TRANSPORT FOR NSW (TfNSW)

QA SPECIFICATION R121

STONE MASTIC ASPHALT

NOTICE
This document is a Transport for NSW QA Specification. It has been developed for use with
roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not
suitable for any other purpose and must not be used for any other purpose or in any other context.
Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev Clause Authorised

Description of Revision Date
Number Number By
Ed 1/Rev 0 Initial issue for trials. GM, RNIC 13.01.00
Ed 1/Rev 1 1.3, 2.1.3(b). Minor changes GM, RNIC 17.08.00
2.3.1(c), Annexure R121/4 changed to Annexure
Annx R121/4 R121/5
Annexure New annexure listing identified records
R121/4
Ed 1/Rev 2 1.3, 2.1.3 RTA 3211 specified for Flyash GM, RNIC 11.02.03
Ed 2/Rev 0 “Notice” RTA PO Box and Fax numbers updated. GM, IC 24.11.09
Foreword Foreword, incorporating copyright clause,
added
Global Specification reformatted.
Text revised to direct imperative style.
“Contractor” replaced by “you”.
“Superintendent” replaced by “Principal”.
“shall” replaced by “must”.
Some clauses moved to Annexures.
Minor editing to clarify intent.
Annex M Reference documents updated.
Ed 2/Rev 1 2.1.3 Reference to spec RTA 3054 changed to GM, IC 02.11.10
RTA 3211.
Annex M Reference to spec RTA 3054 deleted.
Ed 3/Rev 0 Global Clauses rearranged and reworded to improve GM, IC 09.07.13
clarity.
Guide Notes Guide notes simplified. Technical Reference
Notes deleted.
1.1 Reworded to be similar to other asphalt
specs.

Edition 3 / Revision 4 TRANSPORT FOR NSW

September 2020
Ed/Rev Clause Authorised
Description of Revision Date
Number Number By
Ed 3/Rev 0 2 Requirement to comply with APRG 18,
(cont’d) AS 2150 and AS 2734 removed.
2.1.1, 2.1.2 Reference for coarse and fine aggregate
requirements changed to spec 3152.
2.1.3 New clause on recycled materials added.
Subsequent clauses renumbered.
2.1.4 (d) Maximum MBV of filler specified.
2.1.5 Use of PMB mandated through deletion of
reference to spec 3253.
2.1.6 (a) Material requirements for adhesion agents
removed.
2.1.6 (c) Requirements for warm mix asphalt additive
added.
2.1.7 Option to specify tack coat with 3% SBR
deleted.
2.2.1 (a) Requirement for minimum 50% of fine
aggregate to be derived from crushed rock
removed.
Table 121.1 Grading envelopes for SMA10 and SMA14
widened to allow for production tolerances.
2.2.1 (c) Requirements for granulated glass aggregate
added.
2.2.1 (e) Upper limit of 1.0% of adhesion agent added.
2.2.1 (g) Requirements for warm mix asphalt additive
added.
2.2.2 Voids requirements simplified. 80 cycle
requirement and 350 cycle, > 2.5%
requirement deleted.
Test methods changed to RMS tests, and
associated requirement for mix volume ratio
added.
2.2.3 Asphalt moisture content requirement added.
2.2.4 Binder drain down requirement added.
2.2.5 Deformation resistance requirement added.
2.3.1 New subclause. Subsequent subclause
renumbered.
2.3.2 Retitled “Submission of Nominated Mix
Design”.
12 month validity period for Hold Point
release on mix submission added.
2.3.2 (e) Requirements for warm mix asphalt additive
added.

ii
Ed/Rev Clause Authorised
Description of Revision Date
Number Number By
Ed 3/Rev 0 2.4.2.2 Added r equirement that actual production
(cont’d) values must remain within aggregate grading
and binder content limits in Tables 1 and 2.
2.4.4 Temperature and time limits on storage of
SMA added. Required actions for exceeding
storage limit added.
Upper limit of 175°C for production
temperature added.
3.2 Previously clause 3. Subsequent clause 4, 5,
etc renumbered to clause 3, 4, etc.
3.3 Retitled “Method of Placement”.
MTV requirements added.
Course thickness limits of between 3.0 to 5.0
times nominal mix size added.
3.7 Previously clause 4.5. Minimum asphalt
laying temperatures tabulated; different
requirements for different layer thickness
removed.
3.8 Previous clause 4.6, retitled “Paving and
Compaction Temperatures”.
Hold Point for submission of details of
temperature during delivery and placing
added.
Provision for use of infrared thermometer
added.
3.9 Upper limit for tackcoat application rate
increased from 0.3 to 0.4 L/m2.
Provision added for reduced application rate
of tackcoat due to underlying pavement
material such as primerseal or seal.
Requirement for tackcoat to be intact at
commencement of asphalt placement added.
4.1.1 Upper limit of characteristic value of insitu
air void content reduced from 9% to 7.0%.
4.3 Measurement of ride quality changed from
NAASRA counts to IRI.
Previous clause 5.4 titled “Skid Resistance”
deleted.
4.4 Texture depth requirement at time of
construction added.
5.2 Deductions for Insitu air voids added.
Annex B3 Incentives for ride quality added.

iii
Ed/Rev Clause Authorised
Description of Revision Date
Number Number By
Ed 3/Rev 0 Annex E Previous clause 4.8.2 on calculation of
(cont’d) characteristic values moved here. Previous
combined particle size distribution chart
removed.
Annex M Reference documents updated.
Ed 3/Rev 1 2.1.3.2 Requirement for granulated glass aggregate MCQ 24.05.19
to be washed added.
2.2.1 Proportion of granulated glass aggregate in
asphalt clarified.
Ed 3/Rev 2 Global References to “Roads and Maritime DCS 22.06.20
Services” or “RMS” changed to “Transport
for NSW” or “TfNSW” respectively.
Ed 3/Rev 3 Annex L Table L.3 – frequency of testing for filler in MCQ 25.08.20
asphalt changed.
Ed 3/Rev 4 Annex L Table L.3 – Frequency of testing stated MCQ 10.09.20
clarified to be for total filler used in asphalt
production.

iv
GUIDE NOTES
(Not Part of Contract Document)

Using Specification R121

Specification TfNSW R121 is a QA specification and the use of QA specifications requires the
implementation of a quality management system by the Contractor that meets the quality management
system requirements specified in Specification TfNSW Q. To comply with the intention of
government policy as well as TfNSW R121, Stone mastic asphalt works constructed using TfNSW
R121 require adequate surveillance and audit by the Principal.

TfNSW R121 requires the TfNSW Project Manager to select appropriate parameters identified in
TfNSW R121 and nominate them in Annexure R121/A. The Project Manager is also required to
select an appropriate version of TfNSW Q commensurate with the size of the project and the risk to
the Principal.

Introduction

Stone mastic asphalt may be referred to by the acronym SMA. It is promoted primarily for use as a
surfacing course with relatively high surface texture, low permeability and a high resistance to rutting.
The coarse texture tends to reduce the generation of spray during rain periods.

In practice, there is a chance that SMA supplied under this first edition of the specification may be
more permeable than expected and pavement designers will need to take this into account. In some
cases, the application of a sprayed seal will be warranted prior to placing SMA. Development and/or
evolution of the product is expected to continue with a view to minimising permeability and this
should eventually lead to the specification of lower air voids limits without unacceptable risk of
flushing.

SMA is generally not used lower in the pavement as structural asphalt because of its relatively high
cost and lower design stiffness both of which tend to result from a relatively high binder content.
Pavement designers are advised to check with TfNSW Pavements & Geotechnical Section in respect
of design stiffness for SMA.

SMA is designed with a high proportion of coarse aggregate to generate stone on stone contact
between the coarse aggregate particles within the mix with the resulting skeletal voids being partially
filled by the mixture of binder and fines (mastic). Thus the inter-particle friction of the coarse
aggregate is a significant consideration and care must be taken in the selection of source in terms of
shape, fractured faces and particle microtexture.

The mix design and the subsequent production process must ensure that the voids in the coarse
aggregate skeleton are sufficient to contain the mastic and the appropriate air voids if performance is
to be realised. To achieve this, the aggregate will have good shape and the grading will generally be
coarse and gapped in the vicinity of the 2.36 mm and 4.75 mm AS sieves. The quality of aggregate
supply must be consistent for the duration of the work and to this end, the use of museum samples
(glass containers of the constituents used for mix design purposes) as a surveillance tool is strongly
recommended.

