Section 6a – TS06 Specification for Sprayed Bituminous Prime 6aTS06 - i

SECTION 6a
TECHNICAL SPECIFICATIONS

TS06 – SPRAYED BITUMINOUS PRIME

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - ii

TABLE OF CONTENTS

1.0 SCOPE ......................................................................................................................... 1

2.0 APPLICABLE PUBLICATIONS ................................................................................... 1

3.0 PRECEDENCE ............................................................................................................. 1

4.0 MATERIALS ................................................................................................................. 1

4.1. CUTBACK BITUMEN................................................................................................. 1
4.2. BITUMEN ................................................................................................................ 1
4.3. CUTTER ................................................................................................................. 1
4.4. PRIME MIXTURES ................................................................................................... 2
4.5. BLINDING SAND ...................................................................................................... 2
5.0 SAMPLING, TESTING AND CERTIFICATES ............................................................. 2
5.1. GENERAL ............................................................................................................... 2
5.2. TEST REPORTS ...................................................................................................... 2
5.3. JOB SAMPLES ........................................................................................................ 2
6.0 PLANT AND EQUIPMENT........................................................................................... 3
6.1. GENERAL ............................................................................................................... 3
6.2. MAINTENANCE........................................................................................................ 3
6.3. BITUMEN SPRAYERS............................................................................................... 3
6.4. HEATING AND STORAGE FACILITIES FOR BITUMINOUS MATERIALS ............................ 3
6.5. SUCTION SWEEPERS, BROOMS, AND BLOWERS ....................................................... 3
7.0 WEATHER LIMITATIONS............................................................................................ 4

8.0 PREPARATION OF SURFACE ................................................................................... 4

9.0 PROTECTION OF EXISTING STRUCTURES ............................................................. 4

10.0 TEST AREAS ............................................................................................................... 4

11.0 APPLICATION OF PRIMER ........................................................................................ 5

11.1. GENERAL ............................................................................................................... 5
11.2. APPLICATION RATE................................................................................................. 5
11.3. SPRAYING .............................................................................................................. 6
11.4. CURING ................................................................................................................. 6
11.5. EXCESS PRIMER .................................................................................................... 7
12.0 SAFETY AND CARE WITH BITUMINOUS MATERIALS ............................................ 7

13.0 MAINTENANCE OF PRIME COAT .............................................................................. 7

14.0 SPRAYING RECORDS ................................................................................................ 7

15.0 REJECTED MATERIALS AND WORK ....................................................................... 7

16.0 HOLD POINTS AND WITNESS POINTS ..................................................................... 8

16.1. HOLD POINTS ......................................................................................................... 8
16.2. WITNESS POINTS ................................................................................................... 8
17.0 MEASUREMENT AND PAYMENT .............................................................................. 8

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 1

1.0 SCOPE

This section of the Specification states the requirements for the preparation and application of a
sprayed bituminous prime to the finished base on new aircraft pavements, including shoulders.

2.0 APPLICABLE PUBLICATIONS

The following standards and publications form a part of the Specification. Unless specified otherwise,
the standards and publications applicable shall be the editions current at the date of calling tenders.
Each publication has been referenced herein by its basic designation only.

Standards Association of Australia

AS1152 Specification for Test Sieves

AS1289 Methods of Testing Soils for Engineering Purposes

AS2008 Residual Bitumen for Pavements

AS2157 Cutback Bitumen

AS2341 Methods of Testing Bitumen and Related Roadmaking Products

AustRoads

NAS-70 Bitumen Sprayers

NTR-07 Bituminous Surfacing – Sprayed Works

Australian Institute of Petroleum Ltd

CP-20 Code of Practice for Safe Handling of Bitumen Products

3.0 PRECEDENCE

Where the requirements of this Specification are at variance with the published standards, this
Specification shall take precedence.

Further resolution between the standards, if required, will be provided by the Engineer.

4.0 MATERIALS

4.1. Cutback Bitumen

Cutback bitumen for primer shall comply with the appropriate requirements of AS2157 and shall be
class AMCOO, AMCO or AMC1.

