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BRITISH STANDARD BS 594-1:1992
Incorporating
Amendment No. 1

Hot rolled asphalt for


roads and other paved
areas —
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

Part 1: Specification for constituent


materials and asphalt mixtures

UDC 625.85:|625.07 + 665.775|


BS 594-1:1992

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 Aggregate Construction Materials Industries


British Civil Engineering Test Equipment Manufacturers’ Association
County Surveyors’ Society

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


Department of the Environment (Property Services Agency)
Department of Transport
Department of Transport (Transport and Road Research Laboratory)
Institute of Asphalt Technology
Institute of Petroleum
Institution of Civil Engineers
Institution of Highways and Transportation
Low Temperature Coal Distillers’ Association of Great Britain Ltd.
Mastic Asphalt Council and Employers’ Federation
Mastic Asphalt Producers’ Association
Refined Bitumen Association Ltd.
Sand and Gravel Association Limited
Society of Chemical Industry

This British Standard, having


been prepared under the
direction of Technical
Committee B/510, was
published under the authority
of the Standards Board and
comes into effect on
15 September 1992

© BSI 11-1998 Amendments issued since publication


First published April 1985 Amd. No. Date Comments
Second edition September 1992
8397 February 1995 Indicated by a sideline in the margin
The following BSI references
relate to the work on this
standard:
Committee reference B/510/1
Draft for comment 90/16196 DC

ISBN 0 580 20928 8


BS 594-1:1992

Contents

Page
Committees responsible Inside front cover
Foreword ii
Section 1. General
Introduction 1
1.1 Scope 1
1.2 References 1
1.3 Definitions 1
1.4 Sampling and testing 2
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Section 2. Constituent materials


2.1 Binder 3
2.2 Coarse aggregate 3
2.3 Fine aggregate 3
2.4 Added filler 3
Section 3. Rolled asphalt mixtures
3.1 Group 1. Roadbase, basecourse and regulating course mixtures 4
3.2 Group 2. Wearing course design mixtures 4
3.3 Group 3. Wearing course recipe mixtures 7
3.4 Mixing 7
Section 4. Coated chippings for application to wearing course surfaces
4.1 Chippings 10
4.2 Binder coating 10
4.3 Quality of binder coating 10
4.4 Size, shape and grading of coated chippings 10
Annex A (informative) Guidance on the selection of materials and
mixtures 11
Annex B (informative) Recommendations for the application of
design test criteria 13
Annex C (informative) Information to be provided by the purchaser
and the supplier 13
Table 1 — Designation of binders and recommended storage
temperatures 3
Table 2 — Composition of roadbase, basecourse and regulating
course mixtures 5
Table 3 — Composition of design type F wearing course mixtures 6
Table 4 — Composition of design type C wearing course mixtures 6
Table 5 — Composition of design type R wearing course mixtures 7
Table 6 — Composition of recipe type F wearing course mixtures 8
Table 7 — Maximum temperatures of mixed asphalt 9
Table 8 — Gradings of chippings 10
Table B.1 — Criteria for the stability of laboratory design asphalt 13
List of references 16

© BSI 11-1998 i
BS 594-1:1992

Foreword

This Part of BS 594 has been prepared under the direction of Technical
Committee B/510, Road Materials. It is a revision of BS 594-1:1985 which is
withdrawn.
BS 594 comprises two Parts:
— Part 1: Specification for constituent materials and asphalt mixtures;
— Part 2: Specification for the transport, laying and compaction of rolled
asphalt.
This Part includes requirements for asphalt mixtures and their constituent

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materials and for coated chippings applied to the surface of some asphalt wearing
courses.
The requirements and recommendations for transporting asphalt and for site
work are given in Part 2.
Over the years, a considerable number of rolled asphalt mixture compositions
have evolved. During the preparation of this edition, some rationalization of the
previous range has been undertaken by omitting some infrequently used
mixtures and introducing a limited range of preferred mixes, identified in bold
type in Table 2, Table 3 and Table 6. Mixtures suitable for most uses can be
selected from this range and it is intended that specifiers should encourage their
general use.
However, enriched mixtures, designated type R, have been introduced to provide
enhanced fatigue resistance in lightly trafficked, low stiffness pavements and
greater durability in areas of the country which are particularly cold and wet.
Further guidance on selection of mixtures, the application of design test criteria,
recommendations for stability, related to traffic conditions, and information to be
provided by the purchaser and the supplier is given in annexes A, B and C.
The requirements for composition of all mixtures are based on testing the
constituents and the mixture by methods described in BS 598 and other British
Standards. Adjustment values for soluble binder content and material passing
the 75 µm test sieve, previously given in BS 594-1:1985, are now 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.
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.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 16, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on
the inside front cover.

