Crack Sealing and Joint Repair Systems · 2020-01-28 · is the sum of the length of loss of...

Crack Sealing and Joint Repair Systems

AM-PAV-06059

May 2019

TRANSPORT INFRASTRUCTURE IRELAND (TII) PUBLICATIONS

About TII

Transport Infrastructure Ireland (TII) is responsible for managing and improving the country’s national road and light rail networks.

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TII Publication Title Crack Sealing and Joint Repair Systems

TII Publication Number AM-PAV-06059

Activity Asset Management & Maintenance (AM)

Document Set Technical

Stream Pavement (PAV) Publication Date May 2019

Document Number

06059 Historical Reference

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Telephone: +353 1 646 3600

Email: [email protected]

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mailto:[email protected]

TRANSPORT INFRASTRUCTURE IRELAND (TII) PUBLICATIONS

Page i

TII Publications

Activity: Asset Management & Maintenance (AM)

Stream: Pavement (PAV)

TII Publication Title: Crack Sealing and Joint Repair Systems

TII Publication Number: AM-PAV-06059

Publication Date: May 2019

Set: Technical

Contents

1. Introduction ................................................................................................................. 1

2. Use of Crack Sealing and Joint Repair Systems ...................................................... 4

3. Approval of Crack Sealing and Joint Repair Systems ........................................... 11

4. Specifications and Notes for Guidance for Crack Sealing and Joint Repair Systems .............................................................................................................................. 20

5. References ................................................................................................................. 24

6. Annexes ..................................................................................................................... 26

TII Publications AM-PAV-06059 Crack Sealing and Joint Repair Systems May 2019

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Contents Table

1. Introduction ................................................................................................................. 1 1.1 General ............................................................................................................... 1

1.2 Terms, Definitions and Abbreviations ................................................................. 1

1.3 Roles and Responsibilities .................................................................................. 3

1.4 Implementation ................................................................................................... 3

2. Use of Crack Sealing and Joint Repair Systems ...................................................... 4 2.1 Description .......................................................................................................... 4

2.2 Applications ........................................................................................................ 5

2.3 Use Procedures .................................................................................................. 6

3. Approval of Crack Sealing and Joint Repair Systems ........................................... 11

3.1 General ............................................................................................................. 11

3.2 prTAIT Proposal................................................................................................ 13

3.3 Factory Production Control ............................................................................... 13

3.4 System Requirements ...................................................................................... 13

3.5 Installation Requirements Including Failure and Remediation Management .... 14

3.6 System Performance Requirements after Opening to Traffic ........................... 15

3.7 Failure and Remediation Management ............................................................. 17

3.8 PrTAIT Completion and Record of Performance .............................................. 17

3.9 Further Installation of Crack Sealing and Joint Repair Systems ....................... 19

4. Specifications and Notes for Guidance for Crack Sealing and Joint Repair Systems .............................................................................................................................. 20

4.1 General ............................................................................................................. 20

4.2 Works Proposal Requirements ......................................................................... 20

4.3 Systems Requirements ..................................................................................... 20

4.4 Installation Requirements ................................................................................. 21

4.5 Systems Performance Requirements before Opening to Traffic ....................... 22

4.6 Defect Period Requirements ............................................................................. 23

5. References ................................................................................................................. 24 5.1 TII Publications (Standards): ............................................................................ 24

5.2 TII Publications (Technical): ............................................................................. 24

5.3 Other documents .............................................................................................. 24

6. Annexes ..................................................................................................................... 26 6.1 Annex A – Factory Production Control (Normative) .......................................... 26

6.2 Annex B - Minimum Inspection/ Test Frequencies for FPC (Normative) ........... 30


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6.3 Annex C – Example of Qualitative Visual Assessment Report ......................... 35

6.4 Annex D – Substrate Preparation for Tests ...................................................... 36

6.5 Annex E – Test Methods .................................................................................. 38


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1. Introduction

1.1 General

This Interim Technical Advice (ITA) sets out:

i. requirements and guidance for the use of crack sealing and joint repair systems,

ii. requirements and guidance for the approval of crack sealing and joint repair systems, and

iii. Specification and Notes for Guidance for the use of crack sealing and joint repair systems on National Roads.

These systems are intended for use in the repair of cracks and existing joints on National Roads. In particular, this ITA is to be read by the Employer, Designer, the System Manufacturer and the Contractor.

This document shall be read in conjunction with all parts of TII Publications CC-SPW-00900 Specification for Road Works Series 900 Road Pavements Bituminous Materials and CC-GSW-00900 Notes for Guidance on the Specification for Road Works Series NG 900 Road Pavements Bituminous Bound Materials.

1.2 Terms, Definitions and Abbreviations

1.2.1 Terms and Definitions

This Subclause includes terms and definitions not included in CC-SPW-00900. For other terms and definitions refer to CC-SPW-00900.

Surface aggregate

Aggregate at the surface of the CS&JR system and expected to be in contact with vehicle tyres.

Crack sealing and joint repair systems

Proprietary systems for repairing non-structural cracks and existing construction joints in bituminous surfacings, with the exception of porous asphalt.

Defect

Where the product reaches a condition in which it is no longer carrying out its required function.

Defects Period

The period starting on Substantial Completion of the Works, continuing for the period stated in the Public Works Contract and within which the Contractor is liable to remedy defects.

Durability

Ability of a system to maintain its required performance, under the influence of foreseeable actions.

Loss of material

Loss of material from the repair area due to the action of traffic or environmental actions.


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Provisional Type Approval Installation Trial (prTAIT)

The prTAIT consists of a defined section of road where the crack sealing and joint repair system has been installed using Factory Production Control (FPC) and which has been subjected to in-service performance monitoring over a period of one year. The trial demonstrates that the characteristics of the crack sealing and joint repair system comply with the declared characteristics according to this ITA. During this period, detailed information is recorded to clearly identify the system, its performance and the intended uses.

prTAIT Family

Represents a declared sub-group of associated road parameters (traffic volume and transversal location of the repair on the carriageway) to classify systems by their intended uses.

Section

Length of carriageway between two chainages within which cracks or joints are being treated with a crack sealing and joint repair system.

Works Proposal

Works proposed to provide the performance requirements specified by the Designer including constituent materials, preparation, application details and testing requirements.

1.2.2 Abbreviations

For the purposes of this ITA, the following symbols and abbreviations apply:

Ai is the sum of the length of loss of material in the crack sealing and joint repair system section being considered, in linear metres (linear m).

Pi is the proportion of length of loss of material (Ai) in the crack sealing and joint repair system section being considered expressed as a percentage (%) of the length of the section (S).

S is the length of the section treated by the crack sealing and joint repair system for the prTAIT, in linear metres (linear m).

CS&JR system Crack Sealing and Joint Repair system.

COSHH is the law that requires Employers to control substances that are hazardous to health. This is the COntrol of Substances Hazardous to Health Regulations 2002.

REACH it is a European Union regulation concerning the Registration, Evaluation, Authorisation and restriction of CHemicals.

FPC Factory Production Control.

INAB Irish National Accreditation Board.

prTAIT Provisional Type Approval Installation Trial.


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1.3 Roles and Responsibilities

Contractor

Responsible for the approval and installation of the system. The Contractor shall be an approved installer by the System’s Manufacturer.

Designer

Responsible for selecting and specifying the appropriate type of system for the Works.

Employer or Employer’s Representative

As defined in the Public Works Contract.

Manufacturer

Entity manufacturing part or all of the product or system. Responsible for supporting the Contractor in the system’s approval process and responsible for appointing approved Contractors.

TII

Transport Infrastructure Ireland Pilot and Trial team is, in this ITA, the Authority approving and delivering crack sealing and joint repair systems certifications in accordance with Clause 3 of this ITA.

1.4 Implementation

This ITA shall be used forthwith on all projects on National Roads, except where the project has received, prior to publication of this Standard, the statutory approvals required to allow it to proceed.


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2. Use of Crack Sealing and Joint Repair Systems

2.1 Description

CS&JR systems shall be defined as proprietary systems for repairing non-structural cracks and existing construction joints in bituminous surfacings, with the exception of porous asphalt. This ITA does not cover the repair of cracked or jointed concrete pavement materials.

CS&JR systems shall be classified into three types, namely:

i. Type A – ‘Overband Systems’

These systems shall be capable of treating cracks and existing joints up to 5mm wide with no edge deterioration, with the installed overband width not exceeding 40mm.

Overband systems may also be used on hot/cold joints such as those in pavement patch repairs or trench reinstatements to prevent deterioration by water ingress. Overband systems shall in no situation be considered as a replacement option to the requirements of CC-SPW-00900 in terms of treatment of joints but rather as an addition.

These systems will not stop the propagation of cracks but can slow it down.

The use of some overband systems may be limited due to the substrate texture depth.

ii. Type B – ‘Fill and Overband Systems’

These systems shall be capable of treating cracks and existing joints up to 40mm wide. The system shall be installed by infilling the defective area and the application of an overband component, whose width shall not exceed 200mm.