4.2. Bitumen

The bitumen used to manufacture primer shall be class 170 residual bitumen complying with the
requirements of AS2008.

4.3. Cutter

Any primer which is not prepared in a refinery shall be prepared by mixing bitumen and cutter at the
site of the works. The cutter shall be of commercial quality power kerosene or aviation turbine fuel (Jet
A-1). No other type of cutter oil shall be used under any circumstances.
The cutter shall be a clean clear liquid containing no dissolved solids, foreign material or matter in
suspension.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 2

4.4. Prime Mixtures

When cutback bitumen suitable for priming is prepared on site, the proportions shall comply with the
details given in Table 1.

Table 1 Site Mixed Primer Proportions

Parts of Cutter to 100 Percentage Cutter Application
Parts of Bitumen (by Volume in Mixture Temperature Range
(by Volume at 15°C) at 15°C) (°C)
78 40 40-60
82 45 30-50
100 50 20-40

4.5. Blinding Sand

Blinding sand to be used for absorbing excess primer shall be crushed or natural sand containing only
sound, hard, dense, durable and clean particles free from significant amounts of clay, organic matter,
or other foreign material and shall be substantially dry. When tested in accordance with AS1289.3.3.1,
using wet preparation the Plasticity Index of the sand shall not exceed zero.

The particle size distribution of the sand, when tested in accordance with AS1289.3.6.1 shall comply
with the limits given in Table 2.

Table 2 Particle Size Distribution for Blinding Sand

Sieve Size (mm) Percentage by Mass Passing Sieve
6.7 100
4.75 85 to 100
1.18 40 to 100
0.425 10 to 50
0.075 0 to 5

5.0 SAMPLING, TESTING AND CERTIFICATES

5.1. General

If during the progress of the work the Contractor desires to use other materials or materials from other
sources or materials produced from the same source using methods of production different from those
originally approved, new samples shall be taken and tested for compliance with the specification.

All samples shall be tested at the Contractor's expense in a laboratory registered for that testing by
NATA.

5.2. Test Reports

All verification/compliance testing for each bituminous material proposed for use in the Works shall be
supported by test reports indicating compliance of the materials with the properties or requirements
specified herein and issued by a laboratory registered by NATA for the performance of such tests. The
test reports shall be for material which is the supplier’s current production and representing material
produced not more than one (1) month prior to issue of the report.

5.3. Job Samples

During progress of the work, materials shall be sampled and tested by the Contractor as delivered or
as required to check compliance with the specification.

Samples of each bituminous material shall be taken by the Contractor at not least than one sample per
1,000 litres of bituminous material sprayed.

Samples of sand shall be taken by the Contractor and tested for particle size distribution prior to
spreading.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 3

All sampling shall be carried out in accordance with the relevant Australian Standard for the
appropriate material.

Any material which does not comply with the specification requirements herein shall be rejected.

If test results are disputed and/or when requested by the Superintendent during progress of the works
additional samples shall be taken by the Contractor and tested by an independent NATA registered
laboratory to enable the quality of the materials being used to be checked.

6.0 PLANT AND EQUIPMENT

6.1. General

The Contractor shall provide all plant, tools and equipment necessary to carry out and complete the
Works in accordance with the Specification.

6.2. Maintenance

Plant and equipment used on the work shall be maintained in satisfactory working condition at all
times. Plant and equipment used on the Works shall not drip fuel, oil, grease or other material onto the
pavement. Any plant or equipment that does drip fuel, oil, grease or other material shall be removed
from the works until it is repaired.

The Contractor shall inspect all plant and equipment proposed for use prior to commencing work to
check compliance with the Specification. The documented results of the inspection shall be included in
the Project Quality Plan.

6.3. Bitumen Sprayers

Bitumen sprayers shall comply with the requirements of NAS-70 or other national standard.

The Contractor shall include in the Project Quality Plan a copy of the current Authority Certificate for
each bitumen sprayer proposed for use showing compliance with the requirements of NAS-70 or other
national standard.