ii © BSI 11-1998
BS 594-1:1992

Section 1. General

Introduction 1.2 References


1.2.1 Normative references
This Part of BS 594 specifies the properties of
materials used to make rolled asphalt and of the This Part of BS 594 incorporates, by reference,
mixtures manufactured from those materials. provisions from specific editions of other
Roadbase, basecourse and regulating course publications. These normative references are cited
mixtures are specified by conventional recipe at the appropriate points in the text and the
publications are listed on page 16. Subsequent
methods in 3.1.
amendments to, or revisions of, any of these
Wearing course mixtures are specified in two ways. publications apply to this Part of BS 594 only when
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In 3.2 design mixtures are specified, based on the incorporated in it by updating or revision.
mechanical testing of the asphalt mixture to
estimate a “design” binder content. This binder 1.2.2 Informative references
content is normally a good guide to the amount This Part of BS 594 refers to other publications that
necessary to give satisfactory mixtures and is of provide information or guidance. Editions of these
particular value when dealing with aggregates of publications current at the time of issue of this
previously unknown performance. The design standard are listed on the inside back cover, but
method uses laboratory facilities and techniques reference should be made to the latest editions.
additional to those required for routine compliance
testing purposes. Design mixtures are 1.3 Definitions
recommended for heavily trafficked roads. For the purposes of this Part of BS 594 the
The recipe type of wearing course mixture specified definitions given in BS 6100 apply together with the
in 3.3 is the conventional mixture which has proved following.
satisfactory except under heavy traffic for most 1.3.1
applications for many years. Purchasers having
stability
satisfactory experience with recipe mixtures may
wish to continue using them. the maximum resistance to deformation, in
kilonewtons, of a moulded asphalt specimen made
Where rolled asphalt wearing course mixtures, of
and tested in accordance with BS 598-107:1990
nominal 40 % coarse aggregate content or less, are
used in trafficked areas it is usual to apply coated 1.3.2
chippings to provide a suitable level of skidding flow
resistance to the finished road. The properties of the deformation of moulded asphalt specimen in
such chippings and the requirements for their millimetres at the point of maximum resistance,
manufacture are specified in section 4. when made and tested in accordance with the
requirements of BS 598-107:1990
1.1 Scope
1.3.3
This Part of BS 594 specifies requirements for design binder content
mixtures of hot rolled asphalt to be laid as wearing
the binder content of a wearing course design
course, regulating course, basecourse or roadbase on
roads and other paved areas, excluding heavy duty mixture determined in accordance with the
airfield pavements. procedure described in BS 598-107:1990
It also specifies requirements for coated chippings, 1.3.4
but excludes requirements for site-specific target binder content
properties such as polished stone values and the nominal soluble binder content of a wearing
abrasion values of aggregates. course design mixture specified in 3.2, and which is
Guidance on selection of asphalt mixtures and their equal to or greater than the design binder content
constituent materials is also included in annex A. and the specific requirements given in Table 3,
Table 4 or Table 5
1.3.5
added filler
material, a substantial proportion of which passes
a 75 µm test sieve, added to the mixture in excess of
that present in the proportioned coarse and fine
aggregates

© BSI 11-1998 1
BS 594-1:1992

1.3.6 1.4.3 Asphalt mixtures


test sieve Asphalt mixtures shall be sampled and tested in
a sieve conforming to BS 410 accordance with BS 598-100:1987,
BS 598-101:1987 and BS 598-102:1989.
1.4 Sampling and testing NOTE The grading of the mineral aggregate fraction of the
NOTE The tolerances and ranges specified in this Part of mixture is determined by means of wet sieving. The
BS 594 are intended to provide for errors in sampling and testing passing 75 µm fraction as obtained by this method should be
when carried out by a skilled operator as well as for variations in reported without wet/dry correction.
the asphalt due to plant variations and fluctuations in gradings 1.4.4 Coated chippings
of aggregates. Attention is drawn to the difficulties inherent in