The relatively high proportion of binder/mastic requires special attention to be paid to aspects of
process if a homogeneous product is to be achieved. These include the possibility of segregation due
to insufficient mixing time, binder drainage during haulage, binder segregation during paving/rolling
and flushing on opening to traffic.

SMA supplied under this specification is intended to be used as a relatively thin wearing surface and
has a service life of approximately 10 years.

v
The quality and surface condition of the existing pavement impacts on the suitability and performance
of SMA. Existing pavements with low deflection/curvature, good shape and free of cracking offer the
best chance of success.

TfNSW Project Managers may obtain a general guide and past performance information from TfNSW
Pavements & Geotechnical Section. An AAPA Guide to SMA is currently being prepared.

vi
QA S PECIFICATION R121

STONE M ASTIC ASPHALT

Copyright – Transport for NSW
IC-QA-R121

VERSION FOR:
DATE:

Edition 3 / Revision 4 TRANSPORT FOR NSW

September 2020
Stone Mastic Asphalt R121

CONTENTS
CLAUSE PAGE
FOREWORD .................................................................................................................................. III
TfNSW Copyright and Use of this Document ....................................................................... iii
Revisions to Previous Version ............................................................................................. iii
Project Specific Changes ..................................................................................................... iii

1 GENERAL ............................................................................................................................ 1
1.1 Overview .............................................................................................................. 1
1.2 Scope.................................................................................................................... 1
1.3 Structure of the Specification.................................................................................. 1
1.4 Definitions and Acronyms ...................................................................................... 2

2 SUPPLY OF SMA .................................................................................................................. 3

2.1 Materials for SMA ................................................................................................. 3
2.2 Requirements for SMA .......................................................................................... 4
2.3 Nominated Mixes .................................................................................................. 7
2.4 Production of Asphalt ............................................................................................ 8
2.5 Transport of Asphalt .............................................................................................10

3 PLACING ASPHALT ..............................................................................................................11

3.1 General ................................................................................................................11
3.2 Preparation of Pavement .......................................................................................11
3.3 Method of Placement ............................................................................................11
3.4 Protection of Work ...............................................................................................12
3.5 Protection of Services and Road Fixtures ...............................................................12
3.6 Course and Layer Thicknesses...............................................................................12
3.7 Pavement Temperature and Weather Conditions .....................................................12
3.8 Paving and Compaction Temperatures ...................................................................12
3.9 Tackcoat ..............................................................................................................13
3.10 Joints ...................................................................................................................13
3.11 Placement Trial ....................................................................................................14
3.12 Temporary Ramps and Tie-ins to Existing Pavement and Structures ........................15

4 FINISHED PAVEMENT PROPERTIES .......................................................................................15

4.1 Insitu Air Voids ....................................................................................................15
4.2 Course Thickness .................................................................................................16
4.3 Surface Shape.......................................................................................................17
4.4 Ride Quality .........................................................................................................18
4.5 Texture Depth ......................................................................................................18

5 CONFORMITY .....................................................................................................................19
5.1 Homogeneity........................................................................................................19
5.2 Sampling..............................................................................................................19
5.3 Testing.................................................................................................................19
5.4 Process Control ....................................................................................................20
5.5 Nonconformities ...................................................................................................20

ANNEXURE R121/A – PROJECT SPECIFIC REQUIREMENTS ...............................................................21

ANNEXURE R121/B – MEASUREMENT AND P AYMENT AND RESOLUTION OF NONCONFORMITIES.......22

B1 Measurement and Payment ....................................................................................22
B2 Resolution of Nonconformities ..............................................................................23

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R121 Stone Mastic Asphalt

B3 Incentives ............................................................................................................ 25

ANNEXURE R121/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS ............................... 26

C1 Schedule of Hold Points ....................................................................................... 26
C2 Schedule of Identified Records.............................................................................. 26

ANNEXURE R121/D – PLANNING DOCUMENTS .............................................................................. 27

ANNEXURE R121/E – CALCULATIONS ........................................................................................... 29

E1 Calculation of Characteristic Values of Insitu Air Voids ......................................... 29
E2 Calculation of Characteristic Value of Thickness.................................................... 29

ANNEXURES R121/F TO R121/K – (NOT USED).............................................................................. 29

ANNEXURE R121/L – MINIMUM FREQUENCY OF TESTING .............................................................. 30

ANNEXURE R121/M – REFERENCED DOCUMENTS.......................................................................... 33

LAST PAGE OF THIS DOCUMENT IS ................................................................................................. 34

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Stone Mastic Asphalt R121

FOREWORD

TF NSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy
controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW
Internet website: http://www.rms.nsw.gov.au/business-industry/partners-
suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification TfNSW R121 Edition 3 Revision 3.

All revisions to the previous version (other than minor editorial and project specific changes) are
indicated by a vertical line in the margin as shown here, except when it is a new edition and the text
has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is
shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out e.g. Deleted Text.

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TfNSW QA SPECIFICATION R121

STONE MASTIC ASPHALT

1 GENERAL

1.1 OVERVIEW
This Specification sets out the requirements for stone mastic asphalt for use as a thin textured single
layer wearing course. It is suitable for use on high speed traffic roads, but not in high stress locations
such as intersection or roundabouts.

During the first 24 months after the Actual Completion Date:

(a) the asphalt must not ravel, rut, shove, strip or bleed; and
(b) the asphalt for the first 12 months must comply with the surface shape requirements specified in
Table R121.8.

1.2 SCOPE
The work to be carried out under this Specification comprises the following:
(a) design of the asphalt mix(es);
(b) supply of materials, production and transport of the asphalt;
(c) preparation and application of tackcoat on the surface on which the asphalt is to be placed;
(d) placement and compaction of asphalt;
(e) all inspection and testing necessary to demonstrate that the quality requirements of this
Specification have been achieved.

1.3 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.3.1 Project Specific Requirements

Project Specific Requirements are shown in Annexure R121/A.

1.3.2 Measurement and Payment and Resolution of Nonconformities

The method of measurement and payment must comply with Annexure R121/B1.

Acceptance of materials and work must be in accordance with Annexure R121/B2.

1.3.3 Schedules of HOLD POINTS and Identified Records

The schedules in Annexure R121/C list the HOLD POINTS that must be observed. Refer to
Specification TfNSW Q for the definition of HOLD POINTS.

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R121 Stone Mastic Asphalt

The records listed in Annexure R121/C are Identified Records for the purposes of TfNSW Q
Annexure Q/E.

1.3.4 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements shown in
Annexure R121/D and must be implemented.

In all cases where this Specification refers to the manufacturer’s recommendations, these must be
included in the PROJECT QUALITY PLAN.

1.3.5 Requirements for Technical Procedures

Details of calculation for insitu air voids and thickness are shown in Annexure R121/E.

1.3.6 Testing Procedures

The Inspection and Test Plan must nominate the proposed testing frequency to verify conformity of
the item, which must not be less than the frequency specified in Annexure R121/L, except where the
Principal has approved a reduced frequency of testing as per 5.3.1 of the Specification.

Where a minimum frequency is not specified, nominate an appropriate frequency.

1.3.7 Referenced Documents

Unless specified otherwise or is supplied specifically by the Principal, the applicable issue of a
referenced document, must be the issue current at the date one week before the closing date for
tenders, or where no issue is current at that date, the most recent issue.

Standards, specifications and test methods are referred to in abbreviated form (e.g. AS 1234). For
convenience, the full titles are given in Annexure R121/M.

1.4 DEFINITIONS AND ACRONYMS

1.4.1 Definitions

In this Specification:
(a) the terms “you” and “your” mean “the Contractor” and “the Contractor's” respectively;
(b) the term “stone mastic asphalt” includes “asphalt” and “mix”;

Other definitions are in accordance with the Glossary of Austroads Terms.

1.4.2 Acronyms

The following acronyms apply to this Specification:

AAPA Australian Asphalt Pavement Association
IRI International Roughness Index
MTV Material Transfer Vehicle
MBV Methylene Blue Value
NATA National Association of Testing Authorities
N/A Not Applicable

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Stone Mastic Asphalt R121

PAFV Polished Aggregate Friction Value

PQP Project Quality Plan
SMA Stone mastic asphalt
VMA Voids in Mineral Aggregate

2 SUPPLY OF SMA

2.1 MATERIALS FOR SMA

All materials used in the manufacture of asphalt must comply with the requirements of this
Specification and maintain uniform appearance for the duration of the work.

2.1.1 Coarse Aggregates

Coarse aggregate must comply with Specification TfNSW 3152.

When aggregates from a specific source or type, or when aggregate with a high PAFV or other special
characteristics are specified, 100% of the coarse aggregate in the asphalt must comply with this
requirement.

