[ Top ] Hot Rolled Asphalt and Bituminous Macadam
The Idiots' Guide to Highways Maintenance
Copyright © 2000/08, C.J.Summers


THIS IS A GUIDE TO AVAILABLE (BITUMEN) COATED MACADAMS, AS SPECIFIED IN, 
 BS 4987: COATED MACADAM (ASPHALT CONCRETE) FOR ROADS AND OTHER PAVED AREAS

Subject title and associated information

IMPORTANT UPDATE
Major changes have taken place in the way bituminous mixtures are specified, both Coated Macadams and Hot Rolled Asphalts.
These changes were introduced from the 1st.of January 2008, although there will be some delay where existing, binding, contracts refer to BS 4987 and BS 594.
Rather than repeat myself on this page regarding the process of this change may I suggest you study the
Summer 2007 Newsletter to get up to date with how/why the changes have taken place.

However do not throw away your BS 4987's and your BS 594's for a while (if ever), as they contain information on good designs and working practice) and it is likely that you will need them to convert your current "well tried" mixtures to the appropriate equivalent new BS EN 13108 specification.

This page will remain for some time, at least until I believe there has been a successful transition between specifying bituminous mixtures from BS 4987 and BS 594 to specifying generic bituminous mixtures from the BS EN 13108 family of specifications.
And we all know, well all those actively involved in the work of maintaining and constructing highways, how long it takes for new "descriptions" of same materials/mixtures to be taken up by the workforce. 

Read on for information on BS 4987 and its past development :-
Please do not be too discouraged by the amount of changes that have occurred in BS 4987 over recent years, they are in fact relatively minor in relation to the overall content of the specification. 
This remains an excellent document for providing information and guidance on the specifying, transporting, laying and compaction of bitumen coated macadam. 
I still believe using the information provided in the standards BS 4987 and BS 594 (hot rolled asphalt) is a good basis to specifying the requirements of bituminous mixtures for road construction and maintenance.
It is my opinion that "converting" existing generic designs for commonly used bituminous mixtures to the new form of specification is the best and most economical method to adopt, especially for local highway networks.
But you, yes you, must be the one to know which is the best bituminous bound material for your site, you should not, and must not, rely on the contractor or supplier to do your job for you. 
Their choice could be influenced by factors other than the most cost effective option to the customer, i.e. you, and whoever you represent, most probably the general public. 
If you need guidance talk to your Materials or Road Pavement Engineer.
It is now time to be concerned about the European BS EN standards for bituminous mixtures as they will be arriving shortly, if not necessarily on time. 
From what I have seen they will not be as dire as predicted, they are a mixture of good news and bad news.
( I particularly appreciate the publication of the standard for stone mastic asphalt, which now allows you to specify the type of SMA you want, although I personally still believe that no SMA's should be porous.)
Do not panic, as I feel that if you know the nature of the bituminous mixture you require you will be able to specify it from an "official" British (European) Standard, which I regard as good practice.
The danger may come, for local authority Engineers and Engineering Technicians, with the introduction of very large "Alliances" of local authorities to create "Framework" deals with large contractors and suppliers.
These "Alliances" will include the Highways Agency as a major, possibly controlling partner, and the Highways Agency may wish to introduce the practice of only permitting proprietary (branded) bituminous mixtures for surface course layers, as is currently the situation with motorways and trunk roads.



THE MOST RECENT UPDATE, (of what appears the most actively updated specification I am aware of, well apart from hot rolled asphalt, and concrete).
BS 4987 : Part 1 : 2005 : Coated macadam (asphalt concrete) for roads and other paved areas - 
Part 1 : Specification for constituent materials and for mixtures

This edition of
BS 4987 : Part 1 supercedes the 2003 edition and introduces the concept of factory production control (FPC) tolerances in anticipation of future European Standards for asphalt. 
For grading this will involve selecting a target percentage (%) passing value from within a specified range and applying tolerances to this target. 
Compliance to the specification created from this procedure will assess product conformity.