The certificate (or copy) shall be mounted or retained on the sprayer, protected from damage, and
shall be available for inspection at all times.

6.4. Heating and Storage Facilities for Bituminous Materials

Tanks for the storage of bituminous materials shall have thermostatically controlled heating equipment
and be capable of heating the material under effective and positive control at all times to the
temperature requirements specified.

Heating shall be accomplished by steam coils, hot oil, electricity or other means that will not allow any
flame to directly contact the tank containing the bitumen. Armoured thermometers with a range from
10°C to 260°C shall be affixed to the tank so that the temperature of the bituminous material in the
lower third, middle and upper third of the tank may be easily read at all times.

6.5. Suction Sweepers, Brooms, and Blowers

Brooms, vacuum (suction) sweepers and blowers shall be of the power type, and shall be suitable for
cleaning the surfaces which are to receive the primer. Steel bristle brooms shall not be permitted
under any circumstances.

Suitable drag brooms shall also be provided by the Contractor to assist distribution of blinding sand.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 4

7.0 WEATHER LIMITATIONS

The primer shall be applied only when the surface which is to be primed is surface dry, and the
moisture content is not less than 2% below the modified optimum moisture content as determined for
the material. The primer shall be applied only when the pavement temperature of the base is at least
15°C and is expected to remain in excess of 15°C for the duration of the application of the primer.

The primer shall not be sprayed during rain or if rain is anticipated within eight (8) hours of completion
of spraying.

8.0 PREPARATION OF SURFACE

The Contractor’s ITPs shall include the inspection and assessment of the surface to be primed prior to
the time proposed for application of the primer.

Surface preparation to be carried out to the surface to be primed shall include but not be limited to:

a) removal by light sweeping of all loose material, excess aggregate, dirt, clay, dust,
b) removal of oil, fuel or grease deposits using scrapers or detergents or both, and
c) removal by sweeping or vacuum (suction) cleaner, of any foreign matter which may have
contaminated the surface (e.g. windblown sand or dust).

Power operated brooms shall be used with care to avoid hard scrubbing and to avoid removal of
compacted surface fines.

Hand brooms, scrapers and shovels shall be used if necessary.

The prepared surface ready for priming shall consist of a tightly bonded matrix of coarse and fine
aggregates. Any damage to the base resulting from the cleaning operation shall be repaired at the
Contractor’s expense.

The ITPs shall allow for the inspection of the surface to be primed to determine the suitability of the
area to receive the primer immediately before application of the primer.

9.0 PROTECTION OF EXISTING STRUCTURES

The Contractor shall protect all light fittings, manholes, pits, kerbs or other structures by covering with
paper or plastic sheet to avoid splashing or spraying them. Immediately after the completion of the
priming the Contractor shall remove the protective coverings and dispose of them off the Site.

The Contractor shall be responsible for removing any bituminous material which has adhered to
fittings or structures as a result of the Contractor's operations.

If it is not possible to remove the bituminous material, the Contractor shall replace and make good the
splashed or sprayed part, at no additional cost to the Employer.

10.0 TEST AREAS

At least three (3) days prior to the proposed commencement of the general application of primer, the
Contractor shall supply and spray approximately 500 litres of the primer applied at the rate of
application specified or directed, on an area of the works to be selected by the Engineer. The
Contractor shall give at least 24 hours’ notice of the intention to construct any test area.

The Contractor shall select the class of cutback bitumen or proportions of the primer to be used on the
test area such that when sprayed at the specified application rate or other suitable rate which is
reviewed by the Engineer, the primer penetrates the prepared surface to a depth of 5 to 10mm leaving
it free of any pools of bituminous material in not less than six (6) hours and not more than 48 hours
after the time of application.
Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works
Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 5

If the primer penetrates the surface in less than the minimum specified time, the Contractor shall re-
prime the area at no additional cost to the Employer.

The construction of the test area will be observed and inspected by the Contractor who will advise the
Engineer in writing if the trial meets the requirements of the Specification and the class of cutback
bitumen and the rate of application to be used.