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obtaining representative samples of asphalt for analysis and to Coated chippings shall be sampled in accordance
the further (usually smaller) errors in the reduction of the sample with BS 598-100:1987, when their temperature is
and its analysis in the laboratory. It should be realized that,
whenever any sampling and testing procedure is used, complete
below 130 °C, and tested in accordance with
compliance with the specification may not always be achieved BS 598-102:1989.
with every sample tested even when the material is satisfactory Flakiness index shall be determined in accordance
(see BS 598-102).
with the method given in BS 812-105.1:1989. The
1.4.1 Binders condition of the binder on the chippings shall be
Penetration grade bitumens and lake determined in accordance with clause 3 of
asphalt-bitumen blends shall be sampled and tested BS 598-108:1990.
in accordance with BS 3690-1:1989 and
BS 3690-3:1990 respectively.
1.4.2 Aggregates and fillers
Coarse and fine aggregates and fillers shall be
sampled and tested in accordance with the
appropriate Parts of BS 812.

2 © BSI 11-1998
BS 594-1:1992

Section 2. Constituent materials

2.1 Binder NOTE 1 Other slag may be suitable aggregates for rolled
asphalt but are outside the scope of this standard.
The binder shall be one of those designated in NOTE 2 This standard does not include requirements for
Table 1. Penetration grade bitumen shall conform to site-specific properties of aggregates, such as the polished stone
value or the aggregate abrasion value, that may be required to
BS 3690-1:1989. Lake asphalt-bitumen mixtures assist skid-resistance, or the 10 % fines value which indicates
shall conform to BS 3690-3:1990. aggregate strength.
NOTE Guidance on the selection and use of different grades of 2.2.2 Particle shape
binder is given in annex A.
Table 1 — Designation of binders and Flakiness index shall not exceed 45 % for crushed
recommended storage temperatures rock and crushed gravels or 50 % for uncrushed
gravels when tested in accordance with
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Binders Type Grade Recommended


numbers storage
BS 812-105.1:1989.
temperature 2.2.3 Fraction passing 75 µm sieve
°C
When determined by the washing and sieving
1 Bitumen 35 pen 175
method given in BS 812-103.1:1985, the fraction of
2 Lake 35 pen 175 material passing a 75 µm test sieve shall not
asphalt-bitumen exceed 6 % (m/m) of coarse aggregate for crushed
3 Bitumen 50 pen 165 rocks and slags and 4 % (m/m) for gravels.
NOTE There is no acceptable method for determining clay
4 Lake 50 pen 170 content of coarse aggregate but an indication of quantity is given
asphalt-bitumen by using the sedimentation test described in BS 812-103.2.

5 Bitumen 70 pen 160


2.3 Fine aggregate
6 Lake 70 pen 165
2.3.1 Type of fine aggregate
asphalt-bitumen
Fine aggregate shall substantially pass a 2.36 mm
7 Bitumen 100 pen 155 test sieve and shall consist of one of the following:
NOTE 1 The use of grade 40 pen HD bitumen conforming to
BS 3690 may be considered but caution is advised as knowledge
a) sand;
of its in-service behaviour is limited. The recommended storage b) fines produced by crushing coarse aggregate
temperature for 40 pen HD is 175 °C. conforming to 2.2.1;
NOTE 2 Prolonged storage of binders at elevated
temperatures may result in hardening. To reduce this risk, c) a blend of item a) and item b).
binders should be delivered to coating plants at temperatures NOTE Advice on the selection of asphalt mixtures containing
below 200 °C and prolonged subsequent storage above the various types of fine aggregate is given in annex A.
temperatures given in this table should be avoided. (It should be
recognized that binder deliveries may result in short-term 2.3.2 Fraction passing 75 µm sieve
storage temperatures above those recommended in this table.)
When determined by the washing and sieving
method given in BS 812-103.1:1985, the fraction of
2.2 Coarse aggregate material passing a 75 µm test sieve shall not exceed
2.2.1 Type of coarse aggregate the appropriate limit given in 3.1.1.2, 3.2.2.2
Coarse aggregate shall be material substantially or 3.3.2.2.
retained on a 2.36 mm test sieve and shall consist of NOTE There is no acceptable method for determining clay
content of fine aggregate but an indication of quantity is given by
one of the following. using the sedimentation test described in BS 812-103.2.
a) Crushed rock of one or more of the following
groups: 2.4 Added filler
basalt, gabbro, granite, gritstone, hornfels, 2.4.1 Added filler shall be limestone or Portland
limestone, porphyry or quartzite. cement, and shall have a bulk density in toluene of
b) Gravel of one or more of the groups in item a) not less than 0.5 g/ml and not more than 0.9 g/ml.
or flint. 2.4.2 If readily available, an added filler containing
c) Blastfurnace slag conforming to BS 1047:1983. not less than 85 % (m/m) of particles passing
a 75 µm test sieve when determined in accordance
d) Steel slag, either electric-arc furnace or basic
with the procedure for dry sieving in
oxygen slag, which shall be weathered until it is
BS 812-103.1:1985 shall be used (see also A.2).
no longer susceptible to falling. The compacted
Otherwise, an added filler containing not less
bulk density shall be between 1 700 kg/m3
than 75 % (m/m) passing a 75 µm test sieve shall be
and 1 900 kg/m3 when tested in accordance with
used, subject to the approval of the purchaser.
BS 1047:1983.