For cracks and joints no wider than 20mm, the crack or joint may be routed to create a reservoir for the fill material to perform as intended. Additional benefits of routing the defective area are to remove deteriorated edges and stop or slow down the propagation of the crack.

iii. Type C – ‘Inlaid Systems’

These systems shall be capable of treating wide cracks greater than 40mm and existing joints or network of multiple cracks.

In the case of a network of multiple cracks repair, each crack shall not be wider than 40mm. Consideration should be given to the use of other repair options such as Permanent Repair Material Systems (PRMS) or inlay repairs depending on the extent of the defect.

The system shall be installed by routing or milling out the defective area to form a recess and infilling the recessed area.

The depth of routing or milling shall be sufficient to treat the crack or failing joint but shall not be deeper than the thickness of the surface course and binder course layers.

An overband system may be used in conjunction with the inlaid system along the edges.

These systems can stop or slow down the propagation of cracks.


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Figure 1 Crack Sealing and Joint Repair System types

CS&JR systems shall be composed of a mixture of materials that will form a resilient and adhesive compound capable of effectively sealing existing joints and cracks in bituminous surfacings, with the exception of porous asphalt.

The system shall protect against the infiltration of moisture and foreign material throughout repeated cycles of expansion and contraction with temperature changes. Finally, the system shall not deteriorate by loss of material, flow from the joint or be picked up by vehicle tyres at ambient temperatures.

2.2 Applications

CS&JR systems may be appropriate as remedial treatment for surface defects including surface cracks and existing joint surface failures and can contribute to the impermeability of the pavement surface.


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These systems are short to medium term alternatives to rectifying defects in aged pavements.

These systems should not be used as remedial treatment to structural cracks and structurally failing joints except if the identified failure represents an immediate hazard to the public. In this case, CS&JR systems may be used as a temporary solution until an appropriate permanent solution is implemented.

2.3 Use Procedures

2.3.1 Identification of Need and Design

Figure 2 describes the process to be followed to identify the need for use of a CS&JR system and the associated design.

The information that is required in the flowchart is the minimum that shall be included; other items may be included by the Employer depending on site-specific requirements. The information is normative, the layout is informative.


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Figure 2 Identification of need and design


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2.3.1.1 Identification of Need

As soon as a surface crack or failing surface joint has been identified, the Employer’s Representative shall perform a detailed visual inspection. The aim is to collect as much information about the defective area as possible. The information to be recorded includes but is not limited to:

i. Identify the nature and probable cause of the crack or joint failure (surface only or structural failure)

ii. Dimensions and condition of each crack or failing joint (length, width, depth, edge condition)

iii. Location of each crack or failing joint (chainage and transversal location relative to wheel track zone)

iv. Presence of other pavement surface defects in the area

v. Criticality of the defects (consider all users)

vi. Geometry of the road in the defective area (e.g. junction, bend, breaking area)

vii. Nature and condition of the drainage in the area

viii. Photos

The detailed visual inspection may be completed by a desktop assessment of the defective area by consulting records from previous repairs, inspections, surveys or claims.

2.3.1.2 Design

If the crack or failing joint is representing an immediate hazard a CS&JR system may be used as a temporary solution until a more permanent one has been identified.

In addition to the information collected during the detailed visual inspection and potentially during a desktop assessment, the Designer shall also consider the following two elements:

i. Traffic loadings

ii. Presence of surface or sub-surface elements within the defective area (e.g. road markings and studs, counting loops)

The Designer shall take into consideration all the elements mentioned in Subclauses 2.3.1.1 and this Subclause to identify the most cost-effective repair solution. Repair solutions range from doing nothing to fully reconstructing the pavement structure as per AM-PAV-06050.

If the use of a CS&JR system is found to be the most cost-effective repair solution, the Designer shall select which CS&JR system type (A, B or C as per 2.1) is most appropriate and which prTAIT family it shall satisfy (as per Table 1).

2.3.2 Procurement, Installation and Monitoring

Figure 3 describes the process to be followed to procure install and monitor CS&JR system works.

The information that is required in the flowchart is the minimum that shall be included; other items may be included by the Employer depending on site-specific requirements. The information is normative, the layout is informative.


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Figure 3 Procurement and Installation


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2.3.2.1 Procurement

The Designer shall specify the type of CS&JR system (as per Subclause 2.1) and associated prTAIT family (as per Table 1) to be used by the Contractor to repair the defective area. The Designer shall also specify the expected durability of the CS&JR system (e.g. 3, 5 or 8 years).

The Designer may share all relevant information collected during the identification of need and the design phases with the Contractor. This will allow the Contractor to select the most appropriate proprietary CS&JR system.

The Contractor shall select a proprietary CS&JR system in accordance with the Specification.

If the selected CS&JR system has never been certified under the prTAIT process described in Clause 3 or if the CS&JR system has been certified, but for a lower prTAIT family than the one specified by the Designer, then the Contractor shall seek certification through the process described in Clause 3.

If the selected CS&JR system has been certified for a similar or higher prTAIT family than the one specified by the Designer, then the Contractor shall submit a Works Proposal to the Employer as per Subclause 4.2.

2.3.2.2 Installation

Once the Works Proposal has been approved by the Employer, the Contractor may install the CS&JR system as per Subclause 4.4.

After the CS&JR system has been installed and prior to opening to traffic, the Contractor shall validate the performances of the CS&JR system as per Subclause 4.5.

The CS&JR system shall not fail on any of the requirements stated in Table 4 during the Defect Period.


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3. Approval of Crack Sealing and Joint Repair Systems

3.1 General

CS&JR systems are currently not covered by a Harmonised European Standard. Unless the system has been CE marked through the European Technical Assessment (ETA) process, the requirements of this Clause shall apply.

The different types of CS&JR systems are as described in Subclause 2.1.

The Contractor shall carry out one provisional Type Approval Installation Trial (prTAIT) to cover each CS&JR system, and associated prTAIT family, to be placed on the market.

The prTAIT shall be carried out for each family defined in Table 1. A prTAIT demonstrates that the characteristics of the CS&JR system comply with the declared characteristics. The prTAIT shall consist of:

i. Demonstration of Factory Production Control (FPC) covering the lifecycle of the CS&JR system from manufacture to maintenance after installation as per Subclause 3.3,

ii. Laboratory performance tests as per Subclause 3.4,

iii. A defined section of road where a CS&JR system has been installed and tested as per Subclause 3.5,

iv. A one-year period starting from the installation date during which the CS&JR system is being monitored as per Subclause 3.6

The prTAIT process shall be repeated if:

i. The constituents of the proposed system change;

ii. An installation is proposed on a higher traffic category to that already installed; or

iii. There is a change to the documented FPC system.

Table 1 PrTAIT families for crack sealing and joint repair systems

Parameters that limit the application of a prTAIT

System Type1

Overband Fill and Overband Inlaid

Traffic Category

(cv/lane/day) ≤ 250 > 250 ≤ 250 > 250 ≤ 250 > 250

Transversal location relative to wheel-track zone2

out in out in out in out in out in out in

prTAIT family 1 2 3 4 5 6 7 8 9 10 11 12

Notes:

1 System type as defined in 2.1.

2 The wheel track zone shall be taken to be between 0.4m and 1.0m, and between 2.45m and 3.05m from the centre of the nearside lane markings for each traffic lane (or in the absence of lane markings, lane edges)


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Figure 4 PrTAIT Approval process


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3.2 prTAIT Proposal

Before works commence, the Contractor shall submit a prTAIT Proposal to the Employer and TII detailing the proposed method of executing the prTAIT Works. The prTAIT Proposal shall include:

i. All the items listed in Subclause 4.2; and

ii. A performance testing plan complying with Subclause 3.4 to be performed before installation;

iii. A performance testing plan complying with Subclause 3.5.3 to be performed after installation but prior to opening to traffic;

iv. A performance testing plan and programme complying with Subclause 3.6 to monitor the performance of the system under traffic and environmental constraints.

3.3 Factory Production Control

Factory Production Control (FPC) should be in accordance with Annex A – Factory Production Control (Normative) and Annex B - Minimum Inspection/ Test Frequencies for FPC (Normative).

3.4 System Requirements

3.4.1 Requirements on Surface Aggregate

Laboratory testing of the aggregate used in the surface component of the CS&JR system shall comply with the requirements of Table 2.

Table 2 Crack Sealing and Joint Repair Systems – Requirements for Constituent Materials

Test CS&JR systems Test

Method

Aggregate

Resistance to Fragmentation – Los Angeles LA30 IS EN 1097-2

Resistance to Polishing – Minimum PSV PSV60 IS EN 1097-8

Resistance to Surface Abrasion – Maximum AAV

AAV10 IS EN 1097-8

3.4.2 Requirements on Crack Sealing and Joint Repair Systems

Laboratory testing of the CS&JR system shall comply with the requirements of Table 3.