2.1.2 Fine Aggregate

Fine aggregate must comply with TfNSW 3152.

2.1.3 Recycled Materials

2.1.3.1 Reclaimed Asphalt Pavement (RAP) Material

RAP material is not permitted.

2.1.3.2 Granulated Glass Aggregate

Granulated glass aggregate must be washed and comply with Specification TfNSW 3154.

2.1.4 Filler

The total filler in asphalt is the combined fraction of fines produced from the crushing of aggregates
and any added filler which passes the 0.075 mm AS sieve.

Filler must meet the following requirements:

(a) Added filler must conform to Specification TfNSW 3211;
(b) Dry compacted voids content of the total filler fraction in asphalt determined in accordance with
AS/NZS 1141.17 must be 40% or greater;
(c) Methylene blue value of the total filler in asphalt (excluding hydrated lime) determined in
accordance with Test Method TfNSW T659 must not exceed 10 mg/g.

2.1.5 Binder

The class of binder used in the work must be as specified in Annexure R121/A.

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R121 Stone Mastic Asphalt

The binder must conform to the requirements of Specification TfNSW 3252. Provide documentary
evidence of the binder compliance for each delivery used in the work.

2.1.6 Additives

(a) Bitumen Adhesion Agent

Bitumen adhesion agent may be added to improve the resistance of the asphalt’s propensity to
stripping.

(b) Fibre Additive

Use only cellulose fibre as fibre additive.
You may propose an alternative fibre additive for approval by the Principal. Such proposals
must be accompanied by documented evidence of the successful use or trial use of such fibre
additive under circumstances similar to those which exist under the Contract.
In all cases, attach to your PROJECT QUALITY PLAN the technical specification for the fibre
additive and manufacturer’s recommendations on the application, handling and incorporation of
the fibre additive into the asphalt.

(c) Warm Mix Asphalt Additive

Warm mix asphalt additive may be added to asphalt to reduce the asphalt manufacturing
temperature and/or to improve workability during the paving and compaction operations.

2.1.7 Bitumen Emulsion Tackcoat

Bitumen emulsion for use as a tackcoat must be CRS/170-60 complying with AS 1160, unless
approved otherwise by the Principal.

2.2 REQUIREMENTS FOR SMA

2.2.1 Proportions of Constituent Materials

The proportions of constituent materials must be as follows:

(a) Combined Particle Size Distribution of Aggregate

The combined particle size distribution of aggregate, when determined in accordance with
AS/NZS 2891.3.1, must conform to Table R121.1.

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Stone Mastic Asphalt R121

Table R121.1 - Combined Particle Size Distribution Limits

Combined Particle Size Distribution Passing

Limits for Nominal Size of Asphalt
(% by mass)
AS Sieve Size (Asphalt Designation)
10 mm 14 mm
(SMA10) (SMA14)
26.5 mm – –
19.0 mm – 100
13.2 mm 100 76 – 100
9.50 mm 80 – 100 31 – 64
6.70 mm 31 – 64 16 – 44
4.75 mm 16 – 44 14 – 36
2.36 mm 13 – 31 13 – 31
1.18 mm 11 – 27 11 – 27
0.600 mm 8 – 24 8 – 24
0.300 mm 7 – 21 7 – 21
0.150 mm 8.5 – 16.0 8.0 – 16.0
0.075 mm 7.5 – 12.5 7.5 – 12.5

(b) Binder
In the nominated mix design, the proportion of binder expressed as a percentage by mass of the
total mix must comply with the requirements of Table R121.2.

Table R121.2 – Binder Content

Nominal Size of Asphalt 10 mm 14 mm

(Asphalt Designation) (SMA10) (SMA14)
Binder Content (% by mass of total mix) 6.2 – 7.2 6.0 – 7.0
Note: The specified binder content range is applicable to commonly used natural sources of asphalt aggregates
and sands for a known range of densities. If you propose to use constituents of substantially different
density, then for the nominated design mix and use of the mix in the works, you may propose a
nonconforming binder content subject to the approval of the Principal. You must demonstrate that the
volumetric proportions are consistent with the intent of the Specification.
Determine the binder content in accordance with AS/NZS 2891.3.1.

(c) Granulated Glass Aggregate

The proportion of granulated glass aggregate in SMA must not exceed:
(i) 2.5% by mass of total mix in wearing course;
(ii) 10% by mass of total mix in other than wearing course.

(d) Hydrated Lime

The amount of hydrated lime in SMA must not be less than 1.5%, by mass of total aggregate.

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(e) Adhesion Agent

Asphalt may contain bitumen adhesion agent not exceeding 1.0% by mass of the binder.

(f) Fibre Additive

Nominate the amount of fibre in the mix, which must not be less than 0.3% by mass of the total
mix.

(g) Warm Mix Asphalt Additive

The maximum proportion of additive must comply with Table R121.3.

Table R121.3 – Maximum Proportion of Additive in Warm Mix Asphalt

Additive Maximum Proportion

Wax 2.0% by mass of binder
Surfactants Nominated by Contractor
Water (either directly, or in the
0.06% by mass of the total mix
form of water containing crystals)

2.2.2 Volumetric Characteristics

For all asphalt mixes:

(a) The air voids in laboratory compacted briquettes must be:
(i) ≥ 3.0% and ≤ 6.0% when determined in accordance with Test Method TfNSW T662 at
120 cycles of compaction, AS/NZS 2891.7.1 or AS/NZS 2891.7.3, AS/NZS 2891.8 and
AS/NZS 2891.9.2;
and
(ii) ≥ 2.0% when determined in accordance with Test Method TfNSW T662 at 350 cycles of
compaction, AS/NZS 2891.7.1 or AS/NZS 2891.7.3, AS/NZS 2891.8 and AS/NZS
2891.9.2.
(b) The mix volume ratio when determined in accordance with Test Method TfNSW T646 must be
< 1.0. For the purpose of TfNSW T662, apply 120 cycles of gyratory compaction.

2.2.3 Moisture Content

For all mixes produced in a drum plant, the moisture content must be < 0.5% by mass of the total mix
when determined in accordance with Test Method TfNSW T660.

2.2.4 Binder Drain Down

The binder drain down when determined in accordance with Test Method TfNSW T648 must be less
than 0.3% after 4 hours at the maximum nominated production temperature.

2.2.5 Deformation Resistance

The rut depth, when determined in accordance with Austroads AG:PT/T231, must not be greater than
2.5 mm.

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Stone Mastic Asphalt R121

2.3 NOMINATED M IXES

2.3.1 Nominated Mix Design

The submitted nominated mix design is:

(i) materials specific, and substitution of constituent materials during production is not permitted;
(ii) design specific, and variation to the design nominated mix submission is not permitted;
(iii) asphalt plant specific, and, except for component maintenance, changes in the components,
configuration and/or location of the plant is not permitted;
(iv) contract specific, and release of the Nominated Mix Hold Point under another contract is not
applicable to this Contract.

For each new establishment of a mobile asphalt plant, a full nominated mix submission is required.

2.3.2 Submission of Nominated Mix Design

Unless specified otherwise, all asphalt and binder tests relating to the submission must be carried out
within a one month period prior to the date of submission to the Principal. All other tests relating to
the submission must be carried out within a 6 month period prior to the date of submission to the
Principal. All phases of any particular test must be performed at the same laboratory.

Submit to the Principal one nominated mix design for each asphalt mix specified in Annexure R121/A.
The nominated mix design submission must include the following details:

(a) Constituent Materials

(i) Coarse and fine aggregates: source, geological type.

Aggregate of different type or quality from the same quarry face or within a quarry will
be regarded as a different source.

(ii) Added filler: type, grade and source.

(iii) Binder: source, class or grade.

(iv) Recycled materials: recycled glass granulate, the type, source and manufacturer’s
recommendations.

(v) Additives: type, source, trade name and manufacturer’s recommendations.

(b) Mix Design

(i) Proportion of each constituent by percentage of mass of total mix.

(ii) For each nominated mix design, the nominated values and allowable tolerances, where
required, for each requirement for the asphalt specified in Clause 2.2.

(iii) Graphical representation of the nominated combined particle size distribution with
control points as required by the limits of Table R121.1 and the production tolerances in
accordance with Table R121.4.

(iv) Type and identification number of the asphalt mixing plant.

(v) Temperature range at which the asphalt is to be manufactured.

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R121 Stone Mastic Asphalt

(c) Production Trial

All production trial tests on each nominated mix must be from one trial batch. The tests on the
constituent materials must represent the materials used in this trial batch.