At the time of writing the only sieve that is required to meet the FPC tolerance in BS 4987 is the 2mm. sieve, this is explained in more detail in the standard.
In due course this may well lead to "different" materials being supplied from different quarries and production plants.

BS 4987, Parts 1 & 2 were previously updated (August 2003) to include changes brought in due to the introduction of BS EN 13043 which will introduce a number of changes relating to the size designations of aggregate, the material description and associated test methods to determine aggregate and mixture performance.
These changes were introduced on the 1st. of January 2004, I suggest you purchase your copy as soon as possible so that you may begin to understand the changes.

I am still including reference to previous recent changes in BS 4987 for background information. 

Although the material descriptions in the table below have been updated to include how the bituminous mixtures are now described, the actual mixtures are fundamentally the same, with changes in gradings and binder contents being slight.

The information in the tables below will be useful as a GUIDE but only as a GUIDE, refer to the current British Standard for up to date information.

Please be aware that a previous edition of, 
BS 4987:Coated macadam for roads and other paved areas,
 
Part 1:Specification for constituent materials and for mixtures

and 

Part 2:Specification for transport, laying and compaction

prior to 2003, was published in 2001, 

Depending on the nature of the contract you are employing it may still defer to as far back as the 1993 edition or it may default to the most recently published copy of any British Standard.
Although the new BS 4987 is substantially similar to the 1993 edition there are some important differences and it is for you to work to the appropriate edition of the British Standard your current contracts require.
The differences you will find in the new specification relate to the change of
viscosity of binder grades, and the change in terminology of material categories, i.e. wearing course is now called surface course, and it will now have a 125pen. bitumen binder if it previously had a 100pen binder. 
I leave you to purchase a copy of the most recent British Standard and find out the nature of all the changes and how they may affect you.

If previous experience is anything to go by you may find the 1993 edition of BS 4987 referred to for some time.
The important thing is to always be clear between Specifier, Contractor and Supplier that you are all working to the same document.


SUMMARY OF RECENT CHANGES, to specifying Coated Macadam as Asphalt Concrete (from 1st. January 2008)

A great deal of information is presented below on the many bituminous macadams that were specified in BS 4987.
If you wish to use the bituminous mixtures described below in the future, after 1st. January 2008, you will need to convert them to an equivalent bituminous mixture using,
BS EN 13108-1 : 2006 - Bituminous mixtures - Material specifications - Part 1 : Asphalt Concrete
If you were in any way responsible for ordering / purchasing or supervising the laying of bitumen coated macadams you
should have had access to
both Parts 1 and 2, of BS 4987 of the appropriate edition quoted in the contract.
The information contained in them is excellent, and if you follow their guidance to specify "equivalent"  bituminous mixtures you will not go far wrong, but it would be even better if you could also consult with your Materials Engineer / Technician, if your organisation still has such a person.

Guidance on the transformation of specifying from
BS 4987 and BS 594 to BS EN 13108 can be found in, 
PD 6691 : 2007 : Guidance on the use of BS EN 13108 Bituminous mixtures - Materials Specifications

It is also necessary to be aware that the
"Part 2's" of both BS 4987 and BS 594
have been combined in to the document, 
BS 594987 : 2007 : Asphalt for roads and other paved areas - Specification for transport, laying and compaction and type testing protocols.

If you are actively involved in the specifying, ordering or use of Bituminous Mixtures you do need to have access to the above new documents.

BE FULLY AWARE ! ! ! ! !
THE INFORMATION BELOW HAS BEEN SUPERSEDED IT REMAINS FOR GUIDANCE PURPOSES ONLY


MACADAM LAYER THICKNESS - TOLERANCES

By using the "Find" facility of the browser you can obtain a particular bituminous macadam.
With each record of a particular macadam you will find the nominal and minimum thickness for that material to be laid.

In order to achieve required thickness of bituminous layers it is necessary to know about LAYER TOLERANCES that are specified in the DfT. Specification for Highway Works.
The "manipulation" of these tolerances can lead to significant reductions in the individual layer thickness, and the overall pavement thickness of your road design, and subsequently the life of the road.