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Table 3 Crack Sealing and Joint Repair Systems – Requirements of the System

Reference Overband Fill and

Overband Inlaid Requirement Test Method

Skid Resistance Value

• Initial (iSRV)

• Retention after wheel tracking (rSRV)1

✓

✓

✓

✓

✓

✓

≥ 60

≥ 50 Annex E – Test Methods2

Tensile bond to asphalt (N.mm-2)

• Initial

Test at -10 ±2ºC

Test at +20 ±2ºC

✓

✓

✓

✓

✓

✓

To be recorded

≥ 0,5

Test Method 4: Tensile Bond to Asphalt

(sample preparation as per Preparation Method 3: Tensile Bond to Asphalt)

• After heat ageing3

Test at -10 ±2ºC

Test at +20 ±2ºC

✓

✓

✓

✓

✓

✓

To be recorded

≥ 60% of initial value

Wheel tracking / Resistance to permanent deformation

Using EN method

• - WTSAir (µm/cycle)

• - RD (mm)

N/A

N/A

✓

✓

✓

✓

5

10

IS EN 12697-22 (procedure A 50°C small device)

(sample preparation as per Preparation Method 1: Retention of Skid Resistance Value for Overband Systems and Inlaid Systems)

Notes

1 Wheel tracking test to be in accordance with IS EN 12697-22 (procedure A 50°C small device). Procedure to determine retention to be in accordance with Test Method 3: Resistance to Permanent Deformation and Retention of Skid Resistance Value for Inlaid Sealing SystemsError! Reference source not found..

2 For all systems a SRV correlation between the wide slider and the narrow slider will need to be developed as the wheel tracking width is 50mm (see Annex E – Test Methods).

3 Heat ageing at 70 ±2ºC for 28 days.

3.5 Installation Requirements Including Failure and Remediation Management

3.5.1 Pre-Installation Inspection

Prior to installation of the CS&JR system, all pavement surface defects present in the treatment area shall be recorded and evidenced (e.g. high-quality photographs or videos).

The surface water run-off shall be assessed and recorded (e.g. high-quality photographs or videos) prior to any works.


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Any variations from the approved prTAIT Proposal shall be recorded and justified before being shared with the Employer and TII.

3.5.2 Installation

The system shall only be installed by a contractor who shall be an approved installer by the System’s Manufacturer.

The installation of the system shall follow the prTAIT Proposal. If changes to the approved prTAIT Proposal are necessary for a successful installation (i.e. in accordance with the Specification), these shall be recorded and justified before being shared with the Employer and TII.

3.5.3 System Performance Requirements before Opening to Traffic

The Contractor shall inspect and test the installed system in accordance with Subclause 4.5. All inspections and tests shall be recorded and evidenced before being shared with the Employer and TII.

3.5.4 Installation Records

Any changes from the original prTAIT Proposal and any other information considered relevant to the overall performance of the system shall be recorded and shared with the Employer and TII.

3.6 System Performance Requirements after Opening to Traffic

3.6.1 General

After installation, the CS&JR system shall be monitored for a period of one year for the purpose of the prTAIT. The Contractor shall however continue to monitor the prTAIT site past the one-year period and declare the period for which the performance characteristics have been retained. This will aid the Employer in satisfying themselves that there is minimum risk of failure during the declared period with no defect, which can be much longer than the performance term of one year.

3.6.2 Performance Requirements

To successfully pass the trial, the installed CS&JR system shall satisfy the system performance requirements after opening to traffic described in Table 4.

All tests have to be recorded and evidenced before being reported to both the Employer and TII.

The one-year monitoring period should follow the performance and testing plan and programme approved in the prTAIT Proposal and any changes shall be reported and justified to both the Employer and TII.


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Table 4 System performance requirements after opening to traffic

3.6.3 Testing Methodologies

3.6.3.1 Methodology for Visual Assessment

Defects emanating from the substrate (existing pavement) must not be taken into consideration for the calculation of “Pi – Loss of material”. These defects should however be recorded for future reference. Furthermore, defects noted during monitoring of the CS&JR system arising from obvious oil spill, fire or vehicle collisions shall not be deemed as a defect which the System Manufacturer/Contractor has responsibility for rectifying.

Monitored pavement sections may be located anywhere within the section of treated carriageway but the monitored sections shall not overlap. The remainder of the section of treated carriageway that is not chosen for monitoring is deemed to be without defects at the time the monitoring is carried out.

Testing records and report shall, as a minimum, include the information required in Annex C – Example of Qualitative Visual Assessment Report and photographic evidence.

Loss of material – Pi is calculated as per the equation below:

𝑷𝒊 = 𝟏𝟎𝟎 × (𝑨𝒊

𝑺𝒊⁄ ),

where Pi is the loss of material in percentage (%),

Ai is the length of defects in treated section in linear meters (linear m),

Si is the length of treated section in linear meters (linear m).

Technical Performance

Testing Method

Unit Requirement Frequency of

Testing

Visual Assessment of Defects Percentage of defects in the

system

Pi – Loss of material

3.6.3.1 and Annex C – Example of Qualitative

Visual Assessment

Report

% 0 1, 6 and 12

months after installation

Surface Characteristics

Skid Resistance Value

IS EN 13036-4

SRV ≥ 50 for each individual

measurement 1 12 months after

installation

Surface Water Run-off Is standing water present as a result of the

installation of the system?

Visual performance of the surface water

run-off 3.6.3.3 - “Yes (Fail)” or “No (Pass)”

1; 6 and 12 months after installation

1 Skid Resistance Value (SRV) testing shall consist of four tests per kilometre of system installed with a minimum of three tests for any installation.


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3.6.3.2 Methodology for Surface Characteristics

Skid Resistance Value (SRV) testing shall consist of four tests per kilometre of system installed with a minimum of three tests for any installation.

3.6.3.3 Methodology for Surface Water Run-Off Assessment

The installation of the CS&JR system shall not hinder the flow of water across the carriageway.

Large amount of water, proportionate to the size of the repaired crack or joint, shall be poured around the treated section. Once the water has naturally drained away from the treated area, the presence or absence of standing or ponding water shall be recorded and evidenced using high quality photos as a minimum.

If standing or ponding water is present, the test is deemed failed.

3.7 Failure and Remediation Management

Defects may be repaired at any time during and after the installation of the CS&JR system to maintain performance; however, any area repaired after installation and during the one-year monitoring period shall lose their prTAIT status and monitoring shall be stopped. A prTAIT shall not include within its length any sections of repaired material.

Should the performance of the CS&JR system not be deemed suitable in accordance with Subclauses 3.5.3 and 3.6, this shall be deemed as a CS&JR system failure.

In the event of the system failing, the Contractor shall notify both the Employer and TII immediately of the failure.

Upon identification of the failure, the System Manufacturer and/or Contractor shall be obliged to examine the root cause of the system failure and propose an appropriate rectification solution to the Employer in line with the emergency repair plan detailed in the prTAIT Proposal and CC-SPW-00700.

Should the performance of the CS&JR system be deemed unsuitable in accordance with Subclauses 3.5.3 and 3.6, the CS&JR system shall not be permitted for further use within the relevant prTAIT family (and any higher prTAIT family) where the failure occurred. If subsequently proposed for use on a prTAIT family which is lower than where the previous failure occurred, the CS&JR system will be required to fully comply with the procedures in Clause 3.

3.8 PrTAIT Completion and Record of Performance

3.8.1 prTAIT Completion

Providing previous inspections have confirmed suitability of the CS&JR system, testing and a final visual assessment shall be carried out one year after opening to traffic. Where compliance with the requirements of Subclauses 3.5.3 and 3.6 are fulfilled, the CS&JR system shall be deemed suitable for further use within the same prTAIT family upon which the assessed repair was installed. If the CS&JR system is deemed to be suitable, it will also be deemed suitable for use on lower prTAIT families in accordance with Table 1.

Should the CS&JR system be deemed suitable 12 months after opening to traffic, any further repairs to the system shall not be required to undergo the requirements of Subclause 3.7. Details of the repairs shall be recorded for the purpose of Subclause 3.6.1.

Once testing has been completed the Contractor shall confirm in writing to TII that the Works have been installed as per the System Manufacturer’s and/or Contractor’s requirements and the testing


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conducted complies with the requirements of this prTAIT approval process. The CS&JR system is therefore approved for the considered prTAIT family.

3.8.2 Records of Performance

The data recorded for a prTAIT and submitted to TII at the end of the trial shall include the following information:

i. Company details (name, address, phone number etc.);

ii. prTAIT reference number provided by TII;

iii. prTAIT Proposal including any changes made to the original version and the prTAIT family;

iv. CS&JR system proprietary name (if applicable);

v. Description of type of system (refer to Subclause 2.1);

vi. Production office (name, address, phone number etc. (where different from the ‘Contractor’);

vii. Storage, handling and transport procedures and requirements;

viii. Colour retention (if applicable);

ix. Relevant test certificates of constituents and system used (including the data specified in Subclauses 3.4, 3.5 and 3.6);

Laboratory tests include:

i. Los Angeles.

ii. Polished Stone Value.

iii. Aggregate Abrasion Value.

iv. Skid Resistance Value – initial and retention after wheel tracking.

v. Tensile bond to asphalt – initial and after wheel tracking.

vi. Wheel tracking – wheel tracking rate, proportional rut depth, rut rate and rut depth.

