Your cart is empty.
Keep shopping
Teach on Udemy
Turn what you know into an opportunity and reach millions around the world.
Learn MoreFPC System Control According to EN 13108-21
Rating: 4.5 out of 54.5(2 ratings)
2 students
FPC System Control According to EN 13108-21
Mastering Factory Production Control for Asphalt Mixtures in Line with EN 13108-21
Created byAleksandra Milevska Taneska
Last updated 5/2025
English
What you'll learn
- Understand the Scope and Requirements of EN 13108-21
- Apply Monitoring and Documentation Procedures
- Evaluate the Link Between FPC and CE Marking
- Identify and Mitigate Non-Conformities
Explore related topics
Course content
6 sections • 6 lectures • 37m total length
- Introduction 13108-215:05
EN 13108-21
Welcome to this comprehensive overview of EN 13108-21 – a crucial European standard for Factory Production Control (FPC) in the production of bituminous mixtures. This standard defines the systematic controls that asphalt producers must follow to ensure consistent quality and conformity of their products with declared specifications. In this video, we will break down the key clauses, tables, and procedures outlined in the standard.
Let’s begin with the core principle: Factory Production Control. EN 13108-21 mandates that every producer of bituminous mixtures must establish and maintain a permanent internal production control system. This system must cover everything – from raw material intake and mix design, to testing of finished product, and continuous monitoring during production.
Clause 4 defines the general requirements, such as maintaining documentation, defining responsibilities, and ensuring traceability of every batch produced.
Clause 5 is at the heart of the standard. It addresses control throughout the production process – including material storage, temperature control, dosage systems, and real-time adjustments. Subsections like 5.3 and 5.5 define how delivery notes must be used, how sampling is done, and the importance of ongoing verification.
Then come the series of tables – Tables 2 through 8 – each of which defines specific requirements for equipment calibration and testing frequency. For example, Table 2 outlines minimum calibration actions in the plant – covering measurement equipment, flow meters, dosing systems, and temperature sensors. These calibrations must occur daily, annually, or whenever there's doubt about accuracy.
Table 3 deals with void content testing, Table 4 with particle size distribution and filler sieve analysis, and Table 5 addresses binder temperature checks. Table 6 and 7 define daily requirements for checking the temperature of the mixture and documentation of non-conforming products. Finally, Table 8 summarizes the inspections and tests required for each delivery – such as organoleptic inspection, temperature, binder content, and truck cleanliness.
Clause 6 and 6.2 emphasize recordkeeping. The standard requires that all test data, conformity results, and production logs be maintained and accessible – typically for a minimum of five years. These records are essential for audits and CE marking.
Clause 6.3 introduces the requirement for statistical conformity control using predefined thresholds for key parameters, based on 32 test results per mix design, aligned with Annex A.
Clause 7 deals with non-conformities – explaining how to identify, isolate, and take corrective actions for materials or mixtures that do not meet the specification. It separates corrective actions depending on whether the issue is with incoming material, production-phase asphalt, or finished mix testing.
Clause 8 addresses calibration and control of testing equipment. It reinforces the importance of precision, calibration frequency, and documentation. Clause 9 outlines subcontracting conditions – emphasizing that the manufacturer remains fully responsible for all results, even when third-party labs are used.
Clause 10 focuses on the relationship between the FPC system and CE Marking. The declaration of performance (DoP) must be fully supported by documented, verified, and statistically controlled production practices.
Throughout the standard, there is a strong emphasis on documentation, process transparency, and continuous monitoring. The EN 13108-21 standard does not operate in isolation – it connects to other standards like EN 13108-1 and EN 13108-20 for mixture specifications and type testing.
In summary, EN 13108-21 ensures that asphalt producers not only test their product but build quality into every part of the process. From materials and machines to procedures and personnel – every element is part of the quality chain. With clear roles, documentation, and control frequencies, this standard is the backbone of reliable bituminous mixture production across Europe.
Thank you for watching this technical walkthrough. Stay tuned for our next module where we apply these concepts in a lab setting and look at actual test protocols.
- Factory Production Control (FPC) – Structure, Quality Plan, and Compliance10:22
MKC EN 13108-21
Bituminous Mixtures – Technical Specifications for Materials – Part 21:
Factory Production Control4. Requirements
4.1 Factory Production Control (FPC)
Factory Production Control is a permanent internal control system operated during the production process. It includes testing requirements to ensure that the bituminous mixture conforms to the declared characteristics obtained through Type Testing (ITT).
