BS 594-1 2005 Hot Rolled Asphalt For Roads and Othe Rpaved Areas

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BRITISH STANDARD
Hot rolled asphalt for

roads and other paved
areas
Part 1: Specification for constituent
materials and asphalt mixtures
ICS 93.080.20
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BS 594-1:2005
Incorporating
Corrigendum No. 1
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BS 594-1:2005
Committees responsible for this

British Standard
The preparation of this British Standard was entrusted by Technical
Committee B/510, Road materials, to Subcommittee B/510/1, Coated macadam
and hot asphalt, upon which the following bodies were represented:
British Civil Engineering Manufacturers Association
County Surveyors Society
Department for Transport Highways Agency
Highways Agency Safety Standards and Research
Institute of Asphalt Technology
Institution of Civil Engineers
Institution of Highways and Transportation
Mastic Asphalt Council Ltd.
MoD UK Defence Standardization
Quarry Products Association
Refined Bitumen Association
Scottish Office Roads Directorate
Society of Chemical Industry
TRL Transport Research Laboratory
United Kingdom Accreditation Service
Co-opted members
This British Standard was

published under the authority
of the Standards Policy and
Strategy Committee
on 20 October 2005
BSI 20 October 2005
First published April 1985
Second edition September 1992
Third edition December 2002
Fourth edition August 2003
Fifth edition June 2005
The following BSI references

relate to the work on this
standard:
Committee reference B/510/1
ISBN 0 580 46250 1
Amendments issued since publication

Amd. No.
Date
16021
October 2005 To correct errors in 4.2.1, Table 2, Table 6,

Table 7 and 7.2.1
Corrigendum No. 1
Text affected
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BS 594-1:2005
Contents
Committees responsible
Foreword
Page
Inside front cover
ii
Introduction
1
Scope
2
Normative references
3
Terms and definitions
4
Constituent materials
5
Hot rolled asphalt mixtures
6
Mixing
7
Coated chippings for application to surface course surfaces
8
Sampling and testing
1
1
1
2
3
4
12
13
13
Annex A (informative) Guidance on the selection of materials and mixtures

Annex B (informative) Recommendations for the application of design test
criteria
Annex C (informative) Specifying hot rolled asphalt
Annex D (informative) Guidance on the selection of performance related
design criteria for surface course mixtures
Annex E (normative) Specifying performance-specified hot rolled asphalt
Annex F (informative) Factory production control
15
Bibliography
Table 1 Designation of binders and recommended storage temperatures
Table 2 Composition of base (roadbase), binder course and regulating
course mixtures
Table 3 Composition of design type F surface course mixtures
Table 4 Composition of design type C surface course mixtures
Table 5 Table deleted
Table 6 Composition of recipe type F surface course mixtures
Table 7 Maximum temperatures of mixed asphalt
Table 8 Grading of chippings
Table B.1 Consideration of traffic conditons
Table D.1 Limiting wheel-tracking requirements for site classifications
Table D.2 Classification of sites by traffic and stress condition
Table F.1 Hot rolled asphalt mixes Indicative FPC tolerances
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BS 594-1:2005
ii
Foreword
This British Standard has been prepared by Subcommittee B/510/1. It supersedes
BS 594-1:2003, which is withdrawn.
This edition introduces the following changes.
The concept of factory production control (FPC) tolerances is introduced in
anticipation of future European Standards for asphalt (see Annex F).
The following footnote appears in the relevant tables throughout the
standard:
It may be beneficial for producers to record and/or report values obtained
from these and other intermediate sieves for future development of this and
related standards.
The requirements for the aggregate grading of all mixtures have been revised
in order to better align the change from the 2.36 mm to the 2 mm
characteristic sieve introduced in the 2003 edition.
The previous editions of BS 594-1 introduced the following changes.
The requirements for aggregates, the sieve sizes used for the definition of
mixtures and the size designations of mixtures have been amended to align
with BS EN 13043, which is being implemented in the UK on 01/01/2004. The
introduction of BS EN 13043 implies the use of both different size designations
and test methods. Detailed guidance and advice on the changes may be found
in PD 6682-2 and PD 6682-9.
Bitumen grade references in accordance with BS EN 12591.
Terminology which will be used in future European asphalt standards to
familiarize UK users with the new terms.
Reference to the in-plant blending of bitumens.
Requirements for the specification of surface course mixtures based on their
resistance to deformation.
The design type R surface course mixtures were deleted.
BS 594 comprises two parts:
Part 1: Specification for constituent materials and hot rolled asphalt
mixtures;
Part 2: Specification for the transport, laying and compaction of hot rolled
asphalt.
This part includes requirements for asphalt mixtures and their constituent
materials and for coated chippings applied to the surface of some asphalt surface
courses.
The requirements and recommendations for transporting asphalt and for site
work are given in BS 594-2.
Over the years, a considerable number of hot rolled asphalt mixture compositions
have evolved. During the preparation of this revision, some rationalization of the
previous range has been undertaken by omitting the type R enriched mixtures.
The limited range of preferred mixes introduced in the previous edition and
identified in bold type in Table 2, Table 3, Table 4 and Table 6, is maintained. As
mixtures suitable for most uses can be selected from this reduced range, the use
of a preferred mixture is encouraged wherever possible.
Further guidance on the selection of mixtures, the application of design test
criteria and recommendations for stability related to traffic conditions, and
information to be provided by the purchaser and the supplier is given in Annex A,
Annex B, Annex C, Annex D and Annex E.
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BS 594-1:2005
The requirements for the composition of all asphalt mixtures are based on
testing the constituents and the mixture by methods described in BS 598 and
other British Standards (see Clause 2). Adjustment values for soluble binder
content and material passing the 0.063 mm test sieve are given in BS 598-102.
Methods of test to determine the condition of the binder on coated chippings and
their rate of spread, the texture of finished surfaces, the density of cores drilled
from asphalt surfacing and a method for assessing the compaction performance
of other rollers by comparison with the performance of a non-vibrating 8 t roller
are included in other parts of BS 598 (see Clause 2).
It has been assumed in the drafting of this part of BS 594 that the execution of
its provisions is entrusted to appropriately qualified and experienced people.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard does not in itself confer immunity
from legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iii, pages
1 to 25 and a back cover.
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BS 594-1:2005
Introduction
This part of BS 594 specifies the properties of materials used to make hot rolled asphalt and of the mixtures
manufactured from those materials.
Base (roadbase), binder course and regulating course mixtures are specified by conventional recipe
methods in 5.1.
Surface course mixtures are specified in three ways. In 5.2 design mixtures are specified, based on the
mechanical testing of the asphalt mixture to determine a design binder content. This binder content is of
particular value when dealing with aggregates of previously unknown performance. Design mixtures are
recommended for use on heavily trafficked roads.
Since the previous revision of this standard, mixtures have been developed which are suitable for use on
very heavily trafficked sites. These are now specified in 5.4 (performance-specified mixtures). No mix
design method is specified. Instead, the as-laid asphalt mixtures are specified in terms of their resistance
to deformation under varying degrees of traffic stress, from moderate to the most severe.
The recipe type of surface course mixture specified in 5.3 is the conventional mixture which has proved
satisfactory, except under heavy traffic, for most applications for many years.
Where hot rolled asphalt surface course mixtures, of nominal 35 % coarse aggregate content or less, are
used in trafficked areas it is usual to apply coated chippings to provide a suitable level of skidding
resistance to the finished road. The properties of such chippings and the requirements for their
manufacture are specified in Clause 7.
1 Scope
This part of BS 594 specifies requirements for mixtures of hot rolled asphalt to be laid as surface course,
regulating course, binder course or base (roadbase) on roads and other paved areas, excluding heavy duty
airfield pavements.
It also specifies requirements for coated chippings, but excludes requirements for site-specific properties
such as polished stone values and abrasion values of aggregates.
NOTE The terms base (roadbase), binder course and surface course are used throughout this standard in place of the traditional
terms roadbase, basecourse and wearing course respectively to encourage use of the new terminology which will be used in
European asphalt standards to be introduced in the near future.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute
provisions of this British Standard. For dated references, subsequent amendments to, or revisions of, any
of these publications do not apply. For undated references, the latest edition of the publication referred to
applies.
BS 410-1:2000 (ISO 3310-1:2000), Specification for test sieves Technical requirements and testing
Part 1: Test sieves of metal wire cloth.
BS 410-2:2000 (ISO 3310-2:2000), Specification for test sieves Technical requirements and testing
Part 2: Test sieves of perforated metal plate.
BS 594-2:2003, Hot rolled asphalt for roads and other paved areas Part 2: Specification for transport,
laying and compaction of hot asphalt.
BS 598-100:2004, Sampling and examination of bituminous mixtures for roads and other paved areas
Part 100: Methods for sampling for analysis.
BS 598-101, Sampling and examination of bituminous mixtures for roads and other paved areas
Part 101: Methods for preparatory treatments of samples for analysis.
Part 102: Analytical test methods.
Part 107: Method of test for the determination of the composition of design wearing course rolled asphalt.
Part 108: Methods for determination of the condition of the binder on coated chippings and for measurement
of the rate of spread of coated chippings.
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Part 109: Methods for the assessment of the compaction performance of a roller and recommended
procedures for the measurement of the temperature of bituminous mixtures.
Part 110: Methods of test for the determination of wheel-tracking rate and depth.
BS 812-2, Testing aggregates Part 2: Methods for determination of physical properties.
BS 3690-3, Bitumens for building and civil engineering Part 3: Specification for mixtures of bitumen with
pitch, tar and Trinidad lake asphalt.
BS 6100, Glossary of building and civil engineering terms.
BS EN 58 (BS 2000-474), Bitumen and bituminous binders Sampling bituminous binders.
BS EN 197-1, Cement Part 1: Composition, specifications and conformity criteria for common cements.
BS EN 932 (all parts), Tests for general properties of aggregates.
BS EN 933 (all parts), Tests for geometrical properties of aggregates.
BS EN 1097 (all parts), Tests for mechanical and physical properties of aggregates.
BS EN 1367 (all parts), Tests for thermal and weathering properties of aggregates.
BS EN 1744 (all parts), Tests for chemical properties of aggregates.
BS EN 12591, Bitumen and bituminous binders Specifications for paving grade bitumens.
BS EN 13043:2002, Aggregates for bituminous mixtures and surface treatments for roads, airfields and
other trafficked areas.
HIGHWAYS AGENCY, Specification for Highway Works (SHW). London: The Stationery Office.
3 Terms and definitions