Site tests include;

i. Skid Resistance Value before opening to traffic and 12 months later;

ii. FPC documentation for the section used for the prTAIT;

iii. Time of year, temperature and weather conditions during installation;

iv. The time duration between completion of installation and opening to restricted and unrestricted traffic noting any restrictions;

v. Results of visual assessment, as described in Table 4 at one, six and 12 months from the date of opening to traffic;

vi. Records of the prTAIT inspection by means of photographic evidence;

vii. Results of visual check on the performance of the surface run-off, as described in Table 4 at one, six and 12 months from the date of opening to traffic;

viii. Period for which the performance characteristics have been retained;

ix. Name of Contractor’s representative responsible for prTAIT.


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Communication of Performance

The Contractor shall continue to monitor the prTAIT site and declare the period for which the performance characteristics have been retained. This will aid the Employer in satisfying themselves that there is minimum risk of failure during the declared period, which can be much longer than the performance term.

Copies of all documentation relating to the system shall be supplied to TII by the Contractor at the following work stages:

i. Submission of the prTAIT Proposal;

ii. Opening of treatment area to traffic;

iii. Each inspection during the prTAIT process;

iv. Completion of remedial works (if required).

Upon completion of each stage, records shall be submitted to TII within 7 days.

The information from a prTAIT shall be kept and stored securely. If the data is lost, the prTAIT shall no longer be valid.

3.9 Further Installation of Crack Sealing and Joint Repair Systems

Subject to the approval of the Employer and TII, further use of a CS&JR system that is undergoing monitoring in accordance with this prTAIT approval process may be permitted in other locations. These locations shall be in a prTAIT family, as defined in Table 1, which have the same or lower prTAIT family characteristics as the initial repair.

Use of CS&JR system under such conditions shall only be permitted after the initial repair works have been carried out in accordance with the requirements of this prTAIT approval process and monitored successfully for a one-month period with the repair deemed suitable in compliance with the requirements of the prTAIT.

Until such time as the full requirements of the prTAIT are met, these further installations shall be undertaken at the risk of the Contractor.


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4. Specifications and Notes for Guidance for Crack Sealing and Joint Repair Systems

4.1 General

Clause 4 is not intended to be an exhaustive specification for the use of CS&JR system, but rather to form a set of minimum performance related requirements for Designers to specify and System Manufacturers and/or Contractors to comply with.

4.2 Works Proposal Requirements

Before works commence, the Contractor shall submit a works proposal to the Employer detailing the proposed method of executing the Works. The works proposal shall include:

i. Specification for Works from the Designer and planned installation date or period;

ii. Details of the FPC provided as per Subclause 3.3;

iii. All the safety and environmental data required to comply with COSHH and REACH regulations provided by the System’s Manufacturer and made specific by the Contractor;

iv. Confirmation of the System Manufacturer’s approval that the Contractor is authorised and competent to install the system;

v. Evidence of prTAIT approval and associated records of performance for the relevant prTAIT family (for previously approved CS&JR system only);

vi. Installation procedures – including substrate preparation, installation details, application rates, curing period, repairs, on-site storage and handling of materials, plant used, level of installed system compared to existing road level, cleaning. The installation procedures shall include specific method statements and risk assessments inclusive of specific COSHH and REACH requirements;

vii. Weather parameters and measures to address working in different climatic conditions (may be part of the Installation Procedures above);

viii. Existing surface parameter and limitations in respect of existing substrate conditions (may be part of the Installation Procedures above);

ix. A performance testing plan complying with Subclause 4.5 to be performed prior to opening to traffic;

x. An emergency repair plan to cover any non-compliance with the performance requirements stated in Subclauses 3.5.3 and 3.6 in line with CC-SPW-00700.

4.3 Systems Requirements

4.3.1 General Requirements

As CS&JR systems are currently not covered by a Harmonised European Standard, unless such a system has been CE marked through the European Technical Assessment (ETA) process, the requirements of this Clause shall apply.

CS&JR systems shall be produced in plants that are independently accredited to IS EN ISO 9001 or an equivalent quality management system.


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The proposed CS&JR system shall be subject to a provisional Type Approval Installation Trial (prTAIT) in accordance with CC-SPW-00900 and the requirements stated in Clause 3. The CS&JR system shall be deemed suitable after the performance requirements of that same Clause 3 are fulfilled.

It is the responsibility of the System Manufacturer to meet the testing requirements of Subclause 3.4 by having the required tests carried out by an INAB, or equivalent, accredited laboratory. Results of such testing shall be forwarded to the Employer prior to installation of the CS&JR system on site.

The System Manufacturer shall develop and maintain a list of Contractors who shall be approved by the System Manufacturer to install the system.

4.3.2 System Types

The Designer shall specify the appropriate type of CS&JR system and associated prTAIT family to be used by the Contractor as detailed in Subclause 2.3.2.1.

i. Type A – ‘Overband Systems’

ii. Type B – ‘Fill and Overband Systems’ (with or without a reservoir)

iii. Type C – ‘Inlaid Systems’ (for single or multiple cracks)

The use of each type of CS&JR system is detailed in Clause 2.

The associated prTAIT families are detailed in Table 1.

4.3.3 Performance Requirements

The Contractor shall demonstrate that the CS&JR system to be installed has previously been approved as per Clause 3 requirements for the relevant prTAIT family.

4.4 Installation Requirements


The Contractor delivering the Works shall be approved by the System Manufacturer to install the CS&JR system.

The Contractor shall install the CS&JR system in accordance with the System Manufacturer’s requirements and the Works Proposal.

All pieces of plant shall be maintained in accordance with the System Manufacturer’s requirements and be suitable for the system being installed.

4.4.2 Pavement Condition Requirements

The existing pavement condition shall be suitable for treatment in accordance with the detailed visual inspection and suitability requirements detailed in Clause 2.

Before application is commenced the area to be treated shall be free of all loose material. The area as a whole shall be dry, and any damp areas shall be completely free of standing water. The method of installation shall be such that the finished surface is free from loss of material.

4.4.3 Weather Conditions

CS&JR systems shall be installed within any parameter guidelines outlined by the System Manufacturer and shall comply with the requirements of the prTAIT in accordance with Clause 3.


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With regard to the level of relative humidity and temperature, the Contractor should seek the System Manufacturer's recommendations for the particular system proposed for use.

The Contractor shall take account of the weather conditions when planning their working methods.

4.5 Systems Performance Requirements before Opening to Traffic

4.5.1 Site Testing at Installation

Site testing of the CS&JR system after completion of installation shall comply with the requirements of Table 5.

The skid resistance of the system installed shall be tested in accordance with IS EN 13036-4 and the requirements of Table 5. Skid Resistance Value (SRV) testing shall consist of four tests per kilometre of system installed with a minimum of three tests for any installation.

A visual inspection shall be undertaken to ensure performance of the water surface run-off is not compromised by the installed system. Standing water shall not be present as a result of the installation.

As part of allowing surface water to cross the system and ensuring performance of the surface run-off, the creation of gaps in parts of the system that protrude above the finished road level may be required. This may include creating gaps in the second part of two-part component systems. Such measures may be required at sag and rollover locations.

The finished surface shall be planar with the adjoining surface and be in accordance with the requirements of Table 5. The Contractor shall take account of the existing surface water run-off when installing the system to ensure performance of the surface run-off is not compromised.

Table 5 Crack Sealing and Joint Repair Systems – Requirements of the Works at Installation

Reference Requirement (All

systems) Test Method

Surface texture

Skid Resistance Value (iSRV)1 ≥ 60 IS EN 13036-4

Alignment, levels, tolerances & regularity (mm)

Levels Match existing pavement -

Tolerances 0/+3 mm -

Adjacent to surface water or linear drainage channel

+10 – 0 mm -

Performance of the surface run-off No standing water shall be present as a result of system installation.

Visual inspection after spilling water around the treated area. (as per Subclause 3.6.3.3)

Note

1 Where SRV testing is undertaken to confirm compliance, it shall consist of four tests per kilometre of system installed with a minimum of three tests for any installation


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4.5.2 Opening to Traffic

The time period between completion of works and opening to live traffic shall be in accordance with the System Manufacturer’s requirements and the Contractor’s installation method statement. All excess material and debris shall be cleared from the carriageway.

4.6 Defect Period Requirements

The Defect Period shall be as defined in the Conditions of the Contract.

CS&JR systems are considered defective or failing if they no longer satisfy the requirements of Table 4.

As CS&JR system defects are usually obvious, it is anticipated that the need for a full assessment procedure will be rare.

Identification and rectification of defects within the Defects Period shall be treated in accordance with the Conditions of Contract.


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5. References

5.1 TII Publications (Standards):

PE-SMG-02002, Traffic Assessment.

AM-PAV-06049, Pavement Asset Repair and Renewal – Scheme Approval.

AM-PAV-06050, Pavement Assessment, Repair and Renewal Principles.

CC-SPW-00900, Specification for Road Works Series 900 – Road Pavements – Bituminous Materials.