The manufacturer shall operate a Factory Production Control (FPC) system that complies with the requirements of this European Standard.
The manufacturer shall define, document, and maintain the FPC system in such a way as to ensure that the products placed on the market conform to the declared characteristics. The FPC system shall consist of documented procedures, regular inspections, tests and/or assessments, and the use of results to control raw materials, input components, equipment, production processes, and the final product.
The FPC system shall control the conformity of the products with the formulated mixtures documented in accordance with EN 13108-20. As part of the FPC, Type Testing described in EN 13108-20 shall be repeated at intervals not exceeding five years, to confirm the continued validity of the formulated mixture.
This European Standard is based on selected requirements of EN ISO 9001, but it stands as a separate specification and does not require certification to EN ISO 9001 for its application. However, an FPC system that complies with the requirements of EN ISO 9001 and is established specifically for bituminous mixtures may be considered as fulfilling the requirements of this European Standard.
4.2 Quality Plan
The manufacturer shall establish and maintain a strategy and procedures for Factory Production Control in a quality plan.
The quality plan shall include methods for identifying and describing all processes that directly affect the quality and conformity of the product. Specifically, it shall include:
Organizational structure related to quality and conformity
Control of documentation
Control procedures for raw materials, including customer-supplied materials
Process control
Requirements for handling and storage
Calibration and maintenance of equipment
Requirements for inspection and testing of processes and products
4.2 (continuation) Quality Plan
The quality plan shall also include the frequency of inspections and tests. The frequency provided in Clause 6 and Annex A is the minimum frequency to be used initially. It may be adjusted if an acceptable alternative statistical system is developed.
Note: The details of the quality plan and FPC procedures will depend on the plant and the specific production process.
4.3 Organization
4.3.1 Responsibility and Authority
The responsibilities, authorities, and interrelationships of personnel managing, performing, and verifying work affecting conformity and quality shall be defined in the quality plan. This is especially important for personnel who have the authority to:
Initiate actions to prevent the occurrence of product non-conformities
Identify and document any issues affecting product quality
4.3.2 Management Representative
The manufacturer shall designate a person with appropriate authority, knowledge, and experience who will oversee the Factory Production Control to ensure that the requirements of the quality plan are implemented and maintained.
A single individual may oversee multiple plants.
4.3.3 Internal Audits
The manufacturer shall perform internal audits to verify that the FPC activities conform to planned arrangements and to evaluate the effectiveness of the system.
Audit schedules shall be based on the status and importance of the activities. Audits and follow-up actions shall be performed according to documented procedures.Results of audits shall be recorded and communicated to the responsible personnel in the audited area. Management in charge of the audited area shall take timely corrective actions for any non-conformities found and maintain records of the actions taken.
4.3.4 Management Review
The FPC system shall be reviewed at least once per year by the management to ensure its continued suitability and effectiveness.
A record of such reviews shall be maintained.4.3.5 Subcontracted Services
Where subcontracted services are used beyond the manufacturer’s internal resources, a method of control shall be defined and included as part of the manufacturer’s quality control procedures.
4.4 Document Control
The manufacturer shall establish and maintain documented procedures for controlling all documents and data related to the requirements of this European Standard.
5. Control Procedures
5.1. Constituent Materials
Adequate stocks of constituent materials shall be available to ensure continuity of the planned rate of production without compromising product conformity.
The specification and tolerances for input materials necessary to ensure compliance with asphalt specifications shall be defined and communicated to suppliers in the form of written orders.
Control procedures shall verify that suppliers of incoming materials are capable of providing the required material quality and ensuring that the mixture complies with the Initial Type Testing (ITT).
Different types of materials shall be transported and stored in such a way as to avoid cross-contamination, damage, or mixing that could affect the quality and conformity of the product.
The general requirements of this clause may be detailed in specific plant-related requirements, which may include the following:
Aggregates
Procedures for controlling aggregates delivered to the depot
Procedures for controlling aggregates transferred from quarry silos
Requirements for labeling storage zones and silos
Binders
Requirements for heating, temperature control, and insulation of storage tanks
Requirements for labeling tanks
Requirements for verifying delivery of binders to the appropriate tanks
Requirements for the control of additives, fillers, fines, and reclaimed asphalt (RA)
5.2. Client-Supplied Products
All constituent materials provided by the client for inclusion in the mixture shall be handled, stored, and maintained by the manufacturer in a manner that prevents contamination.