For the purposes of this part of BS 594 the terms and definitions given in BS 6100 and the following apply.
3.1
stability
maximum resistance to deformation, in kilonewtons, of a moulded asphalt specimen made and tested in
accordance with BS 598-107
3.2
flow
deformation of moulded asphalt specimen, in millimetres, at the point of maximum resistance, when made
and tested in accordance with the requirements of BS 598-107
3.3
design binder content
binder content of a surface course design mixture determined in accordance with the procedure described
in BS 598-107
3.4
target binder content
nominal soluble binder content of a surface course design mixture specified in 5.2 and which is equal to or
greater than the design binder content and the specific requirements given in Table 3 and Table 4
3.5
added filler
material, a substantial proportion of which passes a 0.063 mm test sieve, added to the mixture in excess of
that present in the coarse and fine aggregates
3.6
test sieve
sieve conforming to BS 410-1 (ISO 3310-1) or BS 410-2 (ISO 3310-2)
3.7
commercial vehicle
vehicle with an unladen weight exceeding 1.5 t
2
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4 Constituent materials
4.1 Binder
The binder used in hot rolled asphalt mixtures shall be one of the binders designated in Table 1. Paving
grade bitumen shall conform to BS EN 12591. Lake asphalt-bitumen mixtures shall conform to BS 3690-3.
NOTE 1 Guidance on the selection and use of different grades of binder is given in Annex A. Improved performance characteristics
may be achieved by the use of modified bitumens but these are outside the scope of this standard. Guidance is available in the Design
Manual for Road and Bridgework, Volume 7 (HD 37/99) [1].
70/100 and 100/150 pen grade bitumen may be produced by blending in the mixer at the asphalt plant. The
grades used for blending shall be no harder than 30/45 pen nor softer than 160/220 pen and shall conform
to BS EN 12591. The producer shall be able to demonstrate that the plant is capable of adequately blending
the bitumens. Measures for ensuring consistency of proportioning of the blend shall be included in plant
quality management systems. These shall include evidence of type tests carried out on a laboratory blend
of the bitumens to demonstrate conformity to BS EN 12591. The quality assurance/management systems
shall also include the steps to be taken to demonstrate the continuing adequacy of the process following
significant changes being made to those parts of the plant involved in the process of bitumen blending.
No grades of bitumen harder than 70/100 pen shall be blended in the mixer.
NOTE 2 Other grades may be in-plant blended provided that the resulting bitumen can be sampled and tested before it is added to
the aggregate and to ensure it conforms to BS EN 12591.
Table 1 Designation of binders and recommended storage temperatures

Binder number
Type
Grade
Recommended storage
temperature
C
Bitumen
30/45 pen
170
Lake asphalt-bitumen
35 pen
175
Bitumen
40/60 pen
165
50 pen
170
Bitumen
70/100
160
70 pen
165
Bitumen
100/150
150
NOTE Prolonged storage of binders at elevated temperatures may result in hardening. To reduce this risk, binders should be
delivered to coating plants at temperatures below 200 C and prolonged subsequent storage above the temperatures given in this
table should be avoided. (It should be recognized that binder deliveries may result in short-term storage temperatures
recommended in this table.)
4.2 Coarse aggregate

4.2.1 Type of coarse aggregate
Coarse aggregate shall be material substantially retained on a 2 mm test sieve and shall conform to all
appropriate requirements of BS EN 13043 and consist of one of the following.
a) Crushed rock of one or more of the following groups: basalt, gabbro, granite, gritstone, hornfels,
limestone, porphyry or quartzite.
b) Gravel of one or more of the groups in a) or flint.
c) Blastfurnace slag.
d) Steel slag, either electric-arc furnace or basic oxygen slag, with a compacted bulk density between
1.60 Mg/m3 and 1.80 Mg/m3 when tested in accordance with BS 812-2.
NOTE 1 Some aggregates other than those referred to in a) to d) have been found to be suitable for hot rolled asphalt. Guidance is
available on the use of secondary and recycled aggregates, e.g. Specification for Highway Works (SHW).
NOTE 2 This British Standard does not include requirements for site-specific properties of aggregates, such as the polished stone
value or the aggregate abrasion value, that may be required to assist skid-resistance, or the Los Angeles value which indicates
aggregate strength.
4.2.2 Particle shape

The coarse aggregate shall conform to flakiness category FI35.
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4.2.3 Fines content

The coarse aggregate shall conform to fines category f4.
NOTE 1 Some aggregates other than those referred to in 4.2.1a) to d) have been found to be suitable for hot rolled asphalt. Guidance
is available on the use of secondary and recycled aggregates, e.g. Specification for Highway Works (SHW).
NOTE 2 This standard does not include requirements for all the properties of aggregates, for example polishing resistance, abrasion
resistance and resistance to fragmentation. Guidance on the specification of such requirements in accordance with BS EN 13043 and
the relationship between the new European aggregate test methods and those previously used in the UK can be found in PD 6682-2.
Specification should be in terms of the categories recommended in PD 6682-2. Further guidance is given in A.5.2.
4.3 Fine aggregate

4.3.1 Type of fine aggregate
Fine aggregate shall substantially pass a 2 mm test sieve and shall be one of the following types:
a) sand;
b) fines produced by crushing coarse aggregate conforming to 4.2.1;
c) a blend of a) and b).
NOTE Advice on the selection of asphalt mixtures containing various types of fine aggregate is given in Annex A.
4.3.2 Fines content

The fines content shall conform to the appropriate fines category specified in 5.1.1.2, 5.2.2.2 or 5.3.2.2.
NOTE For guidance on fines quality see PD 6682-2.
4.4 Added filler

Added filler shall be Portland cement conforming to BS EN 197-1 or limestone.
The grading of added filler shall be in accordance with BS EN 13043:2002, 5.2.1.
The loose bulk density in kerosene of added filler shall be in accordance with BS EN 13043:2002, 5.5.5.
NOTE For all other properties specified in BS EN 13043:2002, Clause 5 it is recommended that the No Requirement category is
used.
5 Hot rolled asphalt mixtures