© BSI 11-1998 3
BS 594-1:1992

Section 3. Rolled asphalt mixtures

3.1 Group 1. Roadbase, basecourse and 3.2.2 Aggregate


regulating course mixtures 3.2.2.1 Coarse aggregate
NOTE 1 Adherence to the requirements of this clause will Coarse aggregate shall conform to 2.2.
generally give mixtures of satisfactory performance. However, it
is impossible in a general specification to cover all suitable 3.2.2.2 Fine aggregate
aggregates, a few of which might necessitate binder contents
other than those given in Table 2. 3.2.2.2.1 Fine aggregate shall conform to 2.3.
NOTE 2 The requirements for composition are based on testing 3.2.2.2.2 For type F mixtures, fine aggregate shall
the constituent materials and the mixture in accordance with
methods referred to in sections 1 and 2. The values of binder contain not more than 5 % (m/m) of material
content are those for the soluble binder content on analysis. retained on a 2.36 mm test sieve and the material

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3.1.1 Aggregate passing a 75 µm test sieve shall not
exceed 9 % (m/m) of fine aggregate.
3.1.1.1 Coarse aggregate
3.2.2.2.3 For type C mixtures, fine aggregate shall
Coarse aggregate shall conform to 2.2. contain not more than 10 % (m/m) of material
3.1.1.2 Fine aggregate retained on a 2.36 mm test sieve and the material
passing a 75 µm test sieve shall not
Fine aggregate shall conform to 2.3. The fraction
exceed 19 % (m/m).
passing the 75 µm test sieve shall not
exceed 25 % (m/m) of the fine aggregate. 3.2.2.3 Added filler
3.1.1.3 Added filler When added filler is required to achieve the
composition given in Table 3, Table 4 or Table 5, it
When added filler is required to achieve the
shall conform to 2.4.
composition given in Table 2, it shall conform to 2.4.
3.2.3 Binder
3.1.2 Binder
The grade and type of binder shall conform to 2.1.
The grade and type of binder shall conform to 2.1.
NOTE Advice on the selection of binder is given in annex A.
NOTE Advice on the selection of binder is given in annex A.
3.2.4 Target binder content
3.1.3 Composition of mixture
The target binder content shall be determined by
The results of a mixture analysis shall be adjusted
adjusting the design binder content (see 1.3.3),
in accordance with clause 6 of BS 598-102:1989. The
where required, to allow for such properties as
adjusted results shall conform to Table 2,
workability and durability.
appropriate to the particular mixture designation
and coarse aggregate. A tolerance of ± 0.6 % (m/m) The target binder content shall be not less than
of the total mixture shall be permitted on the values either the design binder content or the appropriate
for binder content. minimum value in Table 3, Table 4 or Table 5 and
shall be such that the values for stability and flow at
3.2 Group 2. Wearing course design the target binder content are within the specified
mixtures range.
NOTE 1 The manufacturer’s proposals should be verified and
3.2.1 General approved by the purchaser in accordance with annex B.
Design mixtures shall be type F, type C or type R NOTE 2 The factors incorporated in the design method of
BS 598-107 are such that, for most type F mixtures, the design
conforming to Table 3, Table 4 or Table 5. Enriched binder content will prove satisfactory as the target binder
mixtures are designated type R. The requirements content. Addition of extra binder tends to improve workability
for composition of type R mixtures are shown in and durability and is acceptable so long as the resultant mixture
Table 5 and are identical with the equivalent type F properties conform to Table B.1. There is less knowledge of the
design of type C mixtures by this method and greater care is
or type C material except that the target binder necessary to ensure the specified binder content is adequate for
content shall be increased by at least 0.5 %. workability and durability.
NOTE 1 Type F is characterized by a gap grading typical of 3.2.5 Composition of mixtures
traditional rolled asphalt wearing course mixtures usually
associated with the use of a fine sand, although other fine The results of a mixture analysis shall be adjusted
aggregates conforming to the grading limits are not excluded. in accordance with clause 6 of BS 598-102:1989. The
Type C is characterized by a coarser grading usually associated
with the use of crushed rock or slag fine aggregates. However,
adjusted results shall conform to the appropriate
natural sand may be used in part or in total. column in Table 3, Table 4 or Table 5 for aggregate
The designation F reflects a finer grading of the fine aggregate grading. The soluble binder content shall conform to
used in this type of mix. A coarser grading of the fine aggregate the target binder content within a tolerance
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
of ± 0.6 % (m/m) of the total mixture.
source and type of fine aggregate.