(d) Signed Statement

A signed statement certifying that each nominated and production trial mix including all
constituents meet the requirements of Clauses 2.1 and 2.2. The statement must include NATA
endorsed test results for all specified tests. Attach a copy of your completed verification
checklist.

(e) Warm Mix Asphalt Additives

When using warm mix asphalt additives, provide details of the additive in the nominated mix
design submission. Include evidence acceptable to the Principal that the additive is designed
and has proven performance for the purpose described in this Specification.

The nominated mix design will be rejected if the nature, intended purpose and dosage of the
warm mix asphalt additive are not clear in your nominated mix design submission.

Clearly state in your submission:

(i) any proposed amendments to the mix design procedure, operational processes and/or test
methods as a result of the inclusion of a warm mix asphalt additive; and
(ii) the classification of the warm mix asphalt additive.

HOLD POINT
Process Held: Placing of the nominated mix(es).

Submission Details: Documents as detailed in Clause 2.3.2 at least 7 working days before each
asphalt mix is proposed to be used.

Release of Hold Point: The Principal will consider the submitted documents, prior to authorising the
release of the Hold Point. This Hold Point release is valid for a maximum
period of 12 months.

2.4 PRODUCTION OF ASPHALT

2.4.1 Method of Production

Your adopted method of production must:

(a) control the process and target the nominated mix design; and
(b) supply a homogeneous and consistent product at the nominated manufacturing temperature.

2.4.2 Production Tolerances

2.4.2.1 Proportions of Constituents

The proportion of each constituent may be varied for the purpose of process control, provided
that:

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(a) the proportion of each constituent, with the exception of added filler, is not varied by
more than 10% of the value nominated; and
(b) the proportion of each added filler is not varied by more than 15% of the value
nominated.

2.4.2.2 Combined Particle Size Distribution and Binder Content

The actual combined particle size distribution and actual binder content may vary from the
nominated value within the limits shown in Table R121.4, provided that the actual values also
remain within the limits of Tables R121.1 and R121.2 respectively.

Table R121.4 – Production Tolerances

Description Tolerance
Permissible variation to nominated combined particle size distribution
during production (% by mass of total aggregate, AS/NZS 2891.3.1) for
each mix size:
Passing 4.75 mm AS sieve and larger ±7
Passing 2.36 mm and 1.18 mm ±5
Passing 0.600 mm and 0.300 mm ±4
Passing 0.150 mm ± 2.5
Passing 0.075 mm ± 1.5
Permissible variation to the nominated binder content during production ± 0.3
(% by mass of total mix, AS/NZS 2891.3.1)

2.4.3 Asphalt Manufacturing Plant

Operate the asphalt manufacturing plant with adequate production process controls to produce asphalt
of a consistent quality and conforming to the requirements of this Specification. The production
control system must produce auditable records of key process parameters including individual
aggregate and filler feed rates/batch masses, binder application rate/batch mass and various process
temperatures.

Implement a documented procedure for the management and control of the moisture content of each
aggregate material. The moisture content must be determined at least daily, and the asphalt
manufacturing plant must be adjusted accordingly.

The asphalt manufacturing plant must have sufficient capacity, and be able to supply asphalt for the
continuous operation of the paver.

2.4.4 Storage and Handling

(a) Binder
Heating and storage of binder must comply with the temperature and time limits set out in
Advisory Note 7 published by the Australian Asphalt Pavement Association.
Provide details in your PROJECT QUALITY PLAN of the procedures for the acquisition,
storage and handling of binder which identify and prevent segregation and/or contamination of
the binder.

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At the asphalt manufacturing plant, binder supplied in accordance with TfNSW 3252 must be
recirculated in delivery and/or storage tanks to a uniform consistency immediately prior to use
in the manufacturing process.

(b) Asphalt
The asphalt must not be retained in hot storage silos for longer than 4 hours. Asphalt stored for
more than 4 hours must be sub-Lotted and tested for binder content in accordance with AS/NZS
2891.3.1, in addition to the sampling frequency in Annexure R121/L. Results for binder content
must be within the submitted nominated mix production tolerances.

2.4.5 Manufacturing Temperatures

Control the temperatures of constituent materials in response to suitable thermometer elements placed
in the flow of materials from the drier, and in the binder storage system or binder supply line.
Thermometer registrations must be readable and accurate to within ± 2°C.

The difference in temperature between binder and aggregate must not exceed 30°C at the point of
mixing.

Measure and record the temperature of the asphalt when:

(a) the asphalt leaves the pugmill or mixing drum; or
(b) the asphalt discharges from the hot storage bin(s); or
(c) in the trucks prior to leaving the plant.

The dispatch temperature of the asphalt must facilitate the specified density in the finished product.
Project specific process temperatures and the frequency of recording must be detailed in your
PROJECT QUALITY PLAN.

The temperature of asphalt must not at any time in the process exceed 175°C.

2.4.6 Sampling

Asphalt samples are to be taken in accordance with AS/NZS 2891.1.1 at the frequency specified in
Annexure R121/L.

2.5 TRANSPORT OF ASPHALT

The transport of asphalt must be in accordance with the requirements in AS 2150.

State in your PROJECT QUALITY PLAN the method of application and control of release agent to
achieve a uniform, light coating of the vehicle’s tray without ponding of surplus release agent.

Facilitate the continuous operation of the paving train by:

(a) providing and allocating sufficient transport capacity; and
(b) ensuring efficient on-site management of asphalt deliveries.

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3 PLACING ASPHALT

3.1 GENERAL
Your method of placing and finishing asphalt must:
(a) produce a homogeneous product with a tightly bound surface;
(b) achieve a uniform bond to the surface below; and
(c) achieve the finished pavement properties, specified in Clause 4, within the specified tolerances.

Do not induce rapid cooling in the asphalt by the application of water at any stage in the process,
including preparation for trafficking.

3.2 PREPARATION OF PAVEMENT

Prior to placing asphalt, prepare the surface to be paved in accordance with the requirements in AS
2150, including the removal of raised extruded thermoplastic road markings and raised pavement
markers.

3.3 METHOD OF PLACEMENT

Place the asphalt by a self-propelled paving machine equipped and operated with automatic thickness
control and automatic joint matching facility.

Hand placement of asphalt is only permitted for minor corrections of the existing surface and in areas
where placement with a paving machine is impractical.

State in your PROJECT QUALITY PLAN the method of achieving conforming compaction, including
roller type, number of passes and rolling pattern.

If specified in Annexure R121/A, use a Material Transfer Vehicle (MTV) in your paving operations.
The MTV must be a self propelled machine with independent controls which will receive asphalt from
delivery vehicles, store, remix and transfer the asphalt to the paving machine without contact and be
equipped with:
(a) a receiving hopper compatible with delivery vehicles;
(b) conveying mechanisms and anti-segregation devices for remixing asphalt;
(c) conveying mechanisms capable of delivering asphalt to the paver at a minimum rate to suit the
paving output;
(d) a minimum nominal on-board storage capacity of 15 tonnes;
(e) an additional holding bin in the paving machine hopper; and
(f) sufficient power output from the motor to operate with full load on grades up to 6% and travel
in tandem with the paver, either directly in front or in an offset position.

If specified in Annexure R121/A, place the asphalt by echelon paving using a minimum of two paving
machines operating continuously in tandem. The paving run layout must be such that the hot joint is
located to minimise cold joints within the trafficked carriageway, unless approved otherwise by the
Principal.

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3.4 PROTECTION OF WORK

Provide for traffic in accordance with the requirements of Specification TfNSW G10 while
undertaking the work.

Protect the work until the required thickness of asphalt has been placed, compacted and cooled
sufficiently to carry traffic without damage to the work.

3.5 PROTECTION OF SERVICES AND ROAD F IXTURES

Do not allow asphalt or other material used on the work from entering or adhering to grates, hydrants
or valve boxes, service covers, bridge joints and other road fixtures. Immediately after the asphalt has
been placed, clean and remove all waste asphalt from the affected services and road fixtures.

3.6 COURSE AND LAYER THICKNESSES

A course of asphalt must comprise one layer only.

The course thickness must be within the limits of 3.0 to 5.0 times the nominal mix size.

3.7 PAVEMENT TEMPERATURE AND WEATHER CONDITIONS

Measure and record the pavement surface temperature and wind velocity at the point of asphalt
placing. Document the method of measurement and recording in your PROJECT QUALITY PLAN.

Do not commence or continue placing asphalt, unless the pavement surface temperature complies with
the requirements in Table R121.5.