CC-GSW-00900, Notes for Guidance on the Specification for Road Works Series NG 900 – Road Pavements – Bituminous Bound Materials.

CC-SPW-00700, Specification for Road Works Series 700 – Road Pavements – General

DN-PAV-03075, Approval of Specific Products

5.2 TII Publications (Technical):

RE-PTP-07003, Pilot and Trial Project Management Guidelines.

5.3 Other documents

National Standards Authority of Ireland Publications:

IS EN 1097-5, Tests for Mechanical and Physical Properties of Aggregates – Part 5: Determination of the Water Content by Drying in a Ventilated Oven

IS EN 1097-8, Determination of the PSV and AAV

IS EN ISO 9001, Quality Management Systems – Requirements

IS EN 12591, Bitumen and Bituminous Binders – Specifications for Paving Grade Bitumens

IS EN 12697-22, Bituminous mixtures — Test methods for hot mix asphalt — Part 22: Wheel tracking.

IS EN 12697-33, Bituminous mixtures — Test methods for hot mix asphalt — Part 33: Specimen prepared by roller compactor

IS EN 13036-1, Road and airfield surface characteristics — Test methods — Part 1: Measurement of pavement surface macrotexture depth using a volumetric patch technique

IS EN 13036-4, Road and airfield surface characteristics — Test methods — Part 4: Method for measurement of slip/skid resistance of a surface: The pendulum test

IS EN 13043, Aggregates for Bituminous Mixtures and Surface Treatments for Roads, Airfields and Other Trafficked Areas

IS EN 13108-4, Bituminous mixtures – Part 4: Hot Rolled Asphalt


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TRL (Transport Research Laboratory) Reports:

TRL. 1 January 1997. TRL176 – Laboratory tests on high friction surfaces for highways. J. C. Nicholls


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6. Annexes

6.1 Annex A – Factory Production Control (Normative)

6.1.1 General

The System Manufacturer and the Contractor shall establish, document and maintain a Factory Production Control (FPC) system to ensure that the CS&JR system placed on the market conforms to the stated performance characteristics. The FPC system shall consist of procedures, regular inspections and tests and/or assessments and the use of the results to control incoming materials, equipment, the production process and the system. Alternative tests to those referred to in this ITA may be used for FPC, provided they have been shown to correlate.

Where the System Manufacturer/Contractor purchases constituent materials or has the CS&JR system designed, or parts of the production or testing carried out by subcontracting, the FPC of the supplier or subcontractor may be taken into account. However, where this occurs, the System’s Manufacturer/Contractor shall retain the overall control of the CS&JR system and ensure that he receives all the information that is necessary to fulfil his responsibilities according to this ITA. The Contractor who sub-contracts all of his activities shall in no circumstances discharge his responsibilities to a sub-contractor.

All the elements, requirements and provisions adopted by the System’s Manufacturer/Contractor shall be documented in a systematic manner in the form of written policies and procedures. This production control system documentation shall ensure a common understanding of conformity evaluation and enable the achievement of the required component characteristics and the effective operation of the production control system to be checked.

FPC brings together operational techniques and all measures allowing maintenance and control of the conformity and performance of the CS&JR system with its technical requirements. Its implementation may be achieved by controls and tests on measuring equipment, constituents, processes, machines and manufacturing equipment and finished components, including material properties of components, and by making use of the results thus obtained.

A System Manufacturer/Contractor who has a FPC which complies with IS EN ISO 9001 and made specific to this ITA shall be deemed to satisfy the requirements of this Subclause.

The Employer and TII may wish to inspect all or any of the documentation forming part of the System Manufacturer’s/Contractor’s FPC assessment system to be satisfied on the nature of the systems in place at the constituent suppliers.


The FPC system shall at least fulfil the requirements as described in the Clauses of IS EN ISO 9001 specified in Table 6, where applicable:

Table 6 Clauses of IS EN ISO 9001 to be addressed in the FPC

Column 1 2 3

Line Sub-clauses of IS EN ISO 9001:2015

Subject Sub-clause in this ITA for additional requirements or information

1 7.5 Documented information 6.1.3.2

2 5.1.1 e) Leadership and commitment – general

6.1.3.3


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Column 1 2 3

3 5.3 Organisational roles, responsibilities and authorities

6.1.3.4

4 7 Support for FPC system including resources, competence, awareness and communication

5 8.1 except 8.1a) Operational planning and control

6 8.2.1 c) Purchaser feedback

7 8.3 Design and development of products and services

6.1.3.5

8 8.4 Control of externally provided processes, products and services

9 8.5 Production and service provision 6.1.3.6

10 7.1.5 Monitoring and measuring resources 6.1.3.7

11 8.6 Release of products and services 6.1.3.8

12 8.7

10.2

Control of nonconforming outputs

Non-conformity and corrective action 6.1.3.9

13 10.2 Non-conformity and corrective action 6.1.3.10

The FPC system may be part of a Quality Management system, e.g. in accordance with IS EN ISO 9001.

6.1.3 Product Specific Requirements

6.1.3.1 General

The requirements set out in this Subclause provide product specific details.

6.1.3.2 Documented Information

Records shall be stored in such a way that they are identifiable, retrievable, available and maintained for a minimum period of five years from the date of production.

6.1.3.3 Leadership and Commitment

The FPC system shall:

i. Ensure consistency with the requirements of this ITA;

ii. Ensure that the CS&JR system placed on the market conforms with the stated performance characteristics;

iii. Comply with the Clauses of IS EN ISO 9001 listed in Table 6;

iv. Document and demonstrate the testing frequencies regime (see 6.2– Annex B).


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6.1.3.4 Organisational Roles, Responsibilities and Authorities

The responsibility and authority of personnel shall be defined for personnel who have authority to determine that the CS&JR system complies with the requirements of this ITA.

NOTE: An individual may exercise such supervision over a number of sites.

6.1.3.5 Design and Development of Products

The design procedure, including process stages, shall be documented.

Reference to a recognised standard procedure, if used, shall be sufficient.

Information on the traffic category and properties of the existing road can be supplied by the Employer.

6.1.3.6 Production and Service Provision

The Contractor shall produce a works proposal for each site or group of sites for the production and installation of the CS&JR system. The Contractor’s management shall have a working knowledge of, and access to, all relevant documentation including the Contract and relevant TII Standards.

Before site works commence the Contractor shall ensure that the following are documented and issued to the appropriate production personnel:

i. Any special instructions to the site staff relating to the programme of work;

ii. The equipment required for the work and the method of working to meet the requirements of the contract;

iii. Any additional instructions including application requirements.

Actions to be controlled:

i. Cleanliness of substrate;

ii. Preparatory work based on weather conditions;

iii. Conformity of materials purchased to Specification requirements;

iv. Materials identification and traceability;

v. Operation and maintenance of application equipment within documented tolerances;

vi. The use of competent personnel during the application of the CS&JR system;

vii. A system for handling and taking account of any changes made;

viii. Record of the road surface condition prior to installation of the CS&JR system and any local variations to the works proposal;

ix. Procedure and time scale for notifying the Employer of any problems which can affect the work (issues which can require deviation from the original Specifications);

x. Activities to maintain the system until the works are handed to the Employer.

NOTE: Records should be kept of the operation on site that could affect the performance of the CS&JR system, covering the period shortly before operations commence until the opening of the site to unrestricted normal traffic. These records should contain the following:

i. Variations from the original works proposal including those necessitated by site conditions;

ii. Unforeseen problems (weather conditions, emergency vehicle damage, etc.);


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iii. Weather information;

iv. Any other information considered relevant to the performance of the system;

v. Traffic control measures;

vi. Complaints from the public.

6.1.3.7 Monitoring and Measuring Resources

Procedures shall be documented to ensure that test, monitoring and measuring equipment continue to function properly within the tolerances stated in the System’s Manufacturer’s/Contractor’s documented procedures.

All equipment used in the manufacturing and installation process shall be regularly inspected and maintained to ensure use, wear or failure does not cause inconsistency in the manufacturing or installation process.

Rapid checks on the functionality of test equipment may be used e.g., checking a balance with a standard mass.

6.1.3.8 Release of System

The System’s Manufacturer/Contractor shall establish procedures to ensure that the production tolerances allow for the system performances to be in conformity with the values derived from the prTAIT process.

Release of the system shall not proceed until conformity of the system has been established.

The characteristics and the means of verification are given in Table 7.

6.1.3.9 Control of Non-Conforming Systems

The System’s Manufacturer/Contractor shall have written procedures which specify how to deal with non-conforming systems. Any such events shall be recorded as they occur, and these records shall be kept for the period defined in the System’s Manufacturer/Contractor’s written procedures.

6.1.3.10 Non-Conformity and Corrective Action

The System Manufacturer/Contractor shall have documented procedures that instigate action to address the cause of non-conformities in order to prevent recurrence. Non-conformity of the CS&JR system shall involve one or more of the following:

i. Repair and/or remedial action to bring the system up to the required performance;

ii. Written acceptance of the system following agreement by the Employer to accept the non-conforming system;

iii. Rejection and removal of the system.

