AGGREGATE AND APPLICATION RATES

Treatment Type Aggregate Aggregate Binder Class Binder

Size (mm) Spread Rate Application
m²/m³ Rate (BAR)
at 15C (L/m²)

Single coat seal

Single Coat Seal

with Scatter Coat

Double Double
Seal

First coat

Second coat

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509C.3 LINE SPOTTING

1. Seal and reseal sections are spotted at the following intervals:

TABLE 509C3 LINE SPOTTING INTERVAL

Road Feature Spotting Interval (m)

Straight Sections 8

Curved Sections 5

509C.4 RECORD FORMS

a) BITUMINOUS SURFACING - CONTRACTORS SPRAYING LOADING RECORD

b) BITUMINOUS SURFACING - CONTRACTORS DAILY RECORD

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509C.1 Bituminous Surfacing - Contractors Daily Surfacing Record

DATE: BASE MATERIAL PAVEMENT SURFACE COVER AGGREGATE BITUMEN TOTAL QTY OF
BITUMEN USED
CONTRACT NO: TYPE: TYPE: TYPE: **TYPE: 50 170 Emulsion

TIE IN POINTS: CONDITION: SIZE: DUMP: SOURCE:

FROM TO LITRES AT
**CONDITION: Dusty Pre-coated Damp ADHESION AGENT:
15.0°C

ORDERED % OF
SIDE ACTUAL BINDER COMPONENT
APPLICATIO ORDERED
DISTANCE OF SPRAYED AREA BINDER COMPONENTS BINDER QUANTITY USED APPLICATION QUANTITIES USED

Cover Aggregate Used

N APPLICATION
ROAD RATES AT 15° C

Spray Temperature
Road Temperature
RATES RATES

Component No. 3
Component No. 1

Component No. 2
Sprayed at 15°C
Adhesion Agent

Binder at 15° C

Binder at 15° C
Binder at 15 °C

Sprayed Hot
Component

Component

Component

Binder Hot
Dip Before
Aggregate

Aggregate

Aggregate
Spray No.

Full Width

Spraying

Spraying
Dip After

Quantity

Quantity
Additive

Additive
Length

Cover

Cover
Cover
Width
From

Right

Area

No.1

No.2

No.3
Left/
To

m m m m m² ºC % % % % l /m² m²/m³ ºC l l l l m³ l /m² l /m² m²/m³ % % l l l kg

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

TOTALS
* Description Of Component No. 1 Remarks:
Component No. 2
Component No. 3
CONTRACTORS REPRESENTATIVE: ** = Tick Appropriate Box SUPERINTENDENT:
SIGNATURE SIGNATURE

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509C.2 Bituminous Surfacing - Contractors Sprayer Loading Record DATE: ___/___/___

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GRADE OF BITUMEN : ____________________ ROAD : _______________________________ SPRAY LOAD No : ________________

TYPE OF BLEND : _______________________ SPRAY RUN NUMBERS : ________________ CONTRACT No : __________________
A. LOADING INTO EMPTY SPRAYER B. LOADING INTO SPRAYER CONTAINING PRIMER
1 Pavement Temp _____ °C Design Blend __ / __ / __ 1 Pavement Temp _______ °C Design Blend ____ / ____ / _____
_ _ _ _ _
2 Application Rate (Hot) _____ L/M2 Spray Temp (Hot) ____ °C 2 Application Rate (Hot) _______ L/M2 Spray Temp (Hot) ____ °C
_ _
3 Volume Required In _____ L _____ °C 3 Volume Required In _______ L ______ °C
Sprayer _ @ Sprayer _ @
_____ L 15°C _______ L 15°C
_ @ _ @
4 Components To Be Added (15C) 4 Components To Be Added (15C)
Component 1 _____ L OR ______ L @ _____ °C Component 1 _______ L OR ________ L @ _______ °C
Component 2 _____ L OR ______ L @ _____ °C Component 2 _______ L OR ________ L @ _______ °C
Component 3 _____ L OR ______ L @ _____ °C Component 3 _______ L OR ________ L @ _______ °C
Adhesion Agent _____ L 5 Primer Remaining In Sprayer

