Department of State Growth

SECTION 408 - SPRAYED BITUMINOUS SURFACINGS

##This section cross-references Sections 166, 175, 310, 801, 831 and 832.
If any of the above sections are relevant, they should be included in the specification.
If any of the above sections are not included in the specification, all references to those sections should be
struck out, ensuring that the remaining text is still coherent:
408.01 GENERAL
This section covers the requirements for materials, design and application of sprayed bituminous surfacings
including primes and sprayed seals of various types.

408.02 STANDARDS
Table 408.021 Referenced Documents

AAPA Health and Safety Guide

AAPA HSE Guide No.8 Environmental management when spraying bituminous materials

Australian Standards
AS 1160 Bituminous emulsions for the construction and maintenance of pavements
AS 2008 Bitumen for pavements
AS/NZS 2106.1 Methods for the determination of the flash point of flammable liquids (closed cup) Abel
closed cup method
AS 2106.2 Methods for the determination of the flash point of flammable liquids (closed cup)
Determination of flash point - Pensky-Martens closed cup method
AS 2157 Cutback bitumen

Austroads
AGPT4K Guide to Pavement Technology: Part 4K: Selection and Design of Sprayed Seals
AGPT-T530 Calibration of Bitumen Sprayers: General Introduction and List of Methods
AGPT-T531 Calibration of Bitumen Sprayers: Volumetric Calibration of Bitumen Pumping Systems
AGPT-T532 Calibration of Bitumen Sprayers: Transverse Distribution by Fixed Pit Facility
AGPT-T533 Calibration of Bitumen Sprayers: Transverse Distribution by Field Mat
AGPT-T534 Calibration of Bitumen Sprayers: Transverse Distribution by Portable Trough
AGPT-T535 Road Speed and Distance Calibration
AGPT-T536 Viscosity of Calibration Fluid
ATS-3110 Austroads Technical Specification: Supply of Polymer Modified Binders

ASTM International Standards

ASTM D86 Standard Test Method for Distillation of Petroleum Products and Liquid Fuels at
Atmospheric Pressure
ASTM D93 Standard Test Methods for Flash Point by Pensky-Martens Closed Cup Tester
ASTM D276 Standard Test Methods for Identification of Fibers in Textiles
ASTM D445 Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and
Calculation of Dynamic Viscosity)
ASTM D1298 Standard Test Method for Density, Relative Density, or API Gravity of Crude Petroleum
and Liquid Petroleum Products by Hydrometer Method
ASTM D3828 Standard Test Methods for Flash Point by Small Scale Closed Cup Tester
ASTM D4052 Standard Test Method for Density, Relative Density, and API Gravity of Liquids by Digital
Density Meter
ASTM D6140 Standard Test Method to Determine Asphalt Retention of Paving Fabrics used in Asphalt
Paving for Full-Width Applications

VicRoads Test Methods

RC 317.01 Test Method for Surface Texture by Sand Patch
RC 317.03 Test Method for Stripping of Aggregate from Sprayed Seals

Section 175 details the revision dates of the relevant references in this section.

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408.03 DEFINITIONS

Adhesion Agent
A wetting agent designed to promote adhesion of binder to aggregate.

Aggregate Retention
Retention of aggregate particles by the binder under traffic. The degree of aggregate stripping is measured
to assess aggregate retention.

Effective Spray Width

The width that the full design binder application rate is achieved. This width can vary depending on the type
of end nozzles used. Where EAN18 end nozzles are used the effective width is considered to be 100 mm
outside of the end nozzles.

Final Seal (FS)

The application of a sprayed seal treatment to a surface previously treated with an Initial Treatment.

Forward Aggregate Discharge Plant

Any item of plant or device approved by the Superintendent that loads aggregate into a vehicle/truck or
hopper for the use in the process of forward aggregate spreading.

Forward Aggregate Spreading Plant

Any item of plant or device approved by the Superintendent that uniformly spreads aggregate on to the road
surface at a predetermined rate and width while the vehicle is travelling in a forward direction and the
operator/driver of the vehicle is facing in the direction of travel.

Polymer Modified Binder (PMB)

A bituminous binder with modified properties achieved by the addition of a polymer or crumb rubber.

Prime
An Initial Treatment comprising of the application of a bituminous primer to a prepared granular pavement
base or concrete surface without cover aggregate.

Initial Seal (IS)

An Initial Treatment involving the application of a bituminous binder and covered with aggregate to a
prepared basecourse which has not been primed to provide a temporary bituminous surfacing.

Initial Treatment
The application of a bituminous treatment to a prepared granular pavement base either as a prime or Initial
Seal.

Reseal (R)
The application of a sprayed seal treatment over an existing bituminous surfacing.

Residual Binder
The volume of bituminous binder at 15°C including the volume of any polymer, crumb rubber but does not
include the volume of any cutter, water, emulsifier or adhesion agent.

Reverse Aggregate Spreading Plant

Any item of plant or device that uniformly spreads aggregate at a predetermined rate and width while the
vehicle is operating in a reverse direction (e.g. tip trucks with box spreaders attached).

