Volume 1 Series 900

Specification for Road Works Road Pavements – Bituminous Bound Materials

ROAD PAVEMENTS – BITUMINOUS

BOUND MATERIALS
Contents
Clause Title Page

901 Bituminous Base and Surfacing Materials ………………………………. 3

902 Reclaimed Bituminous Materials ………………………………………... 7
903 Dense Macadam Base …………………………………………………… 8
904 Not Used ………………………………………………………………… 8
905 Not Used ………………………………………………………………… 8
906 Dense Macadam Binder Course ………………………………………… 8
907 Regulating Course ……………………………………………………….. 8
908 Not Used ………………………………………………………………… 9
909 Dense Macadam Surface Course ………………………………………... 9
910 Rolled Asphalt Surface Course (Recipe Mix) …………………………... 9
911 Rolled Asphalt Surface Course (Design Mix) …………………………... 11
912 Close Graded Macadam Surface Course ………………………………... 11
913 Not Used ………………………………………………………………… 11
914 Not Used ………………………………………………………………… 11
915 Coated Chippings for Application to Rolled Asphalt Surface Course ….. 13
916 Open Graded Macadam Surface Course ………………………………… 13
917 Cold-milling (Planing) of Bituminous Bound Flexible Pavement ……… 13
918 Slurry Sealing …………………………………………………………… 14
919 Surface Dressing ………………………………………………………… 16

Contents – continued on next page

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Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

ROAD PAVEMENTS – BITUMINOUS BOUND MATERIALS

Contents – continued

920 Bond or Tack Coats and other Bituminous Sprays ……....……………… 17

921 Surface Texture of Bituminous Surface Courses ……….……...………... 17
922 Not Used ……………………………………………….…...…………… 18
923 Not Used …………………………………………………....…………… 18
924 Resin Based High Skid Resistant Surface Treatment …….………...…… 18
925 Testing of Bituminous Mixtures and Their Component Materials …....… 20
926 Not Used ……………….…………...…………………………………… 20
927 Not Used ……………….……………...………………………………… 20
928 Not Used …………………….……………………...…………………… 20
929 Design, Compaction Assessment and Compliance of Base and Binder
Course Macadams …………………….…………………...…….………. 20
930 Heavy Duty Macadam Base with Grade 50 Penetration Binder …....…... 24
931 Use of Rubber in Bituminous Materials …………………………...….… 25
932 Dense Macadam Base with Grade 50 Penetration Binder …...…….….… 25
933 Heavy Duty Macadam Binder Course with Grade 50 Penetration Binder. 25
934 Dense Macadam Binder course with Grade 50 Penetration Binder ….…. 26
935 Not Used ……….………………………………………...……………… 26
936 Not Used ………….……………………………………...……………… 26
937 Not Used …………….………………………………...………………… 26
938 Porous Asphalt Surface Course …………………………………………. 26
939 Binder Drainage Test ……………………….………...…………………. 31
940 Relative Hydraulic Conductivity Test …………………...….…………... 33
941 Modified Binder Storage Stability Test ………………...……….………. 36
942 Thin Surface Coarse Systems …………………………………………… 37

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Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Road Pavements – Bituminous Bound Materials

gravel shall comply with category C100/0
901 Bituminous Base and as defined in IS EN 13043.
Surfacing Materials
Additionally, aggregates for use in
General surface course mixes, surface dressing,
and in coated chippings for application to
1 Bituminous pavement courses shall be rolled asphalt surface courses, shall have
made using the materials described in a uniform and similar colour throughout
Appendix 7/1. For the purpose of this the area of surfacing within the contract.
specification all references to BS EN
12591 bitumen grade penetration 100/150 Resistance to Fragmentation (Hardness)
in BS 4987 ‗Coated macadams (asphalt
concrete) for roads and other paved areas‘ Unless otherwise stated in Clause 938,
shall be replaced by IS EN 12591 942 or Appendix 7/1, coarse aggregates
bitumen grade penetration 70/100. In for bituminous materials shall have the
addition, when 70/100 bitumen grade following property:
penetration is used in coated macadams
(asphalt concrete): (i) The resistance to fragmentation of the
coarse aggregate in accordance with
(i) The maximum temperature of the clause 4.2.2 of IS EN 13043 shall be
mixture at any stage shall be 180oC, LA30 or less.

(ii) The minimum temperature of the Resistance to Freezing and Thawing

mixture in the lorry within 30 (Durability)
minutes after arrival on site shall be
125oC, Unless otherwise stated in Appendix 7/1,
aggregates shall be deemed to be
(iii) The minimum temperature freeze/thaw resistant if they conform to
immediately prior to rolling shall be the water absorption category WA242 in
105oC, accordance with IS EN 13043 Clause
4.2.9.1. Aggregates with water absorption
(iv) The minimum rolling temperature greater than 2% should be considered
shall be 85oC, and satisfactory if they conform to the
magnesium sulfate soundness category
(v) The recommended storage MS25 in accordance with IS EN 13043
temperature of 70/100 bitumen Clause 4.2.9.2.
grade penetration is 160oC.
Cleanness
2 All references in BS 4987 to the
Highways Agency Specification for Unless otherwise stated in Table 9/1, 9/2
Highway Works Clause 929 shall be or Appendix 7/1, the fraction of material
replaced by the National Roads Authority passing the 0.063 mm sieve, for coarse
Specification for Road Works Clause and fine aggregates for bituminous
929. materials, shall not exceed the limits
stated in BS 594: Part 1 and BS 4987:
The aggregate gradings contained in Part 1, when tested in accordance with the
Tables 9/1 and 9/2 of this series shall take washing and sieving method of IS EN
precedence over the aggregate grading 933-1.
requirements of BS 4987 and BS 594.
Transporting
Aggregates for Bituminous Materials
4 Bituminous materials shall be transported
3 Aggregates shall be natural, clean, hard in clean insulated vehicles and shall be
and durable crushed rock or crushed covered while in transit or awaiting
gravel and shall comply with the selected tipping. To facilitate discharge of the
requirements of IS EN 13043. Crushed mixed materials, dust, coated dust, water
or the minimum of liquid soap, vegetable

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Specification for Road Works Road Pavements – Bituminous Bound Materials

oil, or other non-solvent solutions may be pavement up to the joint, and the
used on the interior of the vehicles, but corresponding area beyond it by hand, the
the amount shall be kept to a minimum joint or joint cavity shall be kept clear of
by brushing. Prior to loading, the body surfacing material.
shall be tipped to its fullest extent with
the tailboard open to ensure drainage of 10 With the exception of sand asphalt carpet,
any excess. The floor of the vehicle shall bituminous materials with a temperature
be free from adherent bituminous greater than 125°C shall not be laid or
materials or other contaminants. deposited on bridge deck waterproofing
systems unless adequate precautions are
Laying taken to avoid heat damage in accordance
with a good industry practice. A
5 On each day, and at each location where maximum temperature of 145°C is
bituminous material is laid, at least 300 permitted for sand asphalt carpet.
tonnes from an approved source shall be
placed before material from another 11 Hand placing of bituminous materials
approved source is used. If the Contractor shall only be permitted in the following
demonstrates that the materials from circumstances:
different approved sources are of
equivalent quality and possess equivalent (i) For laying regulating courses of
laying and compaction characteristics this irregular shape and varying
requirement will be waived. thickness.
(ii) In confined spaces where it is
6 Wherever practicable, bituminous impracticable for a paver to operate.
materials shall be spread, levelled and (iii) For footways.
tamped by an approved self-propelled (iv) At the approaches to expansion
paving machine. As soon as possible after joints at bridges viaducts or other
arrival at site the materials shall be structures.
supplied continuously to the paver and (v) For laying mastic asphalt in
laid without delay. The rate of delivery of accordance with BS 1447.
material to the paver shall be regulated to
enable the paver to operate continuously. 12 Hand-raking of surface course material or
The horizontal alignments, surface levels the addition of such material by hand
and surface regularity of the finished spreading to the paved area, for
surface shall comply with Clause 702. adjustment of level, shall only be
permitted in the following circumstances:
7 The travel rate of the paver, and its
method of operation, shall be adjusted to (i) At the edges of the layers of material
ensure an even and uniform flow of and at gullies and manholes.
bituminous material across the screed, so
that the material is free from dragging, (ii) At the approaches to expansion joints
tearing and segregation. at bridges, viaducts or other
structures.
8 Unless otherwise stated in Appendix 7/1,
or elsewhere in this Specification, 13 Hand laid work shall conform with the
materials shall be laid in accordance with requirements of this Clause except those
the requirements and recommendations relating to pavers.
for laying in BS 4987: Part 2 or BS 594:
Part 2, as appropriate. The minimum Compaction
thickness of material laid in each paver
pass shall be in accordance with BS 4987: 14 Bituminous materials shall be laid and
Part 2 or BS 594: Part 2, as appropriate, compacted in layer thicknesses, which
or the full course thickness, where this is enable surface level and regularity
less than the specified minimum in BS requirements to be met and adequate
4987: Part 2 or BS594: Part 2. compaction to be achieved.

9 When laying binder course or surface 15 Compaction of bituminous materials shall

course the paver shall be taken out of use commence as soon as the uncompacted
when approaching an expansion joint of a material will bear the effects of the rollers
structure. In laying the remainder of the without undue displacement or surface

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Specification for Road Works Road Pavements – Bituminous Bound Materials

cracking. Compaction shall be 18 Bituminous materials shall be rolled in a

substantially completed before the longitudinal direction, with the driven
temperature falls below the minimum rolls nearest the paver. The roller shall
rolling temperatures stated in BS 594: first compact material adjacent to joints
Part 2 or BS 4987: Part 2 or Clause 901 and then work from the lower to the
when using bitumen grade penetration upper side of the layer, overlapping on
70/100. Rolling shall continue until all successive passes by at least half the
roller marks have been removed from the width of the rear roll or, in the case of a
surface. pneumatic-tyred roller, at least the
nominal width of one tyre.
16 Except where otherwise specified
compaction shall be carried out using 8- 19 Rollers shall not be permitted to park or
10 tonnes deadweight smooth wheeled stand on warm compacted materials.
rollers having a width of roll not less than
450 mm, or by multi-wheeled pneumatic- Compaction Assessment
tyred rollers of equivalent mass, or by
vibratory rollers or a combination of these 20 Unless stated otherwise in Appendix 7/1,
rollers. Surface course and binder course the compaction level of base and binder
material shall be surface finished with a course macadams shall be determined by
smooth-wheeled roller which may be a the Percentage Refusal Density Test
deadweight roller or a vibratory roller in procedure carried out in accordance with
non-vibrating mode. Vibratory rollers BS 598: Part 104 and as follows:
shall not be used in vibrating mode on
bridge decks. (i) At least 3 days before material from
each source of macadam is first laid
17 Vibratory rollers may be used if they are in the Works, the Contractor shall
capable of achieving at least the standard carry out a trial to demonstrate
of compaction of an 8-tonnes deadweight compaction plant and rolling
roller. They shall be equipped or provided procedures. The trial area shall be
with devices, indicating the frequency at not less than 30 m nor more than 60
which the mechanism is operating and the m long and of a width and thickness
travel speed, which can be read from the approved by the Employer's
ground. The performance of vibratory Representative. If the trial area
rollers proposed for use shall be assessed complies with the Contract it may
as follows: form part of the Permanent Works.

(i) by means of site trials in (ii) The materials, mixing and laying
accordance with BS 598: Part 109; plant proposed for the Works shall
or be used for the trial.

(ii) by the Contractor producing (iii) At three locations selected by the

evidence of independent trials Employer's Representative, two
demonstrating that, under nominal 150 mm diameter cores
comparable conditions, a state of shall be taken by the Contractor
compaction at least equivalent to using an approved coring machine,
that obtained using an 8-tonnes in accordance with BS 598: Part
deadweight roller is achieved by the 100. At least two of the locations
make and model of vibratory roller shall be from the wheel track zones
proposed for use. of the completed carriageway unless
otherwise selected by the
Where compaction is to be determined in Employer's Representative. For the
accordance with sub-Clause 20 of this purposes of this Clause the wheel
Clause, the requirements to prove the track zone shall be taken to be
performance of rollers shall not apply. In between 0.5 m and 1.1 m and
such case the Contractor may use any between 2.55 m and 3.15 m from the
plant to achieve the specified level of centre of the nearside lane markings
compaction and finish at temperatures for each traffic lane.
above the minimum specified rolling
temperature. (iv) The material in the trial area shall be
deemed acceptable if the average

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Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Percentage Refusal Density of the operation shall only be permitted in the

three locations is 93% or more when following circumstances:
determined in accordance with the
Percentage Refusal Density Test (i) In confined spaces, where it is
procedure carried out in accordance impracticable for a chipping
with BS 598: Part 104. Should the spreader to operate.
material not be deemed acceptable
the trial area shall be removed and (ii) As a temporary expedient, when
the trial repeated. adjustments have to be made to the
spreader distribution mechanism.
(v) Further material shall not be laid in
the Works until the Employer's (iii) When hand laying of the surface
Representative has approved the course is permitted.
material laid in the trial area.
(iv) To correct uneven distribution of
(vi) The compaction level of base and chippings.
binder course macadam forming the
Permanent Works shall be tested to 22 Chippings shall be applied uniformly and
the frequency stated in BS 4987: rolled into the surface course so they are
Part 2, at locations as stated above. effectively held and provide the specified
texture depth.
(vii) The material in the Permanent
Works shall be deemed acceptable if Joints
the average Percentage Refusal
Density of the three locations is 23 Except where otherwise specified, where
93% or more when determined in longitudinal joints are made in surface
accordance with the Percentage courses, the material shall be fully
Refusal Density Test procedure compacted and the joint made flush in
carried out in accordance with BS one of the following ways;
598: Part 104. Should the material
not be deemed acceptable it shall be (i) by using two or more pavers
removed and replaced with operating in echelon, where this is
complying material. practicable. The pavers shall be in
sufficient proximity for adjacent
(viii) The walls and bases of holes from widths to be fully compacted by
which core samples have been cut continuous rolling and the
shall be dried, painted with hot longitudinal edges effectively rolled
bituminous binder, and filled to the together whilst hot.
underside of the surface course with
heavy duty or dense macadam as (ii) by cutting back the exposed joint,
appropriate, in accordance with BS for a distance equal to the specified
4987: Part 1, and be well rammed in layer thickness, to a vertical face,
layers not exceeding 50 mm. Where discarding all loosened material and
cores have been cut through the coating the vertical face completely
surface course, the last layer of fill with a hot applied 40/60 penetration
material shall comply with the grade bitumen, or polymer modified
specification for the surface course. adhesive bitumen tape with a
minimum thickness of 2 mm, before
The assessment of compaction of design the adjacent width is laid.
mixes for base and binder courses shall
be carried out in accordance with Clause 24 All joints shall be offset at least 300 mm
929. from parallel joints in the layer beneath.
Joints in surface courses shall coincide
Chippings with either the lane edge or the lane
marking, whichever is appropriate. No
21 The application of coated chippings to joints shall be formed between a hardstrip
areas of asphalt surface course shall be by and the edge of the carriageway, nor
an approved mechanical spreader capable within a hardstrip. Longitudinal joints in
of distributing chippings to an even rate materials subject to Percentage Refusal
of spread. Addition of chippings by hand