4 © BSI 11-1998
BS 594-1:1992

Table 2— Composition of roadbase, basecourse and regulating course mixtures


Column number 2/1 2/2a 2/3 2/4 2/5a 2/6
Designationb 50/10c 50/14c 50/20c 60/20 60/28 60/40
Nominal layer thickness (mm) 25 to 50 35 to 65 45 to 80 45 to 80 60 to 120 75 to 150
Percentage (m/m) of total aggregate
passing test sieve
50 mm — — — — — 100
37.5 mm — — — — 100 90 to 100
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28 mm — — 100 100 90 to 100 70 to 100


20 mm — 100 90 to 100 90 to 100 50 to 80 45 to 75
14 mm 100 90 to 100 65 to 100 30 to 65d 30 to 65 30 to 65
10 mm 90 to 100 65 to 100 35 to 75 — — —
6.3 mm — — — — — —
2.36 mm 35 to 55 35 to 55 35 to 55 30 to 44 30 to 44 30 to 44
600 µm 15 to 55 15 to 55 15 to 55 10 to 44 10 to 44 10 to 44
212 µm 5 to 30 5 to 30 5 to 30 3 to 25 3 to 25 3 to 25
75 µm 2 to 9 2 to 9 2 to 9 2 to 8 2 to 8 2 to 8
Binder content percentage (m/m) of
total mixture for:
Crushed rock or steel slag 6.5 6.5 6.5 5.7 5.7 5.7
Gravel 6.3 6.3 6.3 5.5 5.5 5.5
Blastfurnace slag: bulk density
1 440 kg/m3 6.6 6.6 6.6 5.7 5.7 5.7

1 360 kg/m3 6.7 6.7 6.7 5.9 5.9 5.9

1 280 kg/m3 6.8 6.8 6.8 6.0 6.0 6.0

1 200 kg/m3 6.9 6.9 6.9 6.1 6.1 6.1

1 120 kg/m3 7.1 7.1 7.1 6.3 6.3 6.3


a
Preferred mix (see foreword).
b
The mixture designation numbers (e.g. 50/10 in column 2/1) refer to the nominal coarse aggregate content of the mixture/nominal
size of the aggregate in the mixture respectively.
c Suitable for regulating course.
d
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.
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 % by agreement between supplier and purchaser, where experience
shows this to be advisable to avoid an over-rich mixture.

© BSI 11-1998 5
BS 594-1:1992

Table 3 — Composition of design type F wearing course mixtures


Column number 3/1 3/2a 3/3a 3/4 3/5
Designation b
0/3 c 30/14 35/14 55/10 55/14
Nominal layer thickness (mm) 25 40 50 40 45
Percentage (m/m) of total aggregate
passing test sieve
28 mm — — — — —
20 mm — 100 100 — 100

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14 mm — 85 to 100 87 to 100 100 90 to 100
10 mm — 60 to 90 55 to 88 90 to 100 35 to 70
6.3 mm 100 — — 35 to 70 —
2.36 mm 95 to 100 60 to 72 55 to 67 35 to 47 35 to 47
600 µm 80 to 100 45 to 72 40 to 67 25 to 47 25 to 47
212 µm 25 to 70 15 to 50 12 to 45 5 to 30 5 to 30
75 µm 13.0 to 17.0 8.0 to 12.0 7.0 to 11.0 4.0 to 8.0 4.0 to 8.0
Maximum percentage of aggregate — 14 13 9 9
passing 2.36 mm and retained on 600 µm
test sieves
Minimum target binder content 9.0 6.5 6.4 5.5 5.5
percentage (m/m) of total mixture
a
Preferred mix (see foreword).
b
The mixture designation numbers (e.g. 0/3 in column 3/1) refer to the nominal coarse aggregate content of the mixture/nominal
size of the aggregate in the mixture respectively.
c Suitable for regulating course.

