Specification 201 Quality Systems 14 April 2016.RCN-D1623234100

SPECIFICATION 201
QUALITY SYSTEMS
Copyright MAIN ROADS Western Australia
Specification 201 Quality – 04/10092 Issued 14/04/2016
REVISION REGISTER
Clause Description of Revision Authorised Issued
Number By Date
201.14-201.16 Renumbering of Clauses MPS 14/04/2016
Whole Reformatted to corporate branding MPS 13/04/2016
Document guidelines and numerous typographical
and grammatical corrections
201.01.3, Deleted references to HB90.3 (not
201.02.1 & applicable with new ISO 9001)
Annexure
201C Cl. 2.0
201.02.1 Updated and corrected titles of various
reference documents
201.03.2, Changes made to reflect new ISO 9001
201.06 - 07, including titles and structure
201.11 - 15
201.12.4, Document names and references to
201.12.10 & Main Roads website updated
201.12.11
201.16 Added requirement for monthly reporting
Annexure Title changed
201A
Annexure Reference to ISO 9001 updated
201A Cl 1.0
Annexure Added clarification for where to take core
201A samples
Cl. 1.1.2
Table 201A-1 Corrected name of bridge works
component
Annexure Deleted redundant titles for subgrade
201A construction
Annexure Added testing frequency for bitumen
201A produced by blending
Annexure Re-numbered last item as j)
201C Cl 1.1
Annexure Changed Dual Use Path to Shared Path MPS 30/09/2015
201A
Annexure Testing frequency for geotextile fabric MPS 20/08/2015
201A amended
201.02 Update to title of AS/NZS 2891.10
Annexure Correction of day’s production to
Document No: Dxx#xxxxx Page 2 of 59
Contract No: xxxx/xx Contract Name

REVISION REGISTER
Clause Description of Revision Authorised Issued
Number By Date
201A production shift
Cl. 1.1.2
201.02 Added binder drain off test MPS 13/04/2015
Annexure Testing frequency for PMB segregation
201A amended
Annexure Corrections to requirements for crushed
201A aggregates
Annexure Asphalt manufacture – reformatting and
201A new testing frequency linked to
Specifications 502, 504 and 510. Added
Binder Drain Off test
Annexure Deleted testing for cold mix
201A
Annexure Underlying Viscosity of PMB replaced by MPS 22/05/2014
201A Consistency 6% test
Annexure Methods for water absorption of sealing
201A and asphalt aggregates corrected
201.02 Three test methods added for gyratory MPS 26/02/2014
compaction, stripping potential and
moisture content of asphalt
Annexure Inclusion of S45R binder
201A
Annexure Clarification of sampling of asphalt cores
201A
Cl. 1.1.2
Annexure Formulas for minimum and maximum
201A characteristic values of in-situ air void
Cl. 1.2.2 content of asphalt
Annexure Requirement for testing for stripping
201A potential of asphalt
Annexure Option of testing moisture content of
201A asphalt by NSW method

CONTENTS
Clause Page No
GENERAL .................................................................................................................... 6
201.01 Scope ......................................................................................................... 6
201.02 References ................................................................................................. 6
201.03 Definitions – Quality Plan .......................................................................... 10
201.04 – 201.05 NOT USED .................................................................................... 10
SYSTEM ELEMENTS – ADDITIONAL REQUIREMENTS .......................................... 11

201.06 Monitoring and Measuring Resources (Inspection, Measuring and Test
Equipment) ............................................................................................... 11
201.07 Performance Evaluation (Inspection and Testing) .................................... 12
201.08 Identification and Traceability.................................................................... 12
201.09 Control of Production and Service Provision (Process Control) ................. 14
201.10 Validation of Processes for Production and Service Provision (Special
Processes)................................................................................................ 14
201.11 Control of Externally Provided Processes, Products and Services ............ 14
201.12 Control of Documented Information (Documents and Records) ............... 15
201.13 Control of Non-Conforming Outputs .......................................................... 16
201.14 Improvement............................................................................................. 17
201.15 Monthly Reporting..................................................................................... 17
201.16 – 201.20 NOT USED .................................................................................... 17
HOLD POINTS ........................................................................................................... 18

201.21 Hold Points ............................................................................................... 18
201.22 – 201.80 NOT USED .................................................................................... 18
AS CONSTRUCTED AND HANDOVER REQUIREMENTS ....................................... 18

201.81 – 201.90 NOT USED .................................................................................... 18
CONTRACT SPECIFIC REQUIREMENTS ................................................................. 18

201.91 – 201.99 NOT USED .................................................................................... 18
ANNEXURE 201A ...................................................................................................... 19

Testing Requirements ................................................................................................. 19
1.0 General..................................................................................................... 19
1.1 Test Methods ............................................................................................ 19
1.2 In-Situ Density and Air Voids .................................................................... 20
1.3 Insitu Moisture .......................................................................................... 22
1.4 Standard Deviation ................................................................................... 24
1.5 Procedure for Resolving Disputed Conformance Status ........................... 25
2.0 Minimum Testing Frequency ..................................................................... 28
ANNEXURE 201B ...................................................................................................... 47

Identification and Traceability ...................................................................................... 47
ANNEXURE 201C ...................................................................................................... 48

Monitoring and Measurement of Processes ................................................................ 48

ANNEXURE 201D ...................................................................................................... 54

Validation of Processes for Production and Service Provision .................................... 54
ANNEXURE 201E ...................................................................................................... 55

Requirements for Selected Critical Subcontracts ........................................................ 55

GENERAL
201.01 SCOPE
1. The Contractor shall manage its Contract obligations through

the implementation of a third party certified Quality Management System
compliant with AS/NZS ISO 9001. Third party certification shall be
maintained for the duration of the Contract.
2. This Quality Specification sets out the Principal’s minimum Quality Plan
requirements for establishing, implementing and managing a Quality
Plan for the work under the Contract.
3. The Contractor shall establish, implement and manage a

Contract specific Quality Plan complying with the Contract, the
requirements of AS/NZS ISO 9001
4. For terms and definitions refer to AS/NZS ISO 9000. Definitions
5. The Superintendent shall reserve the right to conduct Surveillance

surveillance and second party audits on the Contractor’s and any and Second
subcontractor’s compliance with Specification 201. The Contractor shall Party Audit
promptly provide the Superintendent upon request any documentation,
records or assistance during the surveillance or audit activity.
201.02 REFERENCES
1. Australian Standards, MAIN ROADS Western Australia

Standards and MAIN ROADS Western Australia Test Methods are
referred to in abbreviated form (e.g. AS 1234, MRS 67-08-43 or
WA 123). For convenience, the full titles are given below:
Australian Standards
AS 2124-1992 General Conditions of Contract
AS/NZS ISO 9000 Quality Management Systems- Fundamentals and

Vocabulary
AS/NZS ISO 9001 Quality Management Systems - Requirements
AS/NZS 1554 Structural steel welding
AS/NZS 2566.2 Buried flexible pipelines – Installation
AS 1012.1 Sampling of concrete
AS 1012.3.1 Determination of properties related to

theconsistency of concrete – Slump Test
AS 1141 Methods for sampling and testing aggregates
AS 1160 Bituminous emulsions for the construction and

maintenance of pavements
AS 1289.3.7.1 Methods of testing soils for engineering purposes
Method 3.7.1: Soil classification tests –
Determination of the sand equivalent of a soil
using a power-operated shaker
AS 1289.5.8.5 Methods of testing soils for engineering purposes-

Method 5.8.5: Soil compaction and density tests –
Nuclear surface moisture-density gauges-Density
of a Type A or Type C standard density block
AS 1379 Specification of the supply of concrete
AS 1523 Elastomeric bearings for use in structures
AS 1544.2 Methods for impact tests on metals
AS 1580 Paints and Related Materials – Methods of test
AS 2706 Numerical Values – Rounding and Interpretation of

Limiting Values
AS 2876 Concrete kerbs and channels (gutters) – Manually
or machine placed
AS/NZS 2891.2.2 Methods of sampling and testing asphalt Method
2.2: Sample Preparation - Compaction of Asphalt
test specimens using a gyratory compactor
AS/NZS 2891.10 Methods of sampling and testing asphalt Method
10: Moisture content of Asphalt
AS/NZS 2891.11 Methods of sampling and testing asphalt Method
11: Degree of particle coating
Austroads Test Methods
AG:PT/T053 Determination of Permanent Deformation and

Resilient Modulus Characteristics of Unbound
Granular Materials Under Drained Conditions
AG:PT/T232 Stripping Potential of Asphalt – Tensile Strength
Ratio
AG:PT/T235 Asphalt Binder Drain Off
MAIN ROADS Test Methods
WA 0.1 Random Sample Site Location
WA 100.1 Sampling Procedures for Soil and Manufactured Granular

Materials
WA 105.1 Preparation of Disturbed Soil and Manufactured Granular
Material Samples for Testing
WA 110.1 Soil and Manufactured Granular Material Moisture
Content: Convection Oven Method
WA 110.2 Soil and Manufactured Granular Material Moisture
Content: Microwave Oven Method
WA 115.1 Particle Size Distribution: Sieving and Decantation
Method
WA 115.2 Particle Size Distribution: Abbreviated Method for Coarse
and Medium Grained Soils
WA 120.2 Liquid Limit: Cone Penetrometer Method
WA 122.1 Plasticity Index

WA 123.1 Linear Shrinkage
WA 133.1 Dry Density/Moisture Content Relationship: Modified

Compaction Fine and Medium Grained Soils
WA 133.2 Dry Density/Moisture Content Relationship: Modified
Compaction Coarse Grained Soils
WA 134.1 Dry Density Ratio (Percent)
WA 135.1 Calibration of Nuclear Moisture/Density Meters: Standard

Blocks
WA 135.2 Check of the Consistency of Measurements by Nuclear
Moisture/Density Meters: Secondary Standard Blocks
WA 136.1 Moisture Ratio (Percent)
WA 140.1 Maximum Dry Compressive Strength
WA 141.1 Determination of the California Bearing Ratio of a Soil:

Standard Laboratory Method for a Remoulded Specimen
WA 143.1 Determination of the Unconfined Compressive Strength of

Laboratory Compacted Specimen
WA 143.2 Determination of the Unconfined Compressive Strength of
Hydrated Cement Treated Crushed Rock Base
WA 201.1 Sampling and Preparation of Granulated Rubber
WA 210.1 Particle Size Distribution of Aggregate
WA 216.1 Flakiness Index
WA 220.1 Los Angeles Abrasion Value
WA 220.2 Los Angeles Abrasion Value of Crushed Limestone
WA 223.1 Crushing Test Value
WA 235.1 Bulk Density of Granulated Rubber
WA 236.1 Particle Size Distribution of Granulated Rubber
WA 237.1 Steel Content of Granulated Rubber
WA 250.1 Colour of Aggregate
WA 313.2 Surface Shape Using a Straightedge
WA 324.1 Dry Density: Sand Replacement Method
WA 324.2 Determination of Field Density: Nuclear Method
WA 701.1 Sampling and Storage of Asphalt
WA 705.1 Preparation of Asphalt for Testing
WA 717.1 Dispersion of Bitumen in Soil
WA 730.1 Bitumen Content & Particle Size Distribution of Asphalt

and Stabilised Soil, Centrifuge Method

WA 731.1 Stability & Flow of Asphalt: Marshall Method
WA 732.2 Maximum Density of Asphalt: Rice Method
WA 733.1 Bulk Density and Void Content of Asphalt
WA 733.2 Bulk Density and Void Content of Asphalt – Vacuum