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Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Density testing procedures shall not be 30 Tack coat or bond coat in accordance
situated in wheel track zones. with Clause 920 shall be spraying grade
cationic bitumen emulsion complying
Bituminous Sprays with Table 3 or Table 5 of the ‗Binder
Specification‘ published by the National
25 All bituminous surfaces shall be treated Roads Authority and shall be applied at
with a tack coat prior to overlay. The the uniform rate of spread specified in
application of the bituminous tack coat Appendix 7/4. The cationic bitumen
spray shall be carried out immediately emulsion shall not be permitted to collect
prior to laying the following course or in any hollows and shall be allowed to
surface treatment, which ever is specified break before the next layer is placed.
in the contract. The bituminous tack coat
spray shall comply with Clause 920 of 31 Construction plant and traffic used on
this series. This requirement shall not pavements under construction shall be
apply to bond and tack coats for thin suitable in relation to the material,
surface course systems complying with condition and thickness of the courses it
Clause 942. traverses so that damage is not caused to
the subgrade or the pavement courses
Protection and Rectification of Bituminous already constructed. The wheels or tracks
Layers of plant moving over the various
pavement courses shall be kept free from
26 Bituminous material shall be kept clean deleterious materials.
and uncontaminated. The only traffic
permitted to run on bituminous material 902 Reclaimed Bituminous
to be overlaid shall be that engaged in
laying and compacting the next course or, Materials
where a binder course is to be blinded or
surface dressed, that engaged on such 1 Reclaimed bituminous materials may be
surface treatment. Should any bituminous used in the production of bituminous
material become contaminated the base. The maximum amount of reclaimed
Contractor shall make it good by cleaning bituminous material permitted shall be
it and, if this proves impracticable, by 20% for coated macadam base complying
rectification in compliance with the 700 with BS 4987. The mixed material shall
Series. comply with the requirements of this
Series.
Regulating Course
2 When the amount of reclaimed
27 Regulating course material shall be made bituminous material comprises 10% by
and laid in accordance with the mass or less, compliance with this Clause
requirements of Clause 907. is not required. However, when it exceeds
10% by mass, the Contractor shall carry
Use of Surfaces by Traffic and Construction out trials to the satisfaction of the
Plant Employers Representative to demonstrate
that the mixed materials comply with the
28 Where a bituminous layer other than the requirements of this Clause.
surface course is to be opened to roadway
traffic as a temporary running surface 3 After mixing with recycled materials, the
without speed restriction, it shall be binder recovered from the mixture shall
surface dressed in accordance with have a recovered penetration value not
Clause 919 using chippings of category less than the value specified below. The
PSV60declared, unless otherwise specified binder shall be recovered from the
in Appendix 7/1. mixture in accordance with the
requirements of BS 2000: Part 397 and
29 All temporary running surfaces shall be tested in accordance with IS EN 1426.
thoroughly cleaned and a tack or bond
coat applied immediately prior to laying Specified Grade of Minimum Recovered
the succeeding course. Binder to IS EN 12591 Penetration Value of
(Paving Grade) Binder after Mixing
40/60 30
70/100 50
160/220 120

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Specification for Road Works Road Pavements – Bituminous Bound Materials

4 When the amount of reclaimed 904 Not Used

bituminous materials to be used in the
mixture exceeds 10%, the recovered
penetration value of the binder in the 905 Not Used
reclaimed bituminous materials before
mixing shall exceed 15 pen, after
recovery of binder in accordance with the
906 Dense Macadam Binder
requirements of BS 2000: Part 397 and Course
testing in accordance with IS EN 1426.
1 Dense macadam binder course designed
5 All reclaimed bituminous materials shall and recipe mixes shall be 0/20 mm
be pretreated before use such that the nominal size aggregate dense binder
material is homogeneously mixed and the course complying with BS 4987, and with
maximum particle size of reclaimed Table 9/1, sub-Clauses 2, 3 and 4 of this
material does not exceed 28 mm. Clause, and the requirements of Appendix
7/1. The nominal layer thickness of
903 Dense Macadam Base material containing aggregate of 20 mm
maximum aggregate size shall be within
1 Dense macadam base designed and recipe the range of 50 to 100 mm.
mixes shall be 0/32 mm nominal size
aggregate dense base complying with BS Aggregate
4987, and Table 9/1, sub- Clauses 2, 3
and 4 of this Clause and the requirements 2 The coarse aggregate shall consist of
of Appendix 7/1. The nominal layer crushed rock or crushed gravel complying
thickness shall be within the range of with Clause 901.3. The fine aggregate
70mm to 150mm. may be crushed rock or sand or mixtures
thereof and the quality of the fine
In the absence of binder course, when aggregate shall comply with the
used as upper base, the material shall requirements of BS 4987. The aggregate
comply with the requirements of clause shall be in a surface dry condition prior to
906 Dense Macadam binder course. mixing.

Aggregate Filler

2 The coarse aggregate shall comply with 3 When the coarse aggregate is crushed
Clause 901.3. The fine aggregate may be gravel, 2% by mass of total aggregate of
crushed rock or sand or mixtures thereof Portland cement or hydrated lime shall be
and the quality of the fine aggregate shall added. The percentage of fine aggregate
comply with the requirements of BS shall be reduced accordingly. Cement or
4987. The aggregate shall be in a surface hydrated lime is not required when
dry condition prior to mixing. crushed limestone gravel is used as the
coarse aggregate.
Filler
Binder
3 When the coarse aggregate is crushed
gravel, 2% by mass of total aggregate of 4 The binder shall be petroleum bitumen of
Portland cement or hydrated lime shall be paving grade 70/100 Pen complying with
added. The percentage of fine aggregate IS EN 12591.
shall be reduced accordingly. Cement or
hydrated lime is not required when
crushed limestone gravel is used as the
907 Regulating Course
coarse aggregate.
1 Regulating courses shall be in accordance
with sub-Clauses 2, 3 and 4 of this Clause
Binder
and the requirements of Appendix 7/1.
Bituminous materials for regulating
4 The binder shall be petroleum bitumen of
courses shall meet the requirements for
paving grade 70/100 complying with IS
the appropriate material, as specified in
EN 12591.
BS 594 or BS 4987 as relevant.

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Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

2 Regulating courses, which may consist of Coarse Aggregate

one or more layers of a bituminous
material, shall have their finished surfaces 3 The coarse aggregate shall comply with
laid to achieve the appropriate tolerances Clause 901.3 and the grading
for horizontal alignments, surface levels requirements of Table 9/2 and BS 594.
and surface regularity, for pavement The resistance to polishing of the coarse
layers, in accordance with Clause 702. aggregate shall be category PSV44 as
defined in IS EN 13043 Clause 4.2.3.
3 Where the total depth of a regulating
course exceeds 100 mm then the course Fine Aggregate
shall be laid so that each regulating layer
has a compacted thickness of between 50 4 The fine aggregate may be crushed rock
mm and 100 mm. or sand or mixtures thereof. The fine
aggregate shall be obtained from a
908 Not Used source, which has proven by experience
to give continuously satisfactory
performance in recipe mixtures. The
909 Dense Macadam Surface source shall be subject to the approval of
Course the Employer's Representative.

1 Dense macadam surface course shall Coated Chippings

comply with BS 4987 for dense surface
course, Table 9/2, sub-Clauses 2, 3 and 4 5 Coated chippings shall be Category 14/20
of this Clause, and with the requirements Gc 85/20 nominal size unless otherwise
of Appendix 7/1. described in Appendix 7/1 and shall
comply with Clause 915 and Table 9/2.
2 The coarse aggregate shall consist of
crushed rock complying with Clause
901.3. The fine aggregate may be crushed
rock or sand or mixtures thereof and the
quality of the fine aggregate shall comply
with the requirements of BS 4987. The
aggregate shall be in a surface dry
condition prior to mixing.

3 The binder shall be petroleum bitumen of

paving grade 70/100 or 160/220 Pen
complying with IS EN 12591, as
described in Appendix 7/1.

910 Rolled Asphalt Surface

Course (Recipe Mix)
1 Rolled asphalt surface course shall
comply with BS 594 for surface course
recipe mixtures and with Table 9/2, sub-
Clauses 2, 3, 4 and 5 of this Clause, and
the requirements of Appendix 7/1. The
mix designation for the material shall be
Type F - 30% 0/14 mm or 35% 0/14 mm.

Binder

2 The binder shall be petroleum bitumen of

paving grade 40/60 Pen complying with
IS EN 12591. The binder content,
expressed as percentage by mass of the
total mix, shall be in accordance with the
requirements of Table 9/2 and BS 594.

May 2005 9
 Table 9/1: Composition of Base and Binder Course mixes
Clause 903 906 930 932 933 934
Heavy Duty Dense Macadam Heavy Duty Macadam Dense Macadam
Dense Macadam Dense Macadam Macadam Base with Base with grade Binder Course with Binder Course with
Description
Volume 1

May 2005
Base Binder Course grade 40/60 Pen 40/60 Pen Binder grade 40/60 Pen Binder grade 40/60 Pen
Binder (HDM50) (DBM50) (HDM50) Binder (DBM50)
Nominal Size 0/32 mm 0/20 mm 0/32 mm 0/32 mm 0/20 mm 0/20 mm
Nominal Layer Thickness (mm) 70 – 150 50 – 100 70 – 150 70 – 150 50 – 100 50 – 100
Min. Thickness at any one point (mm) 55 40 55 55 40 40
Aggregate Grading (% by mass passing)
Specification for Road Works

40 mm 100 100 100

31.5 mm 90 – 100 100 90 – 100 90 – 100 100 100
20 mm 71 – 95 95 – 100 71 – 95 71 – 95 95 – 100 95 – 100
14 mm 58 – 82 65 – 85 58 – 82 58 – 82 65 – 85 65 – 85
10 mm --------- 52 – 72 --------- --------- 52 - 72 52 - 72
6.3 mm 44 – 60 39 – 55 44 – 60 44 – 60 39 - 55 39 – 55
2 mm 24 – 36 24 – 36 24 – 36 24 – 36 24 – 36 24 – 36
250 m 6 – 20 7 - 21 6 – 20 6 – 20 7 – 21 7 – 21
63 m 2 – 9* 2 – 9* 7 – 11* 2 – 9* 7 - 11* 2 – 9*

Binder Content (% by mass of total mixture)

Crushed Rock Aggregate 4.0 % ± 0.6 4.7 % ± 0.6 4.0 % ± 0.6 4.0 % ± 0.6 4.7 % ± 0.6 4.7 % ± 0.6

Crushed Gravel Aggregate 4.5 % ± 0.6 5.0 % ± 0.6 4.5 % ± 0.6 4.5 % ± 0.6 5.0 % ± 0.6 5.0 % ± 0.6

Binder Grade 70/100 Pen 40/60 Pen

Range of Temperatures

10
Max. Mixing Temperature (oC) 180 185
Series 900
Road Pavements – Bituminous Bound Materials

Min. Rolling Temperature (oC) 85 105

* When gravel other than limestone gravel is the aggregate, the material passing the 63 m test sieve shall include Portland cement or hydrated lime to the amount of 2 per cent by mass of the
total aggregate.
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

911 Rolled Asphalt Surface Composition

Course (Design Mix) 7 When determined in accordance with the
procedures of BS 598: Part 102, the
1 Rolled asphalt Surface course shall be composition of the plant mixture shall
designed in accordance with the comply with the requirements for the
procedures of BS 598: Part 107 and shall surface course design mixture.
comply with BS 594 for surface course
design mixtures, and with Table 9/2, with Coated Chippings
sub-Clauses 2 to 7 of this Clause, and the
requirements of Appendix 7/1. The 8 Coated chippings shall be 14/20 Gc 85/20
design mix material shall be designation to IS EN 13043 unless otherwise
Type F - 30% 0/14 mm or 35% 0/14 mm. described in Appendix 7/1 and shall
The design mixture selected by the comply with Clause 915 and Table 9/2.
Contractor shall be notified to the
Employer's Representative prior to its use 912 Close Graded Macadam
in the Works.
Surface Course
Binder
1 Close graded macadam surface course
2 The binder shall be petroleum bitumen of shall comply with BS 4987, and with
paving grade 40/60 Pen complying with Table 9/2, sub- Clauses 2, 3 and 4 of this
IS EN 12591. Clause, and the requirements of Appendix
7/1.
Coarse Aggregate
Aggregate
3 Coarse aggregate shall be crushed rock
complying with Clause 901.3. The 2 The coarse aggregate shall consist of
resistance to polishing of the coarse crushed rock complying with Clause
aggregate shall be category PSV44 as 901.3. The fine aggregate may be crushed
defined in IS EN 13043 Clause 4.2.3. rock or sand or mixtures thereof and the
quality of the fine aggregate shall comply
Marshall Stability and Flow with the requirements of BS 4987. The
aggregate shall be in a surface dry
4 The Marshall stability and flow for the condition prior to mixing.
complete mixture at the target binder
content, determined in accordance with 3 Unless otherwise stated in Appendix 7/1,
the procedures of BS 598: Part 107, shall the coarse aggregate shall have a
be as described in Appendix 7/1. minimum resistance to polishing of
PSV60declared in accordance with IS EN
Verification 13043 Clause 4.2.3. In addition, the
resistance to abrasion of the coarse
5 Verification of the design proposal shall aggregate shall have a maximum category
be carried out using materials obtained of AAV10 in accordance with IS EN
from the plant before manufacture of the 13043 Clause 4.2.4.
surface course commences. Stability and
flow values shall be determined at the Binder
proposed target binder content.
5 The binder shall be petroleum bitumen of
6 The results of design verification for paving grade 70/100 or 160/220 Pen
stability shall fall within 2 kN of the complying with IS EN 12591, as
design proposal. Additionally, the described in Appendix 7/1.
stability shall be not more than 0.5 kN
below the lower range value described in 913 Not Used
Appendix 7/1. The flow value obtained
shall not exceed that stated in BS 594:
Part 1. The target binder content 914 Not Used
determined on verification shall be not
less than the specified minimum value
given in BS 594.