5.1 Group 1: base (roadbase), binder course and regulating course mixtures
NOTE 1 Adherence to the requirements of this clause will generally give mixtures of satisfactory performance. However, it is
impossible in a general specification to cover all suitable aggregates a few of which might necessitate binder contents other than those
in Table 2.
NOTE 2 The requirements for composition are based on testing the constituent materials and the mixture in accordance with
methods referred to in Clause 4, Clause 5 and Clause 8. The values of binder content are those for the soluble binder content on
analysis.
5.1.1 Aggregate
5.1.1.1 Coarse aggregate
Coarse aggregate shall conform to 4.2.
5.1.1.2 Fine aggregate
Fine aggregate shall conform to 4.3 and fines category f22 of BS EN 13043.
5.1.1.3 Added filler
When added filler is required to achieve the composition given in Table 2, it shall conform to 4.4.
5.1.2 Binder
The grade and type of binder shall conform to 4.1.
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5.1.3 Composition of the mixture

The results of a mixture analysis shall be adjusted in accordance with BS 598-102:2003, Clause 7.
The adjusted results shall conform to Table 2, appropriate to the particular mixture designation and coarse
aggregate, and within a tolerance of 0.6 % (m/m) of the total mixture on the values for binder content.
5.2 Group 2: surface course design mixtures
5.2.1 General
Design mixtures shall either be type F or type C conforming to Table 3 or Table 4.
NOTE Type F is characterized by a gap grading typical of traditional hot rolled asphalt surface course mixtures usually associated
with the use of a fine sand, although other fine aggregates conforming to the grading limits may also be used.
Type C is characterized by a coarser grading usually associated with the use of crushed rock or slag fine aggregates. However, natural
sand may be used in part or in total.
The designation F reflects a finer grading of the fine aggregate used in this type of mix. A coarser grading of the fine aggregate is used
in type C mixes. The distinction between types F and C mixtures is in grading only; no restriction should be placed on the source and
type of fine aggregate.
5.2.2 Aggregate
Fine aggregate shall conform to 4.3.
For type F mixtures, fine aggregate shall be 0/2 mm conforming to grading category GA 90 and fines
category f10.
For type C mixtures, fine aggregate shall be 0/4 mm conforming to grading category GA 85 and fines
category f16.
When added filler is required to achieve the composition given in Table 3 or Table 4 it shall conform to 4.4.
5.2.3 Binder
NOTE Guidance on the selection and use of different grades of binder is given in Annex A.
5.2.4 Target binder content

The target binder content shall be determined by adjusting the design binder content, determined in
accordance with the procedure in BS 598-107 (see 3.3), where required, to allow for such properties as
workability and durability.
The target binder content shall be not less than either the design binder content or the appropriate
minimum value in Table 3 or Table 4 and shall be such that the values for stability and flow, tested in
accordance with BS 598-107, at the target binder content are within the specified range selected from
Table B.1.
NOTE 1 Design proposals should be verified in accordance with Annex B.
NOTE 2 The factors incorporated in the design method of BS 598-107 are such that for most type F mixtures, the design binder
content is satisfactory as the target binder content. Addition of extra binder improves workability and durability and is acceptable as
long as the resultant mixture properties conform to Table B.1. As there is less knowledge of the design of type C mixtures using this
method, greater care is needed to ensure the specified binder content is adequate as regards workability and durability.
5.2.5 Composition of mixtures

The results of a mixture analysis shall be adjusted in accordance with BS 598-102:2003, Clause 7. The
adjusted results shall conform to the appropriate column in Table 3 or Table 4 for aggregate grading. The
soluble binder content shall conform to the target binder content within a tolerance of 0.6 % (m/m) of the
total mixture.
NOTE Guidance on the information to be provided at the time of enquiry or order is given in Annex C.
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Table 2 Composition of base (roadbase), binder course and regulating course mixtures
Column number
2/1
2/2a
2/3
2/4
2/5a
Designationb
50 % 0/10c
50 % 0/14c
50 % 0/20c
60 % 0/20
60 % 0/32
Nominal layer thickness (mm)
25 to 50
35 to 65
45 to 80
45 to 80
60 to 150
Percentage (m/m) of total

aggregate passing test sieve
40 mm
100
31.5 mm
100
100
90100
20 mm
100
90100
90100
5080
14 mm
100
90100
65100
3065
3065
10 mm
90100
65100
3575
6.3 mm
3044
3044
4 mm
Report value
2 mm
3555
3555
1 mm
3555
e
Report value
0.5 mm
1355
1355
1355
844
844
0.25 mm
1035
1035
1035
530
530
0.063 mm
18
18
18
17
17
NOTE 1 For mixtures containing crushed rock fine aggregate, a reduction in the upper and lower limits for % passing the 2mm
sieve, of up to 5% is permitted.
Binder content percentage (m/m)

of total mixture for:
Crushed rock or steel slag
6.5
6.5
6.5
5.7
5.7
Gravel
6.3
6.3
6.3
5.5
5.5
1.44 Mg/m3
6.6
6.6
6.6
5.7
5.7
1.36 Mg/m3
6.7
6.7
6.7
5.9
5.9
1.28 Mg/m3
6.8
6.8
6.8
6.0
6.0
1.20 Mg/m3
6.9
6.9
6.9
6.1
6.1
7.1
7.1
7.1
6.3
6.3
Blastfurnace slag: bulk density
1.12 Mg/m
NOTE 2 For mixtures containing crushed rock fine aggregate, and in some instances sands or blends of sand and crushed rock
fines, the binder contents given in Table 2 may be reduced by up to 0.5 %, where experience shows this to be advisable to avoid an
over-rich mixture (see Annex B).
a
b
c
d
e
Preferred mix (see Foreword).

The mixture designation numbers (e.g. 50 % 0/10 in column 2/1) refer to the nominal coarse aggregate content of the mixture and
size of the course aggregate in the mixture respectively.
Suitable for regulating course.
The value of 65 can be extended to 85 where evidence is available that the mixture so produced is suitable. To ensure consistency
of finish of the laid mixture, supplies from any one source should be controlled within a 35 % band within this permitted range.
It may be beneficial for producers to record and/or report values obtained from these and other intermediate sieves for future
development of this and related standards.
The requirements for the aggregate grading of all mixtures have been revised in order to better align the change from the
2.36 mm to the 2 mm characteristic sieve introduced in the 2003 edition.
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Table 3 Composition of design type F surface course mixtures

Column number
3/1
3/2a
3/3a
3/4
3/5
Designationb
0 % 0/2c
30 % 0/14
35 % 0/14
55 % 0/10
55 % 0/14
25
40
45 or 50
40
45

20 mm
100
100
100
14 mm
85100
87100
100
90100
10 mm
6090
5588
90100
3570
100
3570
3547
3547
6.3 mm
4 mm
2 mm
Report value
90100
5872
1 mm
5567
d
Report value
0.5 mm
70100
4572
4067
2547
2547
0.25 mm
3075
1555
1250
535
535
0.063 mm
1216
711
610
48
48
Maximum percentage of aggregate

passing 2 mm and retained on
0.5 mm test sieves
15
14
10
10
Minimum target binder content

percentage (m/m) of total mixture
6.5
6.4
5.5
5.5
a
b
c
d
9.0

nominal size of the course aggregate in the mixture respectively.
Suitable for regulating course.
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Table 4 Composition of design type C surface course mixtures

Column number
Designation
4/1
4/2
4/3
4/4
4/5
0 % 0/2
30 % 0/14
35 % 0/14
55 % 0/10
55 % 0/14
25
40
45 or 50
40
45

20 mm
100
100
100
14 mm
85100
87100
100
90100
10 mm
6090
5588
90100
3570
100
3570
3247
3247
6.3 mm
4 mm
2 mm
Report valueb
90100
6072
1 mm
5068
Report valueb
0.5 mm
3065
2545
2045
1535
1535
0.25 mm
1545
1540
1230
535
535
0.063 mm
1216
711
610
48
48
9.0
6.5
6.4
5.5
5.5
Minimum target binder content

percentage (m/m) of total mixture
NOTE There is no preferred mix for design type C.