5.3 Process Control
The quality plan shall include the following:
a) A description of the material flow and the processing stages from the point of entry into the plant to the final delivery to the customer. A process flow diagram shall also be included.
b) A list of procedures that ensure compliance with the specifications, including procedures for controlling the dosing instructions.
c) A monitoring schedule for the production process, aligned with the minimum testing frequencies specified in Table 1, which will result in a record of plant results versus the defined tolerances.Note: Different elements of process control apply to different production systems, so it is not possible to give an exhaustive list for all applications.
5.4 Handling, Storage and Delivery
The quality plan shall include procedures to ensure that the bituminous mixture is handled, stored, and, where appropriate (see note), delivered with minimal segregation or damage, and within the specified temperature range.
The mixture must be clearly identifiable and traceable with respect to production data. The manufacturer shall maintain records of all relevant production data, including date and time of manufacture, which can be referenced in the delivery note.
This European Standard applies to situations where the manufacturer is responsible for delivery by vehicle to the construction site, as well as when the contractor collects the mixture from the plant using their own vehicle. The manufacturer’s quality plan shall clearly state the point at which their responsibility for handling, storage, and delivery ends.
If a hot storage system is used, the manufacturer’s quality plan shall describe its characteristics and operating procedure.
Through checks, inspections, and records, the manufacturer shall ensure that such systems are properly operated and that the bituminous mixtures remain fit for purpose.
5.5 Plant Calibration and Maintenance
The quality plan shall identify which parts of the measuring equipment require calibration. The calibration frequency shall correspond to the requirements given in Table 2.
Calibration procedures shall be provided, including allowable tolerances for equipment that will continue to be used. The quality plan shall specify the required accuracy for all plant calibrations and identify which elements require traceability to national reference standards (e.g., for mass and weight).
The plant shall be maintained in such a condition that it continues to produce bituminous mixtures in accordance with the required specifications and tolerances.
- Practice test
- Material Control and Testing Frequencies3:10
Explanation of Tables 3 to 8 (EN 13108-21)
In the context of EN 13108-21, Tables 3 to 8 provide clear guidance on the minimum frequencies for inspections and tests required at different stages of asphalt production. These tables ensure that all incoming materials, processing steps, and final products are continuously monitored for quality and conformity.
Table 3 – Aggregates
Aggregates form the bulk of any bituminous mixture, and their properties significantly affect performance. Table 3 outlines tests such as sieve analysis, flakiness index, and water absorption, with testing frequencies ranging from every 500 tonnes to once per source per year. These tests help ensure that the size, shape, and durability of the aggregates meet design expectations.
Table 4 – Filler
Though used in smaller quantities, filler plays a critical role in mixture cohesion. Table 4 recommends frequent testing of particle size distribution and moisture content, typically once every 200 tonnes, to ensure it blends properly with other materials and maintains stability.
Table 5 – Binder
Binder gives asphalt its flexibility and durability. Table 5 requires that each new binder source be tested for penetration, softening point, and viscosity. These tests confirm that the binder behaves correctly under different temperatures and loads. Most of these are done with the first delivery from a new source.
Table 6 – Additives
Additives such as polymers or fibers are introduced to enhance specific properties. Table 6 requires confirmation of additive identity and correct dosage, especially during first use or source changes, and checks dosage with every batch to ensure consistency.
Table 7 – Reclaimed Asphalt (RA)
For recycled materials, it’s essential to understand what’s being reintroduced into the mix. Table 7 outlines testing for residual binder content and aggregate grading, with minimum frequencies of 1 per 200 tonnes. This ensures that the use of reclaimed asphalt does not compromise quality.
Table 8 – Finished Product
Finally, Table 8 focuses on the delivered asphalt mixture. It requires visual inspection of appearance for every load, temperature checks, and periodic testing of grading and binder content. It also includes checks for truck cleanliness and insulation, to prevent contamination or heat loss.
Together, Tables 3 to 8 define a robust testing framework that supports the goals of Factory Production Control — ensuring that every material used and every batch delivered is verified, consistent, and fit for purpose.
- Non-Conformities, Subcontracting & CE Marking5:11
Clause 7 – Non-Conforming Product
The FPC system must identify non-conforming products, investigate the causes, and take corrective actions. Depending on the case, the mixture may be reprocessed, redirected, or rejected entirely.
Clause 8 – Equipment and Clause 9 – Records
Clause 8 ensures all lab equipment is properly calibrated and used according to procedures.