_______ L ______ °C _______ L @ 15°C

ACTUAL COMPONENTS ADDED
A B 6 Actual Primer Composition ____ / ____ / ____

Component 1 ____ L @ ____ °C Component 1 ____ L @ ____ °C 7 Components Remaining in Sprayer

Component 2 ____ L @ ____ °C Component 1 ____ L @ ____ °C Component 1 _______ L Component 3 _______ L
Component 3 ____ L @ ____ °C Component 1 ____ L @ ____ °C Component 3 _______ L
Adhesion Agent ____ L Adhesion Agent ____ L 8 Components To Be Added (15C)
Actual Blend _____ / ____ / ____ Actual Blend ____ / _____ / _____ Component 1 _______ L OR _________ L @ _______ C
Component 2 _______ L OR _________ L @ _______ C

Component 3 _______ L OR _________ L @ _______ C

SIGNATURES : Adhesion Agents _______ L

Contractor’s Rep Description of

1
______________________________________________________________
Components _
Superintendent 2
______________________________________________________________
3
______________________________________________________________
_

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GUIDANCE NOTES
FOR REFERENCE ONLY – DELETE GUIDANCE NOTES FROM FINAL DOCUMENT

1. All edits to downloaded Specifications shall be made using Track Changes, to clearly show
added/deleted text.

2. If all information relating to a clause is deleted, the clause number should be retained and the
words “NOT USED” should be inserted.

3. The proposed documents with tracked changes shall be submitted to the Project Manager for
review, prior to printing the final batch of documents. When this final printing is carried out, the
tracked changes option is to be turned off.

4. Before printing accept all changes in the document, turn off Track Changes and refresh the
Table of Contents.

5. The Custodian of this specification is Bituminous Products Consultant.

1. GENERAL EDITING

When one or more of the types specified in clause 509.01.1 is not required for a Contract, all the
relevant parts of this specification must be deleted.

Treatment Sections to be deleted or

NOT required. marked as "NOT USED"

Strain Alleviating Membrane (SAM) 509.41.03 and amend

509.01

Strain Alleviating Membrane 509.41.02 and amend

Interlayer (SAMI) 509.01

High Stress Seal 509.41.03 and amend

509.01

Waterproof Bridge Deck Membrane 509.07

509.36.02
509.41.02
Amend 509.01

2. BITUMINOUS SURFACING INTENT

Clause 509.01.2 has been inserted to define the intended outcomes of applying a bituminous
surfacing treatment. This specification includes a number of different types of treatment, as
indicated within Clause 509.01.1. The critical intention will vary slightly from treatment to

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treatment. The requirement for a bituminous treatment to be “durable” is constant irrespective of

the type.

The three bullet points in this clause are the essential outcomes of the application of a bituminous
surfacing treatment. If these outcomes are not met, then the treatment is not achieving the desired
intention and further scrutiny should be applied to determine the cause for this failure. This might
include such factors as design, preparation, application, and/or operational practices.

3. AGGREGATE

3.1 PRINCIPAL SUPPLIED AGGREGATE (Clause 509.91)

3.1.1 If screening of Principal-supplied aggregate is required, include Clause 509.91 in

CONTRACT SPECIFIC REQUIREMENTS.

3.1.2 Insert any other requirements concerning Principal-supplied aggregate as necessary in

CONTRACT SPECIFIC REQUIREMENTS, e.g. care of dumpsites (Clause 509.92).

3.1.3 Provide aggregate spread rates. Based on test results where known calculated using the
formula:

Spread rate (m²/m³) = 900/Average Least Dimension (ALD)

adjusted to increase the amount of aggregate per m² for SAM and SAMI treatments by
10%, i.e. Spread rate = 900/1.1ALD.

The provided rate should be adjusted in the field to give the correct stone mosaic.
Typical values are:

7mm 200 to 250 m²/m³

10mm 140 to 170 m²/m³

14mm 90 to 120 m²/m³

16mm 65 to 90 m²/m³

20mm 50 to 70 m²/m³

3.1.4 Provide rate of deduction to allow for the cost of wastage in $/m³ for over-spreading
aggregate. A typical value might be of the order of $50/m³, and would represent the production
cost of the aggregate.

