DRAFT

EUROPEAN STANDARD prEN 12271-10

NORME EUROPÉENNE
EUROPÄISCHE NORM June 2002

ICS

English version

Surface dressing - Specifications - Part 10: Factory production

control

Enduits superficiels d'usure - Qualité - Partie 10: Contrôle Oberflächenbehandlung - Qualitätsnachweis - Teil 10:
de la production en usine Werkseigene Produktionskontrolle

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 227.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same
status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2002 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 12271-10:2002 E
worldwide for CEN national Members.
prEN 12271-10:2002 (E)

Contents

1 Scope and field of application ......................................................................................................................3

2 Normative references ....................................................................................................................................3
3 Terms and definitions....................................................................................................................................4
4 Requirements .................................................................................................................................................4
5 Control procedures........................................................................................................................................6
6 Inspection and testing...................................................................................................................................7
7 Non-conformity ..............................................................................................................................................8
8 Inspection, measuring and test equipment.................................................................................................9
9 Records.........................................................................................................................................................10
10 Training .........................................................................................................................................................10
Annex A (normative) Use of statistical control within factory production for surface dressing ......................16
Bibliography ..............................................................................................................................................................17

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Foreword
This document (prEN 12271-10) has been prepared by Technical Committee CEN/TC 227, "Road materials", the
secretariat of which is held by DIN.

This document is currently submitted to the CEN Enquiry.

This Draft European Standard for Factory Production Control has been written to meet the particular needs of the
Construction Product Directive regarding systems for attestation of conformity. It is also suitable for use in more
general quality systems in the surface dressing industry. The Draft European Standard is based on certain
requirements of EN ISO 9001 but stands alone and does not require reference to EN ISO 9001 for its application.

1 Scope and field of application

This Draft European Standard specifies Factory Production Control (FPC) requirements for use by those designing
and manufacturing surface dressing as a product. It also gives guide for the certification bodies involved with the
factory production control of surface dressing.

The Factory Production Control has the quality aim to give adequate assurance that the surface dressing conforms
to the relevant technical specification and the performance requirements of the surface dressing.

The Factory Production Control is required to be applied to all harmonized elements of European Harmonised
Standards and European Technical Approvals for surface dressing if the CE marking of conformity is to be affixed.
The system may also be applied to non-harmonized elements and situations where CE marking is not mandatory.

These performance levels may be demonstrated using the type approval procedure described in
prEN (WI 00227212) or from a European Technical Approval Guideline.

Procedures and installation processes as well as process control systems are continuously being developed, which
means that new systems for Factory Production Control will be introduced and implemented.

NOTE 1 Design is not part of the harmonized part of the standard for surface dressing, however the FPC document shall
have reference to the method used for any adjustment to the design proposal.

An FPC system conforming to the requirements of the relevant parts of EN ISO 9000 and made specific to the
requirements of this standard is considered to satisfy the requirements.

NOTE 2 A quality assurance system to EN ISO 9001 including test frequencies (such as UK sector scheme 13 or AFNOR or
DIN guidelines) will be acceptable.

2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate places in the text and the publications are listed hereafter. For
dated references, subsequent amendments to or revisions of any of these publications apply to this European
Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the
publication referred to applies.

Here follows a list all the normative references:

prEN (WI 00227212), Surface dressing — Specifications on quality — Type Approval Installation Trail (TAIT).

prEN 12272-1, Surface dressing — Test methods — Part 1: Rate of spread and accuracy of spread of binder and
chippings.

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prEN 13043, Aggregates for bituminous mixtures and surface dressings for roads, airfields and other trafficked
areas.

EN ISO 9000, Quality management systems — Fundamentals and vocabulary.

3 Terms and definitions

For the purposes of this European Standard, the following terms and definitions apply.