Sealing Method
WA 910.1 Chlorides and Total Soluble Salts in Soil and Water
WA 915.1 Calcium Carbonate Content
Roads & Maritime Services NSW Test Methods
T 660 Moisture Content of Bituminous Mixes (Mass Loss

Method)
MAIN ROADS Standards
67-04-2040-1 Standard Density Blocks for Nuclear Moisture/Density

Meter Calibration
67-04-2040-2 Operational Checks for Nuclear Moisture/Density Meter
67-08-43 Digital Ground Survey
67-08-88 Design and Drawing Presentation
MAIN ROADS Specifications
Specification 100 GENERAL REQUIREMENTS
Specification 501 PAVEMENTS
Specification 502 STONE MASTIC ASPHALT
Specification 504 ASPHALT WEARING COURSE
Specification 510 ASPHALT INTERMEDIATE COURSE
Specification 511 MATERIALS FOR BITUMINOUS TREATMENTS
Specification 603 SAFTEY AND TRAFFIC BARRIER SYSTEMS
Specification 820 CONCRETE FOR STRUCTURES
Specification 830 STRUCTURAL STEELWORK
Specification 835 PROTECTIVE TREATMENT OF STEELWORK
Specification 860 BRIDGE BEARINGS
Specification 903 FENCING

201.03 DEFINITIONS – QUALITY PLAN
1. The Quality Plan shall be the document specifying the Definition

processes of the Contractor’s quality management system (including the
product realisation processes) and the resources to be applied to
achieve the specific requirements of the Contract.
2. The Quality Plan shall address the Contractor's management

responsibility, authority and communication requirements and clearly
detail the Contractor's “Quality Management Representative (QMR)” role
with respect to the Contract.
3. The Quality Plan shall include the scope of works detailed in Scope of
the Specification 100 GENERAL REQUIREMENTS for the Contract. Works
The Quality Plan must also address the requirements detailed in
AS 2124 and the Special Conditions of Contract.
4. The Quality Plan shall clearly detail how the Contractor’s

Quality Management System procedures and instructions shall be
applied to meet the requirements of the Contract and shall clearly detail
the cross referencing to all documents of the Contract.
5. The Quality Plan shall clearly address the requirements The Contract
specified in Specification 201 QUALITY SYSTEMS and shall
demonstrate compliance with the Contract.
6. The Quality Plan shall clearly detail the Contractor’s Delegation

delegation of its management responsibilities, authorities and
communication requirements for any subcontracted work under the
Contract.
7. If not submitted and explicitly approved in writing during the Hold Point
Tendering process, the Contractor shall submit a suitable fully
documented Quality Plan to the Superintendent for approval prior to
commencement of work under the Contract.
8. Any amendments to the Approved Quality Plan shall be Amendments

submitted to the Superintendent for approval. Approval
201.04 – 201.05 NOT USED

SYSTEM ELEMENTS – ADDITIONAL

REQUIREMENTS
201.06 MONITORING AND MEASURING RESOURCES
(INSPECTION, MEASURING AND TEST EQUIPMENT)
1. The Contractor shall document in the Quality Plan all test All Equipment
devices required to provide evidence of conformity. Where monitoring or
measurement of a product or process is required in order to demonstrate
conformity of the finished product with the Contract, the Contractor shall
ensure the requirements of AS/NZS ISO 9001 Monitoring and Measuring
Resources for the works are documented and met.
2. Nuclear Moisture Density Meters (NDM) shall be calibrated Nuclear

in accordance with WA 135.1 on standard blocks. The standard blocks Density Meter
shall be calibrated in accordance with Main Roads Calibration Method (NDM)
67-04-2040-1 or AS 1289.5.8.5.
3. The Contractor shall calibrate the NDM to an appropriate Calibration

range between 1.5 t/m³ to 3.05 t/m³ to suit the material being tested in NDM Range
the Contract. A typical low range is 1.5 to 2.65 t/m³, and a high range is
2.65 to 3.05 t/m³.
4. The NDM shall have current density calibrations for the DT Modes
50 mm, 65 mm, 100 mm, 150 mm, 200 mm and 300 mm direct
transmission (DT) modes. The NDM shall be compatible with the normal
operating procedures and test methods of Main Roads Western
Australia.
5. A current NATA endorsed calibration certificate shall be HOLD POINT

supplied to the Superintendent prior to the NDM being used for
conformance testing of the Works.
6. The operational performance of the NDM shall be checked in Test Methods

accordance with Calibration Procedures 67-04-2040-2. The operational
consistency of the NDM shall be determined in accordance with
WA 135.2. The consistency of the NDM shall be determined at the
commencement of the Contract and at least monthly thereafter, using
the one or more consistency blocks provided by the Contractor. The
Contractor shall provide details of these blocks and their location.
7. The direct transmission mode (depth of probe) to be used for In-situ Density
each in-situ density test undertaken shall be stated in the appropriate Test
Inspection Plans(s) [Inspection and Test Plan(s)].
8. The depth of probe shall be the maximum depth of the 6 Probe

calibrations listed above that can be accommodated within the layer at
the time of testing, taking specified construction tolerances into account
(e.g. 150 mm for a 165 mm basecourse layer).

201.07 PERFORMANCE EVALUATION (INSPECTION AND

TESTING)
1. The Contractor shall develop and document Inspection Inspection

Plan(s) [Inspection and Test Plan(s) (ITPs)] to undertake the Monitoring Plans
and Measurement of the Works. The Inspection Plans shall clearly
describe the monitoring, verification and validation activities specific to
the product and the criteria for product acceptance for each product or
service specified in the Contract in accordance with AS/NZS ISO 9001.
2. The Contractor shall prepare detailed test procedures where Test

test procedures required for Inspection Plan(s) are not detailed in either Procedures
Australian Standards or Main Roads’ Test Methods.
3. All quality control testing shall be conducted by a laboratory NATA

holding current National Association of Testing Authorities (NATA)
accreditation for all test methods referred to in the Specifications. NATA
accreditation for all test methods shall be maintained until the completion
of the Contract. All test reports shall be NATA endorsed by a current
approved signatory for the laboratory conducting the testing.
4. At least one week before conducting any materials HOLD POINT

conformance testing the Contractor shall make available to the
Superintendent the Laboratory Quality Manual required by NATA
so that an Initial Audit of the laboratory can be conducted.
5. Sampling methods shall be unbiased and either random or Sampling

systematic in concept or as specified. Random site selection shall be Methods
undertaken in accordance with WA 0.1. The frequency of tests shall at
all times be adequate to demonstrate the work's conformance with the
Specification. The frequency of tests shall be as listed in
Annexure 201A of the Quality System Specification. Full details of all
sampling plans shall be included in the relevant Inspection Plan(s).
201.08 IDENTIFICATION AND TRACEABILITY
1. The principles used to define the limits of any Lot for the Definition of a
Contract shall be: Lot
a) the maximum size of a Lot is limited to the quantity of work
that is the subject of a single conformance decision;
b) the whole of the works included in the Lot shall be

continuous;
c) the Lot has been produced by the same works process;
d) the Lot has been brought to completion at the same time;

and

e) the Lot shall appear to be of a constant quality without

obvious changes in attribute values, whether or not these
attributes form part of the acceptance criteria.
2. In the case of selecting a Lot for the purpose of judging the Lots for In-
conformance of the insitu density, particular attention shall be paid to situ Density
establishing the uniformity of density in a direction transverse to the road Products
alignment. Boundaries of Lots shall be chosen so as to ensure vertical,
transverse and longitudinal homogeneity.
3. The extent of each Lot shall be clearly identified in the field Production
prior to the commencement of any product realisation activity. The Lot
Contractor shall establish, and describe in the Quality Plan, a unique Lot
identification system, for identification and traceability of the product,
compliant with AS/NZS ISO 9001. The Lot shall be demarcated on Site
with markers until the Lot has been brought to completion. As a
minimum the markers shall detail the chainage and Lot identification
clearly legible from the alignment centre line.
4. All Lots defined for the purpose of conformance testing that Testing Lot
form only a part of a Production Lot shall be identified with markers as
detailed for a Production Lot. The identification of the Testing Lot to be
maintained until the Superintendent releases the HOLD POINT
associated with the certification that the Testing Lot conforms to the
requirements of the Specification.
5. The Contractor shall pre-determine, in accordance with the The Lot

Contract, what the portion of the Works shall be taken to constitute a
single Production Lot for each relevant process and the bounds of each
Testing Lot prior to sampling or testing.
6. No work shall proceed for any Lot until field identification has Field
been established for the extent of that Lot. Identification
7. The Contractor shall provide traceability for all manufactured Traceability

products incorporated into the Works in accordance with
AS/NZS ISO 9001 for identification and traceability. Unless otherwise
detailed in Annexure 201B, the trace shall start at the supplier and finish
at the location where product is incorporated into the Works.
8. If the manufacture of products off Site forms part of the Traceability

Contract, the Contractor must provide the Superintendent with the name Records
and address of the manufacturer and the date of commencement of
manufacture, at least seven (7) days prior to the commencement of
manufacture of such product(s). The traceability records associated with
the list in Annexure 201B shall be considered as constructed information
and forwarded to the Superintendent in accordance with the Contract.

201.09 CONTROL OF PRODUCTION AND SERVICE PROVISION

(PROCESS CONTROL)
1. The Contractor shall develop sufficiently detail process Process

descriptions and procedures in the Quality Plan that demonstrate the Control
Contractor’s control of production and service provision in accordance
with AS/NZS ISO 9001 for the Contract.
2. The processes listed in Annexure 201C and Annexure 201E Mandatory

shall, where they apply, be included in the development of the Process
Contractor’s processes for production and service provision in the Descriptions
Quality Plan to meet the requirements of the Contract.
3. Where directed by the Superintendent to undertake work Approval

under the Contract such as Daywork activities, the Contractor shall
develop and submit the relevant process descriptions for the proposed
activities for the Superintendent’s approval.
4. The management of all plant and equipment used to Plant and

undertake the work under the Contract shall be addressed in the Quality Equipment
Plan in accordance with AS/NZS ISO 9001.
201.10 VALIDATION OF PROCESSES FOR PRODUCTION AND

SERVICE PROVISION (SPECIAL PROCESSES)
1. The Contractor shall develop sufficiently detailed process

descriptions and procedures in the Quality Plan that demonstrate the
Contractor’s validation of processes for production and service provision
in accordance with AS/NZS ISO 9001 for activities detailed in
Annexure 201D.
201.11 CONTROL OF EXTERNALLY PROVIDED PROCESSES,

PRODUCTS AND SERVICES
1. Subcontractor, also to mean a Supplier, is a person other Definition

than the Contractor that supplies goods or services required to complete
any portion of the Works under the Contract.
2. The Quality Plan shall define the type and extent of control Control
exercised over those Subcontractors employed for the Contract in exercised
accordance with AS/NZS ISO 9001.
3. The Quality Plan shall address the control of subcontracts for Critical
the critical processes defined in Annexure 201E when any such work, Subcontracts
product or service is subcontracted.
4. The Contractor shall develop and maintain an Audit Audit

Schedule that details the audits to be undertaken by the Contractor of Schedule
the approved Subcontractors for the duration of the Contract. A current
copy of the Audit Schedule shall be forwarded to the Superintendent.