a
b
nominal size of the course aggregate in the mixture respectively.
5.3 Group 3: surface course recipe mixtures
NOTE Adherence to the requirements of this clause will generally give mixtures of satisfactory performance. However, it is
impossible in a general specification to cover all suitable aggregates a few of which might necessitate binder contents other than those
in Table 6.
5.3.1 General
Only type F mixtures, conforming to 5.2.1, shall be used for recipe mixtures. The values of binder content
shall be those for the soluble binder content on analysis.
5.3.2 Aggregates
Fine aggregate shall conform to 4.3.
Fine aggregate shall be 0/2 mm conforming to grading category GA 90 and fines category f10.
When added filler is required to achieve the composition given in Table 6 it shall conform to 4.4.
5.3.3 Binder
NOTE Guidance on the selection and use of different grades of binder is given in Annex A.
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5.3.4 Composition of mixture

The results of a mixture analysis shall be adjusted in accordance with BS 598-102:2003, Clause 7. The
adjusted results shall conform to the requirements given in Table 6 appropriate to the particular mixture
designation, type of coarse aggregate and schedule. A tolerance of 0.6 % (m/m) of the total mixture shall
be permitted on the values for binder content.
NOTE 1 Advice on mixture schedules is given in Annex A.
NOTE 2 Guidance on the information to be provided at the time of enquiry or order is given in Annex C.
Table 5 Table deleted

Table 6 Composition of recipe type F surface course mixtures
Column number
6/1a
6/2a
6/3
6/4
6/5
Designationb
0 % 0/2c
15 % 0/10d
30 % 0/10
30 % 0/14
35 % 0/14
25
30
35
40
45 or 50

20 mm
100
100
14 mm
100
100
85100
87100
10 mm
95100
85100
6090
5588
100
7595
6090
5872
5567
6.3 mm
4 mm
2 mm
Report value
90100
7087
1 mm
5872
Report value
0.5 mm
70100
5587
4572
4572
4067
0.25 mm
3075
2065
1555
1555
1250
0.063 mm
1216
1014
711
711
610
20
15
15
14
Maximum percentage of aggregate

passing 2 mm and retained on
0.5 mm test sieves

Crushed rock or steel slag
Schedule 1A
10.3
8.9
7.8
7.8
7.4
Schedule 1B
10.8
9.4
8.3
8.3
7.9
Schedule 2A
10.3
8.9
7.5
7.5
7.0
Schedule 2B
10.8
9.4
8.0
8.0
7.5
Gravel
a
b
c
d
e

The mixture designation numbers (e.g. 35 % 0/14 in column 6/5) refer to the nominal coarse aggregate content of the mixture.
Nominal size of the course aggregate in the mixture respectively.
Sand carpet.
Suitable for footpaths.
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Table 6 Composition of recipe type F surface course mixtures (continued)

Column number
6/1a
6/2a
6/3
6/4
6/5
Designation
0 % 0/2
15 % 0/10
30 % 0/10
30 % 0/14
35 % 0/14
25
30
35
40
45 or 50

Schedule 3A
1.44 Mg/m3
9.0
7.9
7.9
7.6
1.36 Mg/m3
9.0
8.0
8.0
7.7
1.28 Mg/m3
9.2
8.1
8.1
7.8
9.3
8.2
8.2
7.9
1.12 Mg/m
Schedule 3B
9.4
8.3
8.3
8.0
1.44 Mg/m3
9.5
8.4
8.4
8.1
1.36 Mg/m3
9.6
8.5
8.5
8.2
1.28 Mg/m3
9.7
8.6
8.6
8.3
1.20 Mg/m3
9.8
8.7
8.7
8.4
1.12 Mg/m3
9.9
8.8
8.8
8.5
1.20 Mg/m
a
b
c
d
e

The mixture designation numbers (e.g. 35 % 0/14 in column 6/5) refer to the nominal coarse aggregate content of the mixture.
Nominal size of the course aggregate in the mixture respectively.
Sand carpet.
Suitable for footpaths.
5.4 Group 4: performance-specified surface course design mixtures

5.4.1 General
Performance-specified surface course design mixtures shall conform to 5.2 (except 5.2.4) and shall be
chipped type F mixtures conforming to column 3/3 of Table 3, 35 % stone, with a nominal thickness of either
45 mm or 50 mm.
Mixtures shall conform to a target mixture designed to deliver the specified performance properties. The
conformity of the target mixture shall be established by means of a job mixture trial and this shall
constitute the required type testing procedure.
The job mixture trial shall comprise a sufficient area on which plant mixed asphalt is laid by a paver and
compacted in accordance with BS 594-2. This area shall be sampled in accordance with D.4 and tested in
accordance with D.5 to determine conformity to the following performance requirements:
a) binder volume (as defined in 5.4.2.1) not less than 15.5 % by volume;
b) void content (as defined in BS 594-2:2003, 9.4) not more than 7.5 % for a pair and not more than 5.5 %
for the mean of any six consecutive determinations;
c) wheel tracking to classification 0, 1 or 2 as defined in Table D.1 and as specified.
NOTE 1 Guidance on the selection of site-specific requirements is contained in Annex D.
NOTE 2 The use of performance-specified surface course design mixtures, including the full sampling and testing of laid material in
the permanent works as described in BS 594-2:2003, Clause 9, is only appropriate for major works contracts. The use of these mixtures
in minor works, and in particular those mixtures suitable for the category 2 sites (see Table D.2), is likely to result in very significant
cost penalties. However, if either site category mixture is used in minor works, purchasers are advised to accept mix designs which
have been approved in previous job mixture trials or in previous applications of the mixtures, as long as there have been no consequent
significant changes in the mix constituents or production processes. This acceptance will obviate the relatively frequent sampling and
testing from the laid material which is a requirement on the major works, so that only routine audit samples of loose material are
taken to check the compositional analysis.
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5.4.2 Binder
5.4.2.1 General
The binder shall constitute not less than 15.5 % by volume of the mixture at the target binder content.
The binder content by volume (BVol, %) shall be calculated as follows:
mix
B Vol = B mass --------b
where
Bmass
b
mix
is the binder content as a proportion of the total mixture by mass (%) added at the mixer;
is the density of the binder at 25 C in kilograms per cubic metre (kg/m3);
is the bulk density of the compacted mixture without pre-coated chippings in kilograms per
cubic metre (kg/m3).
Information concerning bitumen processed during refining to provide a binder with enhanced properties
without the addition of a modifier shall be provided in accordance with the requirements in Annex E
(see E.2), unless it has a British Board of Agrment1) HAPAS (BBA/HAPAS) Roads and Bridges certificate.
This information shall include advice on early trafficking of asphalts made with the binder.
5.4.2.2 Binder modifiers
Binder modifiers, if required, shall either be combined with the base binder prior to mixing or blended with
the other component materials of the mixture at the mixer. Information concerning binder modifiers or preblended modified binders shall be provided and approved unless they have a BBA/HAPAS Roads and
Bridges certificate1) (see E.2). This information shall include advice on early trafficking of asphalts made
with the binder in accordance with the requirements in Annex E (see E.2).
NOTE Guidance on the information usually provided on the properties of modified binders and mixtures utilizing modified binders
is given in the Notes for Guidance to the Specification for Highway Works [2].
5.4.3 Job mixture