Table 7 Assessment of performance characteristics

Column 1 2 3

Line Characteristics Inspection procedure and minimum frequency

Notes

1 PSV of aggregate and SRV Table 10 System Manufacturer document inspection


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Column 1 2 3

2 Tensile bond to asphalt Table 14 System Manufacturer document inspection

3 Resistance to permanent deformation

Table 14 System Manufacturer document inspection

4 Dangerous substances Incoming materials System Manufacturer document inspection

5 Skid Resistance Value Table 14 Contractor document inspection

6 Levels Table 14 Contractor document inspection

7 Tolerance Table 14 Contractor document inspection

6.2 Annex B - Minimum Inspection/ Test Frequencies for FPC (Normative)

Table 8 Process control minimum inspection schedule

Column 1 2 3 4

Line Control Area Inspection/Test Purpose Minimum frequency

1 Constituent Aggregates

Visual To check for contamination and moisture content

Every production day

2 Fillers Visual To check storage conditions


3 Binder Stocks Visual and temperature

To check storage conditions


4 Mixed product Visual For comparison with normal appearance

Every batch or continuously

5 Equipment Visual Check for contamination and cleanliness

Before starting application

Notes

For hot applied CS&JR systems, the binder can harden during storage, particularly when circulated. The quality plan shall state the ‘safe’ storage period for binder in its tank configuration and require testing if that period is exceeded without fresh deliveries. In the absence of other information, a period of two weeks shall be adopted.


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Table 9 Plant and equipment calibration requirements

Column 1 2 3 4

Line Item of plant/ equipment

Inspection/ test Purpose Minimum frequency

1 Weighing equipment

Visual inspection as described in procedures

To ascertain that weighing equipment is functioning correctly

Daily

Testing of weighing accuracy — (recalibration)

To ensure accuracy within quality plan requirements

• On installation1

• Every year

• In case of doubt

2 Admixture dispensers

Organoleptic inspection To ascertain that dispenser is functioning correctly

First batch of the day containing admixture

Test for accuracy as described in procedures.



• Every year


3 Flow meters

Comparison of the actual amount with the metered amount by reconciliation



• Every year


4 Batching system (on batch plants)

Comparison of actual mass of constituents in the batch with the intended mass using the method prescribed in the quality plan

To ascertain the batching accuracy in accordance with the quality plan


• Every year


5

Proportioning system (on continuous plants)

Comparison of actual mass in a measured period of time with the intended mass using the method prescribed in the quality plan

To ascertain the accuracy in

accordance with the quality plan


• Every year


6 Temperature, monitoring equipment

Visual as described in procedures

To ascertain the equipment is functioning correctly

Daily

Test of accuracy as described in procedures.

To ensure correct temperatures are recorded


• Every year


Notes

'In case of doubt' refers to the reasonable judgement of an experienced plant operator

1 Or after comprehensive repair.


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Table 10 Minimum inspection and test frequencies for aggregates2

Column 1 2 3 4

Line Inspection/test Purpose Normative references

Minimum frequency

1

Tests for intrinsic properties of aggregate (strength, PSV, etc.)

To check suitability for intended use

IS EN 13043 Source approval before initial use1

2 Sieve analysis To assess compliance with agreed grading where applicable

IS EN 13043

• First delivery from new source

• In case of doubt following stockpile check - 1 per 100t

3 Inspection of delivery ticket

To check consignment is as ordered and from correct source

As described in the quality plan

Each delivery

4 Organoleptic check of stockpile

For comparison with normal appearance with respect to source, grading, shape and impurities


Each day deliveries are made

5 Moisture content Process control IS EN 1097-5 As indicated in the quality plan

Notes

1 Results of tests and inspections by the aggregate supplier, as part of his Factory Production Control (when included in System Manufacturer’s FPC), may be used to satisfy the requirements of this table.

2 This table may include the results of tests and inspections by the supplier as part of his Factory Production Control.

Table 11 Minimum inspection and test frequencies for filler1

Column 1 2 3 4


Minimum frequency

1

Tests for intrinsic properties of filler (bulk density, stiffening properties etc.)

To check suitability for intended use

IS EN 13043 Source approval before initial use




Each delivery


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Column 1 2 3 4

3 Sieve analysis To check compliance with standard or other agreed grading

IS EN 13043

• First delivery from new source

• As indicated in the quality plan

Notes


Table 12 Minimum inspection and test frequencies for binders2

Column 1 2 3 4


Minimum frequency

1 Tests for intrinsic properties of binder

To confirm the characteristics of the product and the conformity to the appropriate specification

IS EN 12591 Source approval before initial use1

2

Grade properties (penetration, softening point or viscosity)

To assess compliance agreed Contractor requirements


1 per 300t




Each delivery

4 Temperature To check that binder is with permitted temperature limits


Each delivery

5 Organoleptic check (by sample or tank inspection)

For comparison with normal perceptible properties


Each delivery or daily in tanks

Notes

1 Results of tests and inspections by the supplier, as part of his Factory Production Control, may be used to satisfy the requirements of this table.

Any samples shall be stored in such a manner that deterioration is kept to a minimum.



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Table 13 Minimum inspection and test frequencies for other constituents and additives2

Column 1 2 3 4


Minimum frequency

1

Tests for intrinsic properties of other constituents or additives

To confirm characteristics of product or check compliance with specification


• Source approval prior to initial use

• As stated in the quality plan

• Updated in accordance with FPC1




Each delivery

3 Organoleptic check of consignment

For comparison with normal appearance etc.


Each delivery, if practicable; otherwise in accordance with quality plan

Notes

1 Results of tests and inspections by the supplier, as part of his Factory Production Control, may be used to satisfy the requirements of this table. Any samples shall be stored in such a manner that deterioration is kept to a minimum.


Table 14 Minimum inspection and test frequencies during production

Column 1 2 3 4


Minimum frequency

1 Organoleptic check on constituents

For comparison with normal appearance with respect to grading, evenness of mixing and adequacy of coating


Every batch

2 Temperature To ensure material conforms with specification or other requirements


Every batch

3 Tensile Bond to Asphalt

To assess conformity Error! Reference source not found.

As detailed in quality plan

4 Resistance to Permanent Deformation




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Column 1 2 3 4

5 Skid Resistance Value



6.3 Annex C – Example of Qualitative Visual Assessment Report

The report below is an example of a suitable layout. Other data may be included. The information that is required in this Annex is the minimum information that shall be provided. The information is normative, the layout is informative.

Qualitative Visual Assessment Report (– estimated)

Employer: ..................................................Contractor: .......................................…………….

Reference of the site: ……………………………….... Total length of site: ...............….... m

Reference of the area where the system is installed and date of installation:

…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Type of system (as per Subclause 2.1): ..............................................…………………...............

1 2 i

Reference of the section Example section

prTAIT Family 3

Lane reference CL2

Exact place of inspection Nearside wheel path

Length of treated section – Si (linear m) 3.7

Length of defects in treated section – Ai (linear m) 0.6

Loss of material: Pi = 100 × (Ai / Si) (%) 16

Remarks:

Name of the person responsible for assessment: …………….………………………………

Date of assessment: …./…./…….. Signature: .......................…………...…..….…


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6.4 Annex D – Substrate Preparation for Tests

6.4.1 Preparation Method 1: Retention of Skid Resistance Value for Overband Systems and Inlaid Systems

i. Introduction

When required, samples of material shall be prepared in accordance with the requirements of this Annex for the measurement of retention of skid resistance for overband and inlaid systems.

ii. Requirements

Slabs with the following properties shall be prepared in a laboratory setting:

a) Slab to consist of concrete class C32/40 with 20mm maximum sized

aggregate.

b) The slab shall not be air entrained.

c) Minimum thickness 50mm.

d) Dimensions 305 ±2 mm by 305 ±2 mm.

e) The top surface of the slab shall have a brushed finish applied.

f) Slabs shall be cured in water at 20 ±2 ºC for minimum 28 days and then

dried in an oven for a minimum of 48 hours at 105 ±5 ºC.

g) Any weak layer of laitance shall be removed using a wire brush.

h) The surface texture depth of the slab shall be in the range 0.50mm to

0.70mm when measured in accordance with IS EN 13036-1.

6.4.2 Preparation Method 2: Retention of Skid Resistance Value for Fill and Overband Systems

i. Introduction

When required, samples of material shall be prepared in accordance with the requirements of this Annex for the measurement of retention of skid resistance for fill and overband systems.

ii. Requirements


a) Slab to consist of concrete class C32/40 with 20mm maximum sized

aggregate.

b) The slab shall not be air entrained.

c) Minimum thickness 50mm.

d) Dimensions 305 ±2 mm by 305 ±2 mm.

e) Slab to have a trapezoidal channel 250mm long, 30mm top width, by 23mm

deep and base width 20mm running centrally along the long axis of the slab

and cast with blinds ends (refer to Figure 5).

f) The trapezoidal channel shall be formed (using a former) at the time of

manufacture of the slab.