Table R121.5 – Minimum Asphalt Laying Temperature

Wind Speed (km/h) Minimum Pavement Surface Temperatures (°C)

0–5 13 and rising
6 – 10 20
11 – 15 25
> 15 30
Note: Wind speed must remain constant over a period of 15 minutes.

Do not place tackcoat and/or asphalt when the pavement surface is wet and/or when rain is imminent.

3.8 PAVING AND COMPACTION TEMPERATURES

Your PROJECT QUALITY PLAN must document the temperatures at which the asphalt is placed and
compacted to achieve the insitu air void requirements specified in Clause 4.1.1

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HOLD POINT
Process Held: Placing of the nominated mix (including placement trial).

Submission Details: Nominate in writing:

(a) the minimum temperature at which asphalt is to be delivered to the
paver; and
(b) the minimum temperature at which initial compaction of the asphalt is
to commence; and
(c) the method of temperature measurement.

Release of Hold Point: The Principal will consider the submitted documents prior to authorising the
release of the Hold Point.

Do not incorporate asphalt that exhibits a temperature variation into the Works unless it has been
remixed to a consistent and adequate temperature for compaction.

Measure and monitor paving and compaction temperatures as described in your PROJECT QUALITY
PLAN with a hand held or machine mounted infrared thermometer readable and accurate to ± 2°C at
the discharge point from a tipper truck or at the distribution auger on the paver.

Carry out verification of the accuracy of the infrared thermometer and determine the correlation factor
daily at the commencement of work, and at any other time at the request of the Principal.

3.9 TACKCOAT
Prior to applying the tackcoat, the existing surface must be clean, dry and free from loose material.

Apply the tackcoat evenly at a rate of between 0.15 and 0.40 litres of residual bitumen per square
metre so that it is effectively bonded to the surface. For joints and chases, double the application rate.
Nominate in writing to the Principal your proposed tackcoat application rate prior to applying the
tackcoat.

You may propose in writing to the Principal a reduced application rate for the tackcoat due to the
existing underlying pavement material. Your proposal must be supported by examples of previous
cases where this has been done, including location and insitu material types and the current pavement
performance.

Provide to the Principal a daily record with your endorsement, of the average tackcoat application rate
applied to each Lot. Report the tackcoat application rate in terms of residual bitumen and state the
percentage dilution of the tackcoat used during spraying.

The tackcoat must be intact at the commencement of asphalt placement.

3.10 JOINTS
Describe in your PROJECT QUALITY PLAN the procedure for the construction of joints. Your
procedure must maximise joint density and include mechanised edge compaction or mechanised edge
trimming. Hand tamping of edges is permitted where the use of a machine is impractical. Do not
spread excess material resulting from hand preparation of edges on the surface of the work.

Remove all loose, cracked and/or boney material at the edge of a paved mat prior to placing the
adjacent mat. Do not incorporate asphalt resulting from clean-up of process trimmings in the work.

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Finish each joint with a smooth, planar surface coinciding with the surface of the rest of the mat and
satisfying the surface shape requirements specified in Clause 4.3.

Longitudinal joints must be:

(a) offset by 150 mm from the joint in the underlying layers;
(b) located within 150 mm of the line of change in crossfall;
(c) coincident with final traffic markings, unless approved otherwise by the Principal.

Transverse joints must be:

(i) located at a minimum of 25 m apart;
(ii) offset by a minimum of 1 m from the joint in the underlying layer;
(iii) formed at the commencement of each paving run;
(iv) formed when a delay in paving causes asphalt temperature to fall below the initial compaction
temperature nominated in Clause 3.8.

3.11 PLACEMENT TRIAL

If specified in Annexure R121/A and prior to commencing work, carry out a separate placement trial
using the plant and personnel proposed for the work for each nominated mix.

Locate each placement trial remote from the work, unless approved otherwise by the Principal. Limit
the size of the placement trial to one production shift.

Design the trial to implement all the procedures described in your PROJECT QUALITY PLAN and
demonstrate conformity with the Specification in respect of:
(a) homogeneity;
(b) insitu air voids;
(c) course thickness;
(d) texture depth;
(e) surface shape;
(f) surface gritting application, where specified;
(g) joint quality; and
(h) ride quality, where specified.

HOLD POINT
Process Held: Placing of the nominated mix

Submission Details: Verification checklist and all relevant test results from the placement trial
demonstrating conformance to the Specification at least 3 working days prior
to further placing of your nominated mix on the work.

Release of Hold Point: The Principal will consider the submitted documents prior to authorising the
release of the Hold Point.

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In the event of nonconformities in the placement trial, or when the Principal determines that a previous
trial is not representative of the materials, asphalt mix proportions, temperature, plant, rate of output
and/or method of placement, implement a new trial.

Where a placement trial forms part of the work, manage all nonconformities in respect of materials,
process and finished pavement properties in accordance with Clause 5.

3.12 TEMPORARY RAMPS AND TIE- INS TO EXISTING PAVEMENT AND

STRUCTURES
For safe trafficking of the work, construct temporary ramps at joints either by placement of dense
grade asphalt complying with Specification TfNSW R116, or by cold milling of the existing or new
asphalt layer to form the ramp.

The length and grade of temporary ramps must be equivalent to those specified for treatment at edges
and structures described in Specification TfNSW R101.

Construct permanent tie-ins to existing pavement by placement of dense grade asphalt complying with
TfNSW R116.

4 FINISHED PAVEMENT PROPERTIES

4.1 INSITU AIR VOIDS

4.1.1 Requirements for Insitu Air Voids

Compact each layer of asphalt uniformly to achieve the specified characteristic values of insitu air
voids.

The asphalt must have a dense appearance with the cut or cored faces of samples exhibiting few, if
any, surface voids.

Do not test asphalt layers less than or equal to 30 mm nominated thickness for insitu air voids.

The characteristic values of insitu air voids for the Lot must comply with Table R121.6.

Table R121.6 – Insitu Air Voids Standard

Limits for Characteristic Values of Insitu Air Voids

VL = 3.0% and VU = 7.0%
Note: VL is the lower limit of characteristic value of insitu air voids and VU is the upper limit of characteristic
value of insitu air voids.

4.1.2 Determination of Insitu Air Voids

Carry out compaction control on Lots using statistical techniques as specified in TfNSW Q.

The calculation for determining the insitu air voids is set out in Annexure R121/E. Determine the bulk
density either by cores in accordance with AS/NZS 2891.9.2 or by nuclear density measurements
taken in accordance with AS/NZS2891.14.2 and using the calibrated procedure described in AS/NZS
2891.14.3. Use only one of these methods to calculate the bulk density.

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Take cores in accordance with AS 2891.1.2. Determine the layer thickness prior to trimming of cores.
Trimming must not reduce the core layer thickness by more than 5 mm.

Do not use the nuclear density method when steel reinforcement exists within 300 mm of the surface
of the layer.

The reference density for the purpose of insitu air voids calculations is the mean maximum density of
the Lot where the individual values are determined in accordance with AS/NZS 2891.7.1 or AS/NZS
2891.7.3.

Determine air voids for:

(a) every change in underlying pavement material and layering within 300 mm of the surface of the
layer being measured; and
(b) every change in nominated mix and specified layer thickness.

4.2 COURSE THICKNESS

4.2.1 Requirements for Course Thickness

The specified course thickness is detailed in Annexure R121/A.

(a) Where finished surface levels are not specified

Comply with either of the following:

(i) Where the SMA is placed over an existing pavement constructed by others, the average
compacted course thickness for each Lot must not be less than the specified course
thickness or greater than the specified course thickness plus the tolerance specified in
Table R121.7 for the nominal size of asphalt.
OR
(ii) Where the SMA is placed over one or more layers placed by you, the Lot is deemed to be
conforming if the lower characteristic value of thickness (TL) for the Lot is not less than
the specified course thickness as shown on the Drawings or specified in Annexure
R121/A and the upper characteristic value of thickness (TU) for the Lot is not more than
the specified course thickness plus the tolerance specified in Table R121.7 for the
nominal size of the asphalt.

Table R121.7 – Allowable Tolerances for Course Thickness

Nominal Size of Asphalt Tolerance

(mm) (Asphalt Designation) (mm)
10 (SMA10) +6
14 (SMA14) +8

(b) Where finished surface levels are specified

Control the course thickness by maintaining the design levels and the surface shape
requirements specified in Clause 4.3, provided that:
(i) The average compacted course thickness of each Lot calculated from surveys must be
consistent with the average compacted course thickness of the respective Lot determined

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from cores. Include in your PROJECT QUALITY PLAN, the statistical technique for
verifying the consistency of the results;
(ii) The average compacted course thickness of each Lot of the wearing course is within 10%
of the specified course thickness.