Table 4 — Composition of design type C wearing course mixtures


Column number 4/1 4/2 4/3 4/4 4/5
Designationa 0/3 30/14 35/14 55/10 55/14
Nominal layer thickness (mm) 25 40 50 40 45
Percentage (m/m) of total aggregate
passing test sieve
28 mm — — — — —
20 mm — 100 100 — 100
14 mm — 85 to 100 87 to 100 100 90 to 100
10 mm — 60 to 90 55 to 88 90 to 100 35 to 70
6.3 mm 100 — — 35 to 70 —
2.36 mm 95 to 100 60 to 72 55 to 67 35 to 47 35 to 47
600 µm 30 to 65 25 to 45 22 to 43 15 to 35 15 to 35
212 µm 15 to 40 15 to 30 12 to 28 5 to 30 5 to 30
75 µm 13.0 to 17.0 8.0 to 12.0 7.0 to 11.0 4.0 to 8.0 4.0 to 8.0
Minimum target binder content 9.0 6.5 6.4 5.5 5.5
percentage (m/m) of total mixture
NOTE There is no preferred mix.
a The mixture designation numbers (e.g. 0/3 in column 4/1) refer to the nominal coarse aggregate content of the mixture/nominal
size of the aggregate in the mixture respectively.

6 © BSI 11-1998
BS 594-1:1992

Table 5 — Composition of design type R wearing course mixtures


Column number 5/1 5/2 5/3 5/4
Designation R 30/14F R 35/14F R 30/14C R 35/14C
Nominal layer thickness (mm) 40 50 40 50
Percentage (m/m) of total aggregate passing
test sieve
20 mm 100 100 100 100
14 mm 85 to 100 87 to 100 85 to 100 87 to 100
10 mm 60 to 90 55 to 88 60 to 90 55 to 88
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2.36 mm 60 to 72 55 to 67 60 to 72 55 to 67
600 µm 45 to 72 40 to 67 25 to 45 22 to 43
212 µm 15 to 50 12 to 45 15 to 30 12 to 28
75 µm 8.0 to 12.0 7.0 to 11.0 8.0 to 12.0 7.0 to 11.0
Maximum percentage of aggregate passing 14 13 — —
2.36 mm and retained on 600 µm test sieves
Minimum target binder content percentage (m/ 7.0 6.9 7.0 6.9
m) of total mixture
NOTE These mixtures are intended for use in the lowest traffic category of Table B.1, or in areas where prevailing conditions are
colder and wetter than normal. They have better fatigue and durability properties than standard type F or C mixtures but can be
expected to have less resistance to deformation.

3.3 Group 3. Wearing course recipe 3.3.4 Composition of mixture


mixtures The results of a mixture analysis shall be adjusted
NOTE Adherence to the requirements of this clause will in accordance with clause 6 of BS 598-102:1989. The
generally give mixtures of satisfactory performance. However, it adjusted results shall conform to the requirements
is impossible in a general specification to cover all suitable
aggregates, a few of which might necessitate binder contents
given in Table 6 appropriate to the particular
other than those given in Table 6. mixture designation, type of coarse aggregate and
schedule. A tolerance of ± 0.6 % (m/m) of the total
3.3.1 General
mixture shall be permitted on the values for binder
Only type F mixtures, as described in 3.2.1, shall be content.
used for recipe mixtures; the values of binder NOTE Advice on mix schedules is given in annex A.
content shall be those for the soluble binder content
on analysis. 3.4 Mixing
3.3.2 Aggregates 3.4.1 General
3.3.2.1 Coarse aggregate Rolled asphalt shall be mixed either by the batch
Coarse aggregate shall conform to 2.2. process or in a continuous or drum mixer. The
moisture content of the asphalt mixture, measured
3.3.2.2 Fine aggregate
by the method given in BS 598-102:1989, shall not
3.3.2.2.1 Fine aggregate shall conform to 2.3. exceed 1.0 % (m/m) of the mixture. On discharge
3.3.2.2.2 Fine aggregate shall not contain more from the mixer the aggregate shall be completely
than 5 % (m/m) of material retained on a 2.36 mm coated with binder with no evidence of balling of the
test sieve and the material passing a 75 µm test fine aggregate.
sieve shall not exceed 9 % (m/m) of fine aggregate. 3.4.2 Temperature of mixed asphalt
3.3.2.3 Added filler Whichever method of mixing is adopted, the
When added filler is required, to achieve the appropriate maximum temperature given in Table 7
composition given in Table 6, it shall conform to 2.4. shall not be exceeded, to avoid the risk of undue
3.3.3 Binder binder hardening. Temperatures shall be measured
in accordance with BS 598-109:1990.
The grade and type of binder shall conform to 2.1. NOTE Minimum delivery and rolling temperatures given in
NOTE Advice on the selection of binder is given in annex A. BS 594-2 should be considered when determining mixing
temperature.