5.4.3.1 For each asphalt mixing plant where the mixture is produced, details of the proposed mixture
design shall be obtained from either a job mixture trial or from a previous use of the mixture, and shall
include all the following particulars:
a) bitumen grade;
b) quantities of binder and aggregate;
c) aggregate source and grading;
d) proprietary name and generic type of any binder modifier or binder modified by processing;
e) quantity of any binder modifier added at the mixer;
1) test results submitted demonstrate that the density gauge has been calibrated for the compacted
mixture with coated chippings, using sand to fill surface depressions;
2) test results submitted establish the correlation between the air voids content, as measured from
cores in accordance with BS 594-2:2003, 9.2.6, and density determined using the calibrated density
gauge;
f) modified binder and any site-specific mixture data requirements.
5.4.3.2 If a modified binder including any proportion of the modifier, is not fully recovered on analysis for
determination of binder content, details of alterations to the test method and/or the correction necessary to
the results together with any supporting data and the proposed mixture design shall be identified (see E.2).
1)
British Board of Agrment, P.O. Box 195, Bucknalls Lane, Garston, Watford, Herts WD25 9BA. www.bbacerts.co.uk.
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5.4.3.3 The mixture shall be designated the job standard mixture provided that:
a) the mixture design proposed conforms to 5.4.1;
b) test results submitted demonstrate that the binder content by volume of the mixture compacted
without pre-coated chippings conforms to 5.4.2;
c) information submitted in accordance with 5.4.3.1 on the mixture design proposed is complete;
d) information submitted in accordance with 5.4.3.2 has been provided;
e) when a density gauge is used to monitor compaction rather than cores:
1) test results submitted demonstrate that the density gauge has been calibrated for the compacted
mixture with coated chippings, using sand to fill surface depressions;
2) test results submitted establish the correlation between the air voids content, as measured from
cores in accordance with BS 594-2:2003, 9.2.6, and density determined using the calibrated density
gauge;
f) test results submitted demonstrate conformity to BS 594-2:2003, 9.4.2, 9.4.3 and 9.4.4.
5.4.3.4 If the mix design or constituent materials of a job standard mixture are changed, details of the
revised mixture shall be submitted for approval in accordance with 5.4.3.1 and 5.4.3.2. Although job
mixture trials may be carried out on- or off-site, material laid for a job mixture trial on-site may or may not
be considered unsuitable as part of the surface course in permanent work, depending on the number of core
holes. However, the material may be retained as part of the permanent binder course if laid at a suitable
level.
NOTE If job mixture trials are carried out off-site, they may be arranged independently or in conjunction with other works.
5.4.4 Mixing, transporting, laying and determining the performance characteristics

The hot rolled asphalt shall be mixed in accordance with Clause 6, then transported and laid in accordance
with BS 594-2. The material shall be sampled and tested as described in BS 594-2:2003, Clause 9 to
determine its conformity to the site-specific requirements.
6 Mixing
6.1 General
Hot rolled asphalt shall be mixed either by the batch process or in a continuous or drum mixer. The
moisture content of the asphalt mixture, measured by the method given in BS 598-102, shall not exceed
1.0 % (m/m) of the mixture. On discharge from the mixer the aggregate shall be completely coated with
binder with no evidence of balling of the fine aggregate.
6.2 Temperature of mixed asphalt
Whichever method of mixing is adopted, the appropriate maximum temperature given in Table 7 shall not
be exceeded, to avoid the risk of undue binder hardening. Temperatures shall be measured in accordance
with BS 598-109.
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Table 7 Maximum temperatures of mixed asphalt

Binder number
1
2
3
4
5
6
7
Type
Bitumen
Bitumen
Bitumen
Bitumen
Grade
30/45
35 pen
40/60
50 pen
70/100
70 pen
100/150
Maximum temperature at any stage

Base (roadbase) or binder
Surface course
175
170
165
155
195
195
190
190
185
185
175
NOTE Minimum delivery and rolling temperatures given in BS 594-2 should be considered when determining
mixing temperature.
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7 Coated chippings for application to surface course surfaces

7.1 Chippings
The chippings to be coated shall be coarse aggregate conforming to 4.2.1.
NOTE The polished stone value and aggregate abrasion value of the chippings are site specific and outside the scope of this standard.
7.2 Binder coating

7.2.1 General
Binder used to coat the chippings shall be 40/60 pen paving grade bitumen conforming to 4.1. Except in the
situation described in 5.4.2 (see Note), the amount of binder used shall yield a binder content on analysis
of (1.5 0.3) % (m/m).
NOTE A higher binder content may be specified for chippings to be used in the situation described in BS 594-2:2003, 7.3, but any
such higher binder content is still subject to a tolerance on analysis of 0.3 % (m/m).
7.2.2 Quality of binder coating

The coated chippings, when tested for the condition of the binder in accordance with BS 598-108:1990,
Clause 3 shall have a mass of sand retained of not less than 40 g/kg for 14/20 mm chippings or 50 g/kg for
8/14 mm chippings. Not more than 7.5 % (m/m) chippings shall fail the visual assessment of sand-cover.
NOTE 1 Before the chippings are coated with binder, they should be dried and fed into a mixer at a maximum temperature of 170 C.
The maximum temperature of the coated chippings on discharge from the mixer should be 160 C.
NOTE 2 In order to minimize formation of insoluble material in the binder the coated chippings should, on discharge from the mixer,
be cooled quickly to ambient temperature by the application of clean water or by spreading in a layer not thicker than 1.0 m.
7.3 Size, shape and grading of chippings

The aggregate recovered from the coated chippings on analysis shall:
a) conform to the appropriate grading given in Table 8 when tested in accordance with BS EN 933-1; and
b) have a flakiness index not exceeding 20 when tested in accordance with BS EN 933-3.
Table 8 Grading of chippings
Test sieve
Percentage (m/m) passing test sieve

14/20 mm size
31.5 mm
20 mm
14 mm
10 mm
6.3 mm
0.063 mm
100
90100
025
04
02
8/14 mm size
100
90100
025
04
02
8 Sampling and testing

NOTE The tolerances and ranges specified in this part of BS 594 are intended to provide for errors in sampling and testing when
carried out by a skilled operator and for variations in the asphalt due to plant variations and fluctuations in gradings of aggregates.
NOTE Attention is drawn to the difficulties inherent in obtaining representative samples of asphalt for analysis and to the further
(usually smaller) errors in the reduction of the sample and its analysis in the laboratory. It should be realized that, whenever any
sampling and testing procedure is used, complete conformity to the specification may not always be achieved with every sample tested
even when the material is satisfactory (see BS 598-102).
8.1 Binders
Paving grade bitumens and lake asphalt-bitumen blends shall be sampled and tested in accordance with
BS EN 58 (BS 2000-474), BS EN 12591 and BS 3690-3.
8.2 Aggregates and fillers
Coarse and fine aggregates and fillers shall be sampled and tested in accordance with the appropriate parts
of BS EN 932, BS EN 933, BS EN 1097, BS EN 1367 and BS EN 1744 (see Clause 2).
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8.3 Asphalt mixtures

Asphalt mixtures shall be sampled and tested in accordance with BS 598-100, BS 598-101 and BS 598-102.
NOTE The grading of the mineral aggregate fraction of the mixture is determined by means of wet sieving. The fraction passing
0.063 mm as obtained by this method is reported without wet/dry correction.
8.4 Coated chippings
Coated chippings shall be sampled in accordance with BS 598-100, when their temperature is below 130 C,
and tested in accordance with BS 598-102.
The condition of the binder on the chippings shall be determined in accordance with BS 598-108:1990,
Clause 3.
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Annex A (informative)
Guidance on the selection of materials and mixtures
A.1 General
The selection of an asphalt mixture for a particular site depends upon many factors, particularly traffic,
climate and layer thickness.
A.2 Aggregate
As there are no satisfactory tests for determining the amount of deleterious materials in aggregates, any
obviously degraded or dirty stone together with contamination, such as by roots, vegetation or particles of
lignite, should be avoided.
NOTE Where experience indicates that an aggregate is prone to stripping, addition of an adhesion agent or 1 % to 2 % (m/m) of
Portland cement or hydrated lime might be beneficial.
A.3 Base (roadbase) mixtures