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g) The top surface of the slab shall have a brushed finish applied.

h) Any weak layer of laitance shall be removed using a wire brush.

Figure 5 Sample material for the measurement of retention of skid resistance for fill and overband systems

6.4.3 Preparation Method 3: Tensile Bond to Asphalt

Note: Test method details outlined below have been adopted from TRL Report 176 Appendix J (and Appendix A and C by association). The test method is included with the kind permission of the Transport Research Laboratory, UK.

i. Introduction

When required, samples of material shall be prepared in accordance with the requirements of this Annex for the measurement of tensile bond to asphalt (initial and after heat ageing) for all systems.

ii. Requirements


a) One set of slabs to be SMA 10 surf 40/60 des. with grading envelope,

minimum binder content as per CC-SPW-00900 Table 8.

b) Each slab shall be prepared in accordance with IS EN 12697-33,

compacted by a laboratory roller compactor, so as not to be damaged by

subsequent handling. Once fully compacted, the slabs shall be 305 ±2 mm

by 305 ±2 mm in plan by 50 ±10 mm deep.

c) Store the slabs flat so that the whole of the bottom surface is supported at a

temperature of (5 ±2 ºC. During transportation, the slabs shall continue to be

supported for the whole of the bottom surface, but the temperature may be

outside the range of 5 ±2) ºC for a total period of not more than 7 days

provided it does not exceed 30ºC.


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6.5 Annex E – Test Methods

6.5.1 Test Method 1: Retention of Skid Resistance Value for Overband Systems

Introduction

Retention of skid resistance for overband systems shall be measured in accordance with the test requirements of this Annex.

Tests shall be carried out as required to confirm system compliance with the requirements of Table 3 – Crack Sealing and Joint Repair Systems – Requirements of the System.

Procedure

i. Three test specimens shall be made up on slabs prepared in accordance with Annex D – Substrate Preparation Method 1.

ii. The overband system shall be applied 40 ±1 mm wide, centrally to each slab. The surface of the concrete may have a primer applied.

iii. Additionally, on one of the slabs, a strip of the overband system, minimum width 100mm, shall be applied between the central strip and the edge of the slab to allow for a correlation between wide and narrow SRV sliders. For preformed overband systems this strip may be made up of several narrow strips laid together with no gaps in between, see Figure 6. The Wide strip is used for the slider correlation only and is not subjected to any further testing.

Figure 6 Layout of slab for slider correlation.

The SRV determined using wide and narrow sliders shall be correlated as follows:

i. On the slab to which the 100mm strip has been applied, determine the skid resistance with the wide slider over 126mm sliding length and scale C in accordance with IS EN 13036-4.

ii. Repeat at the same location with the narrow slider used over the full 126mm sliding length utilising the normal slider scale C.


Page 39

iii. Calculate the narrow slider correction factor for that pendulum on that overband system by dividing the result with the wide slider by the result with the narrow slider.

𝑺𝑹𝑽 𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒊𝒐𝒏 𝑭𝒂𝒄𝒕𝒐𝒓 (𝑪𝑭) =𝑺𝑹𝑽𝑾𝒊𝒅𝒆

𝑺𝑹𝑽𝑵𝒂𝒓𝒓𝒐𝒘

iv. Determine the initial skid resistance value (iSRV) of each specimen at room temperature of 20 ±2 °C, using the narrow slider over 126mm sliding length and scale C. Correct the mean iSRV of the tree test slabs by multiplying by the slider correction factor determined in (ii) c) to give iSRVcorr.

𝒊𝑺𝑹𝑽𝒄𝒐𝒓𝒓 = 𝑪𝑭 × 𝑴𝒆𝒂𝒏(𝒊𝑺𝑹𝑽)

Where CF is the SRV Correction Factor determined in (iii) c)

And Mean (iSRV) is mean of iSRV determined on three slabs prior to wheel tracking

v. Wheel track each specimen using IS EN 12697-22 in using the small device, Procedure A. The specimens shall be conditioned and tested at 50°C.

vi. After testing the slab shall be allowed to cool to room temperature.

vii. Once cooled, determine the retained skid resistance value (rSRV)on each slab at room temperature of 20 ±2°C, using the narrow slider over 126mm sliding length and scale C. Correct the mean of the retained skid resistance value by multiplying by the slider correction factor determined in (iii) c) to give rSRVcorr.

𝒓𝑺𝑹𝑽𝒄𝒐𝒓𝒓 = 𝑪𝑭 × 𝑴𝒆𝒂𝒏(𝒓𝑺𝑹𝑽)


And Mean (rSRV) is mean of rSRV determined on three slabs after wheel tracking.

Reporting of results

Report the iSRVcorr and rSRVcorr.

Both results shall be reported in standard units for SRV.

Note for guidance

It may be necessary to apply talc to the wheel track to stop the material picking up on the wheel. It may also be necessary to re-apply talc periodically throughout the tracking procedure. If talc is used it will be necessary to wash all traces of talc from the specimens prior to SRV testing.

6.5.2 Test Method 2: Retention of Skid Resistance Value for Fill and Overband Systems

Introduction

Retention of skid resistance for fill and overband systems shall be measured in accordance with the test requirements of this Annex.

Tests shall be carried out as required to confirm system compliance with the requirements of Table 3.

Procedure

i. Three test specimens shall be made up on each slab prepared in accordance with Annex D – Substrate Preparation Method 2.


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ii. The trapezoidal channel shall be filled with the fill component of the system in accordance with the System Manufacturer’s requirements. It is advisable to mark the location of the notch on the ends of the slab to facilitate alignment for testing.

iii. The overband component shall then be applied over the fill component and to overlap onto the concrete slab surface in accordance with the System Manufacturer’s requirements. On one of the slabs, the overband component shall be applied a minimum width 100mm, to allow for a correlation between wide and narrow skid resistance value (SRV) sliders

iv. Correlate the skid resistance values determined using wide and narrow sliders as follows:

a) On the slab to which the 100mm strip has been applied, determine the skid

resistance with the wide slider over 126mm sliding length and scale C in

accordance with IS EN 13036-4.

b) Repeat at the same location with the narrow slider used over the full 126mm

sliding length utilising the normal slider scale C.

c) Calculate the narrow slider correction factor for that pendulum on that fill

and overband system by dividing the mean result with the wide slider by the

mean result with the narrow slider.

v. Determine the initial skid resistance value (iSRV) of each specimen at room temperature of 20 ±2°C, using the narrow slider over 126mm sliding length and scale C, ensuring the measurement is made directly over the notch. Correct the mean iSRV of the three test slabs by multiplying by the slider correction factor determined in (iv) c) to give iSRVcorr:


Where CF is the SRV Correction Factor determined in (iv) c)

And Mean (iSRV) is mean of iSRV determined on three slabs prior to wheel tracking.

vi. Wheel track each specimen using IS EN 12697-22 in using the small device, Procedure A. The specimens shall be conditioned and tested at 50°C. Ensure the test wheel tracks directly over the notch.

vii. After testing the slab is allowed to cool to room temperature.


Where CF is the SRV Correction Factor determined in (iv) c)



Report the iSRVcorr, and rSRVcorr.

Both results shall be reported in standard units for SRV.

Note for guidance

It may be necessary to apply talc to the wheel track to stop the material picking up on the wheel. It may also be necessary to re-apply talc periodically throughout the tracking procedure. If talc is used it will be necessary to wash all traces of talc from the specimens prior to skid resistance testing.


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6.5.3 Test Method 3: Resistance to Permanent Deformation and Retention of Skid Resistance Value for Inlaid Sealing Systems

Introduction

Resistance to permanent deformation and retention of skid resistance for inlaid systems shall be measured in accordance with the test requirements of this Annex.

Tests shall be carried out as required to confirm system compliance with the requirements of Table 3.

Procedure

i. Three test specimens shall be made up on slabs prepared in accordance with Annex D – Substrate Preparation Method 1.

ii. The inlaid system shall be applied at a minimum thickness of 20mm or at the System Manufacturer’s maximum declared thickness if greater than 20mm.

iii. Correlate the skid resistance values determined using wide and narrow sliders as follows:

a) On the slab determine the skid resistance with the wide slider over 126mm

sliding length and scale C in accordance with IS EN 13036-4.

b) Repeat at the same location with the narrow slider used over the full 126mm

sliding length utilising the normal slider scale C.

c) Calculate the narrow slider correction factor for that pendulum on that fill

and overband system by dividing the mean result with the wide slider by the

mean result with the narrow slider.

iv. Determine the initial skid resistance value (iSRV) of each specimen at room temperature of 20 ±20 °C, using the narrow slider over 126mm sliding length and scale C, ensuring the measurement is made at the location intended to be tracked Correct the mean initial skid resistance value of the three test slabs by multiplying by the slider correction factor determined in (iii) c) to give iSRVcorr:



And Mean (iSRV) is mean of iSRV determined on three slabs prior to wheel tracking.

v. Wheel track each specimen using IS EN 12697-22, small device, Procedure A. The slab shall be conditioned and tested at 50°C

vi. After testing, the specimens are allowed to cool to room temperature.

vii. Once cooled, final measurements of the following properties are determined:

a) For slab tested using IS EN 12697-22: WTR and RD.

b) The retained skid resistance value (rSRV) at room temperature of 20 ±2 °C,

using the narrow slider over 126mm sliding length and scale C.