3.2 CONTRACTOR SUPPLIED AGGREGATE

In Schedule L of the Conditions of Tender, include an item to cover the Contractor’s

response to clause 509.16(3) resource of aggregate.

3.3 AGGREGATE SIZE

3.3.1 For bridge deck waterproofing membranes use 5mm aggregate with a S45R binder or
7mm aggregate with a S25E binder.

3.3.2 For a Stress Alleviating Membrane (SAM) seal the nominal aggregate size will typically
vary between 10mm to 14mm.

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3.3.3 For a Stress Alleviating Membrane Interlayer (SAMI) seal the nominal size of
aggregate shall be 10mm.

3.3.4 For an enhanced aggregate retention seal the nominal size is that which would have
been used for a seal using Class 170 bitumen.

3.3.5 For a double double seal the stone size in the second coat is of the order of about half
the size of the stone in the first coat where the larger sized stone is applied first. Typical
applications are 14/7mm which can be 14/10mm if 7mm aggregate supply is difficult, however the
control of spreading the 14mm stone has to be managed. A 14/10mm double double seal is not
recommended unless experienced Main Roads supervision is on site.

Larger combinations of 16/7mm, 16/10mm or 20/10mm would be used as an extreme treatment to

regain surface texture. The 16mm sized aggregate is difficult to procure and a Contractor needs a
good lead time to procure the stone. An option is for a region to get its Materials Manager to liaise
with quarries on availability. The use of 20mm sized aggregate should not happen without
discussion with the Materials Engineering Branch first as this is a very large sized stone that will
result in a hungry surface texture which will be uncomfortable for some road users. Neither 16mm,
or 20mm aggregate is to be used for single coat seals as the stones will become large missiles if
dislodged by high speed traffic.

4. RESPONSIBILITY FOR SEAL DESIGN

Amend Table 509C1 to show whether the Principal or Contractor is responsible for the design of
sprayed seals.

5. ROLLING

5.1 STEEL WHEELED ROLLERS

There is no reference to the use of steel wheel rollers in the standard specification. The
use of steel rollers on seal/reseal works is not recommended particularly on softer
aggregates such as granite due to the possibility of over-rolling and crushing the aggregate.

5.2 ROLLER SIZE

Table 509.9 requires that the size of rollers be specified by deleting one of two rows
showing roller size. For sprayed seals that will remain as so for their service life it is
important to achieve the best embedment and alignment of the sealing aggregate at the
time of application. For seals or reseals with a service life to be beyond 1-2 years heavier
rollers with a minimum mass of 18 tonnes must be used. For seals that may not be
trafficked, such as SAMI seals under asphalt or bridge deck waterproofing membranes to
be covered with asphalt smaller sized roller s of at least 11 tonne mass are acceptable.
The use of the 11 tonne rollers can be acceptable also for initial seals (primerseals etc.)
with a trafficked lifetime of no more than 1-2 years.

6. NOTES RE ANNEXURES

6.1 ANNEXURE 509A SCHEDULE OF WORKS

Use only if required (e.g. Minor Works sealing/resealing contract), and insert details on a
road-by-road basis including the type of treatment as shown in Table 509C1 or 509C2.
This schedule is not normally required in Major Works, but could be adapted to suit if
necessary. When Annexure 509A is NOT used, the text of Clause 509.01.3 and the title of
Annexure 509A should be replaced with "NOT USED", while the table in Annexure 509A
should also be deleted.
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6.2 ANNEXURE 509B COVER MATERIALS - PRINCIPAL SUPPLY

Insert relevant details of Principal-supplied aggregate. Insert CONTRACT SPECIFIC

REQUIREMENTS into text of Specification as noted in Item 3 of the Specification Guidance
Notes.

6.3 ANNEXURE 509C APPLICATION DETAILS

Insert relevant details into Table 509C.2.