A.3.1 Thickness
No specific recommendations for the total thickness of hot rolled asphalt bases (roadbases) are included in
this standard as thickness is dependent upon a number of factors including the strength of the sub-base or
formation and the traffic loading. Guidance can be obtained from publications dealing with pavement
design.
A.3.2 Composition of mixtures
Base (roadbase) mixtures should be selected from Table 2 to suit the nominal layer thickness. A 40/60 pen
bitumen is normally suitable for most applications but the softer 70/100 pen bitumen may be used where
traffic loading is unlikely to be intense.
A.4 Binder course and regulating course mixture
A.4.1 Binder
Reference should be made to Table 1. The use of 40/60 pen grade bitumen is generally satisfactory for most
applications. In areas of intense canalized traffic in southern England, 30/45 pen grade bitumen may
provide greater resistance to deformation. In Scotland and northern England 70/100 pen grade bitumen
may be satisfactory for less heavily trafficked roads.
A.4.2 Thickness
Binder course and regulating course mixtures should be selected from Table 2 to suit the required nominal
layer thickness.
The choice of coarse aggregate content depends largely upon the thickness of material laid. For general
applications, 60 % (m/m) of coarse aggregate is recommended; 50 % (m/m) of coarse aggregate is
recommended when a mixture is to be laid as a regulating course.
A.5 Surface course mixtures
A.5.1 Binder
The physical properties of an asphalt mixture are generally determined by the type of fine aggregate and
bitumen. Traditional mixtures for normal traffic have been made with sand fine aggregate and 40/60 pen
grade bitumen. If crushed fines or harsh sands are used, softer bitumen may be suitable, even on heavily
trafficked roads.
For sites with more intense traffic, the use of harder (e.g. 30/45 pen) grade bitumen or crushed fine
aggregate may be considered. For sites with very intense traffic, modified bitumens may by considered. On
lightly trafficked roads and other lightly stressed areas, softer binders, e.g. 70/100 pen grade or
100/150 pen grade, may be used, even with sand fine aggregate.
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A.5.2 Aggregate
The choice of coarse aggregate and of coated chippings depends primarily on their suitability for the traffic
and site conditions. In all circumstances on public roads and in certain off highway applications it is
essential that the required level of skid resistance is maintained. To achieve this an aggregate with suitable
resistance to the polishing effect of traffic should be used.
The resistance to polishing of coarse aggregate should be specified in terms of the appropriate category
from BS EN 13043. In most cases this should be done using the category PSV declared and quoting the
required minimum PSV value.
The rate at which exposed aggregate is abraded by heavy vehicular traffic is important in determining the
retention of texture by the surface course. The resistance to surface abrasion should be specified in terms
of the appropriate category from BS EN 13043. In most cases this should be done using the category AAV
declared and quoting the required maximum AAV value.
NOTE Guidance on the selection of appropriate polished-stone value and aggregate abrasion value for carriageways is published by
the Highways Agency in Departmental Standard HD 36/99 (1999) [2].

A.5.3.1 General
Clause 5 of this standard gives specifications for three groups of surface course mixtures. The groups are
of equal status and it is not intended that preference be given to any group.
The traditional recipe type surface course mixtures (see 5.3) have been successfully used in most
applications. However, on some roads where traffic loadings have reached unprecedented levels, and as the
range of constituent materials proposed for use has greatly widened, recipe mixtures have generally failed
to perform well, and have been replaced by design mixtures and performance-specified design mixtures.
Purchasers having proven materials sources and experience of the satisfactory use of recipe mixtures under
the conditions applicable to their areas may wish to continue with their use, possibly with the additional
resource of harder binders for roads where deformation may become a problem.
A.5.3.2 Group 2 mixtures: design method
When there is little or no experience of the use of the proposed constituent materials (especially the fine
aggregate), or where severe traffic loadings exist or are anticipated, the design method is more suitable
than the recipe method, particularly for major contracts involving high tonnage of surface course material.
The mixture derived from the laboratory procedure described in BS 598-107 should satisfy the traffic
related criteria given in Table B.1. If the criteria are not met, alternative sources of constituent materials
should be sought; normally a different fine aggregate and/or grade of binder should be chosen.
It is not yet possible to give specific guidance on minimum flow values for each traffic category in Table B.1.
The mixtures derived from the use of the design method in BS 598-107 are the result of tests on laboratory
prepared specimens, undertaken well in advance of the works to determine an agreed composition.
Adequate time should be allowed for this work. The laboratory design mix should be checked using
aggregate from the plant bins, or the aggregate feed in the case of a continuous plant.
In normal circumstances the laboratory design procedure is undertaken whenever a new source of fine
aggregate is used or proposed. It may also need to be carried out if the aggregate grading changes
materially during production. When little or no variation has been indicated, a measure of consistency may
be obtained by testing specimens, using plant-produced mixture compacted in accordance with the
procedure in BS 598-107. As the results obtained using such material are not directly comparable with
those obtained on laboratory prepared specimens, the values given in Table B.1 will not directly apply.
Periodic checks on the design should, therefore, be carried out at mixing plants, even when fine aggregate
known to be reasonably consistent is used, to enable a producer to supply, with confidence, asphalt to a
recent mix design conforming to this British Standard, even when the quantity of asphalt required is too
small to justify the full design procedure being carried out.
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Attention is drawn to the limited experience with type C design mixtures. Problems may occur in obtaining
durable material of low permeability because the harshness of this type of mixture makes compaction more
difficult. The problem may be overcome by increasing the binder content by up to 1 % (m/m) of total mixture
above the design binder content, provided the criteria given in Table B.1 are satisfied.
In the case of 55 % 0/10 mm and 55 % 0/14 mm surface course mixtures, which are not chipped,
100/150 pen grade bitumen is normally used where the mixes are laid on secondary roads, housing
estate roads, play areas and similar sites. However, the use of 40/60 pen grade bitumen is advised on highstress sites used by heavy goods vehicles; this material may not be suitable for hand laying. Mixtures
containing 100/150 pen grade bitumen have traditionally been known as medium-temperature asphalt
(MTA), in view of their lower handling temperatures compared with mixtures containing 40/60 pen grade
bitumen.
A.5.3.3 Group 3 mixtures: recipe method
As indicated in Clause 5, this British Standard does not cover all suitable aggregates, a few of which
require binder contents other than those given in Clause 5. If there is little experience with a particular
aggregate, and particularly a fine aggregate, the recipe method should be used with caution. If the mixture
obtained using the recommended recipe is unsuitably brittle or soft, the use of either a softer or harder
binder, or the design method (group 2), should be considered. The soluble binder contents used should be
related to the climatic conditions and the volume of traffic at the specific site. In the majority of cases
mixtures conforming to schedules 1A, 2A and 3A should be used. In cold, elevated, wet conditions, or for
more lightly trafficked roads, mixtures conforming to schedules 1B, 2B and 3B are more appropriate.
A.5.3.4 Group 4 mixtures: performance-specified design mixtures
Performance-specified design mixtures should be considered where severe or very severe traffic conditions
or traffic loadings exist or are anticipated (see Annex D, Table D.1 and Table D.2).
A.6 Cold weather working
The use of some modified binders can facilitate the laying of mixtures in cold weather conditions. The
advice of the asphalt supplier should be sought if laying in these conditions is unavoidable.
A.7 Storage of mixed materials
It is not possible at the present time to give specific guidance on extended storage of bituminous mixtures.
Conditions of storage affect the maximum storage period.
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Annex B (informative)
Recommendations for the application of design test criteria
B.1 Consideration of traffic conditions
When a hot rolled asphalt surface course with chippings is specified in accordance with 5.2, the properties
of the asphalt should be suitable for traffic conditions at the site on which it is to be used. Table B.1 gives
suggested test criteria, measured at the target binder content, for various levels of traffic.
Table B.1 Consideration of traffic conditons
Traffic (in commercial vehicles per lane per day) Stability of complete mix
kN
Less than 1 500