© BSI 11-1998 7
BS 594-1:1992

Table 6 — Composition of recipe type F wearing course mixtures


Column number 6/1a 6/2a 6/3 6/4 6/5
Designationb 0/3c 15/10d 30/10 30/14 35/14
Nominal layer thickness (mm) 25 30 35 40 50
Percentage (m/m) of total aggregate
passing test sieve
28 mm — — — — —
20 mm — — — 100 100

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


14 mm — 100 100 85 to 100 87 to 100
10 mm — 95 to 100 85 to 100 60 to 90 55 to 88
6.3 mm 100 75 to 95 60 to 90 — —
2.36 mm 95 to 100 75 to 87 60 to 72 60 to 72 55 to 67
600 µm 80 to 100 60 to 87 45 to 72 45 to 72 40 to 67
212 µm 25 to 70 20 to 60 15 to 50 15 to 50 12 to 45
75 µm 13.0 to 17.0 11.0 to 15.0 8.0 to 12.0 8.0 to 12.0 7.0 to 11.0
Maximum percentage of aggregate — 18 14 14 13
passing 2.36 mm and retained
on 600 µm test sieves
Binder content percentage (m/m) of
total mixture for:
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
Gravel
Schedule 2A 10.3 8.9 7.5 7.5 7.0
Schedule 2B 10.8 9.4 8.0 8.0 7.5
Blastfurnace slag: bulk
density
Schedule 3A
1 440 kg/m3 — 9.0 7.9 7.9 7.6
1 360 kg/m3 — 9.0 8.0 8.0 7.7
1 280 kg/m3 — 9.2 8.1 8.1 7.8
1 200 kg/m3 — 9.3 8.2 8.2 7.9
1 120 kg/m3 — 9.4 8.3 8.3 8.0
Schedule 3B
1 440 kg/n3 — 9.5 8.4 8.4 8.1
1 360 kg/m3 — 9.6 8.5 8.5 8.2
1 280 kg/m3 — 9.7 8.6 8.6 8.3
1 200 kg/m3 — 9.8 8.7 8.7 8.4
1 120 kg/m3 — 9.9 8.8 8.8 8.5
a
Preferred mix (see foreword).
b
The mixture designation numbers (e.g. 0/3 in column 6/1) refer to the nominal coarse aggregate content of the mixture/nominal
size of the aggregate in the mixture respectively.
c
Sand carpet.
d Suitable for footpaths.

8 © BSI 11-1998
BS 594-1:1992

Table 7 — Maximum temperatures of mixed asphalt


Binder Type Grade Maximum temperature at any stage
number
Roadbase or basecourse °C Wearing course °C

1 Bitumen 35 pen 175 195


2 Lake asphalt-bitumen 35 pen — 195
3 Bitumen 50 pen 170 190
4 Lake asphalt-bitumen 50 pen — 190
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

5 Bitumen 70 pen 165 185


6 Lake asphalt-bitumen 70 pen — 185
7 Bitumen 100 pen — 175
NOTE If 40 pen HD bitumen is used a maximum temperature of 195 °C is appropriate.

© BSI 11-1998 9
BS 594-1:1992

Section 4. Coated chippings for application to


wearing course surfaces
4.1 Chippings 4.4 Size, shape and grading of
The chippings to be coated shall be coarse aggregate chippings
conforming to 2.2.1. 4.4.1 The coated chippings on analysis shall:
NOTE The polished stone value and aggregate abrasion value a) be of either 20 mm or 14 mm nominal size, with
of the chippings are site specific and outside the scope of this
standard.
the appropriate grading given in Table 8; and
b) have a flakiness index not exceeding 25.
4.2 Binder coating Table 8 — Gradings of chippings