A reduction in wearing course thickness by increasing the thickness of the binder course (basecourse),
(all within the contract specification), is what the contractor is usually aiming for, as the wearing course material will be the most expensive to purchase.
Check it out, and do not include any laying tolerance larger than is necessary, as it may well be abused.



BITUMEN MACADAM RATES OF SPREAD

The rate of spread of each particular MACADAM material will be found in the subject entry appropriate to that material,
e.g. the rate of spread of MACADAM, 10MM. SIZE CLOSE GRADED SURFACE COURSE (WEARING COURSE) will be found under that subject heading.
Use the "Find" facilities of the browser to access the particular material you require details about.



BITUMEN MACADAM SURFACE COURSE (WEARING COURSE) MATERIALS - SPECIFICATIONS

This is just a list of the more commonly used MACADAM SURFACE COURSE (WEARING COURSE) materials, from this list you will be able to look at them individually, in the guide, to gain more knowledge on their suitability for particular sites, and their laying criteria :-

0/6mm. SIZE DENSE SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.5)

0/6mm. SIZE MEDIUM GRADED SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.6)

0/10mm. SIZE CLOSE GRADED SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.4)

0/10mm. SIZE OPEN GRADED SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.2)

0/14mm. SIZE CLOSE GRADED SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.3)

0/14mm. SIZE OPEN GRADED SURFACE COURSE MACADAM (BS 4987:PART 1: CL. 7.1)

0/4mm. SIZE FINE GRADED SURFACE COURSE (previously known as 3mm. size fine graded surface course, and before that known as "fine cold asphalt")

But you cannot specify and lay bituminous macadam without a copy of BS 4987, Parts 1 & 2, they will be well worth the money you spend on them.
Buy them now before "Thin Surfacings" take over completely, they will even be useful in understanding the allegedly new "Thin Surfacings"
.


MACADAM, 10MM. SIZE CLOSE GRADED SURFACE COURSE

(This was known as 10mm. Dense Macadam Wearing Course)
With the appropriate BINDER this is a very good general purpose WEARING COURSE.
Specification is :-
B.S.4987:CLAUSE 7.4 (And all information in Parts 1 and 2),

BS 4987:2005 IS CURRENT


Nominal thickness ................30mm. to 35mm.
Minimum thickness at any point ...25mm.
Rate of coverage at 35mm. ........12 sq.metres/tonne

Viscosity ........................100pen ....200pen ....300pen ....100/200secs
Max. delivery temp ...............160 .......150 .......130 .......120
Min. delivery temp ...............120 .......110 .......100 ........75
Minimum rolling temp ..............95 ........85 ........80 ........50
prior to rolling


MACADAM, 0/10MM. SIZE OPEN GRADED SURFACE COURSE

This material often had a CUTBACK BITUMEN binder as the open nature allowed the volatiles in the cutback bitumen to evaporate more quickly..
With an appropriate stiffer (e.g. 100pen.) BINDER this is a good general purpose WEARING COURSE giving a high texture and a quiet running surface.
The material is porous so an impervious basecourse is required, the bitumen binder will also oxidise at a higher rate than a dense material so its life will be shorter in comparison.
Specification is:-
B.S.4987:CLAUSE 7.2 (And all information in Parts 1 and 2).

BS 4987:2005 IS CURRENT.


Nominal thickness ..................30mm. to 35mm.
Minimum thickness at any point .....25mm.
Rate of coverage at 35mm ...........14 sq.metres/tonne

Viscosity ..............200pen ......300pen .......100/200secs .......50secs
Max. delivery temp. ....125 .........115 ..........100 ...............90
Min. delivery temp. .....95 ..........85 ...........60 ...............--
Min. rolling temp. ......75 ..........65 ...........40 ...............-- (prior to rolling)


MACADAM, 0/10MM. SIZE POROUS ASPHALT SURFACE COURSE - PERVIOUS MACADAM

Specification is :-
BS 4987:PART 1:CLAUSE 8.2 (And all information in Parts 1 and 2).
The name POROUS ASPHALT WEARING COURSE has now replaced PERVIOUS MACADAM, since the edition prior to that of 1993, Clause and Table numbers remain the same.