May 2005 11
 Table 9/2: Composition of Surface Course Mixes
Clause 910 911 915 912 909 916

Rolled Asphalt Surface Rolled Asphalt Coated Chippings Close Graded Dense Open Graded
Description Course Surface Course For Rolled Asphalt Macadam Surface Macadam Macadam Surface
(Recipe Mix) (Design Mix) Surface Course Course Surface Course Course
Volume 1

May 2005
Designationa 30% 0/14 35% 0/14 30% 0/14 35% 0/14 14/20 Gc 85/20 0/14 mm 0/10 mm 0/6 mm 0/10 mm
Nominal Layer Thickness (mm) 40 45 or 50 40 45 or 50 N/A 40 – 55 30 – 40 20 – 30 30 – 35
Min. Thickness at any one point (mm) --------- --------- N/A 35 25 15 25
Aggregate Grading (% by mass passing)
40 mm 100
31.5 mm 98 – 100
Specification for Road Works

20 mm 100 100 100 100 85 – 99 100

14 mm 85 – 100 87 – 100 85 – 100 87 – 100 0 – 20 95 – 100 100 100
10 mm 60 – 90 55 – 88 60 – 90 55 – 88 --------- 70 – 90 95 – 100 100 85 – 100
6.3 mm ---------- --------- --------- --------- 0–5 45 – 65 55 – 75 90 – 100 30 – 60
b b b
2 mm 59 – 71 55 – 67 59 – 71 55 – 67 --------- 19 – 33 19 – 33 36 – 52 10 – 18
1 mm --------- --------- --------- --------- --------- 15 – 30 15 – 30 20 – 50 ---------
500 m 44 – 71 40 – 67 44 – 71 40 – 67 --------- --------- --------- --------- ---------
250 m 18 – 62 15 – 55 18 - 62 15 – 55 --------- --------- ----------- 7 – 23 ---------
63 m 7 – 11 6 – 10 7 – 11 6 – 10 0–2 3–8 3–8 2 – 10 2–7
Max. % Aggregate passing 2 mm and Retained
15 14 15 14 --------- --------- --------- --------- ---------
on the 500 m test sieves

Binder Content (% by mass of total mixture)

Crushed Rock Aggregate 7.8 % 0.6 7.4% 0.6 6.5 % Min. 6.4 % Min. 1.5 % 0.3 --------- --------- --------- ---------
Crushed Gravel Aggregate 7.5 % 0.6 7.0% 0.6 6.5 % Min. 6.4 % Min. --------- --------- --------- --------- ---------
Crushed Rock Aggregate (excluding limestone) --------- --------- --------- --------- --------- 5.1% 0.5 5.3% 0.5 6.3 % 0.5 5.3 % 0.5
Crushed Rock Aggregate (limestone) --------- --------- --------- --------- --------- 4.9 % 0.5 5.2 % 0.5 6.0 % 0.5 5.1% 0.5
Binder Grade 40/60 Pen 40/60 Pen 40/60 Pen 70/100 Pen or 160/220 Pen 160/220 Pen
Range of Temperatures

12
Max. Mixing Temperature (oC) 190 170 180 155 145
Min. Rolling Temperature (oC) 105 --------- 85 60 80
Series 900
Road Pavements – Bituminous Bound Materials

a
The mixture designation numbers (e.g. 30% 0/14) refer to the nominal coarse aggregate content of the mixture and nominal size of the coarse aggregate in the mixture respectively.
b
May be increased to 38 in Clause 912 mixes and 60 in Clause 909 mix when sand fine aggregate is used.
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

915 Coated Chippings for aggregate shall have a maximum category

of AAV10 in accordance with IS EN
Application to Rolled 13043 Clause 4.2.4.
Asphalt Surface Course
5 The binder shall be petroleum bitumen of
1 The chippings and the manner of coating, paving grade 160/220 Pen complying
when used for rolling into the surface of with IS EN 12591.
rolled asphalt, shall be in accordance with
BS 594-1, except size and grading shall 917 Cold-milling (Planing) of
be in accordance with Table 9/2 of this
series. The chippings shall also comply
Bituminous Bound
with sub-Clauses 2 and 3 of this Clause Flexible Pavement
and with sub-Clause 901.3,
1 Where cold-milling of bituminous bound
2 Unless otherwise stated in Appendix 7/1, flexible pavement is required, the area of
the resistance to polishing of the carriageway to be milled shall be
chippings shall be category PSV60declared, removed to the specified depth by a
in accordance with IS EN 13043 Clause suitable milling machine. The process
4.2.3. In addition, the resistance to shall be carried out so as not to produce
abrasion of the coarse aggregate shall excessive quantities of either fumes,
have a maximum category of AAV10 in smoke or dust. Dust shall be minimised
accordance with IS EN 13043 Clause by damping with water sprays.
4.2.4. The shape of the chippings shall
comply with FI15 as defined in IS EN 2 The cut edges shall be left neat, vertical
13043 Clause 4.1.6. and in straight lines. The Contractor shall
brush and sweep the milled surface by
3 The polished stone value shall be mechanical means to produce a clean and
determined in accordance with IS EN regular running surface with a groove
1097-8. The aggregate shall be deemed to depth not greater than 10 mm, and with a
comply if the 2 most recent consecutive uniform texture.
results, from tests relating to the material
to be supplied, and carried out within the 3 Carriageways shall be milled to the
previous 12 months by a testing tolerance for surface levels specified in
laboratory approved by the Employer's Clause 702 for binder course. If the
Representative, are equal to or greater tolerances in this Clause are exceeded,
than PSV60declared. the full extent of the area, which does not
comply, shall be rectified by further
916 Open Graded Macadam milling or by regulating with materials in
accordance with Clause 907.
Surface Course
4 Existing ironwork shall not be disturbed
1 Open graded macadam surface course by the milling action. Where necessary,
shall comply with BS 4987, and with surfacing in the vicinity of ironwork and
Table 9/2, sub-Clause 2, 3 and 4 of this in other small or irregular areas shall be
Clause and the requirements of Appendix cut out by pneumatic tools or other
7/1. suitable methods and removed.

2 The coarse aggregate shall consist of

crushed rock complying with Clause 5 Where milling is carried out on a
901.3. The fine aggregate may be crushed carriageway open to traffic, temporary
rock or sand or mixtures thereof and the ramping to ensure the safe passage of
quality of the fine aggregate shall comply vehicles shall be provided in accordance
with the requirements of BS 4987. The with the requirements of Appendix 1/17.
aggregate shall be in a surface dry
condition prior to mixing. 6 If the milled surface profile varies by
more than 10 mm, when measured
4 Unless otherwise stated in Appendix 7/1, transversely or longitudinally by a 3
the coarse aggregate shall have a metre straight edge, adjustments or
minimum resistance to polishing of replacements shall be made to the cutting
PSV60declared in accordance with IS EN teeth on the milling drum before work
13043 Clause 4.2.3. In addition, the continues. Any discontinuity between
resistance to abrasion of the coarse adjacent milling passes exceeding 10 mm,
May 2005 13
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

when measured transversely by a 3 metre Table 9/3: Aggregate Grading

straight edge, shall be rectified by further Percentage by mass of total
milling or regulating before placing aggregate and additive
bituminous materials. passing
Sieve Size
3 mm 1.5 mm
7 Where milling is required over extensive Finished Finished
areas, the Contractor shall programme the thickness thickness
work to allow removal of full lane widths
unless this is impracticable. The 6.3 mm 100 100
Contractor shall notify his proposed 4 mm 80 – 100 100
programme of milling to the Employer's 2 mm 75 – 100 95 – 100
Representative prior to commencement of 1 mm 55 – 90 70 – 95
the work. 500 micron 35 – 70 55 – 75
250 micron 20 – 45 30 – 50
8 Immediately after milling, surplus 125 micron 10 – 25 10 – 30
material shall be removed by a machine 63 micron 5 - 15 5 - 15
of suitable and efficient design and the
milled surface swept to remove all dust Bitumen Emulsion
and loose debris.
4 The slurry seal bitumen emulsion shall
9 Where possible the material removed comply with BS 434: Part 1 and shall be
from the carriageway shall be reused in either:
accordance with Clause 902 or in other
such locations as approved by the (i) Class A4 Rapid Setting or Class K3
Employers Representative. All other capable of producing a slurry which
surplus material shall be run to licensed on laying develops early resistance
tips provided by the contractor. No to traffic and rain and is sufficiently
stockpiling shall be allowed on Site stable to permit mixing with the
unless the material is to be used in the specified aggregate, without
Works. breaking during the mixing and
laying processes, or
10 Carriageways, which are closed to traffic,
shall be resurfaced after milling prior to (ii) Class A4 Slow Setting.
reopening the carriageway to traffic,
unless otherwise agreed by the Tack Coat
Employer's Representative.
5 Where required, or described in Appendix
918 Slurry Sealing 7/3, tack coat shall be cationic bitumen
emulsion complying with BS 434: Part 1.
1 Slurry sealing shall comply with BS 434:
Part 1 and Part 2, and with sub-Clauses 2 Composition of Mixed Material
to 22 of this Clause.
6 The mixed material shall comprise
Aggregate aggregate, bitumen emulsion and, where
necessary, additive complying with sub-
2 Crushed or natural sand free from silt, Clause 3 of this Clause. The amount of
clay or other fine material. The aggregate, emulsion used shall be between 180
whether a mixture or not, shall have a litres/tonne and 250 litres/tonne of dry
smooth grading within the limits of Table aggregate; the precise proportions of each
9/3. constituent being selected after laboratory
tests and trials using the same plant
Additive intended to be used in the Works. When
additive complying with sub-Clause 3 of
3 The additive shall be CEM1 Portland this Clause is used, the proportion shall
cement complying with IS EN 197: Part 1 not normally exceed 2% by mass of
or hydrated lime complying with BS 890. aggregate.
At least 75% shall pass the 63 micron
sieve. Mixing

7 The materials shall be measured into a

mechanical mixer and mixed such that the

May 2005 14
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

aggregate is completely and uniformly particular process. Rolling shall

coated with bitumen emulsion and a commence as soon as the slurry has set
slurry is produced of consistency that can sufficiently to ensure rutting or excessive
be satisfactorily laid as described in sub- movement will not occur.
Clauses 12 to 14 of this Clause. When
required, an additive complying with sub- 14 The finished slurry shall have uniform
Clause 3 of this Clause, shall be used to surface texture and colour throughout the
control consistency, mix, segregation and work, without variations of texture within
setting rate. the lane width, or from lane to lane, due
to segregation of aggregates or colour,
Preparation of Site due to variations in the emulsion/water
content of the mixture.
8 Before applying tack coat or spreading
slurry, any necessary patching of the road 15 The finished surface shall be free from
surface shall be completed. Immediately blowholes and surface irregularities due
before application of bituminous to scraping, scabbing, dragging,
materials, loose material, dust and droppings, excess overlapping or badly
vegetation shall be cleaned from the aligned longitudinal or transverse joints,
existing surface by sweeping, damage by rain or frost, or other defects.
supplemented if necessary by air jet, and Slurry sealing which does not comply
removed from the site. All ironwork, road with this Clause or is non-uniform in
studs and road markings, shall be surface texture or colour 24 hours after
masked. At junctions with surfaces not to laying shall be rectified by removal and
be treated, clean lines shall be defined by replacement with fresh material rolled in
masking, or other suitable means. compliance with the Specification or, if
this is impractical, by having fresh
Laying material superimposed and rolled in
compliance with the Specification. Areas
9 If required, a tack coat shall be applied in so treated shall be not less than 5 m long
accordance with BS 434: Part 2 before and not less than one lane wide. All areas
spreading the slurry seal. being worked on shall be kept free of
traffic until permitted by the Employer's
10 The rate of spread of tack coat shall Representative.
depend on the surface to be treated. For
bituminous surfaces the rate shall be Preliminary Slurry Mixture Design and
0.15-0.30 l/m2 and for concrete surfaces it Trial Areas
shall be 0.4-0.6 l/m2.
16 Using the same plant proposed for the
11 Slurry shall be evenly spread by Works, the Contractor shall make trial
mechanical means such that the aggregate mixes of the slurry, varying the bitumen
cover (dry mass equivalent) is 4-6 kg/m2 emulsion/aggregate ratio to produce a
for 3 mm finished thickness and 2-4 slurry of creamy consistency which,
kg/m2 for 1.5 mm finished thickness. whilst the screed box is travelling at the
laying speed, will flow ahead of the
12 All voids, cracks and surface screeding blade across the whole width of
irregularities shall be completely filled. the spreader at all times. At least three
Spreading shall not be undertaken when trial mixes shall be made, each sufficient
the ground temperature falls below 4°C to spread a trial area of 40 square metres,
or when standing water is present on the to the specified finished thickness. The
surface. In warm dry weather the preparation of the existing surface for the
surfacing, immediately ahead of the trials, the tack coat spreading and the
spreading, shall be slightly damped by rolling methods shall comply in all
mist water spray applied mechanically. respects with this Clause. Trial areas,
which achieve the required spreading
13 The slurry shall be rolled by a self- consistency, will be examined after 24
propelled or towed multi-wheeled smooth hours, for surface texture and adhesion,
tread rubber-tyred roller, having an and if satisfactory the test specified in
individual wheel load between 0.75 and sub-Clause 17 of this Clause shall be
1.5 tonnes, making at least six passes carried out on samples of the same
unless the Contractor demonstrates that composition.
rolling is unnecessary or that a smaller
number of passes is satisfactory for a

May 2005 15
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

17 For each of the satisfactory trial mixes, at Table 9/4: Site Control Test Requirements
least two circular specimens shall be Frequency
prepared, as described in BS 434: Part 2, Test Batch Continuous
for a wet track abrasion test. The
mixing mixing
approved mix proportions for the main
work shall be selected following Wet Track 4 times Every
laboratory tests using a combination of Abrasion Test (BS daily second run
bitumen emulsion, aggregate blended 434: Part 2)
where necessary with additive and water,
having a wet track abrasion test result of Grading of each Every 20 Every 20
less than 500 g/m2. separate stockpile tonnes tonnes
of sand and
18 When a proposed mix has been approved crusher run fine
variations shall not be made in mixing aggregate
time, mix proportions or in the type, size,
grading or source of any of the Grading of 4 times 4 times
constituents without the agreement of the samples of the daily daily
Employer's Representative who may blended aggregate
require further tests to be made.
Percentage of 4 times 4 times
Site Control Tests bitumen in the daily daily
cured seal
19 The mix proportions shall be controlled
and the mass of all materials incorporated 919 Surface Dressing
shall be checked and recorded at least
four times daily. The quantity of 1 Surface dressing shall be designed and
emulsion used, and the rate of spread of carried out in accordance with the
mixed material, in kilogrammes of recommendations of the Institute of
aggregate per square metre, shall be Asphalt Technology (IAT) – Guidelines
recorded for each load of aggregate and, for Surface Dressing in Ireland, published
if required, for each separate run within a in 2003, and the requirements as stated in
load of aggregate. Appendix 7/3.

20 The Contractor shall provide all Aggregates

necessary testing equipment and
whenever spreading is taking place shall 2 The chippings shall be crushed rock or
carry out the tests specified in Table 9/4 gravel complying with the requirements
at the frequency stated therein. A copy of of clause 901.3 of this series.
the results of each of the tests and of each
recorded mass and check for rate of 3 When referencing Table I of the IAT
spread shall be passed to the Employer's guidelines the grading category ―EN
Representative 85/20‖ shall be selected as the grading
category for all chipping sizes.
21 75 gm of the blended aggregate shall be
weighed in a glass beaker or similar 4 The polished stone value requirements
container and the corresponding from Table III of the IAT guidelines shall
quantities of water and cationic emulsion be category PSV60declared, PSV57declared or
in the slurry mix added. The slurry shall PSV52declared as appropriate.
be stirred with a slow deliberate action
(about 60 rpm) for 15 to 30 seconds, after Aftercare
which a specimen of about half the
mixture shall be cast upon an impervious 5 On high speed roads convoy vehicles
surface. shall be introduced in order to keep traffic
speeds low. Masking shall be removed
22 The cast specimen shall exhibit cohesive after the Surface Dressing has been
properties in not more than 10 minutes applied and before opening the road to
and when set and drenched in water shall unrestricted traffic. The Contractor shall
be waterfast as demonstrated by the remove surplus chippings from the road
absence of brown colour in the wash by suction sweeping before it is opened to
water. unrestricted traffic.