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Sprayed Seal
The sprayed application of bituminous binder to a previously primed or sealed surface followed by an
application of aggregate to form an all-weather skid resistant road surfacing.
Types of sprayed seals include:
• Conventional (C), where the bituminous binder is generally Class 170 bitumen.
• High Stress Seal (HSS), where the bituminous binder is a lightly modified PMB (S10E, S35E) or has 9%
(10 parts) of crumbed rubber added to aid aggregate retention on heavily trafficked roads. HSS seals may
be applied as a single/single application (HSS1) or as a double/double application (HSS2).
• Extreme Stress Seal (XSS), is a double/double treatment where the bituminous binder is a heavily
modified binder (S20E, S45R, S15RF), to accommodate extreme stresses imposed by heavy traffic
volumes and high proportions of heavy vehicles or difficult service conditions.
• Strain Alleviating Membrane (SAM), where the bituminous binder is a heavily modified PMB (S20E, S45R
S15RF), to treat cracked pavements.
• Strain Alleviating Membrane Interlayer (SAMI), where the bituminous binder is a very heavily modified PMB
(S25E, S18RF) to inhibit cracks reflecting through to an overlying surface.
• A Geotextile Reinforced Seal (GRS), where the bituminous binder is reinforced by the inclusion of a
geotextile fabric to treat extensively cracked pavements. It is a form of SAM or SAMI where enhanced
crack suppression is required.
• A Fibreglass Reinforced Seal (FRS) is a seal where the bituminous binder is reinforced by the inclusion of
chopped fibreglass strands to treat cracked pavements. It is a form of SAM or SAMI where enhanced
crack suppression is required but where a GRS cannot be placed.
Surface Enrichment (SE)
A light application of cutback bitumen or bitumen emulsion to an existing highly textured bituminous surfacing
in very low or non-trafficked areas to extend the life of an existing sprayed seal or asphalt surface.
Surface Pre-Treatments
Surface pre-treatments include any sprayed bitumen, aggregate, combination of sprayed bitumen and
aggregate, High Pressure Water Retexturing (HPWR), or other treatment approved by the Superintendent
that is applied prior to the specified sprayed seal.
Surface Texture
The mean height of aggregate particles above the level of the binder as determined by VicRoads Test
Method RC 317.01.

408.04 COMMENCEMENT OF WORK

(a) Periodic Resurfacing and Maintenance Works
Within 2 weeks of the Date of Award of Contract the Contractor shall submit to the
Superintendent for review the sealing program for the whole of the works.
During the period of the Contract, the Contractor shall submit by the preceding Thursday a detailed
program of planned sealing jobs for the following week for review by the Superintendent, including
planned dates for each sealing job.
(b) Construction Projects
The Contractor shall include details of all sprayed bituminous surfacing works on the
Construction Program.
During the period of the Contract, the Contractor shall submit by the preceding Thursday a detailed
program of planned sprayed bituminous surfacing works for the following week for review by the
Superintendent, including the planned sprayed bituminous surfacing works for each day.
HP Prior to the works being carried out, the Contractor shall provide written confirmation of the works
that will be undertaken the following day and obtain agreement from the Superintendent to any
variation in the design rates of application to those provided under clause 408.13(a).
HP Work shall not commence until the Contractor and the Superintendent have agreed that the road or
pavement surface is fit and ready for surfacing no more than 24 hours prior to the works occurring.
For Periodic Resurfacing and Maintenance Works this includes patching and other preparatory
works, and for Initial Seals on Construction Projects the requirements of Standard Section 310 shall
be satisfied.

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408.05 LIMITS OF WORK

Where the Job Items are detailed in Table 408.191, the limits of work at the start and finish chainages plus
the limit in any side road have been marked on the pavement surface.

The Works shall include all existing tapers, bell mouths at intersecting roads, pavement widenings (turn
lanes), traffic lanes and sealed shoulders, unless otherwise specified.

The Superintendent may increase or decrease the limits of work for Job Items listed in Schedule 1. The
Contractor will be notified in writing prior to works commencing of such adjustments to the limits of work for
any job. The Contract Sum shall be adjusted on a pro-rata basis using the Item price tendered in Schedule 1
and the difference in area of the revised works.

The areas for items listed in Table 408.191 are accurate to ±5%.

408.06 INCLUSION AND DELETION OF JOB ITEMS

The Superintendent may cancel any work, subject to notice of cancellation being given at least one week
prior to the proposed commencement date.

The Contractor will be notified in writing of such deletion and the Contract Sum adjusted by the price tendered
in Schedule 1 for the job item/s deleted.

No additional payment will be made as a result of the deletion of any job item. However, where the deletion
of job items results in a Contract Sum reduction of more than 20% of the original Contract Sum, the deletion
of job items in excess of this amount will be treated as a variation in accordance with the Contract.

In the event of aggregate having been delivered to a job stacksite and the job is deleted in accordance with
this clause, the cost of the removal of the aggregate and any loss of aggregate shall be treated as a variation
in accordance with the Contract.

The Superintendent may request the Contractor to undertake additional sealing works at sites not listed in
Schedule 1. These works will be treated as a variation in accordance with the Contract.