BS 4987:2005 IS CURRENT


Nominal thickness .................30mm. to 35mm.
Minimum thickness at any point ....25mm.
Rate of coverage at 35mm ..........14 sq.metres/tonne

Viscosity .....................100pen ...............200pen
Max. delivery temp. ...........135 ..................125
Min. delivery temp. ...........110 ..................110
Minimum rolling temp. ..........85 ...................85 (prior to rolling)



MACADAM, 0/14MM. SIZE CLOSE GRADED SURFACE COURSE


This was known as 14mm. Dense Macadam Wearing Course, with the appropriate BINDER this is a good general purpose SURFACE COURSE.
Specification is:-
BS 4987:CLAUSE 7.3 (And all information in Parts 1 and 2),

BS 4987:2005 IS CURRENT.


Nominal thickness ................40mm. to 55mm.
Minimum thickness at any point ...35mm.
Rate of coverage at 50mm. .........9 sq.metres/tonne

Viscosity ...................100pen ......200pen .......300pen .......100/200secs
Max. delivery temp. .........160 .........150 ..........130 ..........120
Min. delivery temp ..........120 .........110 ..........100 ...........75
Minimum rolling temp .........95 ..........85 ...........80 ...........50
(prior to rolling)



MACADAM, 0/14MM. SIZE OPEN GRADED SURFACE COURSE


This material occasionally has a CUTBACK BITUMEN binder and is then "dusted" with a sealing grit, it is usually produced and used in this fashion for hand lay work because of its longer period of workability.

But it is best used as a machine lay material with a penetration grade bitumen, and with the appropriate BINDER this is a good general purpose WEARING COURSE which is a very "quiet" surface with considerable negative texture.
Specification is:-
B.S.4987:CLAUSE 7.1 (And all information in Parts 1 and 2)

BS 4987:2005 IS CURRENT.


Nominal thickness ...................40mm. to 55mm.
Minimum thickness at any point ......35mm.
Rate of coverage at 50mm. ...........10.5 sq.metres/tonne

Viscosity ...................200pen ........300pen ........100/200secs .......50secs
Max. delivery temp ..........125 ...........115 ...........100 ...............90
Min. delivery temp ...........95 ............85 ............60 ...............--
Minimum rolling temp .........57 ............65 ............40 ...............--
(prior to rolling)


MACADAM, 0/20MM. SIZE DENSE BINDER COURSE


This material is specified in :-
B.S.4987:PART 1: CLAUSE 6.5, and it shall be transported/laid/compacted to
B.S.4987:PART 2.

B.S. 4987:2005 CURRENT.

N.B. This material is commonly used as a SURFACE COURSE layer in rural areas, and it will receive a 6mm. surface dressing after 6/18 months, binder content may be increased by 0.5%.


Nominal thickness ...................50mm. to 80mm.
Minimum thickness at any point ......40mm.
Rate of coverage at 60mm. ............7.75 sq.metres/tonne
Viscosity ............................100pen ............200pen
Max. deliverytemp. ...................120 ...............110
Minimum rolling temp. .................95(75) ............85(60)
1st figure) prior to rolling.
2nd figure) shall be substantially complete by this temperature



MACADAM, 0/20MM. SIZE OPEN GRADED BINDER COURSE - DEPOT STOCK - TEMPORARY PATCHING

This material is specified in B.S.4987:PART 1: CLAUSE 6.1,
and it shall be transported / laid / compacted to BS4987:PART 2

BS 4987:2005 IS CURRENT

N.B. This is often used as a DEPOT STOCK / EMERGENCY PATCHING material, when it will be heavily cutback with a volatile oil to keep it workable for several days.


Nominal thickness ..................45mm. to 75mm.
Minimum thickness at any point .....40mm.
Rate of coverage at 60mm. ...........9.0 sq.metres/tonne
Viscosity ...............................200pen .......300pen .......200/100secs
Max. delivery temp. .....................125 ..........115 ..........100
Min. delivery temp. ......................95 ...........85 ...........60
Minimum rolling temp. ....................75 ...........65 ...........40
The minimum rolling temperature figures are the minimum temperatures immediately prior to rolling.