Clause 9 requires that all test results and production records be kept for at least 5 years, or more if required by national law. These records must include sample locations, times, materials, and test results.Clause 10 – Training
- Final Product Verification and Quality Documentation8:31
In this lecture, students will be introduced to the full structure and purpose of EN 13108-21, which governs Factory Production Control (FPC) for bituminous mixtures. The lecture covers all essential clauses, including process control, calibration, material testing, final product verification, and documentation requirements. Students will learn how each part of the standard contributes to consistent quality, CE marking, and legal compliance. This lecture also highlights how to manage non-conformities and maintain traceable records across all production stages.
- Applying Factory Production Control: Testing, Records, and Conformity5:02
Appropriate statistical records must be maintained for monitoring and verifying the production process and product properties.
Checklist:
Control plan for the produced mixture
Who performs the testing (competence, authority)
Equipment used
Calibration plan for measuring equipment
Who performs calibration (accreditation)
Records of completed control
✅ Table 8 – Minimum Frequency of Inspections/Tests for Delivered Product
No.
Inspection/Test
Purpose
Frequency
1
Organoleptic inspection of mixed asphalt
Compare with standard appearance in terms of gradation, uniformity, and coating adequacy
Each load
2
Temperature
Ensure the material meets specification or other requirements
a) As per 5.3
b) Whenever sampling is performed3
Grading and binder content
Ensure the material meets specification
See Annex A
4
Other performance characteristics from spec.
To assess conformity
As defined in the Quality Plan
See Annex B5
Suitability of delivery vehicles (visual inspection)
Verify insulation adequacy
Before first use
In case of doubt6
Cleanliness of delivery vehicles (visual inspection)
Avoid contamination
Each load before loading
See 5.4✅ Section 8 – Equipment Control, Measurement and Testing
The manufacturer shall control, calibrate, and maintain appropriate measuring and testing equipment.
To ensure that testing of incoming materials and the final asphalt is compliant with the relevant specifications, the equipment must be calibrated and accurate to the necessary measuring capacity.
The following points must be respected:
a) Precision and calibration frequency shall conform to the applicable test standard.
b) Equipment must be used in accordance with documented procedures.
c) Equipment shall be uniquely identified.
d) Calibration records must be maintained.
? Required Documentation and Procedures:
Equipment register for the plant
Equipment register for the laboratory
Calibration plan for measuring equipment
Operating procedures and instructions
Procedure for equipment identification
Data storage and calibration record distribution
Designation of calibration personnel (including accreditation)
Procedure for dealing with equipment malfunction
? ANNEX A: Testing Frequency and Tolerances
The conformity assessment period is defined as the time required to obtain 32 individual test results.
Conformity of each pre-defined bituminous mix design (laboratory formula) is confirmed based on:
Laboratory validation of the designed mix
Production validation of the bituminous mixture
Final conformity assessment of the produced mixture
? OCL – Operational Conformity Level Monitoring
Conformity monitoring must follow MKC EN 13108-21:2017, Annex A (Table A.1, A.3, A.4)
Assessment of conformity is based on:
Laboratory test bodies manufactured using the Marshall method
Laboratory validation: per MKC EN 13108-20:2017, Clause 6.5.2
Production validation: per EN 13108-20:2017, Clause 6.5.3
✅ Checklist
Was the test frequency for raw materials and final asphalt mass respected?
Was a conformity assessment report prepared and analyzed?
Was the Operational Conformity Level (OCL) defined?
Requirements
- Basic knowledge of asphalt production processes and material specificatio
Description
This course offers a comprehensive and practical understanding of the EN 13108-21 standard, which governs Factory Production Control (FPC) systems for bituminous mixtures. Designed for professionals working in asphalt production, quality assurance, and certification, the course provides in-depth guidance on how to establish, maintain, and evaluate FPC systems in line with European compliance requirements.
Participants will learn how to interpret and apply the standard’s requirements, covering essential topics such as production process control, material traceability, recordkeeping, and internal inspection procedures. Special attention is given to the connection between FPC and CE marking, including the preparation and justification of the Declaration of Performance (DoP).
The course also explores practical methods for monitoring conformity, identifying non-compliances, and implementing corrective actions to ensure consistent product quality and regulatory alignment. Through real-world examples, documentation templates, and test scenarios, learners will gain the skills necessary to ensure that asphalt production meets both legal and performance standards.
Whether you are a quality manager in a production facility, an auditor from a certification body, or a consultant supporting infrastructure projects, this course will equip you with the tools and knowledge to ensure full compliance with EN 13108-21 and support continuous quality improvement and operational success in practice.
Who this course is for:
- This course is designed for professionals involved in the production, quality control, or certification of asphalt mixtures, including: