Enhancing Road Resilience and Sustainability on Kirkstone Pass with Tufflex D PMB
Product: Tufflex D PMB
Main contractor: Heidelberg Materials Contracting
Overview:
The Kirkstone Pass resurfacing project demonstrates how high performance materials can successfully withstand extreme gradients and harsh weather conditions. By using Tufflex D PMB, the scheme achieved long term durability, improved safety and meaningful carbon reductions. The result is a more resilient, reliable and sustainable route that benefits road users, local communities and the regional economy.
Project description:
Kirkstone Pass is a mountain pass in the lake district. At an altitude of 1,489 feet, it is the district’s highest pass traversed by road. Given the demanding location and steep gradients of up to 25%, selecting a material capable of withstanding harsh environmental conditions was critical to the success of this resurfacing project. To meet the extreme demands of the environment, the team selected Tufflex D PMB for its proven ability to deliver high performance under challenging conditions. This high-performance product was specifically chosen to enhance the durability, safety, and longevity of the road surface. Its technical advantages not only supported faster installation but also ensured long-term resilience, making it ideal for steep gradients, heavy traffic, and extreme weather conditions. The following performance characteristics highlight why Tufflex D was the optimal choice.
Key Performance Benefits
- Superior deformation resistance
- Class 3-wheel track rutting performance
- Lower void content to prevent water ingress
- High bitumen softening point for enhanced durability
- Improved fatigue and skid resistance
- Greater tyre contact and reduced rolling resistance
These attributes ensured faster installation, exceptional long-term durability, and reliable traction for vehicles and cyclists in all weather conditions.
Environmental and social impact
The project was designed to overlay the existing surface, with selective patching carried out to ensure structural integrity. This approach avoided disturbing tar‑bound materials and therefore reduced the amount of hazardous waste produced. It also minimised carbon emissions from heavy machinery and logistics, supported a more sustainable construction process, and reduced time on site, which helped to limit disruption to the local economy, tourism and road users.
Over 34.5 tonnes of CO2 was saved during the scheme. The use of Tufflex D is projected to save an additional 11 tonnes of CO2 annually, thanks to its extended lifespan, with additional carbon savings from fewer interventions.
End users now benefit from significantly improved travel experiences, with shorter journey times thanks to a reduction in road repairs and disruptions. The smoother road surfaces not only enhance comfort but also contribute to safer travel conditions, particularly for cyclists who are more vulnerable to uneven terrain. These improvements in infrastructure have led to a noticeable boost in overall road safety, making daily commutes and leisure travel more efficient, reliable, and enjoyable for all.
In addition, enhanced road conditions have improved connectivity for both people and businesses, facilitating easier access to services, suppliers, and customers. This stronger transport network supports economic growth by reducing logistical barriers and encouraging regional collaboration. Local tourism also receives a boost, as safer and more pleasant travel routes attract visitors and make it easier to explore nearby attractions, helping to sustain and grow the local economy.
The Kirkstone Pass project exemplifies how strategic planning, innovative materials, and sustainable practices can deliver outstanding results. Tufflex D PMB proved to be the ideal solution for a challenging environment, offering long-term performance, reduced environmental impact, and enhanced user satisfaction.