MACADAM, 0/32MM. SIZE SINGLE COURSE

This material is specified in B.S.4987:PART 1: CLAUSE 6.2,
and it shall be transported / laid / compacted to BS4987:PART 2

BS 4987:2005 IS CURRENT

N.B. This material is used as a combined binder course and surface course bituminous mixture, the viscosity of the binder is chosen appropriate to the amount and type of traffic and underlying strength (movement) of the existing road pavement. This material is mainly used on neglected rural highways as a means of adding strength and a good running surface in one operation.


Nominal thickness ..................75mm. to 105mm.
Minimum thickness at any point .....65mm.
Rate of coverage at 80mm. ...........6.0 sq.metres/tonne
Viscosity ...............................200pen .......300pen 
Max. delivery temp. .....................125 ..........115 
Min. delivery temp. ......................95 ...........85 
Minimum rolling temp. ....................75 ...........65 
The minimum rolling temperature figures are the minimum temperatures immediately prior to rolling.


MACADAM, 6/20MM. SIZE POROUS ASPHALT SURFACE COURSE

BS 4987:CLAUSE 8.1 (And all information in Parts 1 and 2).

In BS 4987:1993 PERVIOUS MACADAM WEARING COURSE, or material very similar to it, is now known as POROUS ASPHALT WEARING COURSE with the same clause/table numbers of the previous edition of BS 4987.

This material must be laid on an impervious basecourse to prevent ingress of water into the road pavement.

BS 4987:2005 IS CURRENT

Nominal thickness ....................50mm. to 80mm.
Minimum thickness at any point .......40mm.
Rate of coverage at 60mm. .............9.0 sq.metres/tonne
Viscosity .............................100pen .............200pen
Max. delivery temp. ...................135 ................125
Min. delivery temp ....................110 ................110
Minimum rolling temp ...................85 .................85 (prior to rolling)



MACADAM, 0/32MM. SIZE DENSE BINDER COURSE

This material is specified in B.S.4987:PART 1:CLAUSE 6.4, and it shall be transported, laid and compacted in accordance with BS 4987:PART 2.

BS 4987:2005 CURRENT.


Nominal thickness .....................70mm. to 100mm.
Minimum thickness at any point ........55mm.
Rate of coverage at 75m ................5.75 sq.metres/tonne
Viscosity ..................................100pen ..............200pen
Max. delivery temp .........................160 .................150
Min. delivery temp .........................120 .................110
Minimum rolling temp ........................95 (75) .............85 (60)

(1st) temperature prior to rolling.
(2nd) shall be substantially complete by this temperature



MACADAM, 0/32MM. SIZE DENSE BASE (ROADBASE) 

This material is specified in B.S.4987:PART 1: CLAUSE 5.2, and it shall be transported, laid and compacted in accordance with BS 4987:PART 2.

BS 4987:2005 IS CURRENT


Nominal thickness ......................70mm. to 100mm.
Minimum thickness at any point .........55mm.
Rate of coverage at 75mm ................5.75 sq.metres/tonne
Viscosity ...............................100pen ............200pen
Max. delivery temp ......................160 ...............150
Min. delivery temp ......................120 ...............110
Minimum rolling temp .....................95(75) ............85(60)
(1st) prior to rolling.
(2nd) shall be substantially complete by this temperature


MACADAM 0/4mm. SIZE FINE GRADED SURFACE COURSE (previously known as 3mm. size fine graded surface course, and before that known as "fine cold asphalt")

This material with the appropriate BINDER is an excellent material for footway surfacing (overlays) and patching.
Specification is :- B.S.4987:1993:CLAUSE 7.7 (And all information in Parts 1 and 2)

BS 4987:2005 IS CURRENT


Nominal thickness ......................15mm. to 25mm.
Minimum thickness at any point .........10mm.
Rate of coverage at 20mm. ..............21 sq.metres/tonne
Viscosity .........................200pen .........300pen .........100/200secs
Max. delivery temp. ...............150 ............130 ............120
Min. delivery temp. ...............110 ............100 .............75
Minimum rolling temp. ..............85 .............80 .............50
(prior to rolling)


MACADAM, 40MM. SIZE DENSE BASECOURSE

This material is specified in B.S.4987:1993:PART 1: CLAUSE 6.3, and it shall be transported/laid/compacted in accordance with BS 4987:1993:PART 2.