1 500 to 6 000
Over 6 000
3 to 8a
4 to 8
6 to 10
NOTE 1 For stabilities up to 8.0 kN the maximum flow value should be 5 mm. For
stabilities in excess of 8.0 kN a maximum flow of 7 mm is permissible.
NOTE 2 The stability values referred to should be obtained on laboratory mixes.
NOTE 3 The stability and flow values are those pertaining to the target binder
content.
a
It may be necessary to restrict the upper limit where difficulties in the compaction
of materials might occur.
Traffic is categorized in terms of the estimated average number of commercial vehicles per lane per day
during the year of laying.
Where intense canalization of commercial vehicles occurs, such as at approaches to traffic lights, where
heavy vehicles are continually braking and restarting, and where the rate of growth of traffic is expected
to be abnormally high, the design test criteria should be based on the next higher traffic category.
B.2 Verification of design proposals
The routine submission of design proposals required in the previous edition of this standard is not
considered necessary for designs produced in UKAS accredited laboratories. If a purchaser intends to verify
design proposals these should be specified to be submitted in accordance with BS 598-107:2004, Clause 11.
This verification may be done by supervision or by further testing. An exception may be made for small
contracts using material from a particular source where there is sufficient experience of the mixture for
there to be confidence in the design submitted.
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Annex C (informative)
Specifying hot rolled asphalt
C.1 Information to be provided by the purchaser with the enquiry or order
When the purchaser wishes to select the constituent materials and mix composition from the options given
in this part of BS 594, the following information should be agreed between the purchaser and the supplier
at the time of the enquiry or order:
a) description of course(s) (see Annex A);
b) thickness of layer (see Table 2, Table 3, Table 4 and Table 6);
c) coarse aggregate content for each course (see Table 2, Table 3, Table 4 and Table 6);
d) type of coarse aggregate (see 5.2);
e) type of fine aggregate (see 5.3);
f) type and grade of binder for each course (see 5.1);
g) composition for each course and design method, recipe method or performance specified mixture for
surface course (see Table 3, Table 4 and Table 6);
h) any additional requirements, e.g. coated chippings (see Clause 7), minimum polished stone value of
coarse aggregate or chippings;
i) any additional relevant information (see BS 594-2).
C.2 Information to be provided by the supplier with the quotation
The following information should be provided by the supplier with the quotation, particularly when the
purchaser, after providing the details of the construction to be carried out, has left the choice of the options
given in this part of BS 594 to the supplier:
a) description of course(s) (see Annex A);
b) type, source and size of coated chippings (see Clause 7);
c) coarse aggregate content (see Table 2, Table 3, Table 4 and Table 6);
d) type of coarse aggregate (see 5.2);
e) type and source of fine aggregate (see 5.3);
f) type and grade of binder (see 5.1 and Note to Table 2);
g) composition for each course and design method or recipe method for surface course (see Table 2,
Table 3, Table 4 and Table 6);
h) any additional relevant information (see BS 594-2).
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Annex D (informative)
Guidance on the selection of performance related design criteria for surface
course mixtures
D.1 General
Wheel-track rutting in the surface course may result from deformation in the surface course itself but also
in lower pavement layers, particularly the binder course and, to a lesser extent, the base (roadbase). The
purchaser should not consider using these performance related surface course mixtures unless he/she is
satisfied that the binder course and base (roadbase) will provide the necessary support without undue
deformation. To provide adequate resistance to deformation, it may be prudent to specify binder course and
base (roadbase) macadams that are designed in accordance with BS 4987-1:2004, 4.7 using 40/60 pen grade
binder for the sites in Table D.1.
The aim of 5.4.1 of this British Standard is to specify 35 % stone content hot rolled asphalt in terms of:
a) the component materials (other than binder modifiers) conforming to Clause 5 of this British
Standard;
b) a maximum wheel-tracking rate in the laid mat to limit permanent deformation;
c) a maximum wheel-tracking rut depth to avoid mixtures with a tendency for significant early rutting
but whose rutting subsequently stabilizes;
d) a maximum air voids content in the laid mat to ensure durability; and
e) the surface characteristics (such as texture depth and surface profile) to be as required for the
materials specified in BS 594-2.
D.2 Binder modifiers
Modified binders, where shown to be necessary, are used to enhance the properties of the mixture over
those provided by the available aggregate mixed with unmodified bitumen. In the absence of the Highways
Authorities Product Approval Scheme (HAPAS), details of specific binder modifiers or process modified
bitumens need to be provided (see E.2).
The need for approval of binder modifiers and modified binders is to minimize the possibility of adding
anything to the mixture that may have harmful long-term effects. If there is evidence of successful use of
a binder modifier/modified binder in similar conditions, the presumption should be of approval; if there is
knowledge of the binder modifier/modified binder having had deleterious effects on mixtures, the binder
modifier/modified binder should be rejected. The need for the modifier and the extent of its concentration
are the responsibility of the producer in ensuring that the mixture conforms to the performance
requirements and is durable. This should be especially noted if no data is available.
It is possible that producers may wish to seek approval for more than one modified binder and/or binder
modifiers. Arrangement should be made so that approval for specific modified binder(s) and/or binder
modifier(s) can be given in due time so that those tendering for works can submit tenders based on
approved binders; if all binders submitted by a producer are rejected, there should be sufficient time to
allow for the producer to submit alternative binders for approval.
As analytical test methods for modified binders are outside the scope of BS 598-102, because not all of some
modified binders are recovered using the standard methods, any modifications to the test method and/or
corrections to the results need to be established before work commences with a modified binder.
D.3 Job mixture approval
The producer may submit the results of any tests carried out on the mixture or its component materials as
part of the design that he/she considers relevant for the purposes of mixture approval. This may include
results from a previous contract or trial carried out up to 18 months previously. For the job mixture
approval trial of a mixture from a specific mixing plant, at least 20 t should be mixed, transported, laid,
compacted, sampled and tested. Within the laid total area, a designated section of sufficient size to allow
it to be compacted properly should be left unchipped. This may include results from a previous contract or
trial carried out up to 18 months previously.
20
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BS 594-1:2005
D.4 Job mixture approval sampling

Three samples of uncompacted material should be taken from the paver as near to where cores are to be
taken as is practicable from the paver augers in accordance with BS 598-100:2004, 6.3.
At least six 200 mm diameter cores and six 150 mm diameter cores should be cut from the trial area with
coated chippings; at least six 150 mm diameter cores should be cut from the trial area without coated
chippings.
D.5 Job mixture approval tests
A compositional analysis should be carried out on each sample of uncompacted material in accordance with
BS 594-2:2003, 9.2.3.
The wheel-tracking rate and the rut depth of each 200 mm diameter core should be determined in
accordance with BS 594-2:2003, 9.2.4 at the test temperature specified by the purchaser.
If a density gauge is used, readings should be taken on an area where sand has been applied to fill surface
depressions so as to give a smooth surface adjacent to each core hole in the trial area with coated chippings.
The temperature of the surface when the reading is taken should be recorded.
The density gauge should be calibrated for the mixture being laid. In addition, correlation analyses should
be carried out between the air voids content, as measured from the cores in accordance with
BS 594-2:2003, 9.2.6, and the density determined using the density meter.
The bulk density of each 150 mm diameter core with coated chippings, and the maximum density of each
pair of cores, should be determined in accordance with BS 594-2:2003, 9.2.5 and the air voids content
determined in accordance with BS 594-2:2003, 9.2.6.
To calculate the binder content by volume as specified in 5.4.2.1, the bulk density of the 150 mm diameter
cores taken from the unchipped area should be determined in accordance with the procedure in
BS 598-104:2005, Clause 4. The density of the compacted hot rolled asphalt without coated chippings
should be calculated as the mean bulk density of the individual cores.
The material in a job mixture approval trial carried out on site may have too many core holes to be suitable
for retention as part of the permanent surface course, however the material may be retained as part of the
permanent binder course.
D.6 Testing
Although it is preferable to take cores prior to the surfacing being open to traffic, this may not be possible
when the road has to be re-opened by a specific time. If the time during which the site is available is not
sufficient to allow:
a) the preparation for and laying of the mat and its cooling sufficiently for coring;
b) the coring operation; and
c) the reinstatement of the core hole.
There is no requirement to cut cores before trafficking.
After cores have been cut, a diamond shape can be sawn around the core(s) and the material within the
diamond shape removed to leave the core(s) proud and more accessible for removal to minimize damage,
particularly during warm weather. Reinstatement of a larger area may also permit better compaction by
roller to be achieved. Removing cores which have not cooled sufficiently can reduce their density.
For the reinstatement of core-holes the normal practice of using cold-lay 0/20 mm size dense bitumen
macadam binder course for layers more than 50 mm below the surface and cold-lay 0/6 mm size dense
bitumen macadam surface course for the surface course may not be suitable for high stress sites or diamond
shape cut outs.
D.7 Density gauge
It is recommended that the density gauge is used as a monitoring tool to identify if and when the mixture
or its compaction changes and to indicate possible non-conformity to the specification. This method of
screening is intended to keep the use of coring to a minimum. It is a requirement that on motorway and
trunk road sites a density gauge is used.
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BS 594-1:2005
D.8 Air voids content