3.1
Factory Production Control
permanent internal system of control of production by the producer and comprises the operational procedures and
practices that are adopted to regulate the quality of a product. It includes a record of the design procedure and the
inspection and tests used to monitor the equipment, constituent materials, manufacturing process and the finished
product

The task of Factory Production Control is to give assurance that production conforms to the relevant Technical and
Performance Specifications.

3.2
technical specifications
Harmonized European Standards and European Technical Approvals for surface dressing

3.3
Design Proposal
design proposed (recipe and method statement) to provide the performance requirements specified

3.4
organoleptic check
evaluation made with the senses: sight, touch, smell, hearing, etc. It is a broader concept than the more commonly
used term “visual inspection”

For example, a check on a binder delivery might involve visual (colour, fuming and texture), smell (odour) and
touch (tackiness when cured and at ambient temperature). This would detect whether binder conformed to the
expectations of the tester and would be the quickest way to detect a defective load.

Similar principles apply to aggregates, particularly with stockpile inspection where handling soon reveals
cleanliness, grading or flakiness problems.

NOTE In all cases organoleptic checks should extend only as far as health and safety regulations permit.

4 Requirements

4.1 Factory Production Control

The producer shall operate a factory production control system complying with the requirements of this European
Standard.

4.2 Quality Plan

The Quality Plan shall particularly include:

 the producer’s organisational structure relating to quality;

 document control;

 procedure for adjusting design for the particular site conditions;

 control procedures for constituent materials;

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 process control;

 requirements for the handling and placement of the product;

 equipment calibration and maintenance;

 requirements for inspection and testing of processes and products;

 procedures for handling non-conformity;

 procedures for preventive action and continuous improvement.

The Quality Plan shall also include frequencies of inspection and testing. The frequencies given in the Tables are
the minimum frequencies. They may be changed where an alternative statistical system is developed and is
accepted by the Approved Body in accordance with the National Application Documents.

4.3 Organisation

4.3.1 Responsibility and authority

The responsibility, authority and inter-relation of all personnel who manage, perform and verify work affecting
quality shall be defined in Quality Plan, particularly for personnel who have authority to:

 modify the design locally to adjust to road and environmental conditions;

 initiate action to prevent the occurrence of product non-conformity;

 identify and record any product quality problems;

 determine that the surface dressing is satisfactorily installed to open the road to unrestricted traffic.

4.3.2 Management representative

The producer shall appoint a person with appropriate authority, knowledge and experience to supervise factory
production control and to ensure that the requirements of the Quality Plan are implemented and maintained.

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

4.3.3 Internal audits

The producer shall carry out internal quality audits to verify which quality activities comply with the planned
arrangements and to determine the effectiveness of the quality system. Audits shall be scheduled on the basis of
the status and importance of the activity. The audits and follow up action shall be carried out in accordance with
documented procedures. The results of the audits shall be documented and brought to the attention of the
personnel having responsibility in the area audited. The management personnel responsible for the area shall take
timely corrective action on the deficiencies found by the audit and shall keep a record of the action taken.

4.3.4 Management review

The Factory Production Control system shall be reviewed at least once per year by management to ensure its
continuing suitability and effectiveness. Records of such reviews shall be maintained.

4.3.5 Sub-contract services

Where any sub-contacted services are supplied from outside the producer’s resources, a means of control shall be
established. Records of such sub-contract services shall be maintained.

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4.4 Document control

The producer shall establish and maintain documented procedures to control all documents and data that relate to
the requirements of this Standard.

5 Control procedures

5.1 Constituent materials

Adequate supplies of constituent materials shall be available to ensure that the planned rate of production may be
maintained.

The specification and tolerances for incoming constituent materials necessary to ensure conformity with the design
shall be established and communicated to suppliers by means of written orders.

Control procedures shall verify that suppliers of incoming materials are capable of providing the required quality of
materials.

Different material types and grades shall be transported and stored in such a manner as to avoid intermingling,
contamination or deterioration which may affect the quality of the product.

NOTE The general requirements of 5.2 will need to be translated into more detailed site or contract specific requirements
which may include the following:

 aggregates

 procedures for the control of aggregates delivered to a depot;

 requirements for labelling storage bays.

 binders

 requirements for heating, temperature control and insulation of tanks, both static and spraying equipment;

 requirements for labelling of tanks;

 requirements for controlling delivery of binders into correct tanks;

 control requirements for additives, breaking agents and any other additional constituents.

5.2 Process control

The producer shall produce a method statement for each site or group of sites for the production of the surface
dressing. The producer’s management shall have a working knowledge and access to all relevant documentation
including the contract, relevant European Standards and the quality plan.

Before site work commences the producer shall ensure that the following is documented and issued to the
appropriate site personnel. A copy shall be retained for record purposes.

 any special instructions to the site staff relating to the programme of work;

 the equipment required for the work and the method of working to meet the design proposal and the
requirements of the contract;

 any additional instructions including application requirements.

Processes to be controlled

 ensuring that the purchased materials conform to the contract requirements;

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 ensuring that the materials are clearly identified;

 the presence of competent personnel during the production of the surface dressing;

 a system for handling and taking account of any changes ordered by the purchaser;

 record of the road surface condition prior to production of the surface dressing and any local variations to the
design proposal;

 compliance with requirements of proper traffic control to maintain performance where the site is open to public
use;

 procedure and time scale for notifying the purchaser of any problems which may affect the planned
programme of work;

 activities to maintain the product until the end of the guarantee period.

Records shall be kept of the operation on site covering the period shortly before operations commence until the
opening of the site to unrestricted normal traffic. These records shall contain the following:

 all test results;

 variations from the design proposal including those necessitated by site conditions;

 unforeseen problems (weather conditions, emergency vehicle damage, etc.);

 weather information;

 any other information considered relevant to the performance of the product.

Minimum inspection frequencies are provided in Table 1. The National Application Document may detail increased
frequencies depending on the intended use.

Other information may be recorded as an option when detailed in the National Application Document, such as:

 traffic control measures.

5.3 Traceability

The surface dressing shall be identifiable and traceable with regard to its production data.

5.4 Equipment calibration and maintenance

The Quality Plan shall identify those items of measuring equipment, which require calibration and the frequency of
such calibration which shall comply with the requirements of Table 2 and annex A.

Calibration procedures shall be provided, including the permitted tolerances for the equipment to remain in service.
The Quality Plan shall state the required accuracy of all equipment calibration and shall identify any that require
traceability to national standards.

The equipment shall be adequately maintained to ensure that it continues to be capable of producing surface
dressing to the required specification, design proposal and tolerance.

6 Inspection and testing

6.1 General

All necessary facilities, equipment and personnel shall be available to carry out the required inspections and tests.

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Inspection and testing shall be carried out as set out in the Quality Plan. Table 1 to Table 6 and the National
Application Document set out the minimum frequencies to be applied.

NOTE 1 The purchaser may require more frequent testing.

NOTE 2 Where the producer has demonstrated control and no failures have occurred the testing frequency may be reduced
as detailed in the National Application Document.

6.2 Incoming constituent materials

Incoming constituent materials shall be inspected and tested using procedures detailed in the quality plan and to a
schedule complying with requirements of this clause. Results of tests carried out by a supplier may be used may be
used if the supplier’s quality plan is called up in the producer’s quality plan.

The required inspections of materials in storage shall be maintained to establish that no deterioration has occurred.

Detailed requirements shall be as follows:

 Aggregates (see Table 3);

 Binders (see Table 4);

 other constituents (see Table 5).

Supply certified under an EN ISO 9000 or Factory Production Control system shall be a valid alternative to some or
all of the above requirements, subject to acceptance by the Approved Body.

6.3 Production and performance

Production and performance shall be inspected and tested using procedures detailed in the quality plan and to a
schedule complying with requirements of this clause.

Detailed requirements shall be as follows:

 measurements during production (see Table 6).