201.12 CONTROL OF DOCUMENTED INFORMATION

(DOCUMENTS AND RECORDS)
1. The Quality Plan shall detail the documented procedure for Document
the Control of Documents required by the Contract in accordance with and Data
AS/NZS ISO 9001. Control
2. The Control of Records shall be in accordance with the Control of

requirements of the Contract and AS/NZS ISO 9001. Records
3. The State Records Act 2000 requires Main Roads and its Legislative
Contractors to provide for the keeping of State Records related to Requirement
contracts.
4. The Contractor must implement and manage a Record Record

Keeping Plan in accordance with Main Roads’ Record Keeping Code of Keeping Plan
Practice for the Management of Contract Records. This document is
available from the Main Roads’ website, internet address:
http://www.mainroads.wa.gov.au - under: Building Roads/Contracting to
Main Roads/Records Code of Practice.
5. The Contractor shall supply a copy of the Record Keeping

Plan to the Superintendent within 28 days of Award of Contract.
6. The Contractor shall ensure as a minimum, but not limited to that Records
the following records are kept and forwarded to the Superintendent: Required
- audit reports;
- conformance reports;
- as constructed drawings and information;
- bitumen surfacing daily records and spraying loading records;
- Contractor supplied water bore-hydrological reports;
- commissioning records; and
- operation manuals relevant to the completed Works.

7. All records shall be clearly legible. The Contractor shall at all

reasonable times make available to the Superintendent copies of such
information on request.
8. The Contractor shall prepare a test report for all tests Test Reports
undertaken even when the result of the test will not be used for
compliance measurement. The Contractor shall deliver all test reports
for each Lot to the Superintendent within 24 hours of completing the test
procedure or carrying out a compliance measurement.
9. As Constructed Information shall clearly detail where the As

constructed Works differ from that shown on the current Drawings. The Constructed
Contractor shall detail As Constructed Information in red ink, accurately Information
and legibly on a clean set of current Drawings within (1) one week from
the information becoming available. The Contractor’s marked up
Drawings detailing the As Constructed Information shall be promptly
made available to the Superintendent upon request.
10. All information for incorporation into As Constructed Data Capture

Information shall be captured and stored in accordance with Main
Roads’ Digital Ground Survey standard and shall include METADATA in
accordance with Main Roads’ Metadata Requirements document, both
documents available on Main Roads’ website, internet address:
http://www.mainroads.wa.gov.au - under: Building Roads/Standards
and Technical/Survey and Geospatial Services. This type of As
Constructed Information shall be cross-referenced on the marked up
Drawings.
11. The Contractor shall supply to the Superintendent an Data

electronic record of the As Constructed Information in Autocad format in Lodgement
accordance with Main Roads’ Design and Drawing Presentation
standard, available on Main Roads’ website, internet address:
http://www.mainroads.wa.gov.au - under: Building Roads/Standards
and Technical/Road and Traffic Engineering/Typical Project Processes.
12. Within four (4) weeks from the Date of Practical Completion, Records at
the Contractor shall forward all records to the Superintendent. Practical
Completion
201.13 CONTROL OF NON-CONFORMING OUTPUTS
1. The Quality Plan shall detail the procedures that address the Non -
Control of Non-Conforming Output(s) in accordance with Conformance
AS/NZS ISO 9001.
2. All detected non-conformances shall constitute a HOLD Detected Non-

POINT in the operations of the work under the Contract associated with Conformance
the detected non-conformance and shall be reported to the
Superintendent within 24 hours of being detected.

3. The Contractor shall submit to the Superintendent a

proposed method for the rework, repair or removal of the non-
conforming Lot to ensure conformance to the requirements of the
Specification.
4. Any pavement Lot that is non-conforming in in-situ density In-situ Density

shall be fully reworked. Rework for pavements is defined as the Product
reconstruction of the non-conforming Lot in accordance with the
requirements of the Specification.
5. Prior to the release of the HOLD POINT on a detected HOLD POINT

non-conformance and/or non-conforming Lot, the Contractor shall
certify to the Superintendent and provide conformance records in
accordance with the Contract that the reworked or repaired Lot
conforms to the requirements of the Specification and the
Improvement to the Quality Plan is approved by the
Superintendent.
201.14 IMPROVEMENT
1. The Quality Plan shall detail the procedures for addressing Improvement
corrective and preventative actions for the Improvement of the Quality
Plan in accordance with AS/NZS ISO 9001.
2. The Contractor shall develop and submit a proposed Corrective

Corrective Action to eliminate the cause of a detected non-conformance Action
in accordance with AS/NZS ISO 9001 for the Superintendent’s approval. Approval
Associated action(s) to prevent any reoccurrence shall form part of the
corrective action process.
201.15 MONTHLY REPORTING
1. Within 5 days of the end of each month the Contractor shall Monthly
submit to the Superintendent a completed Monthly Quality Performance Reporting
report using the form available on Main Roads’ website, internet
address: http://www.mainroads.wa.gov.au - under: Building
Roads/Contracting to Main Roads/Contractor Reporting Forms.
The Contractor shall use this form or any updated version as advised by
the Superintendent for all quality reporting required under the Contract.
201.16 – 201.20 NOT USED

HOLD POINTS
201.21 HOLD POINTS
1. A HOLD POINT is defined as that stage in the process of Definition

delivering the work under the Contract, beyond which the Contractor
must NOT proceed to the next activity without the written approval of the
Superintendent.
2. The methodology for identifying, reaching and releasing

HOLD POINT(s) in the Contract shall be addressed in the Quality Plan.
3. To obtain release of the Hold Point for a Lot, the Contractor Hold Point
shall comply with the following requirements: Release for a
Lot
a) The Contractor shall have completed all conformance
inspection reports for any underlying Lot(s) or any adjacent
Lot(s) affected by the Lot in question.
b) All underlying Lot(s) and any adjacent Lot(s) affected by the

Lot in question shall be conforming.
c) The Contractor shall request a "Hold Point Release" in writing

Notice
with all supporting conformance test results at least 24 hours
or such other period detailed in the Specification prior to the
time when the Contractor wishes to proceed with the next
activity which affects the Lot in question.
d) The submission of any "Hold Point Release" to the

Contractor’s
Superintendent by the Contractor is the Contractor’s Certification
"Certificate of Compliance" that the submitted Lot conforms
to the Contract requirements.
201.22 – 201.80 NOT USED
AS CONSTRUCTED AND HANDOVER

REQUIREMENTS
201.81 – 201.90 NOT USED
CONTRACT SPECIFIC REQUIREMENTS

201.91 – 201.99 NOT USED

ANNEXURE 201A
TESTING REQUIREMENTS
In accordance with the requirements of the Contract for monitoring and measurement,
testing procedures and minimum testing frequencies shall conform to the following
details:
1.0 GENERAL
This Annexure sets out the minimum sampling and testing requirements for the
acceptance of various works to be carried out under the Contract. Additional sampling,
testing and acceptance requirements may be detailed elsewhere in the Specification or
in referenced Standards. Where no minimum sampling and testing requirements are
specified the Contractor shall be able to demonstrate conformance of the work in
accordance with Clause 9.1 of AS/NZS ISO 9001.
Included in the test methods shown in the following sections are requirements for test
authorities to be NATA accredited for the following applicable sampling and sample
preparation methods: WA 0.1, 100.1, 105.1, 200.1, 701.1, 705.1 and AS 1012 part 1.
The Contractor shall be responsible for patching holes made as a result of sampling and
testing.
The sample and test holes shall be backfilled immediately after sampling or testing by
the persons responsible for carrying out the sampling and testing. Backfilled material
shall have similar properties and shall be compacted at or near optimum moisture
content to densities matching the surrounding material.
The Contractor's conformance decision shall apply to the whole of the Lot or part of the
Work subject to test.
1.1 TEST METHODS
1.1.1 DENSITY - EARTHWORKS AND PAVEMENT
For the Works in general, density shall be measured in-situ by use of a nuclear
moisture/density meter in accordance with WA 324.2. All measurements shall be made
using the direct transmission mode.
If the in-situ density is outside the range of densities 1.5-3.05 t/m³ for which the nuclear
moisture/density meter can be calibrated then WA 324.1 shall be used.
For the purpose of measuring conformance of all work under the Contract, the in-situ
density shall be expressed as a percentage of the maximum dry density. This
percentage shall be calculated in accordance with WA 134.1.
The maximum dry density shall be determined by WA 133.1 or WA 133.2. Where the
pavement material is stabilised or modified with Portland Cement, the maximum dry
density determinations shall be commenced two (2) hours after mixing is complete and
shall be completed within a further two (2) hours. If Low Heat (LH) Cement or Lime is
used for the stabilisation or modification, these determinations shall be commenced

three (3) hours after mixing is complete and shall be completed within a further three (3)
hours.
1.1.2 DENSITY AND IN-SITU AIR VOIDS - ASPHALT
Density and in-situ air voids shall be determined on the basis of the results of tests of
core samples of asphalt sampled from the pavement in a stratified random manner, after
laying and compaction, in accordance with WA 701.1. Core samples shall not be taken
from asphalt placed on a bridge deck or other concrete structure. Core samples shall be
taken from asphalt placed over a geotextile reinforced seal.
The density of the samples shall be determined in accordance with WA 733.1 or

WA 733.2. The density shall be expressed as a percentage of the mean Marshall
Density of accepted asphalt from the same production shift in accordance with
WA 731.1 and WA 733.1 or WA 733.2. The air voids shall be calculated using the mean
Maximum Density of asphalt from the same production shift in accordance with
WA 732.2 and WA 733.1.
1.1.3 MOISTURE CONTENT
The Moisture content shall be determined using WA 110.1. If it is not practicable to use
this method, then WA 110.2 or WA 324.2 may be used. However, correlation must be
established with WA 110.1 before proceeding with the subsidiary methods WA 110.2
and WA 324.2.
1.1.4 CROSSFALL AND DEVIATION FROM A STRAIGHT EDGE
Crossfall and deviation from a straight edge shall be measured by WA 313.2.
1.2 IN-SITU DENSITY AND AIR VOIDS
1.2.1 IN-SITU DENSITY
The conformance of every Lot of the work under the Contract with respect to density
shall be determined by comparing the Characteristic Dry Density Ratio of the Lot (or the
Characteristic Percent Marshall Density of the Lot for asphalt) and the limits specified in
the Specification.
The dry density ratio (or the Marshall density) shall be determined at the number of
locations per Lot defined in Table 201A-1. The locations shall be selected in
accordance with WA 0.1.
The Characteristic Dry Density Ratio (or the Characteristic Percent Marshall Density),
Rc, of a Lot shall be calculated thus:
Rc = R - ks
where; R is the mean of the results of dry density ratio tests (or the mean of the
results of the percentage of Marshall Density tests) on the Lot being
assessed, reported to the nearest 0.1 percent
k is the multiplier as detailed in Table 201A-1

s is the standard deviation of the results of dry density ratio tests (or the
standard deviation of the results of the percentage of Marshall Density
tests) on the Lot being assessed, calculated in accordance with Clause 1.4
and reported to the nearest 0.1 percent.
TABLE 201A-1 DENSITY TEST REQUIREMENTS
Works Component Number Multiplier k 

of
Tests per Freeways Highways Shared
Lot and Paths
Main
Roads
Embankment Foundation 6 0.72 0.50 0.32
Embankment Construction:
Levees 3 0.31 0.31
Select Fill 6 0.72 0.50 0.32
Kerbing Backfill 3 0.72 0.31
Bedding & Embankment Backfill for 3 0.72 0.31
Culverts and Drainage Structures
Bridge Backfill 6 0.72 0.50 0.32
Bridge Foundation and MSE Wall Backfill 6 0.72 0.72 0.72
Subgrade Preparation 6 0.72 0.50 0.32
Sub-base 9 0.81 0.59 0.41
Basecourse 9 0.81 0.59 0.41
Asphalt Density and In-situ Air Voids:
General 10 0.98 0.75
Shared Path 6 0.32
Sheeting 6 0.50
 Unless otherwise noted, the multiplier ‘k’ shall be based on the major component of the
project i.e. freeway, highway, etc.
Rounding of all calculations should be in accordance with AS 2706.
1.2.2 IN-SITU AIR VOID CONTENT OF ASPHALT
The conformance of every Lot of the work under the Contract with respect to in-situ air
void content shall be determined by comparing the Characteristic In-situ Air Void content

of the Lot and the limits specified in the Specification. The number of core samples per
Lot is defined in Table 201A-1. The location of the core samples shall be selected in
accordance with WA 0.1. The Characteristic In-situ Void Content of a Lot shall be
calculated to the nearest 0.1 percent using the following formulae:
Minimum characteristic value = R - ks
Maximum characteristic value = R + ks
Where: R is the mean of the results of the percentage air void content on the Lot
being assessed, reported to the nearest 0.1 percent.
k is the multiplier as detailed in Table 201A-1.
s is the standard deviation of the results of air-void content on the Lot being
assessed, calculated in accordance with Clause 1.4 and reported to the
nearest 0.1 percent.
1.3 INSITU MOISTURE
The conformance of any Lot with respect to insitu moisture shall be determined by
comparing the Dryback Characteristic Moisture Content or Construction Characteristic
Moisture Content of the Lot and the limits specified in the Specification.
The moisture contents shall be determined at the number of test locations per Lot
defined in Table 201A-2. The test locations shall be selected in accordance with
WA 0.1.
(i) Construction Moisture Control
The Construction Characteristic Moisture Content (CMc) of a Lot shall be calculated

thus:
CMc = m + ks
where: m is the mean of the results of in-situ moisture content tests on the Lot
being assessed, reported to the nearest 0.01 percent.
s is the standard deviation of the results of insitu moisture content tests on

the Lot being assessed, calculated in accordance with Clause 1.4 and
reported to the nearest 0.01 percent.
(ii) Basecourse Dryback
The Dryback Characteristic Moisture Content (DMc) of a Lot shall be calculated thus:
DMUpper = m1 + ks1 and
DMLower = m2 + ks2

where: m1 is the average of the sample moisture contents on the Lot being
assessed, taken from the upper half of the Basecourse layer and
determined in accordance with WA 110.1 reported to the nearest
0.01 percent.
m2 is the average of the sample moisture contents on the Lot being

assessed, taken from the lower half of the Basecourse layer and
determined in accordance with WA 110.1 reported to the nearest
0.01 percent.
S1 is the standard deviation of the sample moisture content determinations

taken from the upper half of the layer, calculated using the following
relationship and reported to the nearest 0.01.
 x i  x 2
S1  i 1
n 1
where: xi is an individual result.
x is the mean of n results.
n is the number of results from one Lot.
S2 is the standard deviation of the sample moisture content determination

taken from the lower half of the layer, calculated using the following
relationship and reported to the nearest 0.01:
 x i  x 2
S2  i 1
n 1
(iii) Dryback of Other Layers
The Dryback Characteristic Moisture Content (DMc) of a Lot shall be calculated thus:
DMc = m + ks

where: m average of the sample moisture contents on the Lot being assessed,
taken from the pavement layer and determined in accordance with
WA 110.1, reported to the nearest 0.01 percent.
s is the standard deviation of the results of insitu moisture content tests on

the Lot being assessed, calculated in accordance with Clause 1.4 and
reported to the nearest 0.01 percent.
Table 201A-2 INSITU MOISTURE CONTENT REQUIREMENTS
Works Component Number Multiplier k 

of
Tests per Freeways Highways Shared
Lot and Paths
Main
Roads
Embankment Foundation 6 0.72 0.50 0.32
Embankment Construction:
Levees 3 0.31 0.31
Select Fill 6 0.72 0.50 0.32
Kerbing Backfill 3 0.72 0.31
Bedding & Embankment Backfill for 3 0.72 0.31
Culverts and Drainage Structures
Bridge Backfill 6 0.72 0.50 0.32
Bridge Foundation & MSE Wall Backfill 6 0.72 0.72 0.72
Subgrade Preparation, Stabilised Subgrade 6 0.72 0.50 0.32
Sub-base 9 0.81 0.59 0.41
Basecourse 9 0.81 0.59 0.41
Sheeting 6 0.50
 Unless otherwise noted, the multiplier ‘k’ shall be based on the major component of the
project i.e. freeway, highway, etc.
Rounding of all calculations should be in accordance with AS 2706.
1.4 STANDARD DEVIATION
Where specified the standard deviation ( S ) of the distribution of the values of a property
shall be calculated as:

 x i  x 2
S i 1
n 1
1.5 PROCEDURE FOR RESOLVING DISPUTED CONFORMANCE STATUS
Where the Superintendent's Audit testing indicates that a Lot is non-conforming and
such status is disputed by the Contractor, the following course of action shall be taken:
a) Where acceptance of a Lot is by statistical analyses for a quality verification
requirement listed in Table 201A-3, the results of the Superintendent’s Audit
Tests and Contractor's Tests shall be combined to determine acceptance or
otherwise of the Lot provided the following conditions are satisfied:
(i) The ratio of the greatest variance (standard deviation squared) to the
least variance of the two sets of results does not exceed the F value in
Table 201A-3.
(ii) The differences between the means of the two sets of results divided by
the standard error of difference (Sw) does not exceed the t value in
Table 201A-3. The standard error of difference shall be calculated using
the formula:
2  s12  s 22 
Sw 
N
where: sw is the standard error of difference
s1 is the standard deviation of audit test results
s2 is the standard deviation of Contractor's test results
N is the total number of results which must be contributed to equally by the audit
and Contractor’s testing.
The combined test results shall be used to calculate the required parameter in
accordance with the Specifications but using the ‘k’ multiplier in Table 201A-3.
b) Where the conditions (a)(i) or (a)(ii) are not satisfied or when acceptance of a
Lot or item is not by statistical analysis for a quality verification requirement
listed in Table 201A-3, the Contractor and Superintendent shall carry out
additional joint testing to determine the acceptance or otherwise of the work.
The joint testing shall be carried out in accordance with the following
requirements:

(i) Joint testing shall be carried out using the Contractor's Laboratory and
Testing Equipment.
(ii) Before the joint testing commences the Contractor’s nuclear
moisture/density meter shall be calibrated at Main Roads Materials
Engineering Branch and that calibration shall be used for the joint
testing and for subsequent testing.
(iii) Testing personnel from both parties shall be present during all phases of
sampling and testing.
(iv) The execution of all testing tasks shall be divided approximately equally
between both parties.
(v) Both parties shall have the right to repeat any non-destructive
measurements.
(vi) Calculations shall be to the satisfaction of both parties.
(vii) The application of joint test results shall be in accordance with the
Contract Specification and the results shall be accepted by both parties
as correct and final.
(viii) The costs of the calibration of the nuclear moisture/density meter and
the joint testing shall be assigned as follows:
- If the additional testing performed as above shows the Lot or item of
work to be conforming, the cost of such testing shall be borne by the
Principal.
- If the additional testing performed as above shows the Lot or item of

work to be non-conforming, the cost of such testing and any
subsequent test on the rectified work shall be borne by the
Contractor.
c) At any time and upon the request of either party, the Superintendent and
Contractor shall carry out an evaluation of their respective testing methods to
determine the reason for any continuing discrepancies and arrive at a uniform
testing technique.

TABLE 201A-3 COMBINATION OF RESULTS
Work Component Quality Total No of Multiplier k F t

Verification Tests/Lot Value Value
Requirement
Freeways Highways Shared
and Main Paths
Roads
Embankment Compaction 12 0.86 0.64 0.46 11 3.2

Foundation Standard
Embankment Compaction 12 0.86 0.64 0.46 11 3.2

Construction, Select Standard
Fill
Levees Compaction 6 0.64 0.64 - 11 3.2

Standard
Bedding & Compaction 6 0.86 0.64 0.46 11 3.2

Embankment Backfill Standard
for Culverts and
Drainage Structures
Bridge Foundation and Compaction 12 0.86 0.64 - 11 3.2

Bridge Backfill Standard
Kerbing Backfill Compaction 12 0.86 0.64 0.46 11 3.2

Standard
Subgrade Compaction 12 0.86 0.64 0.46 11 3.2

Preparation Standard
Stabilised Subgrade
Sub-base Compaction 18 0.93 0.71 0.52 6 2.9
Standard
Basecourse Compaction 18 0.93 0.71 0.52 6 2.9

Standard
Dry back moisture Moisture 18 0.93 0.71 0.52 6 2.9

content, Construction Standard
Moisture Content
Sheeting Compaction 12 0.86 0.64 0.54 11 3.2

Standard
Asphalt Compaction 20 1.06 0.83 0.54 5.4 2.9

Standard

2.0 MINIMUM TESTING FREQUENCY
1. The minimum frequency of testing to determine the conformance of Works

Processes with specified characteristics shall be as detailed in the Minimum Testing
Frequency Table of the Specification or in the following Table:
PRODUCT / QUALITY VERIFICATION MINIMUM TESTING

PROCESS REQUIREMENT FREQUENCY
2.1 ROADWORKS
Embankment FOR CONTROL OF COMPACTION:

Foundation End Product Specification:
 Dry Density Ratio (WA 134.1) As per Table 201A-1
 Particle Size Distribution (WA 115.2) 2 Per Lot
Contractor's Developed Method Spec:
(**1 in 5 Lots tested**)
 Particle Size Distribution (WA 115.2) 2 Per Lot
FOR CONTROL OF
CONSTRUCTION MOISTURE:
 Construction Characteristic 1 per test site as shown in
Moisture Content (WA 110.1 or Table 201A-2
110.2) (**All Lots tested**)
 Optimum Moisture Content 2 per lot
(OMC)
(WA 133.1 or WA 133.2)
(The mean value of these OMCs
shall be taken to represent the
Lot)
Principal's Method Spec:
 Particle Size Distribution (WA 115.2) 2 per Lot
FOR CONTROL OF
WA 110.2) (**All Lots tested**)
 Optimum Moisture Content 2 per Lot
(OMC) (WA 133.1 or WA 133.2)
Lot)


Excavations GEOMETRICS:
 Rural/Freeway As necessary to meet the specified
tolerances of the Technical
Specification
Embankment FOR CONTROL OF IMPORTED MATERIAL

Construction: SUPPLIED BY THE CONTRACTOR:
Culvert Selected  Particle Size Distribution (WA 115.1) 1 per 2,500 m3 bank in the ground
Bedding and Culvert
 Linear Shrinkage (WA 134.1) 1 per 2,500 m3 bank in the ground
Embankment
Lot
Backfill, Select Fill
FOR CONTROL OF COMPACTION:
End Product Specification:
Contractor's Developed Method Spec:
(**1 in 5 Lots tested**)
FOR CONTROL OF
 Optimum Moisture Content (OMC) 2 per Lot
(WA 133.1 or WA 133.2)
Lot)
FOR CONTROL OF
(WA 133.1 or WA 133.2)
Lot)


FOR CONTROL OF DRYBACK MOISTURE:
 Dryback Characteristic Moisture Content As per Table 201A-2
GEOMETRICS:
tolerances in the Technical
Specification
Subgrade FOR CONTROL OF COMPACTION:

Construction
FOR CONTROL OF CONSTRUCTION

MOISTURE:

 Construction Characteristic Moisture 1 per test site as shown in
Content (WA 110.1 or WA 110.2) Table 201A-2
(**All Lots tested**)
(WA 133.1 or WA 133.2)
(The mean value of these OMCs shall be
taken to represent the Lot)
(WA 136.1)
GEOMETRICS:
Specification
Sub-Base FOR CONTROL OF SUB-BASE SUPPLIED BY

THE CONTRACTOR:
 PSD (WA 115.1) 1 per 1,000 m3 of stockpile
 LA Abrasion (WA 220.2) 1 per 5,000 m3 of stockpile
 CaCO3 (WA 915.1) 1 per 5,000 m3 of stockpile
 MDCS (WA 140.1) 1 per 5,000 m3 of stockpile
 Liquid Limit (WA 120.2) 1 per 1,000 m3 of stockpile
 Plasticity Index (WA 122.1) 1 per 1,000 m3 of stockpile


 Linear Shrinkage (WA 123.1) 1 per 1,000 m3 of stockpile
 Soaked CBR (WA 141.1) 1 per 5,000 m3 of stockpile
MOISTURE:
Construction Characteristic Moisture As per Table 201A-2
Content (WA 110.1 or WA 110.2)
Sub-Base FOR CONTROL OF DRYBACK

(continued) MOISTURE:
(WA 136.1)
GEOMETRICS:
tolerances in the Specification.
FOR CONTROL OF COMPACTED SUB-BASE
MATERIAL SUPPLIED BY THE CONTRACTOR:
 PSD (WA 115.1) 1 per 3 Lots
 Linear Shrinkage (WA 123.1) 1 per 3 Lots
Additional FOR CONTROL OF STABILISATION:

Requirements for  Layer depth 9 sites per Lot
Cement Stabilised
 Cement content 6 sites per Lot
Sub-Base
Sheeting (access FOR CONTROL OF COMPACTION:
track)  End Product Specification:
Dry Density Ratio (WA 134.1) As per Table 201A-1
Particle Size Distribution (WA 115.2) 2 per Lot
Layer Depth for Access Track 6 sites per Lot
GEOMETRICS:
 Rural As necessary to meet the specified
tolerances in the Specification
Basecourse FOR CONTROL OF BASECOURSE SUPPLIED

BY THE CONTRACTOR:


 PSD (WA 115.1) 1 per 1,000 m3 of stockpile
 LA Abrasion (WA 220.1) 1 per 5,000 m3 of stockpile
 Flakiness Index (WA 216.1) 1 per 5,000 m3 of stockpile
 CaCO3 (WA 915.1) 1 per 5,000 m3 of stockpile
 MDCS (WA 140.1) 1 per 5,000 m3 of stockpile

 Liquid Limit (WA 120.2) 1 per 1,000 m3 of stockpile
 Plasticity Index (WA 122.1) 1 per 1,000 m3 of stockpile
 Linear Shrinkage (WA 123.1) 1 per 1,000 m3 of stockpile
 Dust Ratio (Contract) 1 per 1,000 m3 of stockpile
 Soaked CBR (WA 141.1) 1 per 5,000 m3 of stockpile
 Wet/Dry Strength Variation (AS 1141.22) 1 per 5,000 m3 of stockpile
 Secondary mineral content in basic 1 per 10,000 m3 of stockpile
igneous rock (AS 1141.26)
Basecourse  Accelerated soundness index by reflux 1 per 10,000 m3 of stockpile

(continued) (AS 1141.29)
 PSD & Bitumen Content (WA 730.1) 1 per 5,000 m3 of stockpile
 LA Abrasion for bitumen stabilised 1 per 5,000 m3 of stockpile
limestone (WA 220.2)
 Bitumen Emulsion (AS 1160) 1 per 10,000 m3 of stockpile
 Bitumen Dispersion (WA 717.1) 1 per 1,000 m3 of stockpile
 Emulsifiers & Wetting Agents Information to be provided by the
(as per Tech Spec) Supplier
 Dry Density Ratio As per Table 201A-1
MOISTURE:
 Construction Characteristic Moisture As per Table 201A-2
Content (WA 110.1 or WA 110.2)
GEOMETRICS:
Specification


FOR CONTROL OF COMPACTED
BASECOURSE SUPPLIED BY THE
CONTRACTOR:
 PSD (WA 115.1) 1 per 3 Lots
 Linear Shrinkage (WA 123.1) 1 per 3 Lots
Additional FOR CONTROL OF STABILISATION:

requirements for  Layer depth 9 sites per Lot
Cement Stabilised
Basecourse  Cement content 6 sites per Lot
Additional  Crushed Rock Base Same as for Basecourse

requirements for  7 day Unconfined Compressive Strength 1 per 5,000 m3 of stockpile tested
Hydrated Cement (WA 143.1) at the lower end of the
Treated Crushed construction hydration period
Rock Base (HCTCRB) range
 Repeated Load Triaxial Test using Test each 10,000 m3 of stockpile at
internal displacement measuring device the upper and lower end of the
(AG:PT/T053) construction hydration period
range
Additional  crushed rock base properties Each trial mix in accordance with
requirements for  7 day Unconfined Compressive Strength Specification 501
HCTCRB Trial Mixes (WA 143.2)
 28 day Unconfined Compressive
Strength (WA 143.2)
 Repeated Load Triaxial Test using
internal displacement measuring device
(AG:PT/T053)
2.2 BITUMINOUS SURFACING
Bitumen Emulsion  Tests as specified in AS 1160 and
Manufacture Specification 511
 pH at 25°C As required for quality control
 Particle Charge 1 test for each production batch for

 Residue from Evaporation each type of emulsion
 Setting Time For CRS 1 test for each production

batch
For other grades 1 test per week
 Sieve Residue 1 test for each type of emulsion
 Consistency at 25°C every month


 Water Content 1 test for each type of emulsion
 Non Aqueous Volatiles Content every 3 months
 Sedimentation
 Stone Coating and Water Resistance CRS only - 1 test every 6 months
Test – Cationic Bitumen Emulsions
(WA 756.2)
 Residue from evaporation – Viscosity at
60°C
Bitumen Emulsion  Residue from evaporation (AS 1160) 1 per delivery tanker
Delivery to Site
Bitumen Produced Tests in accordance with Specification 511
in Western Australia  Viscosity at 60°C 1 test for each production batch for
– Distillation of each binder class
 Viscosity at 135°C
Crude Oil
 Penetration at 25°C
 Viscosity of Residue at 60°C after RTFO
test
 Ductility at 15°C 1 test for each 4th production batch

 Matter Insoluble in Toluene for each binder class
 Density at 15°C As required for quality control but

 Flash Point no less than 1 per year
 Durability In accordance with

Specification 511
Bitumen Produced Tests in accordance with Specification 511

in Western Australia INITIAL BATCH: 1 test for initial batch for each
– Blending of binder class
Bitumens
test
 Matter Insoluble in Toluene
 Density at 15°C
 Flash Point
TRUCK LOADS: 1 test for each 5th load for each
 Viscosity at 60°C binder class
Bitumen Imported Tests in accordance with Specification 511


into Western  Viscosity at 60°C 1 test for each cargo load for each
Australia  Viscosity at 135°C binder class
test
 Ductility at 15°C after RTFO test
 Matter Insoluble in Toluene 1 test for each 4th cargo load for
each binder class
 Density at 15°C As required for quality control but

 Flash Point no less than 1 per year
 Durability In accordance with

Specification 511
Polymer Modified Tests in accordance with Specification 511

Binder  Torsional recovery 1 test for each production batch for
 Softening point each binder class
 Rubber Content (S45R) 1 test every week
 Viscosity at 165°C 1 test for each binder Class every

month
 Segregation Value 1 test for each binder Class every

month
S10E and S20E Classes Only 1 test for each binder Class every
 Consistency at 60°C month
 Stiffness
 Consistency 6% at 60°C
Polymer Modified All Other Binder Classes 1 test for each binder Class every 3
Binder (continued)  Consistency at 60°C months
 Stiffness
 Elastic recovery at 60°C (S25E and S45R
only)
 Consistency 6% at 60°C
 Compression Limit at 70°C (S45R only)
 Flash Point 1 test for each binder class no

 Loss on heating more than every 12 months
Crumb Rubber  PSD 3 per production lot

 Bulk Density
 Iron or Steel Content


Cutter/Flux Oils Certificate of conformance for all tests Currency of certificate to be no
older than two months
Geotextile Fabric for Tests in accordance with Specification 511

Sealing  Wide strip tensile strength 1 test for every 10,000 m2 of fabric
 Mass per unit area
 Maximum elongation
 Thickness
Bitumen retention at 160°C 1 test for every 50,000 m2 of fabric
 UV stabilisation – retained strength 1 test every 12 months

 Melting point
Reclaimed Asphalt Tested in accordance with Specification 511 3 samples for every 1,000 tonne of
Pavement (RAP) RAP
Source Rock  Weathering AS 1726 Table A9 One test per designated source
 Polished Aggregate Friction Value area or one test per year
(AS 1141.40/42)
Crushed Aggregate  PSD (WA 210.1) 3 tests per quarry production Lot
for Sprayed Sealing  Flakiness Index (WA 216.1) 3 tests per quarry production Lot
(Quarry Testing)  LA Abrasion (WA 220.1) 1 test per 6 months
 Water Absorption (AS 1141.6.1) 1 test per 6 months
 Degradation Factor (AS 1141.25.2) 1 test per 12 months
 Wet Strength and Wet/Dry Strength 1 test per 6 months
Variation (AS 1141.22)
 Petrographic Examination 1 test per 12 months per material
type
 Secondary Mineral Content (AS 1141.26) 1 test per 12 months
 Resistance to Stripping (AS 1141.50) 1 test per 6 months
Crushed Aggregate  ALD (AS 1141.20.1) Minimum 3 tests per dump site per
for Sprayed Sealing aggregate size
(On-site Testing)  Moisture Content (WA 212.1 or 212.2) 1 per aggregate size per delivered
lot and after inclement weather
Crushed Aggregate COARSE AGGREGATE

for Asphalt  Colour (WA 250.1) 1 test per Lot crushed material
 Flakines Index (WA 216.1) 1 test per quarry production Lot
 LA Abrasion (WA 220.1) 1 test per 6 months
 Water Absorption (AS 1141.6.1) 1 test per 6 months


 Degration Factor (AS 1141.25.2) 1 test per 12 months
 Wet Strength and Wet/Dry Strength 1 test per 6 months

Variation (AS 1141.22)
 Petrographic Examination 1 test per 12 months per material
type
 Secondary Mineral Content (AS 1141.26) 1 test per 12 months
 Resistance to Stripping (AS 1141.50) 1 test per 6 months

FINE AGGREGATE
 Colour (WA 250.1) 1 test per Lot crushed material
 Water Absorption (AS 1141.5) 1 test per 6 months
Sand Primerseal  PSD (WA 210.1) 3 tests per production Lot or day
Cover Material
Laterite Aggregate  PSD (WA 210.1) 3 per Lot
for Asphalt  Crushing Test Value (WA 223.1) 3 per Lot
 PAFV (AS 1141.40/42) 1 per contract per material type
Geometrics of  Sprayed Edge Position Every 100 m

Sprayed Surfacing
Asphalt Manufacture MINERAL FILLER:
– Materials  PSD 1 test per Lot
ADHESION AGENT:
 Tests to (AS 1672) Certification by producer for each
delivery
Asphalt Full test or partial test in accordance with Specification 502, 504 or 510.
Manufacture The minimum specified number of full tests shall be undertaken before
(routine testing) commencing any partial tests. A full test can be done in lieu of a partial
test.
Asphalt plant production per
shift per mix type and size


 Up to 50 tonnes 1 full test
 Up to 150 tonnes 2 full tests
 Up to 450 tonnes 3 full tests
 Up to 800 tonnes 3 full tests and 1 partial test
 Up to 1200 tonnes 3 full tests and 2 partial tests
 > 2000 tonnes 3 full tests and 5 partial tests
Asphalt  Moisture Content (AS/NZS 2891.10 or 1 test per week

Manufacture T660)
(periodic testing)  Uniform Coating of Binder 1 test per week
(AS/NZS 2891.11)
 Stripping Potential of Asphalt - Tensile 1 test per 5,000 T of 20 mm mix
Strength Ratio Test (AG:PT/T232) – 1 test per 5,000 T of 14 mm mix
Intermediate Course only using
freeze/thaw conditioning
 Asphalt Binder Drain Off (AG:PT/T235) 1 test per shift
Asphalt Laying ASPHALT PAVING:

 Bitumen content of tack coat 1 test per 3 batches – where a Lot
is not more than a day’s production
of tack coat
CONTROL OF COMPACTION:
 Asphalt Temperature on delivery 1 test per 4 trucks taken in paver

on a random basis OR 1 test per
truck load if more than 2 hours
since batching or after inclement
weather
 Percent Marshall Density As per Table 201A-1
 In-situ Air Void content As per Table 201A-1

GEOMETRICS:
 Width Every 10 m
 Depth Every 10 m


Microsurfacing –  Bitumen Emulsion Properties (AS 1160 Producer’s compliance certificate
Component Series) per production Lot.
Material Supply  Aggregate LA Abrasion (WA 220.1) Producer’s compliance certificate
including 1 test per 75000 m3
source rock
 Aggregate Pendulum friction test (PAFV Producer’s compliance certificate
– AS 1141.40 and AS 1141.41 or including 1 test per 75000 m3
AS 1141.42) source rock
 Particle size distribution (WA 210.1) 1 test per stockpile or per 500 m3
which ever is lesser
 Sand Equivalent (AS 1289.3.7.1) 1 test per stockpile or per 500 m3
 Mineral Filler Producer’s compliance certificate
per production Lot
 Polymer Modifier Producer compliance certification
per production Lot
 Additives Producer compliance certification
per production Lot
Microsurfacing  Particle Size Distribution (WA 730.1 and 1 test per lot where a Lot is 100 m3
Production and WA 210.1) or one days production which ever
Laying is lesser
 Binder Content (WA 730.1 or 1 test per lot where a Lot is 100 m3
AS 2891.3.1) or one days production which ever
is lesser
Finished Layer  Shape (WA 313.2) 5 tests per lot where a Lot is
100 m3 or one days production
 Texture Depth (WA 311.1) Wearing 4 Tests per lot where a Lot is
Course 100 m3 or one days production
2.3 DRAINAGE
Drains and Channels  Geometrics 1 cross section per 50 m
Subsoil Drains  Line and Level / Grade Every 5 m
Culvert Barrel  Line and Level / Grade Every 5 m

 Inlet / Outlet Invert Level Each
 Inlet / Outlet Easting and Northing Each
Corrugated Metal  Internal Diameter ( ≤ 750 mm) in Entire barrel length

accordance with AS 2566.2 Appendix O


Pipe  Internal Diameter ( > 750 mm) in Inlet, Outlet and L/2 for barrel
accordance with the Note below: length (L) ≤ 11 m, Inlet, Outlet, L/4,
L/2 and 3L/4 for L > 11 m
Corrugated Metal On completion of installation the Contractor shall measure the internal
Pipe (continued) diameter of the culvert at the pre-marked locations using a calibrated steel
measuring tape or other suitable measuring device as approved by the
Superintendent. The following information shall be recorded and reported:
a) Full details of the culvert tested including date of test and when backfill
was completed.
b) The pre- and post-installation diametric measurements.
c) Calculated installed deflections.
d) Whether each culvert tested was acceptable.
End Treatments and  28 Day Compressive Strength 3 Cylinders per 5 m3

Blinding Concrete  Concrete Slump Test 1 for each 5 m3 or part thereof
Bedding FOR CONTROL OF COMPACTION:

(Including Select Principal’s Method Spec:
Bedding Material)
 Moisture Content 3 per Lot
 Optimum moisture content (OMC) 3 per each material of constant

(WA 133.1 or WA 133.2) quality
(The mean value of these OMC’s shall be
taken to represent each material of
constant quality)
Backfill FOR CONTROL OF COMPACTION:

 Cement Stabilised Backfill Nil
 Embankment Quality Material 3 per Lot
Drainage Sumps CLAY LINING:

 PSD (WA 115.1) 1 per site
 Liquid Limit (WA 120.2) 1 per site
 Plasticity Index (WA 122.1) 1 per site
FOUNDATION BEDDING:
Principal’s Method Spec:
 Optimum moisture Content (OMC) 3 per each material of constant
shall be taken to represent each
material of constant quality)


BACKFILL:
 Cement Stabilised Material Nil
 Embankment Quality Material for As per Table 201A-1
Control of Compaction
GEOMETRICS: 1 cross section per 20 m
Duct Markers  Position, Height, Plumb Each
Floodway Rock  Particle Size Distribution Geometrics 1 per 1 000 m3

Protection 1 cross section per 25 m
Concrete Wall  Geometrics 1 cross section per 25 m
Stone Pitching  Stone Dimensions 1 per load

(Drainage)  Plan Dimensions 1 per site
Gabions  Geometrics 1 cross section per 10 m
Manholes, Gullies  Size, Position and Invert Level Each

and Catchpits FOUNDATION BEDDING:
 Optimum moisture Content (OMC) 3 per each material of constant

(The mean value of these OMCs shall be
taken to represent each material of
constant quality)
BACKFILL:
 Cement Stabilised Material Nil
 Embankment Quality Material for As per Table 201A-1
Control of Compaction
2.4 ROADWORKS MISCELLANEOUS
Guide posts and SLK  Position, Height and Vertical Each
Markers
Signs and Devices CONCRETE FOOTING:
 Compressive strength 3 cylinders per 25 m3 or part
(AS 1012 part 3, 8, 9) thereof
 Footing dimensions Each
 Position, Height and Vertical Each


Kerbing  Line and level Every 10 m (tolerances as per
AS 2876, Section 9
 Strength 3 specimens per 25 m3 or part
thereof
 Shape/Profile 1 cross section every Lot
 Setting Time (AS 1160 Appendix K) 1 per delivery tanker
Kerbing Backfill FOR CONTROL OF COMPACTION:

 Dry Density Ratio (WA 134.1) 3 per Lot
 Moisture Content (WA 110.1 or 3 per Lot

WA 110.2)
Fencing  Position and Line Every 50 m
Shared Path and  Width and Line Every 20 m

Cycleways  For Control of Compaction As Per Table 201A-1
Concrete Barriers  Dimensions and Profile Based on Lot Length

Length < 30 m 1 test
Length > 30 m < 100 m 2 tests
Length > 100 m 3 tests
 Alignment No portion of the barrier finished
outside of tolerances contained in
the “CONCRETE BARRIERS” Clause
of the INSTALLATION Section of
Specification 603
 Cover Minimum cover shall not be less
than specified
 Concrete Strength and Consistency Special Class Concrete
1 per 20 m3 or part thereof (1 test
if less than 20 m3)
N Class as per AS 1379
Wire Rope Safety  Footing dimensions Each Post

Barrier Systems  Post Position, Height and Verticality Each Post
the “WIRE ROPE SAFETY BARRIER
SYSTEMS” Clause of the
INSTALLATION Section of
Specification 603
 Wire Rope Anchor Blocks Dimensions Each Anchor Block


W-beam and Thrie  Hole dimensions Each Post
Beam  Post Position, Height and Verticality Each Post
the “W-beam & Thrie Beam”
Clause of the INSTALLATION
Section of Specification 603
 Foundation Capacity A random post selected every
100 m (minimum of 3 posts in
continuous length barrier)
Steel Rail Barriers  Footing Dimensions Each Post

 Post Position, Height and Verticality Each Post
 Rail Alignment Every 10 m (minimum length over
3 posts in continuous section)
Welding As per AS 1544: Refer to the “WELDING” Clause of

Steel Rail Barriers  Radiographic testing Specification 830 - STRUCTURAL
STEELWORK
 Visual Inspection
 Magnetic Particles
 Inspection
 Dye Penetration Test
 Ultrasonic Testing
End Treatments  Pre-excavated hole dimensions Each Post