4.2.2 Determination of Course Thickness

Determine the characteristic values and average value of thickness of the Lot on the basis of statistical
techniques as specified in TfNSW Q on cores taken in accordance with AS 2891.1.2 where:
(a) core layer thickness is determined prior to trimming of the core;
(b) the core diameter can be less than 95 mm;
(c) the test specimen may comprise more than one layer.

The calculation of the upper and lower characteristic values of thickness for the Lot is shown in
Annexure R121/E2.

4.3 SURFACE SHAPE

4.3.1 Determination of Surface Shape

Determine and report the surface shape in accordance with Test Method TfNSW T183.

The maximum Lot size must be in accordance with TfNSW Q and extended to include the adjacent
longitudinal joints, transverse joints and tie-ins. Carry out testing at the frequency specified in Table
R121/L.5 of Annexure R121/L.

4.3.2 Requirement for Surface Shape

The surface of the course including longitudinal and transverse joints must not pond water.

The surface shape of the course within the traffic lane must not deviate from the bottom of a
straightedge laid in any direction by more than the tolerances specified in Table R121.8. Where the
deviations from a straightedge for an existing surface exceed 10 mm, carry out rectification of those
areas before the new asphalt is placed, unless directed otherwise by the Principal.

Correct any nonconformities before testing ride quality.

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Table R121.8 – Maximum Deviation From Straightedge Placed Within Traffic Lane (mm)

Ramps, Roundabouts and

Through Carriageway
Wearing Course Through Carriageway
≥ 70 kph Speed Zone
< 70 kph Speed Zone
At Actual Completion Date 5 mm 3 mm
12 months after 8 mm 6 mm

4.4 RIDE QUALITY

4.4.1 Determination of Ride Quality

If specified in Annexure R121/A, determine the ride quality from measurements of the longitudinal
profile taken by a vehicular laser profilometer, where the ride quality is the International Roughness
Index (IRIS) determined in accordance with Test Method TfNSW T188 and the Lot is a section within
the test lane as defined in the Test Method.

Develop an Inspection and Test Plan (ITP) for ride quality that meets the requirements of the
Specification. Define the Lots and the start and end locations for testing in your ITP.

Supply the Principal with copies of the TfNSW Accreditation Certificates for each vehicular laser
profilometer driver and operator proposed for use in the Works.

4.4.2 Requirement for Ride Quality

The surface of the wearing course must have a smooth longitudinal profile, and
(a) when construction of the underlying pavement forms part of the Contract; or
(b) when asphalt is placed on any corrective course over a pavement constructed by others; or
(c) when the scope of work targets a ride quality.
the ride quality of each Lot must not exceed an IRIS of 1.56 m/km.

When asphalt is placed over pavement constructed by others, the ride quality of each Lot must not
exceed the IRISa values determined as follows:

IRISa = 0.2 + (0.6 x IRISb), or 1.56 m/km, whichever is the greater.

where: IRISa is the Lane IRI after placing the asphalt layer (m/km)
IRISb is the Lane IRI before placing the asphalt layer (m/km)

When asphalt is placed over a pavement constructed by others, determine and report the ride quality of
the existing surface prior to the work. The Lots of the existing surface selected must coincide with the
Lots of the finished work.

4.5 TEXTURE DEPTH

At the time of construction, the texture depth when determined in accordance with Test Method
TfNSW T240 must be equal to or greater than 1.0 mm.

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5 CONFORMITY
Verify conformity with the Specification by sampling and testing, and providing records of process
control.

5.1 HOMOGENEITY
All asphalt must be homogenous in appearance.

Areas of asphalt that exhibit segregation, cracking, ravelling, bony or fatty material, or have been
damaged during construction must be rectified or replaced.

Any proposal by you that the Principal accepts non-homogeneous and/or segregated material or work
must be in writing and must show:
(a) technical reasons for acceptance;
(b) compliance with the Specification; and
(c) sub-Lotting that minimises performance risk to the surface and structure of the pavement.

5.2 SAMPLING
Nominate all sampling locations, frequencies and test methods in your PROJECT QUALITY PLAN.

In addition to the requirements of TfNSW Q Annexure Q/L, and unless specified otherwise or agreed
with the Principal, boundaries of sub-Lots represented by a single tested sample are deemed to be the
midpoints in production between the sample points for the purpose of B2 in Annexure R121/B of this
Specification.

When the Principal requests loose asphalt samples for testing, you must riffle and/or quarter the
samples.

All samples, including core samples, must be delivered in sealed and labelled containers.

5.3 TESTING

5.3.1 Minimum Frequency of Testing

The minimum frequency of testing is specified in Annexure R121/L. Nominate an appropriate

frequency where a minimum frequency of testing is not specified.

You may propose in writing to the Principal that a reduced minimum frequency of testing be accepted
in accordance with TfNSW Q. Your proposal must be supported by a statistical analysis verifying
consistent process capability and product characteristics.

In the event of a nonconformity, a reduced frequency of testing must revert immediately back to the
specified minimum frequency of testing. You can request a further reduction in the minimum
frequency of testing when you can demonstrate again by statistical analysis that you have gained a
consistent process capability and product characteristics.

5.3.2 Maximum Lot Size

The maximum Lot size must conform to TfNSW Q.

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5.3.3 Time for Submission of Test Results

Complete and report to the Principal:

(i) the tests for binder content, combined particle size distribution and air voids in laboratory
compacted mix within one working day of laying the asphalt;
(ii) the results for insitu air voids, course thickness and course shape within three working days of
placing the asphalt.

5.4 PROCESS CONTROL

You must employ a capable process and implement process control in accordance with or exceeding
the requirements of Australian Asphalt Pavement Association Implementation Guide IG-3.

5.5 NONCONFORMITIES
If a Lot fails to conform to the Specification, such failure will constitute a nonconformity under the
Contract.

If the nonconformity is not accepted in accordance with Annexure R121/B2, rectify or replace the Lot.

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ANNEXURE R121/A – PROJECT SPECIFIC REQUIREMENTS

The requirements below apply to the following pavement types in the project:

NOTES TO TENDER DOCUMENTER: (Delete this boxed text after customising Annexure R121/A)

Insert in the table below details of SMA to be used.

Repeat the table for requirements of each pavement design.

Where “Yes / No” options are shown below, delete whichever option that is not applicable.

Location:

Specified Course
(1)
Nominal Size of Class of Binder Thickness (mm)
Course
Asphalt (mm) (Clause 2.1.5) (Clauses 3.6 &
4.2.1)
Wearing
Note:
(1) Default class of binder to be used is Class A15E.

Description Requirement
3.3 Material Transfer Vehicle required: Yes / No
3.3 Paving in echelon required: Yes / No
3.11 Placement trial required: Yes / No
4.4.2 Measurement of ride quality of pavement required:
- Existing pavement Yes / No
- Finished pavement Yes / No

Measure the following pay items by area (refer Annexure R121/B):

List here pay items to be measured by area.

Other Project Specific Requirements:

List here other project specific requirements.

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ANNEXURE R121/B – MEASUREMENT AND PAYMENT AND

RESOLUTION OF NONCONFORMITIES

B1 MEASUREMENT AND PAYMENT

Payment will be made for all costs associated with completing the work detailed in this Specification
in accordance with the following Pay Items.

Where no specific pay items are provided for a particular item of work, the costs associated with that
item of work are deemed to be included in the rates and prices generally for the Work Under the
Contract.

Unless specified otherwise, a lump sum price for any of these items will not be accepted.

Measurement and payment of asphalt is made on the basis of either mass or area as follows:

(a) Measurement by Mass

Unless specified otherwise in Annexure R121/A, the quantity of asphalt must be measured by
mass and the unit of measurement must be a tonne.

The Principal may approve measurement by batch weights using certified scales certified scales,
the quantity of asphalt in place in the final work must be mutually agreed using the TfNSW
Contract Quantity Agreement Sheet using the tally of the weigh bridge dockets of delivered
asphalt less the quantity of asphalt which is not incorporated in the Works.

Truck weighbridge dockets must be issued at a weighbridge certified by the NSW Office of Fair
Trading and collected at the point of delivery.

(b) Measurement by Area

If specified in Annexure R121/A, the quantity of asphalt is measured by area and the unit of
measurement is the square metre.

The area is to be determined from the dimensions shown on the Drawings or as specified for the
work in Annexure R121/A.

The measurement of tackcoat sprayed is based on the quantity of residual bitumen. The unit of
measurement is the litre determined from sprayer tanker dippings.