Correct the mean of the retained skid resistance value by multiplying by the

slider correction factor determined in (iii) c) to give rSRVcorr:





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Repeatability

For wheel tracking, three samples of each system are tested, and the mean values determined.


Results shall be reported in standard units for SRV, as mm for rut depth, and µm/cycle for wheel tracking rate.

Report the iSRVcorr, and rSRVcorr. Both shall be reported in standard units for SRV.

Notes for guidance

It may be necessary to apply talc to the wheel track to stop the material picking up on the wheel. It may also be necessary to re-apply talc periodically throughout the tracking procedure. If talc is used it will be necessary to wash all traces of talc from the specimens prior to skid resistance testing.

The rut resistance test may result in a ‘shoulder’ of material occurring at the edges of the tracked area. To enable the SRV to be measured it may be necessary to cut off the edges outside the tracked area.

6.5.4 Test Method 4: Tensile Bond to Asphalt

Note: Test method details outlined below have been adopted from TRL Report 176 Appendix J (and Appendix A and C by association). The test method is included with the kind permission of the Transport Research Laboratory, UK.

Summary

This method describes a test for determining the adhesion between a crack sealing and joint repair system and the slab (prepared in accordance with Annex D – Substrate Preparation Method 3: Tensile Bond to Asphalt) to which it is applied when a tensile force, perpendicular to the plane of the specimen, is applied over an area of the crack sealing and joint repair system.

A 100mm by 100mm sample of the crack sealing and joint repair system shall be applied to the slab and a progressive load is applied to the square until failure occurs. The test shall be repeated three times each at two temperatures.

Part 1 – Application

Application of the crack sealing and joint repair system to the slabs prepared in accordance with Annex D – Substrate Preparation Method 3 shall be as outlined below.

Note: The installation of the crack sealing and joint repair system has to be carried out by the System Manufacturer or his representative.

Apparatus

The apparatus shall consist of:

i. Callipers, or other suitable measuring device, capable of measuring thickness in the range 25mm to 75mm to an accuracy of ±0.1mm between flat discs of 10 ±1 mm diameter;

ii. Specialist installation equipment required for the specific system being applied;

iii. Containers in which the sealant (if applicable) can be mixed;

iv. Spatulas, squeegees or other instruments for mixing and spreading the sealant and/or system;


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v. Heaters in which the system can be heated to the required temperature where thermoplastic binders are being used;

vi. Heat-resistant gloves;

vii. Thermometer, capable of measuring surface temperatures between -20°C and 50°C to ±1° C; and

viii. Broom, hard bristled.

Procedure – Slabs

Ensure that the required slabs are dry and at ambient temperature.

Measure the thickness of each slab to ±0.1mm at approximately the third-points along each side, at least 30mm in from the edge, using the callipers or other suitable measuring device. Mark the points on the bottom face of the slab.

When applying an inlaid joint sealant system, a frame which stands above the slab by the installation depth will be necessary to contain the joint sealant until cured or cooled.

Procedure – Applying the Surface System

The System Manufacturer or their representative shall carry out the pre-treatment for the crack sealing and joint repair system to the array of slabs in the same manner that normally occurs on site. Measure the ambient and surface temperatures to ±1°C; if the system involves any heat pre-treatment of the substrate, the surface temperature shall be measured both before and after pre-treatment. If the surface temperature, after any pre-treatment, is outside the range 20 ±15°C, defer applying the surface until the conditions are appropriate, when any necessary pre-treatment shall be repeated.

The System Manufacturer or his representative shall apply the crack sealing and joint system to the array of slabs in the same manner that the system is normally applied on site.

Allow the surface to cool and or cure in accordance with normal procedures for use on site (as far as practicable). For systems were the aggregate is not encapsulated prior to being applied to the substrate, remove any excess and loosely held aggregate from the surface by brushing with a hard-bristled broom.

Check the specimens for adequate and uniform coverage, surface defects and slab damage. Reject any specimens that may bias the results in any manner.

Brush each specimen to remove any loosely adhering aggregate.

Remove any frame installed on the slabs.

Procedure – Thickness

Measure the thickness of the slab plus system to ±0.1mm at the eight points marked (noted in ‘Procedure – Slabs’ paragraph) using the callipers or other suitable measuring device.

Calculate the mean thickness of system applied to ±0.2mm from the differences between the thickness of the slab plus surface and the thickness of the slab alone at the eight points.

Reject any specimens whose thickness is outside the normal range for that system, as claimed by the System Manufacturer.


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Procedure – Storage

If the samples are prepared away from the test laboratory, store the slabs so that the whole of the bottom surface is supported and at a temperature not exceeding 30ºC. On receipt at the test laboratory, condition the coated slabs at 20 ±2 ºC for 10 days prior to testing.

Reporting of Results

The test report shall include the mean thickness of crack sealing and joint repair system to the nearest 0.1mm separately for each slab.

Part 2 – Testing

Apparatus

The apparatus shall consist of:

i. Tensile pull-off apparatus capable of applying a progressive load at a rate of 0.4 ±0.2 kN/s and having a means of measuring the applied load up to a maximum reading of at least 20kN with an accuracy of ±2% of the failure load;

ii. Note: A suitable tensile pull-off apparatus with a tripod holding a hydraulic jack operated by a hydraulic hand pump and the load measured by an integral load cell is shown in Figure 7.

iii. Steel plates, 100 ±2 mm x 100 ±2 mm and not less than 10mm thick;

iv. Saw capable of cutting the asphalt slabs;

v. Saw, capable of cutting through the joint sealant system when cured;

vi. Wire brush; and

vii. Adhesive, suitable for use and capable of resisting tensile stresses of not less than 4N/mm.


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Figure 7 Testing apparatus

Procedure

Manufacture one set of three number (3no.) 305mm by 305mm asphalt slabs in accordance with Annex D – Substrate Preparation Method 3 and apply the crack sealing and joint repair system to the slabs in accordance with Part 1 of this Annex. Remove all aggregate loosely adhering to the surfaces by brushing with the wire brush.

Cut each 305mm by 305mm (standard) SMA specimens into four (small) specimens of approximately 150mm by 150mm in plan. Take one of these small specimens from each slab for testing at -10ºC and another form each slab for testing at +20ºC. Retain the other two small specimens from each slab for repeat testing if it becomes necessary.

Bond a steel plate to the centre of each specimen with the adhesive. Isolate the area of crack sealing and joint repair system under the plate, either before or after bonding the steel plate to the surface, by cutting approximately 1mm into the substrate with the saw, immediately adjacent to the steel plate without disturbing the crack sealing and joint repair system.

Condition three small specimens (one cut from each standard specimen) at -10±2°C for not less than 2 hours. Locate the tensile pull-off apparatus above the surface of the plate on each specimen in turn with the pulling arm vertical and connected to the centre of the plate and load progressively at a rate of 0.4 ±0.2kN/s, up to failure or a load of 20kN, whichever is reached first.

Record for each specimen the load at failure to ±0.1kN and the mode of failure (adhesion or cohesion and in or between which layers) if failure is reached or that failure was not reached, and the maximum load applied.


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Repeat the above for three further small specimens (one cut from each standard specimen) but at a temperature of +20 ±2 °C.

Calculations

The adhesion stress for each temperature is calculated as:

𝝈𝒕 =(𝑳𝒕,𝟏 + 𝑳𝒕,𝟐 + 𝑳𝒕,𝟑)

𝟑𝟏𝟎−𝟒

Where Lt,i (N) is the load at failure for the ith specimen and σt (N/mm2) is the adhesion stress for the test at t°C. If one or more specimens did not fail, then use the maximum load applied and the adhesion stress of the crack sealing and joint repair system is greater than the value obtained. Report the adhesion stress to ±0.01N/mm2.

Reporting of Results

The test report shall include the following information:

i. Date, time and place of test;

ii. Details of the slabs manufacture including:

a) Date and place of manufacture;

b) The material type and specification;

c) The grading and proportion of each aggregate source used;

d) The source, type and grade of the binder and any binder modifier;

e) The temperature at which the slab was manufactured; and

f) The macrotexture depth of the substrate;

iii. Details of the crack sealing and joint repair system including:

a) Date and place of installation;

b) The crack sealing and joint repair system name;

c) The binder and aggregate type;

d) Batch numbers for the binder and aggregate; and

e) The mean thickness of crack sealing and joint repair system on each

specimen;

iv. For the SMA slabs, the load at failure on each specimen and the mean values at -10°C and +20°C for the crack sealing and joint repair system;

v. The stress at failure at -10°C and +20°C for the crack sealing and joint repair system;

vi. A description of the failure mode;

vii. The name of the person taking technical responsibility for the test;

viii. Any test conditions and operational details not provided in this Annex, and anomalies, if any, likely to have affected the results

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