The determination of air voids content employs the concept of maximum density of compacted mixtures.
The test method for determining the maximum density of a compacted mixture is given in BS EN 12697-5.
The method is based on ASTM D 2041.
D.9 Wheel-tracking rate
The test method for wheel-tracking is given in BS 598-110. The option of using paraffin wax in determining
the bulk density of cores should not be used in order to avoid problems with subsequent testing for
maximum density.
The limiting wheel-tracking rut depth after 45 min testing is used to avoid the possibility of materials
deforming significantly in their early life and then densifying so as to achieve an acceptable wheel-tracking
rate in the last 15 min of the test.
When selecting the specified limiting wheel-tracking rate, the limiting wheel-tracking rut depth and the
temperature of the test, all of which are given to producers, the limits given in Table D.1 for site
classifications defined in Table D.2 should be considered.
No.
0
1
2
Table D.1 Limiting wheel-tracking requirements for site classifications

Classification
Test temperature
Maximum wheel-tracking
Description
C
Lightly stressed sites not requiring specific design for

deformation resistance.
Moderate to heavily stressed sites requiring high rut
resistance.
Very heavily stressed sites requiring very high rut
resistance.
Rate
Rut depth
mm/h
mm
Not required
Not required Not required
45
2.0
4.0
60
5.0
7.0
D.10 Combinations of factors which promote wheel-track rutting
The bulk of permanent deformation occurs during the summer months when hot rolled asphalt is at higher
temperatures, particularly in areas where there are slow heavy-goods vehicle movements, such as climbing
lanes, and when newly laid material is not yet fully stable and is less resistant to deformation under wheel
loads. Permanent deformation can occur on road construction sites during summer months when partially
completed pavements are re-opened to highway traffic under contraflow arrangements. The added factor
of concentration of traffic can provide the worst combination of factors to cause permanent deformation.
For this reason, Table D.2 has special categories IA, IIA, IIIA and IVA to cater for schemes in which such
conditions can be anticipated in the early life of the surface course to be laid. Special categories IA, IIA,
IIIA and IVA are also applicable to locations which can be regarded as sun traps, in particular south
facing cuttings where vehicles are travelling uphill.
In assessing the appropriate category, other local factors may also be influential, including areas which
have previously demonstrated high surface temperatures and the need to use aggregate with particular
characteristics such as dark or light colouring. The problems of high surface temperatures can also be
exacerbated on elevated structures which have less thermal capacity than where there is ground support
of the pavement, and consequently experience higher temperatures.
22
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BSI 20 October 2005
Table D.2 Classification of sites by traffic and stress condition

Special
category
Site
category
Site definition
Traffic at design life (Commercial vehicles per lane per day)

Up to
250
I and II
A
B
Motorway (main line)

Dual carriageway (all purpose) non-event
sections
C
Dual carriageway (all purpose) minor junctions
D
Single carriageway non-event sections
E
Single carriageway minor junctions
IA and IIA As I and II but with contraflow anticipated during
summer months
III
F
Approaches to and across major junctions (all
limbs)
G1
Gradient 3 % to 10 %, longer than 50 m:
Dual (uphill and downhill)
Single (uphill and downhill)
L
Roundabout
IIIA
As III, above, but with contraflow anticipated during
summer months or in a south-facing cutting uphill
IV
G2
Gradient steeper than 10 %, longer than 50 m:
Dual (uphill and downhill)
Single (uphill and downhill)
IVA
As IV but with contraflow anticipated during summer
months or in a south-facing cutting uphill
V
J/K
Approach to roundabout, traffic signals,
pedestrian crossings, railway level crossings
and similar
251
500
501
1 000
1 001 1 501 2 001

1 500 2 000 2 500
2 501
3 000
3 001 4 001 5 001

4 000 5 000 6 000
Over
6 001
0
0
0
0
1
1
1
1
2
2
2
2
BS 594-1:2005
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BS 594-1:2005
Annex E (normative)
Specifying performance-specified hot rolled asphalt
E.1 Information to be provided by the purchaser with the enquiry or order
The following information shall be provided by the purchaser:
a) limiting wheel tracking performance (see Table D.1 and Table D.2);
b) any additional requirements, e.g. coated chippings (see Clause 7), polished stone value category of
coarse aggregate or chippings;
c) whether a density gauge is to be used in monitoring the compaction of the as-laid asphalt.
E.2 Information to be provided by the supplier with the quotation

The following information shall be provided by the supplier with the quotation:
a) details of modified bitumens and bitumen modifiers not having BBA HAPAS Roads and Bridges
certificates (see 5.4.2.1 and 5.4.2.2);
b) job mixture approval particulars (see 5.4.3.1);
c) details of alterations to the test method or necessary corrections, supporting data and mix design
(see 5.4.3.2);
d) any additional relevant information, including recommendations for early trafficking (see BS 594-2).
Annex F (informative)
Factory production control
F.1 Concept
The concept of factory production control (FPC) tolerances is introduced here in anticipation of future
European Standards for asphalt.
For grading, this concept involves the selection of a target percentage (%) passing value from between two
specified values and the application of a tolerance around this value. The specification formed is used to
assess product conformity through the analysis of production samples which are routinely taken in
accordance with the factory production control (QMS) system and for samples which may be taken by other
parties to assess product conformity.
The FPC tolerances shown in Table F.1 are indicative of the levels to which the materials will have to
conform when European Standards for asphalt are introduced. The target grading should be such that
when the FPC tolerance is applied, the declared compliance grading should still fall within the overall
grading, e.g. for 30 % 0/14 mm Type F, passing 2 mm sieve: coarsest declared grading would be 5868
(63 5), finest declared grading would be 6272 (67 5), within the overall grading requirement
of 5872.
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Table F.1 Hot rolled asphalt mixes Indicative FPC tolerances

Test sieve
Small aggregates Large aggregates

D<16 mm
D
D/2 or Characteristic coarse sieve
2 mm
Characteristic fine sieve
0.063 mm
8 +5
7
5
4
2
DW16 mm
9 +5
9
7
5
3
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BS 594-1:2005
Bibliography
Standards publications
Part 104: Methods of test for the determination of density and compaction.
BS EN 12697-5:2002, Bituminous mixtures Test methods for hot mix asphalt Determination of the
maximum density.
PD 6682-2:2003, Aggregates Part 2: Aggregates for bituminous mixtures and surface treatments for
roads, airfields and other trafficked areas Guidance on the use of BS EN 13043.
PD 6682-9:2003, Aggregates Part 9: Guidance on the use of European test method standards.
ASTM D 2041:2000, Standard test method for theoretical maximum specific gravity and density of
bituminous paving mixtures.
Other documents
[1] HIGHWAYS AGENCY. Design Manual for Road and Bridgework, Volume 7, (HD 37/99). London: The
Highways Agency.
[2] HIGHWAYS AGENCY. Notes for Guidance to the Specification for Highway Works. London: The
Stationery Office.
BSI 20 October 2005
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BS 594-1:2005
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The following BSI references

ISBN 0 580 46250 1

Amendments issued since publication

October 2005 To correct errors in 4.2.1, Table 2, Table 6,

Annex A (informative) Guidance on the selection of materials and mixtures

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3 Terms and definitions

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Table 1 Designation of binders and recommended storage temperatures

4.2 Coarse aggregate

4.2.2 Particle shape

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4.2.3 Fines content

4.3 Fine aggregate

4.3.2 Fines content

4.4 Added filler

5 Hot rolled asphalt mixtures

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5.1.3 Composition of the mixture

5.2.4 Target binder content

5.2.5 Composition of mixtures

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Nominal layer thickness (mm)

Percentage (m/m) of total

Binder content percentage (m/m)

Blastfurnace slag: bulk density

Preferred mix (see Foreword).

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Table 3 Composition of design type F surface course mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total

Maximum percentage of aggregate

Minimum target binder content

Preferred mix (see Foreword).

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Table 4 Composition of design type C surface course mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total

Minimum target binder content

NOTE There is no preferred mix for design type C.

5.3 Group 3: surface course recipe mixtures

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5.3.4 Composition of mixture

Table 5 Table deleted

Nominal layer thickness (mm)

Percentage (m/m) of total

Maximum percentage of aggregate

Binder content percentage (m/m)

Preferred mix (see Foreword).

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Table 6 Composition of recipe type F surface course mixtures (continued)

Nominal layer thickness (mm)

Binder content percentage (m/m)

Preferred mix (see Foreword).

5.4 Group 4: performance-specified surface course design mixtures

NOTE 1 Guidance on the selection of site-specific requirements is contained in Annex D.