May 2005 16
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

6 The Contractor shall monitor the Surface specified blinding, this shall be done in
Dressing closely for a minimum period of accordance with the requirements as set
2 hours, or as specified in Appendix 7/21, out in Clause 919 in so far as it applies to
after the road is opened to traffic. The the work to be undertaken in accordance
Contractor shall reinstate traffic safety with the under mentioned general
and management procedures or institute requirements and any specified
other remedial action where necessary, requirements as described in Appendix
such as dusting, if there are signs of 7/4.
distress, such as turning of the chippings,
in order to prevent further damage to the 3 The binder shall be spraying grade
Surface Dressing. cationic bitumen emulsion complying
with Table 3 or Table 5 of the 'Binder
7 Further operations to remove Specification' published by the National
subsequently loosened chippings shall be Roads Authority. Where a bond coat
carried out over the next 48 hours. The incorporating a polymer modified
road, and adjacent side roads, footways emulsion is proposed for use it shall have
and paved areas shall be kept prior written approval from the
substantially free of loose chippings for a Employers Representative. The binder
period of 30 days after completion of the shall be sprayed at a rate specified in
work. Appendix 7/4.

8 Any defects arising from deficiencies in 4 The Employer's Representative may

the materials, workmanship and aftercare require the Contractor to provide a test
manifest during or at the end of the certificate showing that a particular
maintenance period shall be rectified by binder distributor has been tested since
the Contractor at his own expense. the previous surface dressing season and
that the test indicates conformity of the
As Built Manual distributor with the requirements of IS
EN 12272-1 for emulsion distributors.
9 Not more than 30 days after completion
of the work the Contractor shall provide a 5 Before spraying is commenced, the
record of the progress of the work in surface shall be free of all loose material,
accordance with section 6 of the IAT the surface as a whole shall be dry and
Guidelines and any such other any damp areas shall be completely free
information that the Employers of standing water.
Representative may reasonably require to
be included. 6 Blinding material, where required by the
Contract, shall consist of a commercial
920 Bond or Tack Coats and grade of hard clean crushed rock, fine
aggregate or sand: it shall contain not
Other Bituminous Sprays more than 15 per cent retained on a 6.3
mm sieve. It shall be applied to the binder
1 This clause shall not apply to bond coats and left unrolled. The rate of application
for proprietary thin surface coarse shall be 5.5-7.0 kg/m2.
systems complying with Clause 942. The
bond coats required for such systems are 7 All loose material on the sprayed surface,
specified in Clause 942-11. A bond or including any blinding material, shall be
tack coat shall be sprayed onto the removed before any further layer of the
existing surface prior to overlay in pavement is laid.
accordance with sub-Clauses 3 and 4.
Bond or tack coats for hot rolled asphalt
and coated macadam shall be in
921 Surface Texture of
accordance with BS 594: Part 2 and BS Bituminous Surface
4987: Part 2, respectively. Application Courses
shall be by spray tanker. For small areas
application may be by hand held sprayer 1 The texture depth of the surface of
with the agreement of the Employer's bituminous surface courses shall be
Representative. measured by the volumetric patch
technique described in IS EN 13036-1.
2 When it is necessary to prepare a surface
for the application of a bituminous spray 2 On high speed roads, unless otherwise
and to undertake the spraying and any stated in Appendix 7/1, the average
May 2005 17
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

texture depth of each 1000 m section of discrepancy between the two methods,
carriageway lane or the complete only results obtained using the volumetric
carriageway lane where this is less than patch technique will be considered for
1000 m, shall be not less than 1.5 mm. compliance purposes.
The average of each set of 10 individual
measurements shall be not less than 1.2 922 Not Used
mm.

3 On low speed roads where the surface 923 Not Used

course is Hot Rolled Asphalt, the rate of
spread for chippings shall be at least 70% 924 Resin Based High Skid
of that required to give shoulder to
shoulder cover.
Resistant Surface
Treatment
Measurement of Surface Texture
1 High skid resistant surface treatments,
4 For newly laid surfaces measure the made with aggregate of high polishing
surface texture depth as soon as possible resistance and resin-based binders, shall
after the surfacing has been laid and consist of a film of binder sprayed on to a
before the surfacing has been opened to sound substrate and covered with
traffic. Make measurements on 50m lane aggregate to provide a textured, durable
lengths regularly spaced along the section matrix of high skid resistance.
and covering not less than one-third of
the section tested. On each 50m length, Binder
take 10 individual measurements of the
texture depth at approximately 5m 2 The binder shall contain an epoxy or
spacings along a diagonal line across the other approved resin component. When
carriageway lane width. Do not take cured the binder shall comply with sub-
measurements within 300mm of the Clause 14 of this Clause.
longitudinal edge of the carriageway.
Aggregate
To reduce the variability, base the
determination of the average texture 3 The aggregate shall be calcined bauxite
depth of a test section on not less than six which has, when determined in
sets of ten individual measurements. For accordance with IS EN 1097-8, a
small schemes it may be practicable to minimum polished stone value of
carry out measurements over all the PSV72declared, unless otherwise described
surface course or over alternate 50m in Appendix 7/1. The grading of the
lengths covering 50 percent of the work. aggregate shall be such that not more than
Where this cannot reasonably be done 5% is retained on a 4 mm sieve and not
make the test measurements over more than 5% passes a 1 mm sieve. The
regularly spaced 50m lengths of aggregate shall be clean and free from
carriageway lane, covering not less than foreign matter.
one-third of the surfacing laid in one lane.
On larger schemes, exceeding a kilometre Mixing of Binder and Accuracy of Spraying
in length, select test sections of
carriageway lane 1000m long in the same 4 The binder shall be sprayed by a metered
way. machine that accurately and continuously
batches together the components of the
5 For rolled asphalt surface courses the binder; intimately mixing them before
surface texture may be measured using spraying. A control mechanism shall
the TRL Mini Texture Meter provided it maintain each component within 5% by
is calibrated with the volumetric patch mass of the normal proportion specified
technique described in IS EN 13036-1. by the resin manufacturer and a calibrated
flow meter (or other approved means)
6 Whilst measurement of macrotexture shall be provided for each component. If
depth for compliance purposes is to be by the components of the binder are heated
the volumetric patch technique specified to facilitate spraying, the temperature
in IS EN 13036-1 only, the TRL Mini shall not exceed the maximum
Texture Meter may be used as a screening recommended by the resin manufacturer.
procedure, as recommended by BS 598: A temperature gauge accurate to ± 2°C
Part 105. In the event of dispute or

May 2005 18
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

shall be used with all binders that require 9 Hand application of the binder, to areas
heating. not accessible to the mechanical sprayer,
will be permitted if the Employer's
5 The vessels containing the components Representative approves the proposed
shall each be provided with an approved methods of batching, mixing and
method of measuring the volume of application of binder to the road surface.
material used. Similarly, in areas not accessible to the
mechanical aggregate spreader, hand
6 The machine shall spray the binder, such application of the aggregate will be
that the amount collected on any permitted.
longitudinal stretch of the surface 50 mm
wide within the width of the spray shall Aftercare
not be less than 90% of the overall
minimum requirement for the surface 10 The material used as masking shall be
being treated (see sub-Clause 8 of this removed together with the binder sprayed
Clause). The mean amount of binder upon it and the remainder of the binder
collected on any four adjacent 50 mm allowed to cure. During the curing period
wide strips shall be not less than 95% of no disturbance or trafficking of the
the overall minimum requirement. Before treated surface will be permitted. Before
work commences, and thereafter at opening to traffic at the end of the curing
intervals not exceeding one month, the period the excess aggregate shall be
Contractor shall provide evidence that the removed by vacuum sweeper or other
sprayer and all metering gauges complies approved means.
with the requirements of the
Specification. If required, the test to 11 The Contractor shall have regard to the
measure the spray pattern shall be made increase in cure time of the resin binder
in the presence of the Employer's with decrease in temperature in order to
Representative. allow sufficient time for the resin binder
to cure between the end of the spray
Preparation operation and the time when the road is to
be opened to traffic. Details of cure time
7 The surface shall be vigorously brushed variation of the resin with respect to
to remove dust, laitance and other loose temperature shall be supplied by the resin
matter. Any oil visible on the surface manufacturer.
shall be removed by washing and
scrubbing with a detergent solution Checking and Testing
followed by flushing with clean water or
by another approved method. The surface 12 A check shall be made by the Contractor
shall be allowed to dry before application at the end of each working shift to
of the binder. Existing road markings, determine the quantities used of each
ironwork and road studs shall be suitably binder component. The check shall be
masked. made by means of dip-sticks or other
approved devices. The measured
Application volumetric quantities of the components
shall be converted to mass units to
8 The binder shall be sprayed on to a dry estimate the average rate of spread of
surface at a rate which will vary binder upon the surface, by dividing the
according to the texture and porosity of total mass of the components by the
the surface. On a smooth close textured measured area of the surface treated. The
surface the amount of binder shall be not net aggregate coverage rate shall also be
less than 1.35 kg/m2 or such rate specified recorded.
by the resin manufacturer; on a more
rugous surface a greater rate of spread 13 The average accuracy of batching shall be
may be required. Heated binders shall be determined from the known used masses
allowed to cool before application of the of the components. The relative
aggregate. A mechanically metered plant proportions of components so determined
shall be used to cover the binder shall fall within the limits specified in
uniformly with an excess of aggregate. sub-Clause 4 of this Clause.
Rolling of the aggregate is not permitted.
14 The Contractor shall provide the
Employer's Representative with samples
of the binder, from the spraybar of the

May 2005 19
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

sprayer, at a rate of not less than two 929 Design, Compaction

samples for each shift worked or each
1,000 square metres completed, Assessment and
whichever is the lesser. Each sample shall Compliance of Base and
be poured to a depth of 3.2 mm ± 0.4
mm, into a shallow tray of at least 150
Binder Course Macadams
mm x 150 mm which shall be supplied by
the Contractor. The binder shall be cured, Where a design mix is proposed for use in base
with no further mixing, at 23°C ± 5°C or binder course macadams the following
and after 7 days tested as described in BS requirements shall apply:
2782: Part 3, Method 320A: 1976 (1986)
except that the rate of grip separation 1 The Contractor shall nominate a target
shall be 5 mm per minute with a tolerance aggregate grading and target binder
of 20%. Although the test piece shall be content for his proposed mixture which
cut to the dimensions shown in Figure 1, shall fall within the limits of the
Method 320A, the requirement that the appropriate table within BS 4987-1, for
narrow parallel portion shall nowhere Group one or for Group two dense
deviate by more than 2% from the mean mixtures and comply with the appropriate
shall be deleted. The conditioning period Clause within this Specification.
at 23°C ± 1°C shall be at least 2 hours Additionally, for HDM mixtures, the
immediately before testing takes place. target percentage of aggregate passing the
The tensile strength of the specimens 0.063 mm sieve shall not be less than
shall be not less than 10.5 N/mm2 and the 7.0%. For compliance purposes the
elongation at break not less than 30%. binder content and aggregate grading
limits shall be those obtained by applying
15 The Contractor shall guarantee the the tolerances stated in Table 9/5 to the
integrity of the high friction surfacing target binder content and target aggregate
materials and workmanship for a period grading. The aggregate grading curve
of three years from the date of opening shall be smooth and continuous and shall
the surfacing to traffic. This guarantee not vary from the low limit on one size of
shall exclude defects arising from damage sieve to the high limit on the adjacent
caused by settlement, subsidence or sieve size or vice-versa.
failure of the carriageway on which the
surfacing has been applied. 2 The compaction of base and binder
course macadams shall be assessed by
measurement of:
925 Testing of Bituminous
Mixtures and Their (i) in situ and refusal air void contents
of cores subjected to the Percentage
Component Materials Refusal Density (PRD) test
procedure carried out in accordance
1 The sampling, testing and analysis of with BS 598: Part 104; and
bituminous mixtures shall comply with
BS 598 except where otherwise stated in (ii) in situ density using a nuclear
this series. density gauge.
2 A bulk sample of coated chippings shall Job Mixture Approval Trial
be obtained as described in BS 598: Part
100. Hot sand testing shall be carried out 3 At least three days before material from
in accordance with BS 598: Part 108. each source of macadam is first laid in the
Works, the Contractor shall carry out a
trial to demonstrate compaction plant and
926 Not Used rolling procedures. Subject to the
agreement of the Employers
Representative the trial may be carried
927 Not Used out off site. The trial area shall be not less
than 30 m or more than 60 m long and of
a width and thickness required in the
928 Not Used Contract. If the trial is carried out on site
and complies with this specification then
it may form part of the Permanent Works.
The materials, mixing and laying plant

May 2005 20
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

proposed for the Works shall be used for The air void contents shall be calculated
the trial. to ± 0.1 per cent as follows:

4 During the laying of the trial area, two Air voids content = (1 – ρ/ρMax) x 100%
samples of loose mixture shall be taken at
three evenly spaced locations along the where:
trial length, in accordance with BS 598: ρ is the bulk density in accordance with
Part 100, six samples in total. The BS 598: Part 104 (Mg/m3); and
maximum density of one sample of ρMax is the maximum density in
mixture from each location shall be accordance with IS EN 12697-5 (Mg/m3).
determined in accordance with IS EN
12697-5. The average value of maximum TABLE 9/5: Tolerances for Aggregate
density ρMax expressed in Mg/m3 shall Grading and Binder Content to be applied to
then be used for subsequent calculation of the Agreed Target Grading and Binder
the air void content of the compacted Content
mixture. The remaining samples shall be Tolerance for aggregate
analysed to determine their composition grading in percent by mass of
in accordance with BS 598: Part 102. Test Sieve
aggregate passing test sieve
(mm)
0/32 mm base 0/20 mm
5 At three locations, four nominal 150 mm course binder course
diameter cores shall be taken using a 63 ±0
suitable coring machine, in accordance 40 ±0
with BS 598: Part 100, twelve cores in 31.5 ±10* ±0
total. Two of the locations shall be from 20 ±12 ±5*
the wheel-track zones of the completed 14 ±12 ±10
traffic lane, the third location shall be 10 — ±10
agreed by the Employers Representative. 6.3 ±8 ±8
For the purposes of this Clause the wheel-
2.0 ±7 ±7
track zone shall be taken to be between
0.25 ±6 ±6
0.5 m and 1.1 m and between 2.55 m and
0.063 ±3.5 ±3.5
3.15 m from the centre of the nearside
0.063
lane markings for each traffic lane. Two ±2 ±2
cores from each location shall be tested (HDM)
using the PRD test procedure in
accordance with sub-Clause 2 of this Binder
±0.6 ±0.6
Clause. Content
Note: Application of the above tolerances to
6 At or adjacent to the location of the cores, the agreed aggregate target grading and binder
the density of the macadam shall be content may result in limits outside those
measured using a nuclear density gauge permitted by the appropriate table in BS 4987.
and the results correlated with the in situ Provided the target grading and target binder
air void contents determined in content of the mixture proposed for use, and
accordance with sub-Clause 7 of this agreed after trials, are within the limits
Clause. contained in BS 4987, then the limits obtained
by applying the above table shall prevail over
7 The air void contents of each core those implied in BS 4987.
subjected to the PRD test procedure shall
be determined, as follows: *The upper limit may be less than +5% (or
+10%), depending on the agreed aggregate
(i) The in situ air void content shall be grading.
calculated using, as the bulk density
ρ, the initial dried bulk density 8 The percentage binder volume Bvol shall
determined in accordance with BS be calculated for each location in
598: Part 104, and expressed in accordance with the following
Mg/m3; expression:

(ii) The refusal air void content shall be Bvol = BMass x (ρ/ρ b)
calculated using, as the bulk density
ρ, the refusal density determined in where: BMass is the target binder
accordance with BS 598: Part 104, content by mass added at the
and expressed in Mg/m3. mixer expressed as a

May 2005 21
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

percentage of the total this Clause. If the trial area fails to

mixture. comply with the requirements of Sub-
Clause 11 and was intended to form part
ρ is the average initial dried of the Permanent Works, it shall be
bulk density of macadam at removed. In the event that the trial area
each location determined fails to comply, the Contractor may
from the pair of cores nominate an alternative target aggregate
subjected to the PRD test grading and target binder content and the
procedure. trial shall be repeated until compliance
has been demonstrated. The target
ρb is the density of the binder aggregate grading and target binder
at 25°C. content of the complying mixture shall be
used in the Permanent Works.
9 The remaining pair of cores from each
location shall be used for the 11 Compliance Requirements
measurement of Stiffness Modulus and
Deformation Resistance, as follows: (i) The average in situ air void content
of the core samples to be subjected
(i) The in situ air void content of each to the PRD testing procedure shall
core shall be calculated from the not exceed 7.0% in binder course or
equation given in sub-Clause 929.7, upper base without a binder course,
using the dried bulk density ρ or 8.0% in other base layers.
determined in accordance with BS
598: Part 104 and the maximum (ii) The average value of in situ air void
density ρMax determined in content of the pair of core samples
accordance with sub-Clause 929.4. from each location to be subjected
to the PRD testing procedure shall
(ii) Each core shall be tested for not exceed 8.0% in binder course or
Stiffness Modulus in accordance upper base without a binder course,
with DD 213: 1993. or 9.0% in other base layers.

(iii) Following the determination of (iii) The average air void content at
Stiffness Modulus, one core from refusal density of the core samples
each location shall be tested for subjected to the PRD testing
Deformation Resistance in procedure shall be not less than
accordance with DD 226: 1996, and 1.0%.
the other core shall be tested
similarly except that the DD 226 test (iv) The minimum binder volume at
procedure shall be modified in each location shall be as stated in
accordance with TRL Paper PA Table 9/6.
3287/97. Within 28 days copies of
the test sheets and results for TABLE 9/6: Aggregate Size and Minimum
stiffness modulus and deformation Binder Volume
resistance measured for each core Mixture Minimum Binder
shall be supplied to the Employers Size/Designation Volume (%) of the Total
Representative. Additionally if the Size (mm) Volume of the Mixture
trial area is on site, the exact 0/32 8
location of the cores, their dried 0/20 9.4
bulk densities, in situ air void
contents, the composition of the (v) The compositional analysis of
mixture determined using the aggregate grading and binder
methods specified in BS 598: Part content carried out in accordance
102 and the percentage binder with BS 598: Part 102 shall
volume determined in accordance demonstrate compliance with the
with sub-Clause 929.7 shall be requirements set out in sub-Clause
reported. No limits are specified for 929.1.
the Stiffness Modulus, except for
materials complying with Clause (vi) The horizontal alignments, surface
902, or for Deformation Resistance. levels and surface regularity of the
finished surface shall comply with
10 The trial area shall be acceptable if the Clause 702.
mixture complies with sub-Clause 11 of

May 2005 22
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Sampling and Testing from the Permanent 16 Samples of uncompacted material shall
Works be taken from the paver augers in
accordance with BS 598: Part 100, Clause
12 The compaction of macadams laid in the 6.3, as near to each location from which
Permanent Works shall be assessed by cores are to be taken as is practicable and:
determination of:
(i) The maximum density of a sample
(i) in situ air void content calculated of the mixture shall be measured in
from in situ density measured using accordance with IS EN 12697-5.
a nuclear density gauge on a running The value of maximum density so
basis; and determined, ρMax expressed in
Mg/m3, shall be used for the
(ii) in-situ and refusal air void contents subsequent calculation of the air
of pairs of cores taken every 500 void contents of the compacted
lane metres and subjected to the mixture at that location.
Percentage Refusal Density (PRD)
test procedure carried out in (ii) The compositional analysis of a
accordance with BS 598: Part 104. sample shall be carried out to
determine the aggregate grading and
13 The compaction of base and binder binder content in accordance with
course macadams shall be continuously BS 598: Part 102.
assessed using the nuclear density gauge
with readings taken at 20m intervals in 17 Each core extracted shall be examined for
alternate wheel-tracks, commencing with evidence of excessive voidage below the
readings at a location from which a pair depth to which the nuclear density gauge
of cores is to be extracted. Additional penetrates. If excessive voidage is
readings shall be taken 300 mm from the observed, further cores should be taken to
edge of the mat adjacent to each core determine its extent.
location. The Contractor shall take
corrective action as is necessary whilst 18 Each layer of macadam shall be sampled
the material is still above the minimum and tested separately. Where separate
rolling temperature specified in BS 4987- coring of each layer would unreasonably
2 if low densities are indicated at the time delay placing a second layer, subject to
of laying. the approval of the Employers
Representative, both layers may be cored
14 Initially the calibrations of the nuclear together and the resulting core split prior
density gauges established in accordance to testing.
with sub-Clause 6 of this Clause shall be
used. When results are available from 19 Cores shall be extracted without the use
loose samples and pairs of cores taken of excessive force. Cores shall not be
every 500 lane metres, each gauge shall taken until the material has cooled to a
be re-calibrated if the density measured temperature of 40°C or less at mid-depth
by that gauge and the density of the cores of the course to be cored. The walls and
show a different bias. Each gauge used base of all holes from which core samples
shall be individually calibrated. have been cut shall be dried and painted
with hot bituminous binder or cold
15 For material from each mixing plant, a applied polymer modified intermediate or
pair of nominal 150 mm diameter cores premium grade bitumen emulsion
shall be taken every 500 lane metres laid, immediately prior to making good. Core
one core from each wheel-track zone of holes shall be backfilled with dense
the completed carriageway as defined in bitumen macadam in accordance with BS
sub-Clause 929.5. Cores shall be 4987-1, or with coldlay 0/20 mm nominal
extracted using a suitable coring machine, size dense bitumen macadam binder
in accordance with BS 598: Part 100. course. Dense bitumen macadam
Each core shall be subjected to the PRD incorporating fluxed binder shall not be
test procedure carried out in accordance used. The backfill material shall be
with BS 598: Part 104, and the air void compacted to refusal with a circular
contents shall be determined in headed vibrating hammer, in layers not
accordance with sub-Clause 929.7 using exceeding 75 mm. Where cores have
the maximum density ρMax expressed in been cut through the surface course, the
Mg/m3 determined in accordance with last layer of backfill material shall
sub-Clause 929.16.

May 2005 23
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

comply with the specification for the shall nominate an alternative target
surface course. aggregate grading and target binder
content and a further Job Mixture
20 Two copies of the final nuclear density Approval trial shall be carried out in
test results obtained and their correlation accordance with this Clause. Laying
with in situ air void contents shall be shall not recommence in the
passed to the Employers Representative Permanent Works until compliance
within 24 hours. has been demonstrated.

Compliance Requirements for the Permanent (iv) The compositional analyses of

Works aggregate grading and binder
content carried out in accordance
21 For material from each mixing plant: with BS 598: Part 102 shall
demonstrate compliance with the
(i) The average in situ air void content requirements set out in sub-Clause
calculated from any six consecutive 929.1.
nuclear density readings shall not
exceed 7.0% in binder course or (v) The horizontal alignments, surface
upper base without a binder course, levels and surface regularity of the
or 8.0% in other base layers. If the finished surface shall comply with
average in situ air void content Clause 702.
exceeds the limit specified, then six
cores shall be taken from the same Binder Course Macadams Below Porous
locations and the in situ air void Asphalt Surface Course
contents determined. If the average
in situ air void content of the cores 22 Designed binder course macadams below
also exceeds the limit specified, then porous asphalt shall comply with sub-
defective lengths shall be removed Clauses 1 to 21 of this Clause except that
and replaced such that compliance is every third pair of cores from the
re-established. Lengths of not less Permanent Works shall be taken across a
than 15 linear metres shall be longitudinal or transverse joint as agreed
removed and replaced, unless by the Employers Representative.
otherwise agreed by the Employers
Representative. 930 Heavy Duty Macadam
(ii) The average in situ air void content Base with Grade 40/60
of each pair of cores taken every Penetration Binder
500 lane metres shall not exceed
8.0% in binder course or upper base
(HDM50)
without a binder course, or 9.0% in
other base layers. If the average in 1 Heavy duty macadam base with grade
situ air void content of a pair of 40/60 penetration binder designed and
cores exceeds the limit specified, recipe mixtures shall comply with BS
then density readings with the 4987 for heavy duty base, Table 9/1, sub-
nuclear gauge and if necessary Clauses 2 to 6 of this Clause, and the
further cores, shall be taken to requirements of Appendix 7/1.
determine the extent of the defective
area to be removed. Lengths of not Aggregate
less than 15 linear metres shall be
removed and replaced unless 2 The coarse aggregate shall consist of
otherwise agreed by the Employers crushed rock or crushed gravel complying
Representative. with the requirements of Clause 901.3.
The fine aggregate may be crushed rock
(iii) The average values of air void or sand or mixtures thereof and the
content at refusal density of pairs of quality of the fine aggregate shall comply
cores taken every 500 lane-metres with the requirements of BS 4987: Part 1.
and subjected to the PRD testing The aggregate shall be in a surface dry
procedure shall be reported. If the condition prior to mixing.
average air void content at refusal of
any three consecutive pairs of cores
falls below 0.5% the Contractor
shall cease laying. The Contractor

May 2005 24
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Filler The fine aggregate may be crushed rock

or sand or mixtures thereof and the
3 When the coarse aggregate is crushed quality of the fine aggregate shall comply
gravel, 2% by mass of total aggregate of with the requirements of BS 4987: Part 1.
Portland cement or hydrated lime shall be The aggregate shall be in a surface dry
added. The percentage of fine aggregate condition prior to mixing.
shall be reduced accordingly. Cement or
hydrated lime is not required when Filler
limestone gravel is used as the coarse
aggregate. 3 When the coarse aggregate is crushed
gravel, 2% by mass of total aggregate of
Binder Portland cement or hydrated lime shall be
added. The percentage of fine aggregate
4 The binder shall be petroleum bitumen of shall be reduced accordingly. Cement or
paving grade 40/60 Pen complying with hydrated lime is not required when
IS EN 12591. limestone gravel is used as the coarse
aggregate.
Mixing
Binder
5 The material shall be mixed in a plant
which has a facility to incorporate added 4 The binder shall be petroleum bitumen of
filler during the mixing process. The paving grade 40/60 complying with IS
maximum temperature of mixed EN 12591.
macadam at any stage shall not exceed
185°C. Mixing

Laying 5 The material shall be mixed in a plant

which has a facility to incorporate added
6 Compaction shall be carried out while the filler during the mixing process. The
temperature of the mixed macadam is maximum temperature of mixed
greater than or equal to 105°C. macadam at any stage shall not exceed
185°C.
931 Use of Rubber in
Laying
Bituminous Materials
6 Compaction shall be carried out while the
1 When rubber is described in Appendix temperature of the mixed macadam is
7/1 as a required additive to bituminous greater than or equal to 105°C.
materials, manufacture and use of the
rubberised material shall comply with the
recommendations in Road Note 36:
933 Heavy Duty Macadam
"Specification for the Manufacture and Binder Course with Grade
Use of Rubberised Bituminous Road 40/60 Penetration Binder
Materials and Binders".
(HDM50)
932 Dense Macadam Base with 1 Heavy duty macadam binder course with
Grade 40/60 Penetration grade 40/60 penetration binder designed
Binder (DBM50) and recipe mixtures shall comply with BS
4987, with Table 9/1 and with sub-
1 Dense macadam base with grade 40/60 Clauses 2 to 7 of this Clause, and the
penetration binder designed and recipe requirements of Appendix 7/1.
mixtures shall comply with BS 4987: Part
1 for dense base, Table 9/1, sub-Clauses 2 Aggregate
to 6 of this Clause, and the requirements
of Appendix 7/1. 2 The coarse aggregate shall consist of
crushed rock or crushed gravel complying
Aggregate with the requirements of Clause 901.3.
The fine aggregate may be crushed rock
2 The coarse aggregate shall consist of or sand or mixtures thereof. The quality
crushed rock or crushed gravel complying of the fine aggregate shall comply with
with the requirements of Clause 901.3. the requirements of BS 4987: Part 1. The

May 2005 25
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

aggregate shall be in a surface dry Filler

condition prior to mixing.
3 When the coarse aggregate is crushed
Filler gravel, 2% by mass of total aggregate of
Portland cement or hydrated lime shall be
3 When the coarse aggregate is crushed added. The percentage of fine aggregate
gravel, 2% by mass of total aggregate of shall be reduced accordingly. Cement or
Portland cement or hydrated lime shall be hydrated lime is not required when
added. The percentage of fine aggregate limestone gravel is used as the coarse
shall be reduced accordingly. Cement or aggregate.
hydrated lime is not required when the
gravel is limestone. Binder

Binder 4 The binder shall be petroleum bitumen of

paving grade 40/60 complying with IS
4 The binder shall be petroleum bitumen of EN 12591.
40/60 penetration grade complying with
IS EN 12591. Mixing

Mixing 5 The material shall be mixed in a plant

which has a facility to incorporate added
5 The material shall be mixed in a plant filler during the mixing process. The
which has a facility to incorporate added maximum temperature of mixed
filler during the mixing process. The macadam at any stage shall not exceed
maximum temperature of mixed 185°C.
macadam at any stage shall not exceed
185°C. Laying