408.07 CALIBRATION OF BITUMEN SPRAYERS

All sprayers used for application of bituminous materials shall have a current Certificate of Calibration
showing compliance with Austroads test methods AGPT-T530 through to AGPT-T536. The Certificate of
Calibration shall be renewed every 12 months. If any sprayer has its spray equipment overhauled or
replaced, it shall be calibrated and issued with a new Certificate of Calibration prior to use.

408.08 BITUMINOUS MATERIALS

(a) Bitumen
Unless otherwise specified, bitumen shall be Class 170 complying with the requirements of AS 2008.
The value for the long-term effect of heat and air shall be not be less than nine days.
Bitumen incorporating up to 5% (five parts) of crumb rubber shall be considered to be an unmodified
bituminous binder. Bitumen incorporating manufactured polymers that provide a similar level of
modification may also be considered to be unmodified binders, subject to the approval of the
Superintendent.

(b) Bitumen Emulsion

Bitumen emulsion shall comply with the requirements of AS 1160.
The use of any non-standard proprietary classes of bitumen emulsion shall be subject to the Contractor
providing evidence that the product has demonstrated satisfactory field performance for a period of at
least three years. Restricted use of untried products on a trial basis shall be subject to the approval of
the Superintendent.

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(c) Cutback Bitumen

Cutback bitumen shall comply with the requirements of AS 2157. An equivalent product may be used
subject to the Contractor providing evidence satisfactory to the Superintendent that the proprietary
product has demonstrated acceptable field performance for a period of at least three years. Restricted
use of untried products on a trial basis shall be subject to the approval of the Superintendent.
(d) Polymer Modified Binder (PMB)
The class of PMB shall comply with the requirements of Austroads Technical Specification ATS-3110.
Alternative or ‘ungraded’ PMBs which do not comply with the specified test requirements of ATS-3110
shall not be used without approval by the Superintendent and will be subject to the Contractor providing
evidence that the product has delivered satisfactory field performance for a period of at least three
years. Restricted use of untried products at nominated trial sites shall be subject to the approval of the
Superintendent.
(e) Primer
The primer shall be cutback bitumen complying with the requirements of clause 408.08(c) and shall be
water resistant, of uniform appearance and capable of providing a strong bond between the bituminous
surfacing and the pavement. Proprietary classes of bitumen emulsion may be accepted by the
Superintendent as an alternative to cut back bitumen if evidence is provided to show that the emulsion
product meets the same functional requirements.

408.09 OTHER MATERIALS

(a) Adhesion Agent
Adhesion agent may be added to the aggregate precoat or binder to promote adhesion to the cover
aggregate and/or pavement surface. The type of adhesion agent and the percentage to be used shall
be subject to the Contractor providing evidence that the proprietary product has satisfactory field
performance. When adhesion agent is added to the binder, the total volume of adhesion agent and
diluent shall not exceed 1% by mass of the binder.
(b) Aggregate Precoating Material
Aggregate precoating material shall be a distillate, distillate-based product, cutback bitumen, emulsion
or proprietary product subject to the Contractor providing evidence that the proprietary product has
demonstrated satisfactory field performance for a period of at least three years. Restricted use of
untried products on a trial basis shall be subject to the approval of the Superintendent.
(c) Crumb Rubber
Crumb rubber must be sourced from waste tyres generated in Australia and processed by a Tyre
Stewardship Australia accredited supplier and shall be free from cord, wire, fluff and other deleterious
material.
(d) Cutter
All cutters shall comply with the properties in the Table 408.091.
Table 408.091 Properties of Cutter
Cutter(1)
Property Requirement Method of test
Min. Max.
Appearance Clean, bright and visually free from –
solid matter and undissolved water
at ambient temperature
Flash point (°C) 61.5 – AS/NZS 2106.1 or AS 2106.2 or
ASTM D93 or ASTM D3828(2)
Distillation range ASTM D86
Initial boiling point (IBP) (°C) 140 –
Final boiling point (FBP) (°C) – 300
Viscosity at 40°C (mm2/s) 0.7 2.5 ASTM D445
Density at 15°C (kg/m3) Report ASTM D1298 or ASTM D4052
Notes to Table 408.091
1 Cutter shall be completely miscible with bitumen and no precipitation shall occur.
2 Whichever of the listed test methods that is applicable for the flash point range of the material.

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Other cutters which do not comply with the requirements of Table 408.091 but have a flash point of
61.5ºC or higher, or other methods of temporarily lowering the viscosity of the binder may be used
subject to the Contractor providing evidence that such methods or products have demonstrated
satisfactory field performance for a period of at least three years.
Restricted use of untried products or processes on a trial basis shall be subject to the approval of the
Superintendent.

(e) Geotextile Fabric

Unless otherwise specified or approved by the Superintendent, all geotextile fabric used for geotextile
reinforced seals shall be a non-woven needle punched fabric. The mass of the fabric shall be a
minimum of 135 g/m² for seals of nominal maximum size of 14 mm and under, and 175 g/m² for seals of
nominal maximum size of larger than 14 mm. The geotextile fabric shall have a melting point when
determined in accordance with ASTM D276 at least 10ºC above the maximum binder spraying
temperature. The binder retention allowance shall be determined in accordance with ASTM D6140 with
a C170 bitumen.

