AUSTROADS Seal Design Test SDT 10.

0:2001
Calibration of Bitumen Sprayers
Part 0: General Introduction, List of Methods and
Calibration Test Certificate

PREFACE
This Seal Design Test Method was prepared by an APRG Working Group on behalf of
AUSTROADS. Representatives of AUSTROADS, ARRB Transport Research and Industry through
the Australian Asphalt Pavement Association (AAPA), and the National Association of Testing
Authorities (NATA) have been involved in the development and review of this test method.
____________

FOREWORD

A significant factor contributing to the establishment of Australia’s 250,000km of surfaced roads has
been the successful application of sprayed sealing technology. For a consistent and high quality of
sprayed work to be undertaken, and for sealing to remain a viable surfacing option in the face of
increasing traffic levels, and higher wheel-loads, the achievement of well defined and controlled
binder application rates is a most important factor.

Sprayer calibrations have been undertaken on a state by state basis with varying levels of
sophistication, but generally in accordance with the 1989 NAASRA publication “Performance
Requirements for mechanical Sprayers of Bituminous Materials”. Closure of State Road Authority
sprayer calibration facilities in Victoria and New South Wales, and similar moves in other States have
stimulated the need to develop a National Sprayer Calibration Method with sufficient flexibility to
encourage new technologies while maintaining the high standards required for current and future
surfacing practice. The development of these new procedures has been based on the following
objectives:

1. The sprayer calibration procedures shall incorporate the best practices currently available, and
encourage the development of more efficient and cost effective methods, particularly those based
on mobile facilities and in service calibration procedures using actual binders.
2. The methods shall recognise the importance of ongoing field calibrations for pump throughput and
encourage the optimal application of pump speed and forward speed controls to maintain correct
sprayer performance between routine calibrations.
3. The methods shall be developed through consultation with the National Association of Testing
Authorities (NATA) to ensure a NATA acceptable approach is developed with potential for
independent assessment in the future.
4. Where possible, the adopted method(s) shall allow existing approaches to sprayer calibration to be
retained where such procedures have been accepted as achieving best practice in sprayed sealing.
5. A National approach to testing and calibration is to be pursued.

March 2001 Version 1 Page 1 of 7

 AUSTROADS SDT 10.0:2000

The Working Group responsible for drafting these new procedures identified the following issues:

• Sprayers presented for calibration shall include current, traceable calibration certificates for
sprayer tank volume, and instruments which control sprayer operation;
• Calibration Oils shall conform to an agreed specification and be validated by an agreed procedure;
• End jets (EAN18) for calibration purposes shall be of the West Australian design Copley jets
when AN18 intermediate jets are use. EA4 end jets may be used in lieu of the EAN18 jets with
existing A4 intermediate jets
• Intermediate jets may be either a full set of A4 Copley jets or a full set of AN18 Copley jets. They
should not be mixed in the spray bar as their performance characteristics and output are different.
It is expected that with normal wear and tear the A4 jets will no longer be used within 2 to 3
years;
• The test method shall allow metric and imperial (equivalent) systems to be used.
• The test method only applies to mechanical type bitumen sprayers. Other types of sprayers, such
as pressure type sprayers for use with bitumen emulsion etc, can not be calibrated by this method.

Note: Through out this series of test methods, the use of the term nozzle and jet is used
interchangeably.

METHOD

1 SCOPE
The procedures described in this test method cover the introduction to the calibration of bitumen
sprayers that generally follow the procedure detailed in NAASRA 1989. The test method provides a
listing of procedures to be followed to obtain a valid test certificate for the calibration of a bitumen
sprayer.

The following test methods apply:

SDT 10.0 General introduction, list of methods, and calibration test certificate including
APPENDIX A - Check lists for calibration assessment and routine field set-up (this
method).
SDT 10.1 Volumetric calibration including APPENDIX A - Spreadsheet based method for
determining pump output calibration.
SDT 10.2 Transverse distribution by fixed pit facility.
SDT 10.3 Transverse distribution by RTA field method.
SDT 10.4 Transverse distribution by BCA field method.
SDT 10.5 Road Speed Calibration.
SDT 10.6 Viscosity of Test Oil.

2 RELATED AND REFERENCED DOCUMENTS

The following documents are related or referred to in this series of test methods:

AS2341 Methods of testing bitumen and related road making products.

October 2000 Version 1 Page 2 of 6

 AUSTROADS SDT 10.0:2001

AUSTROADS Bitumen Sealing Safety Guide, AP - 41/96.

BCA-New Zealand Test Methods for Bitumen Sprayers, BCA T/1 - T/4

Copley Enterprises Spraying nozzles

Main Roads WA Development of Improved Bitumen Tankers and Distributors,
Report 0001R.
NAASRA Bitumen Surfacing Sprayed Work, Technical Report, January 1989.
NAASRA Bitumen Sprayers. NAS 70, 1989.
RTA NSW 1260 Performance Requirements for Mechanical Sprayers of Bituminous
Materials.

3 REPORT
3.1 Issue of Test Certificate

There is no standard test certificate specified as part of the test method, but a Pro-Forma Sprayer Test
Certificate has been included to assist with presentation of the required test data.

For a sprayer to be issued with a valid test certificate, the following shall be undertaken:
• Test Method SDT 10.0, Appendix A – Produce a check list report indicating that the instruments
and equipment required to operate the sprayer have been checked and are in an acceptable
condition for calibration.
• Test Method SDT 10.1 – Pass the Volumetric Calibration of the pump as tested by this method
• Test Method SDT 10.2, 10.3 or 10.4 – Pass the Transverse Distribution as tested by one of these
methods.
• Test Method SDT 10.5 – Have the necessary Road Speed and Distance Calibration Data as tested
by this method in order to calculate the values for the Forward Speed (in m/min) of the sprayer for
the specified range of rates of application, and to calculate the distance correction factor to
convert distance recorded to actual distance (in m).

A valid Sprayer Test Certificate shall be issued if the sprayer conforms to all of the above. The
certificate must clearly state that the sprayer has ‘Passed’ the above-nominated tests.

3.2 Validity of Test Certificate

For a Certificate to be valid it must be signed and dated and stamped by the NATA accredited tester
who is certified to operate the specific testing equipment used to carry out the testing procedures as
stipulated above.
The Certificate is valid for a period of 12 months calculated from the end of the month of issue. For
example a sprayer checked and calibrated and issued with a Certificate on 14th September 2000, the
Date of Expiry of the Certificate will be 30th September June 2001.

The Expiry Date must be clearly indicated on the Certificate.

March 2001 Version 1 Page 3 of 7

 AUSTROADS SDT 10.0:2001

3.3 Distribution of Test Certificate

Distribution of the test Certificate is as follows:
• Copy to the Registered Owner of the sprayer
• Copy to Australian Asphalt Pavement Association (AAPA) for Registration of the Test Certificate
located at Level 2, 5 Wellington Street, KEW, Vic, Australia, 3101.
• Copy kept for record purposes as required by NATA

3.4 Published Listing of Certified Sprayers

AAPA will maintain a listing of all certified bitumen sprayers on their web site located at:

www.aapa.asn.au

March 2001 Version 1 Page 4 of 7

 AUSTROADS SDT 10.0:2001

APPENDIX A Check lists for calibration assessment

List for checking the bitumen sprayer instruments and equipment

prior to starting the testing and calibration procedures.

A1 General
This procedure shall be followed to assess the condition of the bitumen sprayer’s essential instruments
and equipment, and thus ensure it is mechanically in an acceptable condition that should enable it to
be tested and calibrated.

It is the responsibility of the owner of the sprayer being presented for testing and calibration to ensure
the unit is roadworthy, and complies with all the relevant acts and regulations required to legally
operate in the intended area(s) of sprayed works for the next twelve months.

A2 Sprayer identification
Check and record:

(a) Registration details – including expiry dates etc

(b) Registered owner
(c) Make and model of sprayer unit
(d) Nominal tank capacity

A3 Sprayer tank interior

The tank interior and pipe work must be inspected to ensure that it is clean and free from bitumen and
solvents to avoid contamination of the test oil. Failure to do this may affect the test oil to the extent
that it will be outside the specified limits for viscosity and may invalidate the test results.

A4 Instruments and equipment

Check that the instruments and equipment fitted to the sprayer unit are in accordance with the
appropriate specifications and that these have been checked/calibrated as required by an authorised
service centre, and have a certificate valid for at least twelve months from this inspection date. The
instruments and equipment items that generally require checking are those that measure or control the
following functions:

(a) Forward speed and distance

(b) Bitumen pump revolutions
(c) Engine revolutions
(d) Pressure – tank circulate and/or spraying
(e) Temperature
(f) Tank volume (dipstick)

March 2001 Version 1 Page 5 of 7

 AUSTROADS SDT 10.0:2001

A4.1 Operating controls

Check that all controls required to operate the functions of the bitumen sprayer are clearly marked,
including their operational settings.

A4.2 Spraybar
The full operational width of spraybar shall be fitted, including extensions.

The bar must be complete with intermediate jets, and an end jet at each end of the bar. The jets must
be fitted correctly with the slot in the intermediate jets at 30 degrees to the bar. Standing behind the
sprayer facing in the direction of spraying the end jets must show “L” f
RH side of the bar.

The distance between the spraying jets must be checked and should be uniform at either 100mm or
101.6mm (4”) centre to centre spacing, depending on the age and design of the sprayer. If the spacing
between the jets varies by more than ± 2mm, then this must be recorded.

The spraybar must be straight, both horizontally and vertically, and any extension pieces fitted must
align correctly with the main bar section. The bar must be set up at about 250mm from the face of the
jest to the trough or pavement when carrying out the transverse distribution tests.

Where jet output is controlled by more than a single valve/tap for the width of bar being tested
(usually a number of taps linked and operated by a rack or other means along the bar), the operation
of these need to be checked to ensure that all the taps open uniformly and to their full capacity. If any
taps do not open fully, then the control system must be adjusted appropriately.

A4.3 Spraying jets

The test is based on using jets with a rated output of 18 L/min at an average pressure of about 95kPa.
Existing intermediate type jets are A4 and A4N Copley jets and the updated Austroads version is an
AN18 Copley jet. Austroads end type jets are EAN18 Copley jets.

A full set of spraying jets, sufficient to fill the maximum width of bar to be tested, must be supplied.
A modern bitumen sprayer generally uses 70 to 75 intermediate jets and 2 end jets. These may be
either new jets, or used jets that have been checked, accepted and certified. New jets will be stamped
with the year of manufacture. Checked and approved used jets must be stamped with the year of last
inspection. All jets must be checked to ensure they comply and if there is any doubt the slot should be
checked with the “standard” gauge (available from Copley Enterprises). Any visibly damaged jets
must be replaced.

March 2001 Version 1 Page 6 of 7