Laying 6 Compaction shall be carried out while the

temperature of the mixed macadam is
6 Compaction shall be carried out while the greater than or equal to 105°C.
temperature of the mixed macadam is
greater than or equal to 105°C. 935 Not Used
934 Dense Macadam Binder 936 Not Used
Course With Grade 40/60
Penetration Binder 937 Not Used
(DBM50)
938 Porous Asphalt Surface
1 Dense macadam binder course with grade Course
40/60 penetration binder designed and
recipe mixtures shall comply with BS General
4987: Part 1 for dense binder course,
Table 9/1, sub-Clauses 2 to 6 of this 1 Porous asphalt is exclusively a
Clause, and the requirements of Appendix bituminous surface course material used
7/1. in road construction to reduce surface
water spray and road-tyre noise. The
Aggregate mixture is gap-graded containing 14mm
nominal size aggregate and the binder is
2 The coarse aggregate shall consist of polymer modified. The mixture shall
crushed rock or crushed gravel complying satisfy the composition requirements as
with the requirements of Clause 901.3. set out in the following sub-Clauses, and
The fine aggregate may be crushed rock the mandatory tests specified in Table
or sand or mixtures thereof and the 9/11. The surface course is normally laid
quality of the fine aggregate shall comply on an impervious binder course or other
with the requirements of BS 4987: Part 1. impermeable surfacing having sufficient
The aggregate shall be in a surface dry crossfall and longitudinal gradients to
condition prior to mixing. facilitate surface water removal. The
nominal compacted layer thickness is 45
mm. The layer is bonded to the

May 2005 26
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

underlying layer with a polymer modified Table 9/8 Target Aggregate Grading and
bonding coat. permitted tolerances.
Column 1 Column 2 Column 3
Aggregate ISO Sieve Percent Tolerances
(mm) Passing around Target
2 The coarse aggregate shall consist of Grading
crushed rock or crushed gravel complying 20 100 **
with the requirements of Clause 901.3. 14 95 – 100 **
When tested in accordance with the 10 55 – 75 ±10
procedures of IS EN 933-3, IS EN1097-2 6.3 15 – 25 ±4
and IS EN 1097-8, each source of coarse 2 10 - 17 **
aggregate shall additionally have the 0.063 4 – 5.5* **
properties described in Table 9/7 or as Note: *Including 2% hydrated lime by weight of
stated in Appendix 7/1. The fine aggregate total aggregate. **Tolerances as for grading in
shall be crushed rock fines or natural column 2. Application of the above tolerances to the
sands or a mixture thereof. target grading may result in limits outside those
permitted by the appropriate envelope in Column 2
Table 9/7: Coarse Aggregate Properties of the table. This is acceptable.
Property Category
Binder
Polished Stone Value
PSV 60declared
(PSV) 5 The binder shall be preblended polymer
Resistance to modified bitumen and shall comply with
Fragmentation (Los LA25 the selected requirements of IS EN 14023
Angeles Test) as detailed in Table 9/9. During storage
Aggregate Abrasion the binder shall be agitated/circulated in
AAV10 an agreed manner to ensure the
Value (AAV)
homogeneity of the binder. When tested
Flakiness Index (10 – in accordance with Clause 941, 'Modified
FI15
14mm fraction) Binder Storage Stability Test' preblended
Flakiness Index (6.3 – modified binders shall meet the original
FI20
10mm fraction) specification for softening point and
penetration for that binder after the four
3 When sampled and tested in accordance day storage period. The supplier shall
with IS EN 12697-27, IS EN 12697-28 ensure the preblended modified binder is
and BS 598 part 102, the target aggregate manufactured to the same specification as
Grading shall fall within the envelope that for the sample submitted for the
formed by the limits given in column 2 of 'Binder Drainage Test', Clause 939.
Table 9/8. The agreed grading for the
mixture shall be obtained by applying the Binder Content
tolerances given in column 3 to the target
aggregate grading. The grading curve of 6 The target binder content (polymer
the aggregates shall be broadly parallel to modified bitumen) shall be established
the limits of the envelope and shall not from binder drainage tests as described in
vary from the low limit on one size of Clause 939. In addition, at the target
sieve to the high limit on the adjacent binder content the porous asphalt mixture
sieve or vice-versa. shall comply with the requirements of the
Cantabro Wear Test as specified in sub-
Filler Clause 938.17, with the Water Sensitivity
Test as specified in sub-Clause 938.16
4 At least 2.0 percent by mass of the total and with the Relative Hydraulic
aggregate shall be hydrated lime filler. Conductivity requirements as specified in
The minimum calcium and magnesium Clause 938.15. The tolerance for the
hydroxide content of the hydrated lime binder content to be used in the works
shall be 90%. shall not exceed ±0.3% of the target
value. Notwithstanding the above
requirements the found binder content on
analysis shall not be less than 5% of the
total mixture.

May 2005 27
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

Additives tight fitting covers. To facilitate discharge

of porous asphalt, the floor of the vehicle
7 Inorganic or organic fibres may be used may be coated with the minimum of
to assist in preventing binder draining liquid soap, vegetable oil, or other non-
from the aggregate. Adhesion agents or solvent solution. When a coating is used
other additives may be added to the then, prior to loading the body shall be
binder to improve the stripping resistance tipped to its fullest extent, with the
of the mixture. tailboard open, to ensure drainage of any
excess. The floor of the vehicle shall be
Trials and Trial Sections free from adherent bituminous materials
or other contaminants. Porous asphalt
8 At least two months before surfacing is to shall be delivered to site within the
commence the Contractor shall submit to temperature range shown in Table 9/10.
the Employer's Representative, full
details of the constituent materials of the Bonding Coat
mixture, of the test results and of the
mixing and laying proposals that is 11 On all occasions that porous asphalt is
intended to be used. At least one month used the substrate should be sprayed with
prior to the commencement of laying a polymer modified bitumen emulsion
porous asphalt in the permanent works bonding coat. The rate of application of
the Contractor shall lay a trial length of at the bonding coat shall be such as to
least 100m adjacent to the permanent site ensure that the residual bitumen coverage,
using the materials, mix composition, after curing, is between 0.4kg/m² and
method of mixing, method of laying and 0.7kg/m². The bonding coat shall be
layer thickness, intended to be used in the allowed to break before porous asphalt is
works. For the trial to be acceptable it laid and shall be of a composition to
shall, without remedial works, comply prevent 'pick up' on the tyres of pavers
with all the requirements of this and delivery trucks.
specification. If the trial length does not
conform to all the requirements of this Laying
specification the contractor shall lay
further trial lengths until such trials do 12 Porous asphalt shall be laid by machine
conform to all the requirements of this and compacted within three hours of
specification. mixing. The thickness of the porous
asphalt layer, after compacting, shall be
Mixing 45 ±5 mm. Where more than one lane is
to be covered, and where possible, porous
9 The constituent materials shall be asphalt shall be laid by at least two pavers
accurately weighed into a mechanical working in echelon, so that longitudinal
mixer of approved type and thoroughly joints can be effectively rolled together
mixed in such a manner that all particles whilst hot. The stagger between paving
are completely coated. All weighing machines shall not exceed 20 metres.
mechanisms shall be properly maintained Bitumen coating shall not be applied to
within the accuracy's recommended by exposed longitudinal edges. ' Throwing-
the manufacturer. The Contractor shall back' of material and walking on the
supply a service certificate showing that uncompacted porous asphalt shall not be
the weighing devices have been allowed. Except in circumstances
calibrated against standard loads, in approved by the Employer's
accordance with the quality plan and Representative all construction plant must
audited to ISO 9001, within six months be kept off the surface before opening to
prior to the start of the contract. The traffic in order to prevent damage to and
mixing temperature shall be as shown in clogging of the material. Porous asphalt
Table 9/10 and this is based on a required shall not be laid during rain or when
binder viscosity of 0.5 Pas. To minimize standing water is present. Porous asphalt
temperature fluctuations, production shall shall be laid within the limits of air
be continuous, and where practicable, not temperature and wind speed stated in
interrupted. Figure 9/1. Laying shall not be permitted
at any temperature if the average wind
Transporting speed over the preceding hour exceeds
50km/h at 10m height (40km/h at 2m
10 Porous asphalt shall be transported to site height). Wind speed shall be measured
in double-sheeted insulated vehicles with either by anemometer erected at a height

May 2005 28
Volume 1 Series 900
Specification for Road Works Road Pavements – Bituminous Bound Materials

of 10m ±0.5m situated at the site office, edge. Where an impermeable surface is to
or by portable anemometer erected at a be laid downstream of the porous asphalt,
height of 2m ±0.1m situated in close the lane ends of the porous asphalt shall
proximity to the laying works. The be staggered across the carriageway in the
anemometer shall be fitted with a digital direction of the drainage path in order to
accumulative device. prevent excess rainwater from welling up
over the transverse joint. Porous asphalt
Compacting shall be designed to finish on a level
grade or on an up-grade and shall not
13 Porous asphalt shall be compacted using finish/commence at a junction.
at least two 6-8 tonne, non-vibrating, steel
wheel tandem drum rollers for each Relative Hydraulic Conductivity
paving machine. If a vibratory type roller
is used it shall be operated in the non- 15 After the porous asphalt has cooled to
vibrating mode. To avoid pick-up, the ambient temperature, and before
rollers drum surfaces shall be initially trafficking, the relative hydraulic
clean and completely wetted prior to and conductivity of the material shall be
during rolling. Rubber tyred rollers and 3- measured, in accordance with the
wheeled rollers shall not be used. Rolling procedures specified at Clause 940. The
shall commence at the highest mat average value, from any 5 consecutive
temperature consistent with no shoving determinations at 20m spacings in the
and shall be substantially completed near-side wheel track of each lane of a
within the temperature range given in carriageway, shall be not less than 0.12s-1
Table 9/10. The first roller pass shall be and no single value shall be less than
on the low edge of the mat, followed by 0.08s-1.
the high edge. Rolling of the rest of the
mat shall then proceed from low to high Water Sensitivity
side and shall continue until all roller
marks have been removed. 16 The water sensitivity shall be determined
in accordance with IS EN 12697 Parts 12
Longitudinal and Transverse Joints & 23. The ratio of wet to dry strength
shall not be less than 0.75. The specimen
14 Wherever possible pavers shall be used in compacting procedure shall be such as to
echelon, as described in sub-Clause 12 of provide the air voids content expected in
this Clause, to eliminate longitudinal the field, i.e. in the range 20-28 percent
joints. Where exposed longitudinal joints without causing significant crushing of
are unavoidable they may be cold butted, the large aggregate particles as observed
provided that the edge of the porous from analysis of the specimens and
asphalt layer laid previously has not been measurement of any reduction in size. A
damaged and is clean. Where damage to reduction such that the grading no longer
edges has occurred they shall be trimmed lies within the grading envelope shall not
by power saw with appropriate measures be acceptable.
including suction extraction, to prevent
clogging of the pores with detritus. Abrasion (Cantabro Wear Test)
Longitudinal joints shall be placed
adjacent to pavement lane markings or 17 When tested in accordance with the
outside wheel track zones and shall be procedure described in NRA report RC
formed by butting-up to the adjacent 369 the wear of the mixture shall not
porous asphalt to form a tight joint. exceed 25 percent at 18°C or 20 percent
Transverse joints shall be formed against at 25°C.
a 200 mm wide and 45 mm thick hard
timber stop-end nailed to the road surface (i) The Cantabro test shall be carried
in advance of the paving operation. The out on mixture specimens
cutting of edges shall be avoided but unconditioned by any simulated
where transverse edge cutting is essential, aging procedures or by soaking in
only sawing with appropriate measures, water and,
including suction extraction shall be (ii) The specimen compaction shall
permitted. Nothing shall be done, nor any achieve maximum air voids up to 28
articles positioned, such as to impede the per cent without causing significant
run-off water freely entering the drainage crushing of the coarse aggregate as
channel or filter drain provided to remove defined in sub-Clause 16 of this
the water from the pavement surface Clause.

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Figure 9/1: Limiting weather conditions for laying porous asphalt

Table 9/9: Properties of Polymer Modified Porous Asphalt Binder

Properties Test Method Specified Value

Penetration at 25°C 0.1mm IS EN 1426 65 - 105

Softening Point, °C IS EN 1427 >70
Fraass Brittle Point, °C IP 80 < -15
Storage Stability, °C difference in
softening point, top-bottom, after Clause 941 <5
four days at 160°C
Resistance to hardening (Rolling
Thin-film Test) Mass Change, ASTM D2872 < 1.0
(percent)
Retained Penetration (Percent) > 60

Softening point increase °C <8

Softening point decrease °C <2

Table 9/10: Mixing and Handling Temperatures

Mixing Temperature Delivery Temperature Minimum Compacting
Binder Type
Range (°C) Range (°C) Temperature (°C)
Polymer In accordance with Start Finish
145 - 170
modified manufacturers requirements 140 115

Table 9/11: Mandatory Design Tests Required on Porous Asphalt Mixtures

Performance Applicability of
Design Tests Parameter
Levels Test
Drainage characteristics of
Binder Drainage Test At Design and
the binder from asphalt Target binder content
170 °C Quality Control
mixture
Per Cent Max. air void content 28
Void Content Design
Air Voids percent
Measurement of water Relative Hydraulic
Relative Hydraulic Design and
outflow under specific Conductivity Ave. 0.12
Conductivity Test Quality Control
conditions seconds (min value 0.8 s)
Tensile strength test in
Water Sensitivity Test* accordance with IS EN Ratio wet to dry 0.75 Design
12697 Parts 12 & 23
Mass loss < 25 % at 18°C
Cantabro Wear Test* Per cent loss Design
(20 % at 25°C)
*The specimen compaction procedure shall be such as to provide a maximum air void content of 28 percent. The
procedure shall not alter the determined grading of the mixture on any sieve by more than +/- 3 percent.
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939 Binder Drainage Test (vii) Metal trays, approximately 150 mm

square and 10 mm deep, ten in
Scope number.

1 This test determines the target binder (viii)Metal boxes, approximately 150 mm
content for porous asphalt, which is the by 150 mm by 150 mm, eleven in
highest binder content at which excessive number.
binder drainage will not occur during
manufacture, transportation and laying. (ix) Aluminium foil, of thickness 0.015
± 0.005 mm.
Summary of method
Materials
2 The quantity of binder lost through
drainage, after a specified time at the 4 Sufficient aggregates and binder to
maximum mixing temperature, shall be manufacture at least 20 kg of porous
measured in duplicate for mixes with the asphalt are required. The aggregates shall
same aggregate contents but with be dried and graded in the fractions
different binder contents. The target appropriate to the specified grading.
binder content shall be defined as the
value 0.3 per cent less than that at which Procedure
0.3 per cent binder drainage occurs, see
also sub-Clause 9 below. 5 The procedure shall be as follows:

Apparatus (i) The test shall be carried out at the

maximum mixing temperature at
3 The apparatus shall consist of: which the modified binder viscosity
is 0.5 Pas. In the absence of
(i) Balance of not less than 2kg viscosity data, the test temperature
capacity, accurate to 0.1g shall be 170°C ±3°C.

(ii) Oven, with fan-assisted air (ii) Weigh eleven batches of 1.1 kg of
circulation, fitted with thermostatic combined aggregate, in the
control to maintain the temperature proportions for each fraction, to the
to ±3°C in the range of 80°C to nearest 1g to give a grading
200°C and having sufficient internal complying with the mid-point of the
volume to accommodate 10 specified grading limits in Table
drainage baskets and trays. 9/8, Clause 938. Place each batch in
a separate tin.
(iii) Mechanical mixing unit of more
than 8 litres capacity, capable of (iii) Pre-heat the oven to the maximum
combining 1500g of aggregate, filler mixing temperature and place the
and binder speedily and thoroughly, tins with aggregates in the oven for
without loss, as described in BS at least 3 ± 1 hours prior to use.
598: Part 107.
(iv) Pre-heat, stir and sub-divide the
(iv) Whisk, as described in BS 598: Part binder by the method stated in BS
107. 598: Part 107.

(v) Drainage baskets, ten in number, (v) Wrap each tray with aluminium foil.
constructed from perforated metal Weigh each tray with foil to the
with 3.1 ± 0.1mm diameter holes nearest 0.1g (W1).
and with 38 ± 3 per cent open area,
on sides and base to form 100 ± 2 (vi) Pre-heat the mixing unit to the
mm cubes, with feet, at each corner maximum mixing temperature for at
of the base, of 3 ± 0.5 mm diameter least 1.5 ± 0.5 hours prior to use.
and 5 ± 1 mm height.
(vii) Transfer a 1.1kg batch of aggregate
(vi) Spatula, with a blade approximately to the mixing bowl.
150 mm long by 25 mm wide.

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(viii) When natural rubber powder is to the binder content in step (ix) to 5.0,
be used, add the required quantity to 5.5 and 6.0 per cent by mass,
the mixing bowl. Fit the mixing respectively.
bowl to the mixer and fit the whisk.
Dry mix for 30 ± 3 s before adding (xix) When a modifier other than natural
the bitumen. rubber is used, the procedure for
incorporating the modifier shall be
(ix) Stir the heated binder in its according to the manufacturers'
container and weigh by difference instructions.
the required amount of binder to the
nearest 0.5g, into the mixing bowl to Calculations
give 4.5 per cent by mass in the unit.
6 For each mix, the retained binder (per
(x) When natural rubber latex is to be cent), R, shall be calculated from R% =
used; after adding the bitumen fit 100 x B [1-D/(B+F)]/(1100+B) Where:
the mixing bowl to the mixer and fit
the whisk. Mix the aggregates and D is the mass of binder and filler drained
bitumen for 60 ± 6s. Stir the latex [W2 - W1] (g)
well and add the required quantity
evenly over the mix. B is the initial mass of binder in the mix
(g)
(xi) Fit the mixing bowl to the mixer; fit
the whisk and mix for another 60 ± F is the initial mass of filler in the mix (g)
6s. Using the spatula, scrape around
the top of the bowl and whisk and 7 If, for any pair of mixes at the same
transfer the scraped material into the binder content, the difference in retained
mix. Continue mixing for a further binder per cent exceeds 0.5 per cent of
60 ± 6s. binder, the procedure in sub-Clause 5 and
calculation in sub-Clause 6 of this Clause,
(xii) Discard the first mix. for the pair of mixes at the same binder
content, shall be repeated.
(xiii) Repeat steps (vii) to (xi)
8 The mean retained binder shall be
(xiv) Transfer the material to a basket, calculated for each binder content. The
ensuring that the mixer bowl and retained binder shall be plotted against
whisk are scraped thoroughly using the initial mixed binder content, together
the spatula. Carry out this operation with the line of equality where the
as rapidly as possible to minimize retained binder equals the mixed binder
heat losses. content. A smooth curve shall be drawn
through the plotted values and
(xv) Place the basket with the mix on a extrapolated to intercept the line of
pre-wrapped tray in the oven at the equality in Figure 9/2. The critical binder
maximum mixing temperature for content, the maximum mixed binder
between 3 hours and 3.25 hours. content, and the maximum retained
binder content shall be recorded.
(xvi) Remove the basket and tray from
the oven. Remove the basket from Determination of Target Binder Content
the drainage tray. When the tray has
cooled sufficiently, weigh the tray 9 From Figure 9/2, the mixed binder
and aluminium foil to the nearest content (M) shall be determined where
0.1g (W2). the binder drainage is 0.3 per cent (yz).
The target binder content shall be (M-0.3)
(xvii) After placing the first mix in the per cent. As a check, the abscissa, (xy),
oven, repeat the procedure in steps should also equal 0.3 per cent between
(xiii) to (xvi) for a duplicate sample the line of equality and the point on the
at the same binder content. drainage curve where the binder drainage
is 0.3 per cent (yz).
(xviii) Repeat the procedure in steps (xiii)
to (xvii) four times, but increasing

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Figure 9/2: Binder drainage test plot – Diagram indicating definitions

940 Relative Hydraulic

Conductivity Test
critical dimensions as described in
Scope DD229: 1996.

1 This test determines the in situ relative (ii) Stopwatch, accurate to 0.1s.
hydraulic conductivity, at specific
locations, of a permeable road surfacing. (iii) Thermometer, with an accuracy of
An estimate of the average value for the at least ± 1°C in the range 0 to 25
surfacing is obtained from the mean value °C.
of a number of determinations on each
section of road. (iv) Clean water, in the range 0 to 25 °C.

Summary of Method. Definitions

2 A radial-flow, falling-head, permeameter 4 The outflow time shall be the time that
shall be used to determine the time taken elapses for an outflow of 2.0 litres
for a specified amount of water, under through the permeameter, between the
known head conditions, to dissipate meniscus at the 2.5 litre mark and when it
through an annular area of the surfacing. falls to the 0.5 litre mark. The series
The reciprocal of the corrected outflow resistance time, r, shall be the outflow
time shall be used to calculate the relative time(s), corrected to 20°C, when the
hydraulic conductivity of the surfacing. outlet is not restricted by a surfacing. It
shall be subtracted from measurements of
Apparatus outflow time when the permeameter is
used on a surfacing. The parallel leakage
3 The apparatus shall consist of: time shall be the outflow time when the
outlet is restricted by an impermeable
(i) Radial-flow falling head surface. The relative hydraulic
permeameter and standing board, conductivity (HC) is the reciprocal of the
constructed to the requirements and outflow time, after correction to 20°C,
less the series resistance time.

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Apparatus Constants and Calibration standing board. Fit the plunger in

the orifice. Fill the standpipe
5 The following checks shall be performed completely with clean water.
before using the equipment: Remove the plunger and hang by its
rest on the top of the standpipe.
(i) Dimensions Allow air bubbles to rise to the top
and, if necessary, add more water to
All dimensions shall comply with those bring the water level above the 2.5
given in DD 229.1996. litre mark after all bubbles have
ceased rising. Start the stopwatch
(ii) Volume Calibration when the meniscus falls to the 2.5
litre mark. Stop the stopwatch when
Stand the permeameter on a flat and the meniscus falls to the 0.5litre
level surface. After inserting the mark, or end the test if the outflow
plunger, fill the standpipe with 500 time exceeds 10 minutes. If the
± 0.25 ml of water, using a outflow time is less than 5 minutes,
calibrated volumetric flask of 500 leakage is excessive and the
ml capacity. Mark the standpipe permeameter is unsuitable for use
permanently at the meniscus level. for this test.
Now fill the standpipe with a further
2000 ± 0.6ml of water, using a Procedure
calibrated volumetric flask of 2000
ml capacity, and again mark the 6 The procedure shall be as flows:
standpipe permanently at the new
meniscus level. (i) Place the permeameter over the
surfacing at the point where the
(iii) Series Resistance Time, r. relative hydraulic conductivity is to
be measured. Fit the standing board
Place the permeameter on blocks, of on the base. Fit the plunger in the
not less than 80 ± 5 mm height, to orifice. An operative shall stand on
expose the 100 mm diameter each side of the standing board,
aperture in the base. Fit the plunger throughout the duration of the test,
in the orifice. Fill the standpipe to hold the permeameter in place
completely with clean water. and compress the rubber annular
Measure and record the temperature disc to provide a seal.
of the water in the standpipe to the
nearest 1°C. Remove the plunger (ii) Fill the standpipe completely with
and hang by its rest on the top of the clean water. Measure the
standpipe. Start the stopwatch when temperature of the water in the
the meniscus falls to the 2.5 litre standpipe and record it to the nearest
mark. Stop the stopwatch when the 1°C.
meniscus falls to the 0.5 litre mark.
Record the outflow time and repeat (iii) Remove the plunger and hang by its
the measurement a further nine rest on the top of the standpipe.
times. Calculate the average outflow Allow air bubbles to rise up through
time and correct to 20°C by dividing the water in the standpipe until they
by the appropriate temperature no longer rise through the water,
correction factor from Table 9/12. which is dissipating into the road
Record the series resistance time, r, surface.
as the corrected average outflow
time, to the nearest 0.1s. (iv) Replace the plunger and refill the
standpipe to at least 50 mm above
(iv) Parallel Leakage Time the 2.5 litre mark. Without delay,
remove the plunger and hang by its
Place the permeameter on a flat and rest on the top of the standpipe. Start
level impermeable surface. Fit the the stopwatch when the meniscus
standing board on the base. Two falls to the 2.5 litre mark. Stop the
operatives of approximately similar stopwatch when the meniscus falls
mass, within the range 75 ± 25 kg to the 0.5 litre mark. Record the
shall stand, one on each side of the outflow time, t1, to the nearest 0.1s.

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(v) Repeat step (iv) to obtain t2. (viii)Report the relative hydraulic
conductivity, corrected to 20°C, to
(vi) Calculate the average outflow time the nearest 0.01s-1.
and the range, both to the nearest
0.1s. If the range exceeds 5 per cent Measurement of the Average Relative
of the average outflow time, repeat Hydraulic Conductivity of a Section.
step (iv) until the range criterion is
met by two successive outflow 7 The procedure shall be as follows:
times and discard other readings.
Correct the average outflow time to (i) Measure the relative hydraulic
20°C by dividing by the appropriate conductivity as soon as possible
temperature correction factor from after the surfacing has been laid and
Table 9/12 and record the corrected cooled to ambient temperature, but
average outflow time, t, to the before the surfacing has been
nearest 0.1s. opened to traffic. The road shall be
clean and free from loose material.
Table 9/12: Temperature Correction Measurements can be made when
Factors the road is wet, but not if in a frozen
Temperature of Temperature state.
water (°C) Correction factor
0 1.79 (ii) Make individual determinations of
1 1.73 the relative hydraulic conductivity
2 1.67 in the nearside wheel path at 20m
3 1.62 intervals along each carriageway
4 1.57 lane.
5 1.52
6 1.47 (iii) Calculate the running mean of each
7 1.43 5 consecutive measurements along
each carriageway lane.
8 1.39
9 1.34
(iv) Report the average relative
10 1.31
hydraulic conductivity and the
11 1.27 individual results, all corrected to
12 1.24 20°C, of each running mean of 5
13 1.20 individual determinations along
14 1.17 each carriageway lane to the nearest
15 1.14 0.01s-1.
16 1.11
17 1.08 (v) When an individual determination
18 1.06 does not comply with the specified
19 1.03 minimum requirement for relative
20 1.00 hydraulic conductivity, further
21 .98 determinations shall be carried out
22 .96 at 5 m intervals in the wheel-path on
23 .94 either side of the noncomplying
24 .91 location to determine the extent of
25 .89 the non-complying length. If the
non-complying length exceeds 20
(vii) The relative hydraulic conductivity m, rectification shall be carried out
(HC), corrected to 20°C is by removing the full depth of the
calculated from: course and replacing it with fresh
material laid and compacted in
HC = 1/(t-r) s-1 accordance with the Specification.
The area rectified shall be the full
Where t is the average outflow width of the paving laid in one
time(s) corrected to 20°C; operation, and at least 30 m long.

r is the series resistance outflow

time(s) corrected to 20°C.

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941 Modified Binder Storage (iv) Apparatus for determining the

penetration and softening point of
Stability Test bitumen in accordance with IS EN
1426 and IS EN 1427.
Scope
(v) Transfer dishes (3), made of metal,
1 This test determines the susceptibility of each of a capacity sufficient to hold
a preblended modified binder to at least one third of the test sample.
separation or instability during prolonged
storage at high temperature. Test Procedure

Summary of Method 4 The procedure shall be as follows:

2 A sample of modified binder shall be (i) The bulk sample of modified binder
contained in a closed vessel of specific shall be obtained by sampling in
dimensions and shall be maintained at accordance with BS 3195-3 and IS
160 ± 2°C for 4 days ± 2 hours. A binder EN 58.
sample shall then be taken from the top
and bottom thirds of the vessel and both (ii) Place the bulk sample of modified
samples shall be tested for compliance binder and the glass cylinder (or
with the binder specification. metal tube or equivalent vessel) in
the preheated oven at 160 ± 2°C for
Apparatus a period not exceeding 3.75 ± 0.25
hours.
3 The apparatus shall consist of:
(iii) Remove the bulk sample from the
(i) Cylinder, made of heat resistant oven and thoroughly mix by stirring
glass, 190 ± 30 mm long and 65 ± 5 to ensure obtaining a representative
mm internal diameter having a test sample.
removable lid, flush fitting to
exclude air when the cylinder is (iv) Remove the glass cylinder (or metal
filled with binder, and provided with tube or equivalent vessel) from the
three drain-valves, one at the base, oven and completely fill with the
the other two spaced equally down modified binder test sample to allow
the side of the cylinder, to allow the no air space when the lid is fitted.
sample to be divided into three
equal portions as in sub-Clause 4 (v) Support the filled cylinder in a
(vii) of the procedure. Alternatively, vertical position in the holder and
a thin-wall sheet metal tube or transfer to the oven which shall be
similar vessel such as a 500 ml controlled at a temperature of 160 ±
beverage can, of similar dimensions 2°C and allow to stand undisturbed
to the glass cylinder, and having a for a period of 168 ± 2 hours.
similarly removable lid, fitted either
with or without drain- valves. (vi) If a vessel having drain-valves has
been used for the test proceed using
(ii) Oven, electrically heated, fan Method A below, otherwise proceed
assisted, and capable of maintaining using Method B.
a temperature of 160 ± 2°C, having
interior dimensions not less than (vii) Method A
330 mm from the top of the heating
element to the top of the chamber (a) Remove the glass cylinder (or
and not less than 305 mm in width alternative approved vessel)
and depth. from the oven, keeping the
cylinder vertical.
(iii) Tube holder, made of metal, that
will hold either the glass cylinder or (b) Open the upper-most drain-
sheet metal can, in a vertical valve and run off the top third
position, such that the base of the portion of the test sample into a
cylinder or can is not in direct transfer dish for testing.
contact with the oven floor.

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(c) Open the middle drain-valve 942 Thin Surface Course

and run off the middle third
portion of the test sample into a Systems
suitable container and discard.
General
(d) Open the lower drain-valve and
run off the bottom third portion 1 Hot laid thin surfacings are here defined as
of the test sample into a transfer an application of a polymer modified
dish for testing. bitumen emulsion bond coat overlaid by a
hot bituminous mixture.
(viii) Method B
This specification is for hot laid thin
(a) Remove the tube or vessel surfacings with a compacted thickness of
containing the test sample from 20mm to 40mm, in which the aggregate
the oven and allow it to cool at particles are necessarily gap-graded to
room temperature for 2 ± 0.25 form a stone to stone contact and to
hours whilst maintaining the provide an open surface texture.
vessel vertical in the holder.
Quality Control for Manufacture
(b) When the vessel of modified
binder has cooled to ambient 2 The thin surfacing shall be manufactured
temperature, remove it from the by a company that is accredited to ISO
tube holder and make two cuts 9001, or equivalent, and who can
through the vessel and the demonstrate quality control measures at
sample at positions one-third least equivalent to sub-Clause 3, 4, 5 and 6
and two-thirds of the length of this Clause.
from, and parallel, to the base.
3 The Contractor shall provide details of the
(c) Retain the top and bottom thirds thin surfacing manufacturer's quality
of the test sample for further control system. Unless otherwise agreed
testing and discard the middle with the Employer's Representative, such
third. a system shall include at least the
following:
(ix) Determine the penetrations and
softening points of the top and (i) an independent initial inspection
bottom thirds of the test sample, in of the manufacturing facility;
accordance with IS EN 1426 and IS
EN 1427. (ii) a Factory Production Control
System;
Reporting
(iii) continuous surveillance,
5 For both the top and bottom thirds of the assessment revision and approval
test sample the following shall be of Factory Production Control;
reported:
(iv) procedures for tracing and
(i) The penetration to IS EN 1426. rectifying defects;

(ii) The softening point, to IS EN 1427. (v) traceability of materials.

(iii) Whether Method A or Method B Initial Inspection

was used.
4 The Contractor shall demonstrate that the
(iv) The location and date of obtaining thin surfacing manufacturer satisfies at
the bulk sample, and the dates of least the following requirements:
test.
(i) a Quality Manual has been
produced for the organisation's
operations and processes;

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Specification for Road Works Road Pavements – Bituminous Bound Materials

(ii) the manufacturing processes are (ii) the prescribed frequency of

documented in the form of inspections and tests to be carried
specific procedures in the Quality out during manufacture;
Manual;
(iii) the provision of reasonable
(iii) a specific procedure for the handling and storage, so that the
receipt of incoming materials has products and/or constituents
been established by the remain in conformity with the
manufacturer; technical specifications;

(iv) materials are traceable to test (iv) the control of equipment and
certification proving their machines required to
conformance to specification, manufacture the thin surfacing,
which shall be held on file for all including the necessary
thin surfacings; verification equipment (e.g.
gauges);
(v) personnel are trained and
qualified to operate the relevant (vi) assessment of the personnel
manufacturing processes qualified to carry out the relevant
including ongoing testing as manufacturing processes.
appropriate;
Continuous Surveillance
(vi) quality control measures are
operated and records kept of all 6 The Contractor shall ensure the
measurements on materials etc; manufacturer provides evidence that they
exercise continuous surveillance of their
(vii) continuous surveillance of the Quality Control system. This shall take the
processes and procedures are form of inspection reports highlighting the
undertaken and reports produced areas and procedures inspected and the
to identify non-compliance with outcome of these inspections.
the Quality Manual.
Aggregate
Factory Production Control
7 The coarse aggregate shall comply with
5 The Contractor shall ensure that the the requirements of Clause 901.3. When
manufacturer exercises continuous internal tested in accordance with the procedures
control of production. All elements, of IS EN 933-3, IS EN 1097-2 and IS EN
requirements and provisions adopted by 1097-8, each source of coarse aggregate
the manufacturer shall be documented in a shall additionally have the properties
systematic manner in the form of written described in Table 9/13 or as stated in
policies and procedures. This Production Appendix 7/1. The fine aggregate may be
Control System documentation shall crushed rock or sand or a mixture thereof
ensure a common understanding of but shall be subject to the approval of the
Factory Production Control and enable the Employers Representative.
achievement of the required product
characteristics and the effective operation Tabe9/13: Coarse Aggregate Properties
of the Production Control System to be Property Category
inspected. Factory Production Control
Polished Stone Value (PSV) *PSV 60declared
shall be a documented procedure in the
Quality Manual. Resistance to Fragmentation
LA25
(Los Angeles Test)
The manufacturer's documentation shall Aggregate Abrasion Value
be appropriate to the technical description AAV10
(AAV)
of the products and processes.
Flakiness Index FI15
Production control operations shall * Unless otherwise stated in Table 3.1 of HD36
comprise at least the following: (NRA DMRB 7.5.1).

(i) the inspection of raw materials

and constituents;

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Specification for Road Works Road Pavements – Bituminous Bound Materials

8 The maximum nominal aggregate sizes in range of binder contents shall be 5.0 to 6.5
the mixture shall be 0/14mm or 0/10mm. percent.
The requirements for the grading shall be
expressed in terms of the target grading, Bond Coat
which shall be within the maximum and
minimum values stated in table 9/16 for 11 On all occasions that hot applied thin
the percentage passing the following surfacings are used the substrate should be
sieves: sprayed with a polymer modified bitumen
1.4D; emulsion (PMBE). The rate of application
D; of the bonding coat shall be such as to
Up to two optional sieves ensure that the residual bitumen coverage,
between D and 2mm; after curing, is between 0.4kg/m2 and
2mm; 0.7kg/m2. The bond coat and thin
One optional fine sieve between surfacing shall be applied either by a
2mm and 0.063mm; and paving machine fitted with spray bar i.e.
0.063mm; integrated paver or alternatively the bond
coat can be applied separately provided
The notation ― D ‖ refers to the nominal that after a reasonable time period (10 to
size sieve e.g. in a thin surfacing material 20 minutes) it is resistant to ―pick up‖ on
0/14mm the ― D ‖ refers to sieve size the wheels of rubber tyred vehicles and the
14mm. The target proportions passing the footwear of operatives. In this case it shall
various test sieves, expressed as percent provide a strong bond between the
by mass of total aggregate shall be substrate and the hot-mixed thin surfacing
provided by the contractor at least eight when the latter is applied by a
weeks before paving is to commence. conventional paving machine. Fine
aggregate dust shall never be used to
The ranges between maximum and prevent ―pick up‖ as this will inhibit
minimum values, for the grading bonding between substrate and the thin
envelopes, shall be selected as a single surfacing.
value within the given limits (both
included) from Table 9/17. At the target Additives
composition the mixture shall conform to
the specified requirements. 12 Inorganic or organic fibres may be used to
assist in preventing binder drainage from
This specification has adopted the changes the aggregate. The nature and properties of
in grading designation that have occurred all additives e.g. cellulose, mineral or
as a result of the adoption of IS EN glass fibre etc. shall be declared. Fibres
13043:2002 – Aggregates for bituminous shall be added automatically into the
mixtures and surface treatments for roads, mixer to ensure that a homogeneous
airfields and other trafficked areas. dispersion of the fibres is achieved.

Filler Material that is proposed for use as an

additive shall have a proven established
9 The filler shall be crushed rock or suitability for use in bituminous surfacing
limestone or hydrated lime or Portland systems.
cement as approved by the Employers
Representative and not less than 75 Mixture requirements
percent shall pass the 0.063mm sieve. It
shall conform to IS EN 13043, as 13 The target composition of the mixture in
appropriate. terms of its constituent materials, the
percentages passing the specified sieves,
Binder the binder type and binder content and the
percentage and type of additive shall be
10 The binder shall be preblended polymer declared and documented.
modified bitumen and shall comply with
the selected requirements of IS EN 14023 The target aggregate grading and target
as detailed in Table 9/14. The tolerance binder content proposed by the Contractor
for the binder content in the mix shall be ± shall be that which is required to satisfy
0.3 percent of the target binder content the clauses of this specification. In
given by the Contractor. The permitted addition compacted specimens at the

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target composition shall meet the wheel certificate showing that all weighing
tracking requirements of Table 9/18 and devices have been calibrated in
shall have a Water Sensitivity value of accordance with the quality plan and
greater than 75 percent. The method of audited to ISO 9001, within six months
laboratory compaction is by the Gyratory prior to the contract.
compaction method in accordance with IS
EN 12697-31. Laying

The water sensitivity is a measure of 16 Thin surface course materials shall not be
retained stiffness and is expressed as the laid during rain or when standing water is
indirect tensile strength ratio (ITSR). The present. It shall be laid within the limits of
ITSR is calculated as the ratio of the air temperature and wind speed stated in
indirect tensile strength of wet (water Figure 9/3. The range of delivery and
conditioned) specimens to that of dry rolling temperatures shall be as stated in
specimens, expressed in percent. This test Table 9/15. Prior to laying operations the
should be carried out in accordance with Contractor shall carry out any necessary
IS EN 12697-12 and at a test temperature remedial repairs. The type and extent of
of 25°C. such repairs shall be agreed with the
Employers Representative. Where
Trials necessary, existing surfaces shall be
regulated, in accordance with the
14 At least two months before surfacing is to requirements of Clause 907, in advance of
commence the Contractor shall submit to laying surfacing material to this clause.
the Employers Representative full details
of the constituent materials of the mixture, Performance requirements
all test results and the mixing and laying
proposals including mix temperatures both 17 The Contractor shall guarantee the
at production and delivery to site. At least performance, surfacing materials and
one month prior to the laying of thin workmanship for a period of three years
surfacing in the permanent works the from the date of opening the surfacing to
Contractor shall lay a trial length of at traffic or as otherwise specified in
least 100m adjacent to the site using the Appendix 7/1. In the event of failure of
materials, mix composition, method of the surface to meet the performance
mixing, method of laying including bond specification for the guarantee period, the
coating and layer thickness to be used in Contractor shall replace the material in
the main contract. For the trial to be accordance with this specification. The
acceptable it shall, without remedial requirements for Skid Resistance and
works, comply with the full requirements Texture Depth – initial and after three
of this specification. Alternatively, with years in service shall be as stated in Table
the agreement of the Employers 9/19 and Table 9/20.
Representative, the trial may form part of
the permanent works if the material Skid resistance shall be measured using
installed complies with all the the SCRIM machine. This testing shall be
requirements of this specification. If the carried out at a test speed of 50Km/h.
trial does not conform to all the
requirements of this specification, the The texture depth of the surfacing after
Contractor shall remove all non-compliant compaction and before opening to traffic
material from the permanent works and shall be measured by the volumetric patch
lay further trial lengths until full technique described in IS EN 13036-1 and
compliance with this specification is shall conform to the requirements of Table
achieved. 9/20. The initial measurements should be
made over 50 metre lengths, regularly
Mixing spaced along the section, and covering not
less than one third of the area of surfacing.
15 The materials including any added filler On each 50 metre lane length, 10
shall be accurately weighed into a individual measurements shall be made at
mechanical mixer of approved type and 5 metre intervals, along a diagonal line
thoroughly mixed in such a manner that all across the carriageway lane width, but not
particles are completely coated. The within 300mm of the carriageway edge.
Contractor shall supply a service

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Surface texture measurements made after

periods in service shall be made in the
nearside wheel track at 5 metre intervals
in a longitudinal direction. These shall be
carried out on both sides of the
carriageway, i.e. in both traffic directions.

After five years in service visual

assessment shall show no loss of the
surfacing material due to attrition or
debonding or ravelling or surface
disintegration or cracking. The guarantee
shall exclude defects arising from damage
caused by settlement, subsidence or failure
of the carriageway on which the material
has been laid.

Figure 9/3: Limiting weather conditions for laying Thin Surfacing Materials.

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Table 9/14: Properties of Thin Surface Course Polymer Modified Binder

Properties Test Method Specified Value

Penetration at 25°C 0.1mm IS EN 1426 65 - 105

Softening Point, °C IS EN 1427 >60
Fraass Brittle Point, °C IP 80 < -15
Storage Stability, °C difference in
softening point, top-bottom, after four Clause 941 <5
days at 160°C
Resistance to hardening (Rolling Thin-
ASTM D2872 < 1.0
film Test) Mass Change, (percent)
Retained Penetration (Percent) > 60

Softening point increase °C <8

Softening point decrease °C <2

Table 9/15: Mixing and Handling Temperatures

Delivery Minimum
Binder Mixing Temperature
Temperature Range Compacting
Type Range (°C)
(°C) Temperature (°C)
Polymer In accordance with Start Finish
145 - 170
modified manufacturers requirements 140 115

Table 9/16: Overall Grading Limits of Target Composition and Composition tolerances
Nominal Size 0/10 Grading** 0/14 Grading**
Tolerances Tolerances
Nominal
+/- for +/- for
Layer 20-30mm 20-40mm
0/10mm 0/14mm
Thickness
ISO Sieve
10A* 10B* 10C* 14
(mm)
20 100
14 100 100 100 90-100 -8/+5
12.5
10 90-100 90-100 90-100 -8/+5 35-50 7
8
6.3
4
2 15-25 25-35 25-35 6 15-30 6
1
0.063 4-6 7-9 10-12 2 6-12 2

Note: * Hot laid thin bituminous surfacings shall be designated by their nominal size i.e. the upper
sieve size of the aggregate in the mixture, in mm and where relevant, by an indication of the type, A, B
or C.
** Application of the above tolerances may result in limits outside those permitted by the appropriate
envelope. This is acceptable.

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Table 9/17: Ranges between maximum and minimum values for the selected grading envelope
Ranges. Percent by mass
Sieve
Smallest range Widest range
First optional sieve between nominal 10 25
sieve and 2mm
Second optional sieve between 10 25
nominal sieve and 2mm
2mm 5 15

Optional fine sieve between 2mm 4 15

and 0.063mm
0.063mm 2.0 6.0
Note: This table specifies the permitted width of the selected grading envelope e.g. in the first optional
sieve the smallest range allowed between the minimum and the maximum percent passing that
particular sieve is 10 percent and the widest range permitted between the sieves is 25 percent.

Table 9/18: Wheel Tracking requirements for site classifications

Test
Classification Maximum wheel tracking values
temperature

Rut rate
Road category Rut depth (mm)
(mm/hr)
Very heavily stressed sites requiring high
60°C 5.0 7.0
rut resistance
Moderately stressed sites requiring high rut
45°C 2.0 4.0
resistance

Table 9/19: Requirements for Skid Resistance (sfc units)

Mean sfc Not more than 15% Minimum sfc
(Initial) below (After 3 Years)
>0.55 0.55 0.50

Table 9/20: Requirements for Texture Depth.

Where maximum vehicle speed
≤ 50km/h > 50Km/h
is:
Nominal stone size of mix (mm) 10 14 10 14
Initial, after laying
Average for each lane Km or
Surfaced length if less than 1 ≥1.2mm ≥1.2mm ≥1.5mm ≥1.5mm
Km.
Average of each set of ten
≥1.0mm ≥1.0mm ≥1.2mm ≥1.2mm
measurements
After 3 years
Average for each lane Km or
Surfaced length if less than 1 ≥1.0mm ≥1.0mm ≥1.3mm ≥1.3mm
Km.
Average of each set of ten
- - ≥1.0mm ≥1.0mm
measurements

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