If the test area is unacceptable the Contractor shall construct another test area as directed by the
Engineer. Test areas that do not meet the requirements of the Specification shall be rejected and shall
be reconstructed at no additional cost to the Employer. The test areas complying with the specification
will generally be incorporated in the final work and will be paid for as part of the completed work.

The Contractor shall not be entitled to claims for delays or extensions of time resulting from the need
to construct test areas.

The Contractor’s ITPs shall include the determination of the appropriate application rate for the
bituminous prime.

11.0 APPLICATION OF PRIMER

11.1. General

All bituminous materials shall be applied using a bitumen sprayer complying with the specification.

The primer shall be sprayed uniformly using a bitumen sprayer at the specified spraying temperature
to all points on the surface to be primed and at the specified application rate.

Before commencement of application the primer shall be circulated in the sprayer for 15 minutes or
such longer time as may be necessary to completely mix the cutter and bitumen.

Upon filling or refilling the sprayer with primer and prior to commencing or recommencing spraying, the
spray nozzles shall be checked by examination and by test spraying a small quantity of primer in an
area not on the pavement to ensure that all spray nozzles are working correctly and are not blocked.
Nozzles found to be malfunctioning shall be cleaned or replaced with satisfactory nozzles.

11.2. Application Rate

The required application rate of the primer is dependent upon the condition of the surface and the
viscosity of the primer. The actual application rate shall be determined by the Engineer as a result of
2
trials, but will typically be in the range 0.50 to 1.35 l/m of residual bitumen, measured at 15°C. The
Contractor’s ITPs shall include the inspection and assessment of the surface and determination of the
application rate to be used prior to the time proposed for application of the primer.

Following completion of each spray run and before commencing any subsequent runs, the average
application rate of the primer for that run shall be determined by dipping of the tank. The application
rate calculated shall be converted to the corresponding rate at 15°C using the temperature adjustment
factors in Table 3 and recorded on spraying record sheets.

Any necessary adjustments to the spraying operation shall be made to ensure that the specified or
ordered application rate is maintained in subsequent spray runs.

If the average application rate of primer on any spray run is less than 95% or more than 105% of the
specified or ordered application rate, or if the whole area being sprayed is not uniformly primed, then
that spray run shall be rejected.

The Project Quality Plan shall provide for the regular monitoring of the application rate so as to avoid a
trend towards the minimum rate of application during the execution of the Works.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 6

Table 3 Temperature Adjustment Factors

Observed Multiplier Observed Multiplier
Temperature Temperature
(°C) (°C)
15 1.000 111 0.941
18 0.998 114 0.939
21 0.996 117 0.937
24 0.994 120 0.936
27 0.993 123 0.934
30 0.991 126 0.932
33 0.989 129 0.930
36 0.987 132 0.928
39 0.985 135 0.927
42 0.983 138 0.925
45 0.981 141 0.923
48 0.979 144 0.921
51 0.978 147 0.920
54 0.976 150 0.918
57 0.974 153 0.916
60 0.972 156 0.914
63 0.970 159 0.913
66 0.968 162 0.911
69 0.967 165 0.909
72 0.965 168 0.907
75 0.963 171 0.905
78 0.961 174 0.904
81 0.959 177 0.902
84 0.957 180 0.900
87 0.956 183 0.899
90 0.954 186 0.897
93 0.952 189 0.895
96 0.950 192 0.893
99 0.948 195 0.892
102 0.946 198 0.890
105 0.945 201 0.888
108 0.943

11.3. Spraying

Unless the distributor is equipped to obtain satisfactory results at the junction of previous and
subsequent applications, building paper shall be spread on the surface to be treated for a sufficient
distance back from the ends of each application so that flow from the sprays may be started and
stopped on the paper, and so that all sprays will be operating correctly when on the surface to be
treated. Immediately after the application, the building paper shall be removed and destroyed.

All areas or spots missed by the distributor shall be correctly treated with primer by hand spraying.

The width of the primed surface shall be 100mm wider on each side of the sealed surface as specified
or directed by the Engineer.

The edges of the area primed shall be true to the lines ordered within a tolerance of ±50 mm.