408.10 BINDERS FOR TREATMENT TYPES

(a) Initial Seal Binder

The binder to be used in Initial Seals shall be a suitable cutback bitumen, bitumen emulsion or a 9%
(10 parts) crumb rubber modified binder. Other modified binders may be used subject to approval of the
Superintendent.
The Initial Seal shall be waterproof and capable of adhering to the pavement surface while retaining
sufficient binder on the surface to hold the aggregate in place.

(b) Final Seal and Reseal Binders

Unless otherwise specified in Table 408.191, one of the following binder classes and seal sizes outlined
in Table 408.101 shall be used.
Table 408.101 Binder Class for Treatment Types

Treatment Typical Aggregate

Binder Class Seal Type
Type Sizes

Conventional C170, C240, C320 Single/single 7,10,14

Double/double 10/5, 10/7, 14/7, 20/7
HSS S10E, S35E Single/single 7, 10, 14
10 parts rubber Double/double (1) 10/5, 10/7, 14/7, 20/7

XSS S20E, S15RF S45R Double/double (1) 14/7, 20/7

SAM S20E, S15RF, S45R Single/single 10, 14
Double/double (1) 10/5, 10/7, 14/7, 20/7

SAMI S25E, S18RF Single/single 10, 14

Double/double (1) 10/5, 10/7, 14/7
GRS SAM C170, C240, C320 Double/double 14/7, 20/7

GRS SAMI C170, C240, C320 Single/single 10, 14

Double/double 10/5, 10/7, 14/7

Notes to Table 408.101

(1) These treatments may incorporate a geotextile fabric layer where specified.

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408.11 AGGREGATE

(a) Aggregate Specification

Aggregate shall comply with the following Standard Specification Sections:
801 - Source Rock for the Production of Crushed Rock and Aggregates
831 - Aggregate for Sprayed Bituminous Surfacing
832 - Sands for Sprayed Bituminous Surfacing.

(b) Aggregate Precoating

The Contractor shall provide either plant precoated aggregate or field precoated aggregate.
Aggregate precoating shall be undertaken using a purpose-built item of plant to apply the precoating
material in a controlled manner that produces a uniform coating

408.12 USE OF STACKSITES

(a) General
Any stacksites used by the Contractor during the Contract shall be cleaned and returned to their original
condition within four weeks of completion of the use of that stacksite for works under the Contract.
Where the Contractor does not clean any stacksite used as specified, the Superintendent may arrange
for it to be done by others at the Contractor's expense.
No additional stacksites are to be constructed on the road reserve.
The use of stacksites on other road reserves (such as municipal stacksites), or on other public or private
land require the approval of the relevant authority or owner prior to use for items under the Contract.
Aggregate stored at stacksites shall be managed to avoid contamination from other materials on the
stacksite or from other sources such as vegetation, debris etc.

(b) Placement of Stacks

The following requirements shall apply to the placement of aggregate and materials:
(i) stacks shall be placed so they do not unduly reduce sight distance at locations such as
intersections and curves
(ii) stacks shall not be placed under or immediately adjacent to power lines and shall comply with all
“No-Go Zones” and the relevant requirements for electrical spotters
(iii) stacks shall not be placed at locations where any sealing operations, including aggregate delivery
will interfere with trees or structures
(iv) stacks shall be placed clear of the road formation, drains, gateways and side tracks
(v) for aggregate placed on roadside stacksites, stacks shall be placed within the limits of the existing
cleared area at the stacksite.

(c) Safe Work Method Statement

Prior to using any stacksite, the Contractor or relevant parties shall submit a Safe Work Method
Statement addressing the requirements of the SWMS Checklist in Appendix ##:

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408.13 APPLICATION OF BITUMINOUS MATERIAL, AGGREGATE AND GEOTEXTILES

(a) Design Rates of Application
The Contractor shall determine the design rates of application for primer, binder, surface pre-
treatments, remedial works and aggregate in accordance with the procedures set out in the Guide to
Pavement Technology: Part 4K. The design calculation shall clearly show how design rates have been
determined including all traffic and EHV allocations to each lane, voids factors, allowances, assumptions
and any supporting data.
All rates of application of bituminous material shall be expressed in L/m². In the case of binder, rates of
application shall refer to residual binder at 15°C.
All rates of application of aggregates shall be expressed in m 2/m3 and rates of application of precoat
shall be expressed in L/m3.
Traffic data and default rates of application for bituminous material are specified in Table 408.191.
HP At least one week prior to the commencement of work, the Contractor shall submit the initial
design rates of application for bituminous material, aggregate, and rates for pre-treatment for
review by the Superintendent.
Final design rates or primer, binder, surface pretreatments, remedial works and aggregate may be
varied at any time prior to the application of the treatment where notification of any such adjustments are
provided to the Superintendent in writing.

(b) Surface Pre-treatment

Surface pre-treatments to correct variable surface texture shall be allowed for by the Contractor and
carried out as part of the works to meet the requirements of Surface Texture and Aggregate Retention
specified in Tables 408.152 and 408.153. Where the Superintendent has included a requirement for
pre-treatment in Table 408.191 this does not limit the Contractor’s responsibility for pre-treatments on all
jobs. The cost of surface pre-treatments shall be included in the lump sum works.
The acceptance criteria for Surface Texture and Aggregate Retention shall apply as specified in
Tables 408.152 and 408.153 unless these requirements are waived in Table 408.191.