Appropriate statistical records shall be maintained in order to monitor and verify process capability and product
characteristics.

7 Non-conformity
The supplier shall establish and maintain documented procedures to ensure that product that does not conform to
specification is identified, documented, evaluated for disposition, remedial action and for immediate notification to
management and the purchaser.

7.1 General

Non-conformity may arise at the following stages:

1) in incoming constituent materials;

2) in constituent materials during storage;

3) in producing the product.

In the event that a non-conforming design, material, process or product is identified, investigations shall be initiated
to determine the reasons for non-conformity and effective corrective action shall be implemented to prevent
recurrence in accordance with the procedures laid down in the Quality Plan.

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7.2 Non-conformity of constituent materials

In the case of non-conforming constituent materials, corrective action may involve:

1) downgrading the material;

2) reprocessing the material to conform;

3) adjusting process control to allow for constituent non-conformity;

4) rejection and disposal of the non-conforming material.

7.3 Non-conformity in producing the product

Non-conformity during production (eg wrong rate of spread) shall be evaluated and procedures for taking corrective
action shall be followed. Such action may involve:

1) repair and/or remedial action to bring the product up to the required standard;

2) acceptance of the product following agreement by the purchaser to accept the non-conforming product;

3) rejection and removal of the product;

4) downgrade the expected life of the product;

5) repeat the work (it may be necessary to use a different design to take into account the product already in
place).

7.4 Non-conformity of product

Non-conformity of product shall be evaluated and procedures for taking corrective action shall be followed. Such
action may involve:

1) repair and/or remedial action to bring the product up to the required standard;

2) acceptance of the product following agreement by the purchaser to accept the non-conforming product;

3) rejection and removal of the product;

4) downgrade the expected life of the product;

5) repeat the work (it may be necessary to use a different design to take into account the product already in
place);

8 Inspection, measuring and test equipment.

The producer shall provide, control, calibrate, and maintain suitable measuring and test equipment.

In order to ensure the testing of incoming constituent materials, during production and finished product conforms to
the relevant test method specification, the test equipment is required to be in a known state of calibration and
accuracy, consistent with the required measurement capability.

The following points should be addressed:

1) accuracy and frequency of calibration, which should be in accordance with the relevant test standards;

2) whether rapid checks on the test equipment is relevant (eg checking a balance with standard mass on a
regular basis);

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3) equipment, particularly that used on site, shall be handled with care in accordance with documented
procedures to avoid damage;

4) equipment shall be used in accordance with documented procedures;

5) equipment to be uniquely identified;

6) calibration records to be maintained.

9 Records
The results of Factory Production Control are to be recorded. The design, sample or test location, date and time, as
well as details of the product and constituent materials shall be recorded together with any other relevant
information.

Where the constituent materials or the product does not satisfy the requirements of the appropriate specification,
records shall be kept of corrective actions taken to ensure the quality of final product is maintained.

Records shall be stored and maintained in such a way that they are retrievable and be retained for a minimum
period of 5 years or such longer period that may be required under the legislation of individual states.

10 Training
The producer shall establish and maintain procedures for the training of all personnel involved in activities affecting
quality. Personnel performing specific assigned tasks shall be suitably qualified on the basis of appropriate
education, training or experience, as required. Training records shall be maintained.

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Table 1 — Process control inspection schedule

Column 1 2 3 4
Line Control Area Inspection/Test Purpose Frequency
1 Chipping stocks visual to check for as set out in the
contamination quality plan
2 Binder storage (static) tank temperature to check storage daily
tanks conditions
a viscosity measure to check for binder as described in the
(e.g. penetration, stv property changes quality plana
or engler) as de-
scribed in the quality
plan
3 Binder spray tanks tank temperature to check that before starting to
temperature is within spray and then as set
spraying range out in the quality planb
4 spray bar pressure or to check that pressure at start of spraying
metering device or volume control is and then as set out in
within operating range the quality plan
5 Spray bar height length measurement to ensure overlap from before starting to
adjacent spray jets is spray and then as set
correct out in the quality plan
6 Spray pattern of jets as set out in the to check jets for at start of spraying
(non-overlapping) quality plan blockage and other and then as set out in
malfunction or the quality plan
individual jets.
7 Streaking visual to check for continual
malfunction of spray
bar
8 Chippings on delivery visual to check for every delivery
to spreader contamination
9 Spread of chippings visual to check for continual
malfunction of
spreader
a Cut back and penetration grade binders can harden thus becoming more viscous during storage. Emulsions may lose or
gain viscosity during storage. The quality plan should state the ‘safe’ storage period for binder in its tank configuration and
require testing if the period is exceeded without fresh deliveries. In the absence of other information a period of one week
should be adopted for unmodified binders.
b It is important that binder is sprayed at the correct viscosity which is controlled by temperature. In most spray tankers
there is a binder level below which it is not possible to use the binder heaters. All these limitations should be set out in the
quality plan.

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Table 2 — Plant calibration requirements

Column 1 2 3 4
Line Item of plant Inspection/Test Purpose Frequency
1 Temperature meas- visual inspection to ascertain the daily
urement and recording equipment is
equipment functioning correctly
2 test of accuracy to ensure correct 1) on installation
temperatures are 2) after significant repair
measured and/or 3) annually
recorded 4) in case of doubt
3 Pressure measure- visual inspection to ascertain the daily
ment and recording equipment is
equipment (if metered functioning correctly
flow, pressure need
4 not be measured, see test of accuracy to ensure correct 1) on installation
‘Flow meters’ below) pressures are 2) after significant repair
measured and/or 3) annually
recorded 4) in case of doubt
5 Speed control devices visual inspection to ascertain the daily
equipment is
functioning correctly
6 test of accuracy to ensure correct 1) on installation
speeds are measured 2) after significant repair
and/or recorded 3) annually
4) in case of doubt
7 Flow meters comparison of to ensure accuracy 1) on installation
(mechanical metering) actual amount with within quality plan 2) after significant repair
the metered requirements 3) annually
amount 4) in case of doubt
8 Dip stick or other comparison of to enable total amount 1) on installation
device for indication of measurement with sprayed on a site to be 2) after significant repair
volume or mass of metered amount measured within limits to tank
binder in the tank set out in the quality 3) in case of doubt
plan
9 Weighing equipment visual inspection to ascertain the equip- daily
ment is functioning
correctly
10 test of accuracy to ensure correct 1) on installation
masses are measured 2) after significant repair
and/or recorded 3) annually
4) in case of doubt
11 Roller sprinklers water spray visual to ensure wet rollers during warm weather
inspection are available during conditions once per day
warm weather and per site
conditions
12 Sweeper brush, water maintain efficiency of once per day
sprinklers and sweeping process
suction inspection
NOTE Not all surface dressing equipment will have all the above equipment installed and methods of calibration may
vary according to the plant types and facilities available.

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Table 3 — Inspection and test frequencies for aggregates

Column 1 2 3
Line Inspection/Test Purpose Frequency
1 Tests for intrinsic properties of to check properties against the source approval before initial
aggregate (strength, PSV etc.) design proposal use. Updated in accordance
with EN 13043
2 Inspection of delivery ticket to check consignment is as each delivery
ordered and from correct
source
3 Organoleptic check of for comparison with normal each day deliveries are made
stockpile appearance with respect to
source, grading, shape and
impurities
4 Sieve analysis to assess compliance with 1) first delivery from new
standard of other agreed source
grading 2) in case of doubt following
organoleptic check
3) the National application
Document may detail the
frequency of the test
depending on the
requirements for the particular
site for example:
1 per 2000 tonnes
5 Shape, crushed particle index to assess compliance with 1) first delivery from new
etc standard or other agreed source
specification 2) in case of doubt
3) as indicated in the quality
plan
NOTE 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.

Table 4 — Inspection and test frequencies for binders

Column 1 2 3
Line Inspection/Test Purpose Frequency
1 Tests for intrinsic properties of to check properties against the source approval before initial
binder (viscosity of supplied design proposal use. Updated in accordance
binder; for recovered binder: with quality plan
cohesion; and other properties
for identification)
2 Inspection of delivery ticket to check consignment is as each delivery
ordered and from correct source
3 Temperature to check the binder is within each delivery
permitted temperature limits
4 Grade properties (viscosity of to assess compliance with 1) first delivery from new source
supplied binder; for recovered standard or other agreed 2) in case of doubt following
binder: penetration; softening specification organoleptic check
point; binder content for 3) the National Application
emulsions; etc. Document will detail the
frequency of the test depending
on the requirements for the
particular site for example: 1 per
300 tonnes
5 Organoleptic check (by sample for comparison with normal each delivery or daily when
or tank inspection) appearance, smell, tackiness spraying
etc
NOTE 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

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Table 5 — Inspection and test frequencies for other constituents and additives

Column 1 2 3
Line Inspection/Test Purpose Frequency
1 Tests for intrinsic properties of to check against design source approval before initial
other constituents or additives proposal use. Updated in accordance
with quality plan
2 Inspection of delivery ticket to check consignment is as each delivery
ordered and from correct
source
3 Grade properties appropriate to assess compliance with 1) first delivery from new
to the material standard or other agreed source
specification 2) in case of doubt following
organoleptic check
3) as stated in the quality plan
4 Organoleptic check of for comparison with normal each delivery and in accord-
consignment appearance etc ance with the quality plan
NOTE 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

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Table 6 — Inspection and test frequencies during production

Column 1 2 3
Line Inspection/Test Purpose Frequency
1 Rate of spread of binder to ensure the quantity of 1) annually
(EN 12272-1) binder on the road is within 2) the National application
the design requirements Document may detail the
frequency of the test depending on
the requirements for the particular
2
site for example: every 2 000 m
2
initially and every 10 000 m once
consistency has been achieved
2 Accuracy of spread of binder to ensure spray bar 1) at start of contract and for each
(EN 12272-1) conforms to specification different type of dressing
2) the National application
Document may detail the
frequency of the test depending on
the requirements for the particular
2
site for example: every 50 000 m
3 Rate of spread of chippings to ensure the quantity of 1) at start of contract and for each
(EN 12272-1) chippings on the road is different type of dressing
within the design 2) the National application
requirements Document may detail the
frequency of the test depending on
the requirements for the particular
2
site for example: every 2 000 m
2
initially and every 10 000 m once
consistency has been achieved
4 Accuracy of spread of to ensure chip spreader 1) at start of contract and for each
chippings (EN 12272-1) conforms to specification different type of dressing
2) the National application
Document may detail the
frequency of the test depending on
the requirements for the particular
2
site for example: every 50 000 m
NOTE 1 These frequencies may be increased according to the type of site, traffic intensity, difficulty of site, etc. see
National Application Document.
NOTE 2 Change of binder grade or chipping size should be tested as though it was the start of a new section

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Annex A
(normative)

Use of statistical control within factory production for surface dressing

Member States to write if required.

NOTE An example would be the use of computer control for rate of spread and accuracy of spread of binder for “combined
machines” used by Germany.

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Bibliography

prEN 12271-2, Surface dressing – Specifications — Part 2: Chippings.

EN 12591, Bitumen and bituminous binders — Specifications for paving grade bitumen.

prEN 13808, Bitumen and bituminous binders — Framework for specifying cationic bitumen emulsions.

prEN (WI 0033608), Specifications for cutback and fluxed bitumen.

prEN 14023, Bitumen and bituminous binders — Specifications for polymer modified bitumens.

EN ISO 9001, Quality management systems — Requirements.

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