Pay Item R121P1 - Supply and Application of Tackcoat

(Including Preparation of Surface)

Unless specified otherwise in Annexure R121/A, the quantity of tackcoat used in the work is
determined by volume and the unit of measurement is a litre of residual bitumen.

The volume must be determined by multiplying the nominated application rate of residual bitumen by
the specified area of the road surface to be tackcoated.

Tackcoat applied to faces of joints, kerbs and other structures is deemed to be included in the rate.

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Pay Item R121P2 - Stone Mastic Asphalt in Wearing Course

R121P2.1 10 mm Nominal Size

R121P2.2 14 mm Nominal Size

Pay Item R121P3 - Incentives and Deductions in accordance with Annexure R121/B

R121P3.1 All deductions as per Table R121/B.1 and B.2

R121P3.2 All incentives (Table R121/B.3)

Incentives and deductions under this pay item are not subject to rise and fall adjustments.

B2 RESOLUTION OF NONCONFORMITIES

B2.1 General

If the nonconformity is not acceptable in accordance with Annexure R121/B2.2, the nonconforming
material must be replaced or the nonconforming section of work must be either replaced or corrected.

The cost of rectifying nonconformities, including any restoration work to any underlying or adjacent
surface or structure, which becomes necessary as a result of such replacement or correction, must be
borne by you. Materials removed from the site by you must be replaced with materials that conform
to this Specification.

B2.2 Acceptance of Nonconformities

You may propose in writing to the Principal that pre-determined dispositions be applied to
nonconformities in the following properties:
(a) Combined particle size distribution and binder content in asphalt
(b) Insitu Air Voids
(c) Ride quality.

Deductions apply to the schedule rate for the quantity of asphalt represented by the test sample and
must be recorded against Pay Item R121P3.1.

B2.2.1 Combined Particle Size Distribution and Binder Content

Deductions in accordance with Table R121/B.1 must be applied to accepted nonconformities in

combined particle size distribution and binder content provided that:
(a) For any individual sieve size and the binder content, nonconformities greater than twice the
production tolerance specified in Table R121.4 must not be accepted; and
(b) Deductions are cumulative and nonconformities must not be accepted if combined deductions
exceed 20%.

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Table R121/B.1 – Deductions for Combined Particle Size Distribution and Binder Content

% by which nonconformity Deductions

exceeds production tolerance (in % of
(Clause 2.4.2) schedule rate)
Combined Particle Size
(% by mass of total aggregate)
Distribution Element
Pass 13.2 mm AS sieve Each 2 or part thereof 1
Pass 9.50 mm AS sieve Each 2 or part thereof 1
Pass 6.70 mm AS sieve Each 2 or part thereof 1
Pass 4.75 mm AS sieve Each 2 or part thereof 1
Pass 2.36 mm AS sieve Each 1 or part thereof 1
Pass 1.18 mm AS sieve Each 1 or part thereof 1
Pass 0.600 mm AS sieve Each 1 or part thereof 1
Pass 0.300 mm AS sieve Each 1 or part thereof 2
Pass 0.150 mm AS sieve Each 0.5 or part thereof 2
Pass 0.075 mm AS sieve Each 0.5 or part thereof 2
Binder Content (% by mass of total asphalt mix)
SMA10 or SMA14 Each 0.1 or part thereof 3

B2.2.2 Insitu Air Voids

Deductions in accordance with Table R121/B.2 must be applied to accepted nonconformities in excess
of the upper characteristic insitu air voids provided that, nonconformities must not be accepted when
the upper characteristic insitu air voids exceeds the specified limit by more than 2.0 %.

Table R121/B.2 – Deductions for Nonconforming Insitu Air Voids

Insitu air voids outside of Deduction (in per cent

specified limit VU by of value of Lot)
< 0.5% 2.5 %
0.5% – 1.0% 15 %
1.1% – 1.5% 25%
1.6% – 2.0% 50%
> 2.0% Reject

B2.2.3 Ride Quality

Deductions in accordance with Table R121/B.3 must be applied to accepted nonconformities in ride
quality provided that, nonconformities must not be accepted when the ride quality exceeds the
specified limit by more than 0.80 m/km.

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Table R121/B.3 - Deductions for Ride Quality

Ride quality in excess of Deduction (in per cent

specified limit by (m/km) of value of Lot)
< 0.25 2
0.25 – 0.43 4
0.44 – 0.61 8
0.62 – 0.80 16

B3 INCENTIVES
It may be proposed in writing to the Principal that pre-determined incentives be applied in accordance
with Table R121/B.4 to the Ride Quality of the asphalt wearing course, provided that:
(a) the Lot conforms to all requirements of this Specification, and
(b) for all three adjacent Lots in all directions, the ride quality is conforming.

Table R121/B.4 - Incentives for Ride Quality

Ride quality below Incentive (in per cent of

specified limit by (m/km) the value of the Lot)
< 0.44 0
0.44 – 0.61 1
0.62 – 0.80 2
> 0.80 3

Incentives apply to the schedule rate for the quantity of asphalt represented by the test sample and
must be recorded against Pay Item R121P3.2.

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ANNEXURE R121/C – SCHEDULES OF HOLD POINTS AND

IDENTIFIED RECORDS
Refer to Clause 1.3.3.

C1 SCHEDULE OF HOLD POINTS

Clause Description
2.3.2 Submission of nominated mix design details
3.8 Submission of paving and compaction temperature details to achieve conformity
3.11 Submission of verification checklists and test results from placement trial

C2 SCHEDULE OF IDENTIF IED RECORDS

The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.

Clause Description of Identified Record

2.1.5 Documentary evidence of binder conformity for each delivery
2.1.6 Documentary evidence of fibre additive to be used
2.3.1 Documents as detailed for each nominated asphalt mix
2.3.1 Documents as detailed for proprietary information
2.4.3, Recorded process parameters, including process temperatures, during asphalt
2.4.5 manufacture
3.7 Pavement temperatures and weather conditions
3.8 Measure asphalt paving and compaction temperature
3.9 Daily record of average tackcoat application rate in each Lot
3.11 Verification checklist and all listed test reports of trial section for each combination of
materials, mix proportions, equipment, rate of paving and methods for placement,
compaction and finishing
4.3.1 The location and frequency of straightedge measurements including testing at
longitudinal and transverse joints
5.3.1 Test reports of all specified properties and characteristics at the minimum frequency of
testing

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ANNEXURE R121/D – PLANNING DOCUMENTS

Refer to Clause 1.3.4.

The following documents are a summary of documents that must be included in the PROJECT
QUALITY PLAN. Review the requirements of this Specification and others included in the Contract
to determine additional documentation requirements.

Clause Description
1.3.4 Manufacturer’s written recommendations
2.1 For each constituent material, Lot/stockpile sizes, method of defining each Lot and
allocating a unique Lot Number
Procurement, handling and storage of each constituent material
Nominated particle size distribution and tolerances for each constituent aggregate
2.1.6 Proposed fibre additive
2.3.1 Development and authorisation of the nominated mix submission
2.4 Method of defining each Lot and allocating a unique Lot Number
Calibration of the asphalt manufacturing plant, including all weigh scales, flowmeters
and thermometers
Process control, including plant operating instructions, key temperature targets and
records, and response to process control charts
Acquisition, storage and handling of binder, including identification and prevention of
segregation and/or contamination
Control of plant feed proportions, including regular checks on grading and moisture
content
Daily asphalt manufacturing plan to ensure timely and uninterrupted progress on site
Storage and handling of binder
2.5 Loading, delivery and unloading procedures that maintain adequate mix temperature and
do not interrupt progress of the paving train
Method of application and control of release agent
3 For each paving and related activity, method of defining each Lot and allocating a
unique Lot Number
Calibration of all thermometers and other measuring equipment
Process control for surface preparation, tackcoating, placing, joint construction,
compaction and cleanup, including plant operating instructions, key temperature targets
and records, patterns for paving and compaction operations, and process monitoring
3.3 Allocation of appropriate plant and equipment, including backup in case of breakdown
Rolling pattern including roller type and number of passes
3.6 Nominated layer thicknesses where these have not been specified by the Principal
3.7 Method of measurement and recording of pavement temperatures and weather
conditions
3.8 Paving and compaction temperature to achieve insitu air void requirements

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Clause Description
3.9 Proposed application rates for tackcoat.
3.10 Joint construction procedure
3.11 Design, execution and quality verification of a placement trial
4.1 Compaction
4.2.1 Requirements for course thickness
4.2.2 Determination of course thickness
5.1, 5.2 & Inspection and Test Plan, including methods and frequencies of sampling, methods and
5.3 frequencies of testing, verification checklists, and timeframe for submission of test
results

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ANNEXURE R121/E – CALCULATIONS

E1 CALCULATION OF CHARACTERISTIC VALUES OF INSITU AIR VOIDS

Calculate the upper (VU) and lower (VL) characteristic values of insitu air voids of the Lot as follows:
VU = a + ks VL = a – ks
where: s = the standard deviation of sub-Lot air voids expressed as a percentage
k = value stated in TfNSW Q Annexure Q/L L3.2
a = the arithmetic mean of insitu air voids expressed as a percentage for all sub-Lots

and a =  MD − BD  × 100%
 MD 
MD = mean maximum density of the Lot determined in accordance with AS/NZS
2891.7.1 or AS/NZS 2891.7.3
BD = bulk density of the sub-Lot determined in accordance with
(i) AS/NZS 2891.9.2 for cores
(ii) AS/NZS 2891.14.2 and AS/NZS 2891.14.3 for nuclear density gauge

Round and report the values of VU and VL to the nearest 0.1%.