(c) Geotextile Fabric Sprayed Seals

Geotextile fabric shall be fixed to the pavement surface free of wrinkles and/or folds. Transverse joins
shall be butt jointed.
Longitudinal joins shall be overlapped by approximately 150 mm and be located along lane lines. The
Contractor shall make an allowance for additional binder to be applied along the join so that both
geotextile layers are adequately saturated with bitumen. This allowance shall be included in the
Contractor’s seal design.
Bond coats shall be applied so that the effective width of the bond coat extends approximately 100 mm
beyond the width of the fabric being placed.

(d) Minimum Temperature

Unless otherwise approved by the Superintendent, the Contractor shall not apply any sprayed
bituminous treatments unless the air and pavement temperature are above those listed in
Table 408.131 and rising. The minimum temperature shall not apply for Strain Alleviating Membrane
Interlayer (SAMI) treatments which will not be trafficked, prior to the SAMI being overlaid.
In addition to Table 408.131 priming and initial sealing shall only be undertaken when the prevailing
weather conditions, when assessed in accordance with AAPA HSE Guide No.8 – Environmental
management when spraying bituminous materials, have a risk rating of ‘low’ or less and appropriate
work practices to minimise risks are in place.

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Table 408.131 Minimum Temperatures for Spraying Bituminous Materials

Minimum air
and pavement
Treatment Type
Temperature
(C)
Initial Treatments
Primes 10
Initial seals (single/single) 15
Initial seals (double/double) 10
Reseal Treatments
C170 and crumb rubber modified PMBs 15
Other PMBs 20
Geotextile Reinforced seals 20

(e) Aggregate Spreading

The Contractor shall include in their quality plan a method to measure and assess the aggregate spread
rates applied.

(f) Forward Aggregate Spreading

Not applicable

(g) Additional Payment for Forward Aggregate Spreading

Not applicable

(h) Rolling of Aggregate

Rolling of aggregate shall:
(i) be undertaken over the full width of the pavement being sealed including any untrafficked areas
(ii) be undertaken by static rubber tyred rollers or rubber coated steel drum rollers unless otherwise
specified or approved by the Superintendent.
Rolling of aggregate using rollers where the operator faces in the direction of travel of the roller at all
times is encouraged but not mandatory for sealing works delivered prior to 1 July 2030.
From 1 July 2030 the only rollers that shall be used for sealing works will, at all times, have the operator
facing in the direction of travel of the roller.
There shall be no additional payment for forward facing rollers prior to 1 July 2030.

(i) Sweeping of road surface prior to application of a seal treatment

All surfaces shall be inspected prior to the application of a sprayed seal treatment to ensure that a clean
surface is available for sealing works that is free from dirt, loose aggregate and other detritus.
HP For multiple application treatments, intermediate sprayed seal layers shall be thoroughly swept
to ensure that loose aggregate particles are removed prior to the application of the subsequent
sprayed seal layers. This includes areas where an overlap of aggregate has occurred during the
spreading operation.

408.14 REMOVAL OF LOOSE AGGREGATE

After the completion of a sprayed seal treatment, the Contractor shall remove and dispose of all loose
aggregate within the maximum time limits as specified in Table 408.141. This includes loose aggregate on
all trafficked areas, and areas where loose aggregate has been swept, or moved by traffic onto sealed
shoulders or non-trafficked areas, or into other areas such as concrete channels, traffic islands, medians,
open drains, drainage pits, footpaths, nature strips, or verges.

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Table 408.141 Maximum Time Limit for Removal of Loose Aggregate

Traffic Volume (AADT) * Maximum Time Limit
>5000 and all Freeways Within 8 hours of sealing
>2000 to 5000 Within 24 hours of sealing
>500 to 2000 Within 48 hours of sealing
<500 Within 5 days of sealing
* Annual Average Daily Traffic - refer to Table 408.191 for AADT for each Job Item

Until loose aggregate is removed from the sealed surface, traffic speed shall be controlled by signing and
installation of road works speed limits in accordance with Standard Specification Section 166.
Loose aggregate shall not be removed until the aggregate has properly bedded down into the binder by either
trafficking or rolling. Any damage to the sprayed seal resulting from removal of loose aggregate shall be
repaired by the Contractor.
Rotary brooms and/or suction sweepers are permitted to remove loose aggregate from the trafficked areas,
unless otherwise specified.
Loose aggregate may be temporarily stored at the stack sites nominated in Table 408.192.
For seals of nominal size 10 mm and over, including multiple application seals:
After the removal of loose aggregate and at any time during the Defects Liability Period, no more
than 40 loose stones in any square metre of pavement shall remain. This includes stones that
have originated from the area sealed under the Contract and which have accumulated on
adjacent sealed areas such as intersections, additional traffic lanes (in either direction), shoulders
and flanks.
On job items where 40 loose stones or more are measured, warning signs shall be erected within
eight hours, and the site shall be re-swept, or the loose stones removed within 48 hours of
measurement.
For seals of nominal size 7 mm and under:
After the removal of loose aggregate and at any time during the Defects Liability Period, no more
than 60 loose stones in any square metre of pavement shall remain. This includes stones that
have originated from the area sealed under the Contract and which have accumulated on
adjacent sealed areas such as intersections, additional traffic lanes (in either direction),
shoulders, and flanks.
On job items where 60 loose stones or more are measured, warning signs shall be erected within
eight hours, and the site shall be re-swept, or the loose stones removed within 48 hours of
measurement.