7. MINOR WORKS CONTRACTS

7.1 WORKING HOURS (CLAUSE 509.93)

Where sealing works are organised as a separate Minor Works contract, a Clause for
Working Hours should be added in CONTRACT SPECIFIC REQUIREMENTS if not already
covered elsewhere (e.g. in the Conditions of Contract). The hours stated here are typical –
vary to suit the conditions, particularly in heavily trafficked areas.

7.2 CLEARING (CLAUSE 509.94)

Add this Clause if required.

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CONTRACT SPECIFIC REQUIREMENTS

The following clauses are to be placed under the CONTRACT SPECIFIC REQUIREMENTS, as
required. After inserting the clause, change the clause number and heading to style “H2 SP” so it
appears in the Table of Contents.

509.91 SCREENING REQUIREMENTS

1. Aggregate supplied by the Principal for use in the Works shall be screened
prior to being used as cover aggregate.

2. All rejected material and by-products of the screening operations shall

remain the property of the Principal and shall be stockpiled within each
dumpsite as directed by the Superintendent.

3. All screened aggregate shall meet the Particle Size Distribution specified in
Clause 509.16 when tested in accordance with WA 210.1.

509.92 COVER MATERIAL DUMP SITES

1. The Contractor shall be required to remove star picket fencing from the
perimeter of dumpsites of Principal supplied aggregate in order to gain
access. Fences shall be carefully dismantled and fencing materials stacked
at the dumpsites without damage. The fences will be re-erected by the
Principal at the completion of the Works. The Contractor shall be liable for
any damage to fencing or dumpsite signs caused by the Contractor's
operations.

2. Cover material dumpsites shall be left in a tidy condition. Residual

stockpiled aggregate shall be re-heaped into a single uniformly shaped
stockpile for each sized aggregate.

509.93 WORKING HOURS AND DAYS

1. The Contractor may work up to 120 hours per fortnight with a maximum of
10 hours on any day between the hours of 6 am and 6 pm. In addition, the
Contractor shall complete each day's spraying by 5.00 pm at the latest,
unless otherwise authorised by the Superintendent. The Contractor shall
notify the Superintendent of the delivery times and dates for each dump site
for the aggregate, and work start times and working days for the sealing
work prior to commencement of work on site. The Superintendent may
approve variation to the start and finish times and/or working days.

2. The Contractor may work outside the nominated working hours for the
following activities:

a. Repairs to plant.

b. Travelling to and from worksite by personnel.

c. Travelling of plant and personnel from one worksite to another.

d. Receipt and reheating of bitumen at worksite.

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e. Screening of Principal’s aggregate (if specified).

509.94 CLEARING

1. Prior to the clearing of any area for any purpose, the Contractor shall HOLD POINT
notify the Superintendent.

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AMENDMENT CHECKLIST

Specification No. 509 Title: Polymer Modified Bituminous Surfacing Revision No:

Project Manager: Signature: Date:

Checked by: Signature: Date:

Contract No: Contract Description:

ITEM DESCRIPTION SIGN OFF

Note: All changes/amendments must be shown in Tracked Changes mode until approved.
2. Project Manager has reviewed Specification and identified Additions and
Amendments.
CONTRACT SPECIFIC REQUIREMENTS addressed? Contract specific
materials, products, clauses added? (Refer Specification Guidance Notes for
guidance).
Any unlisted materials/products proposed and approved by the Project
Manager? If “Yes” provide details at 16.
Standard clauses amended? MUST SEEK approval from Manager
Commercial.
Clause deletes shows as “NOT USED”.
Appropriate INSPECTION AND TESTING parameters included in Spec 201
(Text Methods, Minimum Testing Frequencies verified).
ANNEXURES completed (refer Specification Guidance Notes).
HANDOVER and AS BUILT requirements addressed.
Main Roads QS has approved changes to SMM.
Project Manager certifies completed Specification reflects intent of the
design.
Completed Specification – independent verification arranged by Project
Manager.
Project Manager’s review completed.
SPECIFICATION GUIDANCE NOTES deleted.
TABLE OF CONTENTS updated.
FOOTER updated with Document No., Contract No. and Contract Name.
Supporting information prepared and submitted to Project Manager.
Further action necessary:

Signed: (Project Manager) Date:

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Contract No: XXX/XX [Contract Name]