 Post Position, Height and Verticality Each Post
 Alignment No portion of the end treatment
finished outside of tolerances
contained in the “W-beam & Thrie
Beam” Clause of Specification 603
Crash Attenuators  Foundation / Footing Each foundation / footing
Road Marking Paint  Producer Certification Per Delivery Load
Drop-on Glass  Producer Certification Per Delivery Load

Beads
Application of Paint  Application Rate Per Application Run
and Glass Beads  Geometry of Lines Every 100 m
2.5 BRIDGEWORKS AND BOX CULVERT

Bridge Foundations FOR CONTROL OF COMPACTION:
and Bridge Backfill End Product Specification:



GEOMETRICS:
 Rural As necessary to meet the specified
tolerances of the Specification
Structural Concrete  Consistency (Slump Test) 1 per 20 m3 or part thereof

(AS 1012.3.1) (1 test if less than 20 m3)
Where concrete batch plant
facilities are used outside the
Metropolitan area, a slump test
shall be carried out on each truck
delivering concrete to site.
 Strength (AS 1012 part 8 & 9) 1 per 20 m3 or part thereof
(1 test if less than 20 m3)
Fine Aggregate  Clay and Fine Silt (settlement method) 2 Monthly

(Concrete) (AS 2758.1)
 Organic Impurities other than Sugar 2 Monthly
(AS 2758.1)
 Particle Size Distribution (AS 2758.1) Monthly
 Water Absorption 6 Monthly
Coarse Aggregate  Particle Size Distribution (AS 2758.1) Weekly

(Concrete)  Water Absorption 6 Monthly
 Reactive Alkali (Part 2 of Report No. TR3 1 per source material per Contract
by the Cement & Concrete Association
of New Zealand).
Water  MRWA Test Method WA 910.1 Monthly
Concrete Trial Mixes (AS 1012 part 3): Each trial mix in accordance with
 Consistency (Slump Test) Specification 820
 Strength
Welding AS PER AS 1544: Refer Specification 830

Steel Beams; Road  Radiographic Testing
Safety Barrier  Visual Inspection
Systems and Traffic  Magnetic Particles
Barriers for
 Inspection
Structures
 Dye Penetration Test
 Ultrasonic Testing


Galvanising  Thickness Refer Specification 835
1 per m2
4 or 6 per m
4 per post
Paintwork  Dry Film Thickness Refer Specification 835

(AS 1580 OR BS 3900) 1 per m2
4 or 6 per m
4 per post
Elastomeric AS PER AS 1523: Refer Specification 860

Bearings  Compression
 Stability
 Proof Loading
 Stiffness
Abutment  Plan Dimensions 1 per Abutment site

Protection  Stone Dimensions 1 per Load
Parapet Panels  Dimensions Each

 Line/Level Every 5 m
Reinforced Earth  Panel Dimensions/Finish Each

BACKFILL:
 PSD 1 per Abutment
 Resistivity 1 per Abutment
 pH 1 per Abutment
 Dissolved Salts 1 per Abutment
 Panel Line/Level/Plumb Every 5 m
POLYMERIC REINFORCING STRIPS: (Under Refer Specification 802
job specific environmental conditions)
 Loading 1 per Bridge
 Exposure to Water 1 per Bridge
 Site Damage 1 per Bridge
 UV Exposure 1 per Bridge
 Temperature 1 per Bridge
Wall (including  Cross Section and Height 1 cross section per 25 m

footing)
 Position and Line Every 50 m
Fencing  Position and Line Every 50 m
Fence Post/Pier  Verticality Each Post/Pier


Footings  Footing Dimensions Each Post/Pier
Limestone Blocks  Refer Clause 903.22 of Specification 903 1 per 200 blocks
Anti-Graffiti Coating  Dry Film Thickness (ASTM D 6132) 1 per every m2 for each surface
Systems / panel painted
Paintwork  Dry Film Thickness (AS/NZS 1580) 1 per surface less than 1 m2
 Adhesion 1 per every 25 m2 for each coating
system layer
2.6 ELECTRICAL
Light Pole  Concrete Footings (AS 1012 part 3, 8, 9) 3 specimens per 25 m3 or part
Foundations thereof
 Footing Dimensions Each installation
Steel Light Poles  Welding (AS 1554) Each assembly

and Arms  Galvanising (AS 1650) Each assembly
 Fabrication (including lap joint) Each assembly
 Slip Base Torquing Each assembly
Pole Installation  Grouting Each installation

 Slip Base Retorquing Each installation
 Pole Position and Plumb Each installation
 Luminaire Focusing Each installation
Electric Cabling  Insulation Each circuit

 Earth Resistance Each installation
Luminaire  Focusing Each installation

Installation
Mast Installation  Pole Position and Plumb Each installation
 Orientation Each installation

ANNEXURE 201B
IDENTIFICATION AND TRACEABILITY
In accordance with the requirements of the Contract for product identification and
traceability, Traceability shall apply to:
1 STRUCTURAL CONCRETE The trace shall start at the batching plant at

the start of manufacture.
2 CONCRETE – GENERAL WORKS The trace shall start at the batching plant at
the start of manufacture.
3 WELDING FOR FABRICATION OF STEEL The trace shall start at the point of
BEAMS manufacture.
4 PRESTRESSING CABLES The trace shall start at the point of
manufacture
5 BRIDGE BEARINGS The trace shall start at the point of
manufacture
6 ASPHALT/BITUMEN The trace shall start at the asphalt/bitumen
supplier
7 PAINTS (INCLUDING ANTI-GRAFFITI The trace shall start at the point of
COATINGS) manufacture
8 CONTRACTOR SUPPLIED PAVEMENT The trace shall start at the point of
MATERIALS manufacture
9 GUIDEPOSTS The trace shall start at the point of
manufacture
1. The boundaries of each Lot of asphalt placed shall be recorded using Main Roads
chainages and SLK’s.
2. The location of asphalt represented by each grading and Marshall property test
result shall be recorded in terms of these identified Lots.

ANNEXURE 201C
MONITORING AND MEASUREMENT OF PROCESSES
1. MINIMUM REQUIREMENTS
In accordance with the requirements of the Contract for control of production and service
provision, the Contractor shall develop detailed process descriptions/procedures for the
following processes.
1.1 ROADWORKS
a) Clearing, Topsoil Removal and Respreading
b) Embankment Foundation Compaction
c) Earthworks and Excavation (Including Rock)
d) Pits and Quarries, Clearing, Topsoil Removal, Overburden Removal
e) Embankment Construction including Selected Fill
f) Subgrade Preparation
g) Sub-base Construction
h) Basecourse Construction
i) Cement Stabilisation of Basecourse
j) Road Safety Barrier Systems
1.2 DRAINAGE
a) Culvert Installation
b) Backfill to Conduits, Pipes, Box Culverts and Grids
c) Culvert Base Slabs and End Treatment Construction
1.3 MISCELLANEOUS ROADWORKS

a) Fencing
1.4 BRIDGEWORKS
a) Fabrication and Erection of Steel Beams
b) Manufacture of Precast Prestressed Concrete Beams
c) Concrete Manufacture, Transport, Placing and Curing
d) Bridge Foundation Compaction
e) Mechanically Stabilised Earth Abutments
f) Falsework Construction

g) Formwork Construction
h) Reinforcement Installation
i) Supply, Fabrication and Surface Treatment of Bridge Balustrades and Traffic

Barriers for Structures
j) Surface Finishes to Concrete
k) Prestressing Cables: Installation, Stressing and Grouting
l) Protective Treatment for Steel Surfaces
m) Manufacture and Installation of Bearings
n) Installation of Shear Keys
o) Installation of Expansion Joints
p) Pile Driving
q) Abutment Protection
r) Limestone Retaining Walls
1.5 ELECTRICAL
a) Lighting Pole Manufacturing, Base and Pole Installation
b) Conduits and Cable Pit and Electrical Cabling Installation
c) Telephone Foundation Installation
1.6 CRUSHED ROCK PRODUCTS

a) Source Rock Production
b) Crushed Products - Production and Stockpiling
c) Preparation of Conforming Products Stockpile
1.7 BITUMINOUS SURFACING

a) Preparation of Surface
b) Prime, Primerseal and Seal
c) Rubberised Seal
d) Asphalt Production and Laying - to demonstrate that manufacturing

processes are under control, the Contractor will need to address the
following aspects with appropriate documentation or procedures.
1.7.1 Aggregate Control

a) Supplier to have quality system to AS/NZS ISO 9001.

b) Contractor to audit suppliers’ Quality System and product.
c) Incoming inspection to include examination of documentation

demonstrating required level of NATA endorsed testing carried out by
supplier. These records are to be available to the Superintendent.
d) Product identification and traceability to be maintained.
e) Action plans to correct non-conformances to be documented.
f) Storage and stockpiling at asphalt plant should allow for:
(i) all incoming material to be separately stockpiled until conformance is

verified;
(ii) separate storage for each size and type, with appropriate
identification;
(iii) preparation and maintenance of stockpile floor (e.g. concrete);
(iv) measures to prevent contamination;
(v) accountability and traceability for product movement;
(vi) action plan to correct non-conformances; and
(vii) non-conformance limits to be established for properties not given
limits in Specification (e.g. PSD).
1.7.2 Bitumen Control

a) Incoming inspection to include:
(i) examination of appropriate documentation given producer

certification; and
(ii) checking of load and bitumen temperature on delivery.
b) Separate identified storage for each class of bitumen.
c) Continuous recording of temperature in the ring (production) line.
1.7.3 Control of Hydrated Lime and Other Materials

a) Inspection of documentation demonstrating conformance certification from
supplier.
b) Appropriate separate and dry storage for hydrated lime and any other filler.
1.7.4 Asphalt Production by Continuous Plants
The process control procedures shall address the following:

a) Aggregate Cold Feed (including Filler)
(i) documentation of proportions of and PSD limits for each component

required
(ii) calibration of the feed system of each component over the full range
of material feed rates
(iii) regular monitoring of moisture content determinations on feed
aggregate with action plan for adjustment of feed rate

(iv) visual inspection of feeds (4/day)

b) Bitumen Feed
(i) calibration of bitumen feed over full range of feed rates and
temperatures
(ii) regular documented checks on bitumen feed rate at operating
temperature (1/week)
(iii) establishment of conformance limits for feed rates
(iv) establishment of action plans in event of non-conformance
c) Mixing
(i) continuous recording of mix discharge temperature

(ii) regular testing of particle (AS/NZS 2891.11)
(iii) regular testing of moisture content (AS/NZS 2891.10 - weekly)
(iv) establishment of action plan in event of non-conformance
d) Storage and Delivery
(i) duration of storage at plant to be recorded

(ii) delivery truck cleanliness to be checked
(iii) check that mix is covered during delivery
(iv) temperature on delivery to be tested in accordance with testing
schedule (attached)
e) Final Inspection and Testing
Conformance testing shall be carried out in accordance with the testing

schedule for each Lot. A Lot is defined as one day's production of a specified
mix type or less if changes are made which result in the creation of a new
Lot. All test reports shall be NATA endorsed and reported to the
Superintendent as a conformance record. When a non-conformance is
detected its disposition shall be in accordance with documented procedures.
1.7.5 Asphalt Production by Batch Plants

a) Aggregate Cold Feed
As for continuous plants (4(i)).