E2 CALCULATION OF CHARACTERISTIC VALUE OF THICKNESS

Calculate the upper (TU) and lower (TL) characteristic values of thickness for the Lot as follows:
TU = x + ks TL = x – ks
where: s = the standard deviation of sub-Lot attribute test results
k = value stated in TfNSW Q Annexure Q/L L3.2
x = the average height of a core (mm) based on measurements taken at four equidistant
points at the circumference of the core.
x = the arithmetic mean of attribute test results for all sub-Lots
(Note: x , x and s are in mm and T is rounded to the nearest whole millimetre.)

ANNEXURES R121/F TO R121/K – (NOT USED)

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ANNEXURE R121/L – MINIMUM FREQUENCY OF TESTING

The minimum frequency of testing of the materials, production, placing and finished pavement are
listed in Tables R121/L.1 to R121/L.5.

Table R121/L.1 - Minimum Frequency of Testing of Asphalt

Quantity of Asphalt
Minimum Frequency of Testing
Supplied in Each Shift
Less than 100 tonnes One per 50 tonnes or part thereof
101 to 300 tonnes One per 100 tonnes or part thereof
301 to 600 tonnes One per 150 tonnes or part thereof
Over 600 tonnes One per 200 tonnes or part thereof
Note: A "shift" must be continuous work not exceeding a period of 12 hours.

Table R121/L.2 – Constituents

Clause Constituent Minimum Frequency of Testing (2)

2.1.1 Coarse Aggregate As per TfNSW 3152
2.1.2 Fine Aggregate As per TfNSW 3152
2.1.3 Granulated Glass Aggregate As per TfNSW 3154
2.1.4 Filler As per TfNSW 3211
2.1.5 Binder As per TfNSW 3252
2.1.7 Bitumen Emulsion Tackcoat As per AS 1160
Notes:
(1)
The nominated mix design submission must also include complying test results for each specified
characteristic of each constituent.
(2)
The minimum frequency of testing must be in accordance with the specific TfNSW Test Method or
Australian Standard.

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Table R121/L.3 – Asphalt Production

Test Method /
Clause Characteristic Minimum Frequency of Testing
Procedure
2.1.4 Total filler in asphalt – Dry AS/NZS 1141.17 One per 10,000 tonnes or part thereof
compacted voids used in asphalt production, and at
change in source of mineral matter
2.1.4 Total filler in asphalt – TfNSW T659 One per 10,000 tonnes or part thereof
Methylene blue value used in asphalt production, and at
change in source of mineral matter
2.2.1 Binder content AS/NZS 2891.3.1 As per Table R121/L.1
2.2.1 Combined particle size AS/NZS 2891.3.1 As per Table R121/L.1
distribution
2.2.2 Air voids in laboratory TfNSW T662 As per Table R121/L.1
compacted mix (120 AS/NZS 2891.7.1 or
cycles) AS/NZS 2891.7.3,
AS/NZS 2891.8,
AS/NZS 2891.9.2
2.2.3 Moisture content TfNSW T660 One per mix type per shift
2.2.6 Deformation resistance AG:PT/T231 One test with each nominated mix
submission.
2.4.5 Production temperature of Your documented As specified in PROJECT QUALITY
asphalt procedure PLAN
2.4.5 Dispatch temperature of Your documented Each delivered load
asphalt procedure

Table R121/L.4 – Asphalt Placing

Clause Characteristic Test Method / Procedure Minimum Frequency of Testing

3.7 Pavement temperature Your documented procedure 1 measurement every 2 hours
3.7 Wind velocity Your documented procedure 1 measurement every 2 hours
3.8 Temperature at initial Your documented procedure Each delivered load
compaction
3.9 Tackcoat application Your documented procedure Each paving Lot
rate
5.1 Homogeneity Visual assessment Each paving Lot

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Table R121/L.5 – Finished Pavement Properties

Clause / Test
Clause Characteristic Minimum Frequency of Testing
Method
4.1 Insitu air voids Clause 4.1.2 As specified for relative compaction > 100.0 in
TfNSW Q L3.1
4.2 Course thickness Clause 4.2.2 As specified for relative compaction > 100.0 in
TfNSW Q L3.1
4.3 Surface shape TfNSW T183 (a) Within lane:
one measurement in longitudinal direction
and 1 measurement in transverse direction
every 60 m2
(b) Longitudinal joint excluding crowns:
one measurement per 10 lineal metres
(c) Transverse joint:
one measurement in each wheel path in each
lane except at the boundaries of the Contract
4.4 Ride quality TfNSW T188 Each Lot as defined in TfNSW T188
4.5 Texture depth TfNSW T240 1 test per 100 m of traffic lane length or part there
of.

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ANNEXURE R121/M – REFERENCED DOCUMENTS

Refer to Clause 1.3.7.

TfNSW Specifications

TfNSW G10 Traffic Management

TfNSW Q Quality Management System
TfNSW R101 Cold Milling of Road Pavement Materials
TfNSW R116 Heavy Duty Dense Grade Asphalt
TfNSW 3152 Aggregates for Asphalt
TfNSW 3154 Granulated Glass Aggregate
TfNSW 3211 Cements, Binders and Fillers
TfNSW 3252 Polymer Modified Binder for Pavements
TfNSW 3259 Bitumen Adhesion Agent (for Bitumen)
TfNSW 3269 Bitumen Adhesion Agent (for Polymer Modified Binder)

TfNSW Test Methods

TfNSW T183 Surface Deviation using a Straightedge

TfNSW T188 Project Ride Quality (Vehicular Laser Profiler)
TfNSW T230 Resistance to Stripping of Aggregates and Binders
TfNSW T240 Road Surface Texture Depth
TfNSW T646 Mix Volume Ratio (Dry Mix)
TfNSW T648 Static Binder Drainage Test
TfNSW T659 Methylene Blue Value of Road Construction Material
TfNSW T660 Moisture Content of Bituminous Mixes (Mass Loss Method)
TfNSW T662 Compaction of Asphalt Test Specimens (Using a Gyratory Compactor)

Australian Standards

AS 1141 Methods for sampling and testing aggregates

AS/NZS 1141.17 Voids in dry compacted filler
AS 1160 Bituminous emulsions for the construction and maintenance of pavements
AS 2150 Hot mix asphalt – A guide to good practice
AS 2891 Methods of sampling and testing asphalt
AS/NZS 2891.1.1 Sampling – Loose asphalt
AS 2891.1.2 Sampling – Coring Method
AS/NZS 2891.3.1 Binder content and aggregate grading – Reflux method
AS/NZS 2891.7.1 Determination of maximum density of asphalt – Water displacement method

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AS/NZS 2891.7.3 Determination of maximum density of asphalt – Methylated spirits

displacement
AS/NZS 2891.8 Voids and volumetric properties of compacted asphalt mixes
AS/NZS 2891.9.2 Determination of bulk density of compacted asphalt – Presaturation method
AS/NZS 2891.14.2 Field density tests – Determination of field density of compacted asphalt
using a nuclear thin-layer density gauge
AS/NZS 2891.14.3 Field density tests – Calibration of nuclear thin-layer density gauge using
standard blocks

AUSTROADS Test Methods

AG:PT/T231 Deformation Resistance of Asphalt Mixtures by the Wheel Tracking Test

AAPA Documents

Advisory Note 7 Guide to the Selection, Heating and Storage of Binders for Sprayed Sealing and
Hot Mixed Asphalt
IG-3 Asphalt Plant Process Control Guide

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