408.15 ACCEPTANCE OF WORK

(a) Rates of Application for Binder
The Contractor shall produce evidence to show that the actual rate of application for a Job Item, or
segments of a Job Item with different design rates of application, complies with the final submitted
design rates of application. Variation between the actual rates and the design rates will be assessed in
accordance with Table 408.151.
If a payment deduction or rectification is required in respect of unsatisfactory surface texture or
aggregate loss as specified in parts (b) and (c) of this clause, deductions under Table 408.151 will not
be applied.

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Table 408.151 Variation in Rates of Application of Bituminous Material

Variation from the Design Rates of
Assessment
Application for Bituminous Material (L/m²) *
< 0.1 L/m² below the design rate of application Accept
≥ 0.1 L/m² to 0.2 L/m² below the design rate of Deduct $0.75/m² for the affected area provided that
application minimum texture and aggregate retention
requirements are met
> 0.2 L/m² below the design rate of application Deduct $1.50/m² for the affected area provided that
minimum texture and aggregate retention
requirements are met
* The variation from the Design Rate of Application for SAM seals or SAMIs may be increased
by 0.05 L/m².
Acceptance or otherwise of the criteria specified in Table 408.151 shall not relieve the Contractor from
its obligations under the Contract.

(b) Surface Texture

Acceptance of work for surface texture and surface enrichment shall be based on visual assessment.
However, in marginal cases the Superintendent may request that nominated areas be tested in
accordance with VicRoads Test Method RC 317.01 and assessed in accordance with Table 408.152.
The test lot size shall not be less than 100 m of single traffic lane or more than 600 m of single traffic
lane. For any testing undertaken on areas other than within traffic lanes, the minimum lot size shall be
not less than 400 m² or more than 2500 m².

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Table 408.152 Surface Texture Requirements

SINGLE/SINGLE TREATMENTS

Mean Texture Depth (mm)

Treatment Action Required
Size 5 Size 7 Size 10 Size 14

Seals 1.0 to 1.6 1.3 to 1.8 1.5 to 2.5 2.0 to 4.0 Accept
(All Types) (1)
0.8 to 1.0 1.2 to 1.3 1.3 to 1.5 1.7 to 2.0 The Superintendent may require
or or or or rectification of the works or elect to
1.6 to 1.8 1.8 to 2.0 2.5 to 3.0 4.0 to 4.5 reduce payment for the lot by $1.00/m²

< 0.8 < 1.2 <1.3 < 1.7 Work to be rectified

or or or or
> 1.8 > 2.0 > 3.0 > 4.5

Initial Seals (2) N/A 1.0 to 2.0 1.2 to 3.0 N/A Accept

N/A < 1.0 < 1.2 N/A Work to be rectified

or or
> 2.0 > 3.0

Surface N/A 0.8 Accept

Enrichment (1)
N/A < 0.8 Work to be rectified

DOUBLE/DOUBLE TREATMENTS

Mean Texture Depth (mm)

Treatment Action Required
Size 10/5 Size 10/7 Size 14/5 Size 14/7 Size 20/7

Seals 1.3 to 2.1 1.3 to 2.2 1.3 to 2.4 1.3 to 2.4 1.4 to 2.5 Accept
(All Types) (1)
1.2 to 1.3 1.2 to 1.3 1.2 to 1.3 1.2 to 1.3 1.3 to 1.4 The Superintendent may require
or or or or or rectification of the works or elect to
2.0 to 2.3 2.1 to 2.4 2.4 to 2.7 2.4 to 2.7 2.5 to 2.8 reduce payment for the lot by
$1.00/m²

<1.1 <1.1 <1.2 <1.2 <1.3 Work to be rectified

or or or or or
>2.3 >2.4 >2.7 >2.7 >2.8

Initial Seals (2) 1.0 to 2.0 1.0 to 2.0 N/A N/A N/A Accept

< 1.0 < 1.0 N/A N/A N/A Work to be rectified

or or
> 2.0 > 2.0

Notes: (1) Surface texture measurements for sprayed seals and surface enrichment may be undertaken
at any time during the Defects Liability Period, but final acceptance of works is not affected
until the end of the Defects Liability Period.
(2) Surface texture measurements for initial seals shall be undertaken between 10 and 15 weeks
after placement. If tests are not undertaken in this period and later test results require the
works to be rectified, the later test results are to be used for acceptance of the works.