BS 4897:2005 IS CURRENT.
(NOTE the use of 40mm. size aggregate is no longer specified from, and including, the 2003 edition.)

Nominal thickness ........................95mm. to 140mm.
Minimum thickness at any point ...........80mm.
Rate of coverage at 100mm .................4.5 sq.metres/tonne
Viscosity ............................100pen .............200pen
Max. delivery temp ...................160 ................150
Min. delivery temp ...................120 ................110
Minimum rolling temp ..................95(75) .............85(60)
(1st) prior to rolling.
(2nd) shall be substantially complete by this temperature



MACADAM, 40MM. SIZE DENSE ROADBASE

This material is specified in B.S.4987:1993:PART 1 : CLAUSE 5.1, and it shall be transported, laid and compacted in accordance with BS 4987:1993:PART 2.
This is a good load spreading material when used in thick roadbase layers.


BS 4987:2005 IS CURRENT  (NOTE the use of 40mm. size aggregate is no longer specified from, and including, the 2003 edition.)

Nominal thickness ......................90mm. to 150mm.
Minimum thickness at any point .........80mm.
Rate of coverage at 100mm. ..............4.5 sq.metres/tonne
Viscosity ...............................100pen .............200pen
Max. delivery temp. .....................160 ................150
Min. delivery temp. .....................120 ................110
Minimum rolling temp. ....................95 (75) ............85 (60)
(1st) temperature prior to rolling.
(2nd) rolling shall be substantially complete by this temperature



MACADAM, 0/6MM. SIZE DENSE SURFACE COURSE

This material is widely used for footway surfaces often with a 100sec binder for easy working, but 300/200pen would be better choice of binder for material stiffness and durability.
A straight run 300pen. binder is a good compromise viscosity for hand lay footway work.

Specification is B.S.4987:CLAUSE 7.5 (And all information in Parts 1 and 2),
A viscosity less viscous (less stiff) than 100secs is NOT specified in BS 4987:1993

BS 4987:2005 IS CURRENT


Nominal thickness ....................20mm. to 25mm.
Minimum thickness at any point .......15mm
Rate of coverage at 25mm. ............17 sq.metres/tonne
Viscosity ............................100pen .....200pen .....300pen .....100/200secs
Max. delivery temp. ..................160 ........150 ........130 ........120
Min. delivery temp. ..................120 ........110 ........100 .........75
Min. rolling temp. ....................95 .........85 .........80 .........50
(prior to rolling)


MACADAM, 0/6MM. SIZE MEDIUM GRADED SURFACE COURSE

This is used for footway surfaces, patching, and minipaver work, it is suitable for use with cutback binders as the volatiles evaporate more readily from the open nature of the material matrix.
It is also an excellent material with a stiff (100/50pen. polymer enhanced binder) as a thin surfacing on urban roads.
It can be laid at a 20mm. thickness and has good texture and durability, and with a high PSV aggregate has a good skid resistance value (SRV).
Specification is B.S.4987:CLAUSE 7.6 (And all information in Parts 1 and 2),

BS 4987:2005 IS CURRENT


Nominal thickness .....................20mm. to 25mm.
Minimum thickness at any point ........15mm.
Rate of coverage at 25mm. .............17 sq.metres/tonne
Viscosity .............................200pen ...........300pen ..........100/200secs
Max. delivery temp. ...................125 ..............115 .............100
Min. delivery temp. ....................95 ...............85 ..............60
Minimum rolling temp. ..................75 ...............65 ..............40
(prior to rolling)

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