b) Screening and Storage in Hot Bins
(i) description of bin and screen monitoring process;

(ii) action plan for correcting problems.
NB: A description of current practice should be sufficient.
c) Proportioning
(i) documentation of proportions of each hot bin component required

and PSD limits for each component;
(ii) calibration of aggregate weigh bin over full range;
(iii) regular documented checking of weighing;
(iv) recording of mass of each component for each batch mixed;

(v) calibration of bitumen weigh bucket or metering device over full

range;
(vi) regular documented checking of bitumen weighing;
(vii) recording of mass of bitumen in each batch;
(viii) recording of the discharge temperature of each batch;
(ix) regular testing of particle coating (AS/NZS 2891.11 weekly);
(x) regular testing of moisture content (AS/NZS 2891.10 weekly);
(xi) establishment of conformance limits and non-conformance action
plans.
d) Storage and Delivery
As for continuous plants (4(iv)).

e) Final Inspection and Testing
As for continuous plants (4(v)).
1.7.6 Asphalt Placing and Compaction
The installation phase of the Contract will be described by a documented

process description which will need to cover the following aspects where
relevant:
a) Identification of Lots for placing and traceability of material
b) Traffic control measures
c) Transport of asphalt from plant to site
d) Preparation of surface
e) Application of tack coat
f) Placing of material, including joints
g) Compaction
h) Inspection and testing covering insitu density and geometric requirements
i) Protection of work
1.8 PAVEMENT MARKING

a) Road Surface Preparation
b) Road Marking Paint Application
c) Glass Bead Application
d) Retroflective Raised Pavement Markers
2.0 DOCUMENTED PROCESS DESCRIPTIONS
The process descriptions shall address, but not be limited to, the following:
a) the sequence of operations;

b) the types of equipment required, its maintenance, calibration etc;
c) any special working environment aspects;
d) competency and skills of personnel;
e) the work methods;
f) materials to be used;
g) division of work into Lots;
h) characteristics, tolerances and workmanship standards to be met;
i) inspection, test and control points;
j) how the process will be monitored to ensure its continuing suitability; and
k) records to be maintained.
Prescribed customer requirements shall also be explicitly addressed.

ANNEXURE 201D
VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE PROVISION
1. SPECIAL PROCESS PROCEDURES
1.1 In accordance with the requirements of the Contract for validation of

processes for production and service provision, Procedures shall be prepared for
the following processes:
1.1.1 SURVEYING
a) Compliance with the criteria detailed in Specification SERIES 100 - SURVEY
INFORMATION.
b) Monitoring, verification and validation of ALL survey activities undertaken to

meet the requirements of the Contract.
c) Survey records of observations and calculation undertaken for verification of

Lot conformance.
d) Survey equipment.
1.1.2 PRESTRESSING
1.1.3 GALVANISING
1.1.4 STRUCTURAL CONCRETE
1.1.5 WELDING
1.1.6 STEEL FABRICATION
1.1.7 PAINTING

ANNEXURE 201E
REQUIREMENTS FOR SELECTED CRITICAL SUBCONTRACTS
Subcontractors for the following critical processes must have Third Party Certification of
their Quality Management System to AS/NZS ISO 9001 for the manufacture and supply
of:
 Aggregate
 Asphalt / placement
 Bitumen stabilised limestone
 Bitumen products
 Cement stabilisation of pavements
 Concrete
 Culverts - pipe and box type
 Drainage structures (including manholes and gullies)
 Electrical Installation (including lighting, traffic signals & ITS installations)
 Limestone
 Pavement marking
 Prestressing / post tensioning
 Prime, Primer Sealing, Sealing, Resealing and Enrichment
 Rockbase
 Sealing
 Signs (supply only)
 Steel fabrication
 Steel reinforcing
 Structural Components for Bridges including, but not limited to, beams, bearings,
expansion joints and piles

SPECIFICATION 201 GUIDANCE NOTES

DELETE THESE GUIDANCE NOTES FROM FINAL DOCUMENT AFTER USING FOR
REFERENCE
All edits to downloaded TDP documents shall be tracked (most word processing
software allows this to be done automatically). Deletions shall be struck through e.g.
example. Insertions shall be in italics e.g. example. If all information relating to a clause
is deleted then the clause number should be retained and the words "NOT USED"
should be inserted.
The proposed documents with tracked changes shall be submitted to the Project
Manager for review, prior to printing the final batch of documents. When this final
printing is carried out, the tracked changes option is to be turned off.
The Custodian of this specification is the Manager Project Services.
1. ANNEXURE 201A TESTING
The list of minimum testing frequencies shown in Clause 2 must be appropriately

amended to suit the requirements of the Contract.
2. ANNEXURE 201B IDENTIFICATION AND TRACEABILITY
The list of elements must be appropriately amended to suit the requirements of the
particular works.
3. ANNEXURE 201C MONITORING AND MEASUREMENT OF

PROCESSES
The list of processes must be amended to suit the requirements of the particular works.
4. ANNEXURE 201D VALIDATION OF PROCESSES FOR PRODUCTION

AND SERVICE PROVISION
particular works.
5. ANNEXURE 201E REQUIREMENT FOR SELECTED CRITICAL

SUBCONTRACTS
particular works.
6. AS CONSTRUCTED INFORMATION
If as constructed information other than that detailed at Clause 201.13 (“Control of

Records”) is required then that additional information will need to be added to the
CONTRACT SPECIFIC REQUIREMENTS Section of the Specification.

CONTRACT SPECIFIC REQUIREMENTS TO ADD OR DELETE
The following clauses are to be placed under the CONTRACT SPECIFIC

REQUIREMENTS as required.
NONE AT THIS TIME.

SPECIFICATION AMENDMENT CHECKLIST
Specification: 201 – QUALITY SYSTEMS Revision No: ______
Project Manager: Name: _______________Signature: _____________Date:________
Checked By: Name: _______________Signature: _______________Date:________
Contract No: _______Contract Description: __________________________________
ITEM DESCRIPTION SIGN OFF

Note: All changes/amendments must be shown in Tracked Change mode until approved.
1. Project Manager has reviewed Specification and identified Additions
and Amendments.
2. CONTRACT SPECIFIC REQUIREMENTS addressed? – Contract specific
materials/products/clauses added? (Refer Specification Guidance
Notes for guidance).
3. Any unlisted Materials/Products proposed and approved by the
Project Manager? – if “Yes” provide details at 15.
4. Standard Clauses amended? – MUST SEEK approval from Manager
Commercial
5. Clause deletions shown as ‘NOT USED’.
6. Appropriate INSPECTION & TESTING parameters included in Spec 201
(Test Methods, Minimum Testing Frequencies verified).
7. ANNEXURES completed (Refer Specification Guidance Notes).
8. HANDOVER and AS CONSTRUCTED requirements addressed.
9. Main Roads QS has approved changes to SMM.
10. Project Manager certifies completed Specification reflects intent of
the design.
11. Completed Specification – independent verification arranged by
Project Manager
12. Project Manager’s review completed.
13. SPECIFICATION GUIDANCE NOTES deleted.
14. TABLE OF CONTENTS updated.
15. FOOTER updated with Document No., Contract No. and Contract
Name.
16. Supporting information prepared and submitted to Project Manager.
Further action necessary:
Signed: (Project Manager) Date: _______________


Specification 201 Quality Systems 14 April 2016.RCN-D1623234100

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Specification 201 Quality Systems 14 April 2016.RCN-D1623234100

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SPECIFICATION 201

Document No: Dxx#xxxxx Page 2 of 59

Contract No: xxxx/xx Contract Name

Document No: Dxx#xxxxx Page 3 of 59

Contract No: xxxx/xx Contract Name

SYSTEM ELEMENTS – ADDITIONAL REQUIREMENTS .......................................... 11

HOLD POINTS ........................................................................................................... 18

AS CONSTRUCTED AND HANDOVER REQUIREMENTS ....................................... 18

CONTRACT SPECIFIC REQUIREMENTS ................................................................. 18

ANNEXURE 201A ...................................................................................................... 19

ANNEXURE 201B ...................................................................................................... 47

ANNEXURE 201C ...................................................................................................... 48

Contract No: xxxx/xx Contract Name

ANNEXURE 201D ...................................................................................................... 54

ANNEXURE 201E ...................................................................................................... 55

Document No: Dxx#xxxxx Page 5 of 59

Contract No: xxxx/xx Contract Name

1. The Contractor shall manage its Contract obligations through

3. The Contractor shall establish, implement and manage a

4. For terms and definitions refer to AS/NZS ISO 9000. Definitions

5. The Superintendent shall reserve the right to conduct Surveillance

1. Australian Standards, MAIN ROADS Western Australia

AS 2124-1992 General Conditions of Contract

AS/NZS ISO 9000 Quality Management Systems- Fundamentals and

AS/NZS 1554 Structural steel welding

AS/NZS 2566.2 Buried flexible pipelines – Installation

AS 1012.1 Sampling of concrete

AS 1012.3.1 Determination of properties related to

AS 1160 Bituminous emulsions for the construction and

AS 1289.5.8.5 Methods of testing soils for engineering purposes-

AS 1523 Elastomeric bearings for use in structures

AS 1544.2 Methods for impact tests on metals

AS 1580 Paints and Related Materials – Methods of test

AS 2706 Numerical Values – Rounding and Interpretation of

Austroads Test Methods

AG:PT/T053 Determination of Permanent Deformation and

MAIN ROADS Test Methods

WA 0.1 Random Sample Site Location

WA 100.1 Sampling Procedures for Soil and Manufactured Granular

WA 122.1 Plasticity Index

Document No: Dxx#xxxxx Page 7 of 59

Contract No: xxxx/xx Contract Name

WA 123.1 Linear Shrinkage

WA 133.1 Dry Density/Moisture Content Relationship: Modified

WA 135.1 Calibration of Nuclear Moisture/Density Meters: Standard

WA 140.1 Maximum Dry Compressive Strength

WA 141.1 Determination of the California Bearing Ratio of a Soil:

WA 143.1 Determination of the Unconfined Compressive Strength of

WA 210.1 Particle Size Distribution of Aggregate

WA 216.1 Flakiness Index

WA 220.1 Los Angeles Abrasion Value

WA 220.2 Los Angeles Abrasion Value of Crushed Limestone

WA 223.1 Crushing Test Value

WA 235.1 Bulk Density of Granulated Rubber

WA 236.1 Particle Size Distribution of Granulated Rubber

WA 237.1 Steel Content of Granulated Rubber

WA 250.1 Colour of Aggregate

WA 313.2 Surface Shape Using a Straightedge

WA 324.1 Dry Density: Sand Replacement Method

WA 324.2 Determination of Field Density: Nuclear Method

WA 701.1 Sampling and Storage of Asphalt

WA 705.1 Preparation of Asphalt for Testing

WA 717.1 Dispersion of Bitumen in Soil

WA 730.1 Bitumen Content & Particle Size Distribution of Asphalt