(c) Aggregate Retention

Acceptance of work for aggregate retention shall be based on visual assessment. However, in marginal
cases the Superintendent may request that nominated areas be tested in accordance with the VicRoads
Test Method RC 317.03 and assessed in accordance with Table 408.153. Depending on the measured
Degree of Aggregate Stripping, the Contractor shall take action as specified in Table 408.153. The test
lot size shall not be less than 100 m of single traffic lane or more than 600 m of single traffic lane. For
any testing undertaken on areas other than within traffic lanes, the minimum lot size shall be not less
than 400 m2 or more than 2500 m2.

Department of State Growth - December 2020

Section 408
 Department of State Growth

Table 408.153 Assessment of Aggregate Retention

Degree of Aggregate
Action Required
Stripping
0 to 2 Accept
3 to 5 Work to be re-tested within one month prior to the end of the Defects Liability
Period. If the Degree of Aggregate Stripping has increased since it was last
tested, the work shall be rectified before the end of the Defects Liability Period.
Greater than 5 Work shall be rectified within 5 days.
Note: Aggregate retention measurements may be undertaken at any time during the Defects Liability
Period, but final acceptance of works is not affected until the end of the Defects Liability Period.

(d) Visual Uniformity

The Contractor shall provide a surface with uniform colour and texture to provide a consistent
appearance for each job item. Any aggregate used for repairs and/or remedial works shall be supplied
from the same source.

408.16 MAINTENANCE OF SEALS

The Contractor shall be responsible for the monitoring and maintenance of seals from the time of application
until the end of the Defects Liability Period. Monitoring of seals shall include regular and timely inspection of
work, management of traffic and monitoring of any deterioration in the surface condition.
The Contractor shall carry out any work necessary to protect and maintain the seal or to effect repairs to any
seal failure. Such failures include but are not limited to emulsification, flushing, bleeding, fatty areas,
significant areas of bitumen on kerb and channel, excess bitumen without aggregate cover, aggregate
stripping, non-uniform aggregate spreading and streaking of binder but do not include pavement failures or
events beyond the reasonable control of the Contractor.
HP The Contractor shall advise the Superintendent in writing of the proposed treatment to affect the
above work before undertaking the work.
HP The Contractor shall obtain the agreement of the Superintendent of the proposed treatment before
undertaking the work.
The Contractor shall undertake the protection or repair work within 48 hours of notification by the
Superintendent. The Contractor shall be responsible for the installation and maintenance of appropriate
traffic management as approved by the Superintendent until the repairs are completed.
For urgent repairs, the Contractor shall take action to preserve the work and make the road safe within
48 hours of being notified or becoming aware of the defect.
Payment will be made for the cost of repairs undertaken by the Contractor and approved by the
Superintendent for damages that are the result of incidents outside the Contractor’s control, including but not
limited to, damage caused by others involving oil spills, accidents, vehicle fire or tearing due to heavy braking
and skidding.

408.17 RECORDS
The Contractor shall forward to the Superintendent a Job Completion Report (Sealing) using the proforma
included as Attachment A to this Section 408, or an equivalent proforma as approved by the Superintendent,
for each job item in Schedule 1. The completed form shall be submitted within seven days of completion of
sealing each job.
The Contractor shall ensure that where a representative of the Superintendent is on site during the works,
that officer validates the works as provided on the Job Completion Report (Sealing).
The Contractor shall carry out at least two inspections of each job during the Defects Liability Period and
provide a condition report to the Superintendent. The condition report shall detail the condition of the seal,
any defects and the proposed corrective action.

408.18 DEFECTS LIABILITY PERIOD

All defects shall be rectified six months prior to the conclusion of the Defects Liability Period, to an agreed
corrective action. This does not limit the Contractor’s responsibility to undertake protection or urgent repair
works under clause 408.16. The Defects Liability Period for repaired work shall recommence on the date of
repair in accordance with the provisions of the Contract.

Department of State Growth - December

© VicRoads May 2020
2019
Section 408
 Department of State Growth

***
408.19 SCHEDULE OF DETAILS
Table 408.191 Schedule of Details
TRIPS (1) Traffic Data Default
Treat- Single Min
Job Treat- Binder
Approx Approx Approx ment or Two Agg Agg 24 hr Rates of Pre-treat
Item Chainage Area ment 24 hr
Highway or Road Name Road No. Link / Cwy Length Width Descrip- Appli- Sizes Class % AADT/ Appli- Other Requirements
(refer km Type AADT Y/N?
Sch 1)
m m m2 (2)
tion cation mm (A, B EHV Lane cation
(3) (4) or C) (5)
(6) L/m2
## Note to author - The following items are examples only. Change text to suit your specification - DELETE THIS ROW BEFORE PRINTING:
1 Bass Highway A0249 Link 25 / Cwy A 7.00-8.00 1000 7.4 7400 FS C S 10 B 1400 15 700 1.3
2 Tasman Highway A0113 Link 07 / Cwy B 5.00-6.00 12000 15 see
under
2.1 PD2 (slow lane) 5.00-6.00 1000 3.7 3700 R GRS D 14/7 A 4500 2.4 Min. PSV of ##: is required for
aggregate
2.2 PD1 (fast lane) 5.00-6.00 1000 3.7 3700 R SAM S 14 A 1500 1.8 PMB Class ##: is required
2.3 Shoulders x 2 5.00-6.00 1000 2 x 2.4 4800 R SE S N/A B ≤50 0.8
3 Lyell Hwy A0197 Link 23 / Cwy A 2.00-3.00 1000 7.4 7400 R SAM S 14 B 1000 10 500 1.6

If any space is left blank it shall be read as “Not Applicable”.