11.4. Curing

Following the application of the primer, the surface shall be allowed to cure without being disturbed for
a period of not less than 48 hours or longer as may be necessary to attain penetration into the surface
and evaporation of the volatiles from the primer.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 7

11.5. Excess Primer

If, after the designated curing period, any pools of bituminous material remain on the surface, the
Contractor shall remove the excess primer using approved methods of absorption or spread the pools
of primer using squeegees or other suitable means.

12.0 SAFETY AND CARE WITH BITUMINOUS MATERIALS

No smoking, fires or flames other than the heaters that are a part of the equipment shall be permitted
near heating, distributing or transferring operations of bituminous materials.

Bituminous materials shall be kept completely free of all contaminants prior to application.
Care shall be taken to avoid either local or total overheating.

Any bitumen heated to or stored at a temperature in excess of 200°C or held at a temperature in

excess of 160°C for more than 48 hours (except within the refinery) shall be rejected.

Any primer held at a temperature exceeding that appropriate to the particular class listed below for
more than six (6) hours shall be rejected:

i. AMCOO 40°C
ii. AMCO 60°C
iii. AMC1 85°C

13.0 MAINTENANCE OF PRIME COAT

The Contractor shall maintain the prime coat by protecting the coat from any damage which will affect
the continuity of the coat, and repairing any breaks or defects in the coat when they appear.

At the completion of spraying operations, all areas utilised by the Contractor during the Works shall be
cleaned of spilt primer and other materials which may constitute contamination of the area and remove
the same from the Site.

Maintenance shall be carried out by the Contractor at no additional cost to the Employer.

14.0 SPRAYING RECORDS

The Contractor shall maintain an up to date record of the application of the primer on Site at all times.

The record shall include the location and date of the spray run, the temperature of the primer
immediately before spraying, the tank dipping before and after each spray run, the pavement
temperature, the calculated application rate of primer at the spraying temperature and at 15°C and any
other pertinent information.

A copy of the spraying records shall be handed to the Engineer at the conclusion of each days
spraying.

15.0 REJECTED MATERIALS AND WORK

Materials which do not meet all the requirements of the Specification shall be rejected.

Areas of prime coat which do not meet all the requirements of the Specification or which contain
rejected materials shall also be rejected.

All rejected work shall be repaired, rectified or removed and replaced by the Contractor such that all
the work complies with the Specification.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018
Section 6a – TS06 Specification for Bituminous Prime 6aTS06 - 8

16.0 HOLD POINTS AND WITNESS POINTS

The Contractor shall incorporate the requirements of this Clause in the Project Quality Plan. Hold
Points shall be certified by the Contractor’s Project Quality Representative (PQR) and Witness Points
shall be reviewed or witnessed by the Engineer.

16.1. Hold Points

a) Quality verification and compliance test reports and certificates for bituminous prime coat
materials and sprayers,
b) Quality verification, compliance test report, and certificate for blinding sand,
c) Inspection of plant and equipment,
d) Inspection of surface to be primed,
e) Rates of application for primer in each spray run,
f) Inspection of primer after curing, and
g) Rates of application for primer for completed lot.

16.2. Witness Points

a) Completion of surface preparation prior to application of primer.

17.0 MEASUREMENT AND PAYMENT

Payment for all Works covered by this specification section shall be deemed to be included in the Bid
Price.

In the event that the Contractor fails to carry out the required repairs, rectifications, and/or works as
specified herein to the satisfaction of the Engineer, the Employer reserves the right to employ another
Contractor to effect such repairs and deduct the cost of such repairs from the Contract Price.

Payment will not be made for work and/or material rejected under the terms and conditions of this
Specification.

Payments shall be made progressively during the contract period in proportion to the amount of works
completed provided that evidence of conformance with the requirements of the Specifications have
been provided by the Contractor and accepted by the Engineer.

Bidding Document – ICB No. CADIP-B3-20-2A1 Procurement of Works

Runway Extension, New Terminal and Associated Works at Wewak Airport, East Sepik Province, PNG April 2018