Notes on Table 408.191
(1) DSG TRIPS References.
(2) Treatment Type - Prime Only (PO), Initial Seal (IS), Prime and Seal (P&S), Final Seal (FS), Reseal (R) Surface Enrichment (SE).
(3) Treatment Description - Conventional (C), Single/Single High Stress Seal (HSS1), Double/Double High Stress Seal (HSS2), Extreme Stress Seal (XSS), Strain Alleviating Membrane (SAM),
Strain Alleviating Membrane Interlayer (SAMI), Geotextile Reinforced Seal (GRS), Fibreglass Reinforced Seal (FRS).
(4) Single or Two Application - Single(S) or Double Application (D) of Binder and Aggregate.
(5) AADT is the Annual Average Daily (24 hr) Traffic and % EHV is the percentage of the AADT calculated from number of heavy vehicles and large heavy vehicles.
(6) AADT / lane is the Average Annual Daily (24 hr) Traffic for the traffic lane being considered. Where this is not given it shall be proportioned by the Contractor from the AADT figures.
(7) Typical ‘Other Requirements’ include: Specific PMB Class (Cl. 408.08 & Cl 408.10), Aggregate PSV >48 (Section 831), If plant precoated aggregate is specifically required (Cl. 408.11), Need
for gritting of trafficked areas for Prime Only treatments (PO), Notification to abutting landowners, Placement of variable message boards or other additional advisory signs, suction sweeper
required (Cl. 408.12), Specific programming requirements.
Department of State Growth – December 2020
Section 408
 Department of State Growth

Table 408.192 Stacksite Locations

Not applicable.

Contractor to identify and manage own Stacksite Locations.

Table deleted.

Department of State Growth – December 2020

Section 408
 Department of State Growth

ATTACHMENT A TO SECTION 408

JOB COMPLETION REPORT (SEALING) CONTRACT No. …..….…..
JOB SPECIFICS

Job No: Treatment:

Road Name: Seal Date:

Start Chainage: Stacksite Location:

End Chainage:

EXISTING CONDITIONS (circle or fill in)

Weather: Sunny Clear O’Cast Windy Showers Wet
Air Temp: Pavement Temp:
Pavement: Isolated stone loss stripping flushed wheel paths flushed patching cracking
Regulatory Speed Limit: 100 km 80 km 60 km 40 km < 40 km other
Aggregate Conditions: clean dry dusty dirty damp wet
Aggregate Pre-coat: pre-delivery onsite no pre-coat
NCR Required? Yes No Reasons: NCR No:

TRAFFIC CONTROL (circle or fill in)

Subcontractor Managing Traffic Control? Yes / No Subcontractor: Subcontractor Initials:
SIGNS
During Work Installed to WTM Code Yes / No Date / Time Installed: Speed Limit km/hr
Removed Yes / No Date / Time Removed: TMP No. Used
After Work Installed to WTM Code Yes / No Date / Time Installed: Speed Limit km/hr
Removed Yes / No Date / Time Removed: TMP No. Used
Traffic Delays Average Delay to Vehicles: minutes
Queues Average Queue Length: vehicles

SEALING WORKS
RUN NO. Pre-treatment / Run 1 Run 2 Run 3 Run 4 Run 5 Totals
Start Chainage
End Chainage
Lane Description
Air Temperature
Pavement Temperature
Length (m)
Width (m)
Area (m2)
Binder Type
Tank Dip Start (litres)
Tank Dip End (litres)
Quantity Sprayed (litres)
Actual Application Rate (L/m2) Average
Design Application Rate (L/m2) Average
Mix - Bitumen/Flux Oil/Cutter/Additive 100 / / / 100 / / / 100 / / / 100 / / / 100 / / /
AGGREGATE
Aggregate Size
Quantity (m3)
Average Least Dimension (ALD)
Aggregate Design Spread Rate (m2/m3) / ALD / ALD / ALD / ALD / ALD
Actual Design Spread Rate (m2/m3) / ALD / ALD / ALD / ALD / ALD
Rolling Time (hrs)
FORWARD AGGREGATE SPREADING PLANT
Proportion of forward aggregate spreading
use on run (e.g. 1/3, 4/5, All)
Existing RRPMs Removed Yes / No Date:
DELINEATION
TRRPMs Installed Yes / No Date: Spacings: m
Uncovered Yes / No Date:
Reinstatement Pavement Markings - 1st Coat Specified Date Due:
Actual Date Done:
Pavement Markings - 2nd Coat Specified Date Due:
Actual Date Done:
RRPMs Specified Date Due:
Actual Date Done:
Weather Delays to Linemarking: days

I, .............................................................................................................................. certify the above details as correct

(Contractor’s Representative, print name)

.............................................................................................................................. / /
(Contractor’s Representative, signed)

I, .............................................................................................................................. concur with the above

(Superintendent’s Representative, print name)

.............................................................................................................................. / /
(Superintendent’s Representative, signed)
Version 3 - May 2017