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


Binder used to coat the chippings shall be 50 pen Test sieve Percentage (m/m) passing test sieve
grade conforming to 2.1. Except in the situation
20 mm nominal size 14 mm nominal size
described in 4.4.2 (see note), the amount of binder
used shall yield a binder content on analysis 28 mm 100
of (1.5 ± 0.3) % (m/m). 20 mm 90 to 100 100
NOTE A higher binder content may be specified for chippings to
be used in the situation described in 4.4.2, but any such higher 14 mm 0 to 25 90 to 100
binder content is still subject to a tolerance on analysis
of ± 0.3 % (m/m). 10 mm 0 to 4 0 to 25
6.3 mm — 0 to 4
4.3 Quality of binder coating
75 µm 0 to 2 0 to 2
The coated chippings, when tested for the condition
of the binder in accordance with clause 3 of 4.4.2 When the chippings are to be used on asphalt
BS 598-108:1990 shall have a mass of sand retained laid on roads for which a minimum texture depth
of not less than 40 g/kg for 20 mm chippings of 1.5 mm is specified, not less than 75 % (m/m) of
or 50 g/kg for 14 mm chippings. Not more the chippings shall be of the specified size as defined
than 7.5 % (m/m) chippings shall fail the visual in BS 63-1:1987.
assessment of sand-cover. NOTE Application of coated chippings is dealt with in
NOTE 1 Before the chippings are coated with binder, they BS 594-2.
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.

10 © BSI 11-1998
BS 594-1:1992

Annex A (informative) A.4.3 Composition of mixtures


Guidance on the selection of materials The choice of coarse aggregate content depends
and mixtures largely upon the thickness of material laid. For
general use, 60 % (m/m) of coarse aggregate is
A.1 General recommended; 50 % (m/m) of coarse aggregate is
recommended when a mixture is to be laid as a
The selection of an asphalt mixture for a particular regulating course.
site depends upon many factors, particularly traffic,
climate and layer thickness. It requires knowledge A.5 Wearing course mixtures
and judgement on the part of the purchaser and the
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

contractor. The information in A.2 to A.6 is intended A.5.1 Binder


for guidance. The physical properties of an asphalt mixture are
generally determined by the type of fine aggregate
A.2 Aggregate and grade of binder. Traditional mixtures for
There are no satisfactory tests for determining the normal traffic have been made with sand fine
amount of deleterious materials in aggregates. Any aggregate and 50 pen binder. If crushed fines or
obviously degraded or dirty stone or other harsh sands are used, softer binders may be
contamination, such as by roots, vegetation or suitable, even on heavily trafficked roads.
particles of lignite, should be avoided. For sites with more intense traffic, the use of harder
NOTE Where experience indicates that an aggregate is prone to (e.g. 35 pen or 40 pen HD) bitumen or crushed fines
stripping, addition of an adhesion agent or 1 % to 2 % (m/m) of may be considered. On lightly trafficked roads and
Portland cement or hydrated lime might be beneficial. other lightly stressed areas, softer binders,
e.g. 70 pen or 100 pen, may be used, even with sand
A.3 Roadbase mixtures
fines.
A.3.1 Thickness All the binders specified in this Part of BS 594 are
Specific recommendations for the total thickness of designed to assist in providing a suitable surface
rolled asphalt roadbases are not included in this texture on the wearing course.
standard. Thickness is dependent upon a number of A.5.2 Aggregate
factors including the strength of the sub-base or
formation and the traffic loading. Guidance can be The choice of coarse aggregate and of coated
obtained from publications dealing with pavement chippings depends primarily on their suitability for
design. the traffic and site conditions. In some situations,
such as on bends, on roads carrying high speed
A.3.2 Composition of mixtures traffic and on roundabouts, resistance to skidding is
Roadbase mixtures should be selected from Table 2 especially important. In such situations, aggregate
to suit the nominal layer thickness. A 50 pen grade of high resistance to the polishing effect of traffic
binder is normally suitable but the softer 70 pen should be used for the coated chippings and for the
grade may be used where traffic loading is unlikely coarse aggregate in unchipped wearing courses. The
to be intense. test for the measurement of polished-stone value is
given in BS 812-114.
A.4 Basecourse and regulating course The rate at which exposed aggregate is abraded by
mixtures heavy vehicular traffic is important in determining
A.4.1 Binder the retention of texture by the wearing course; for
Alternative grades of binder are included in Table 1. this reason it is desirable that the aggregate
The use of 50 pen binder will generally be abrasion value of the coated chippings and of the
satisfactory. In areas of intense canalized traffic in coarse aggregate in unchipped wearing courses
southern England, 35 pen grade may provide should be taken into consideration when selecting
greater resistance to deformation. In Scotland and the aggregate. The test for aggregate abrasion value
northern England 70 pen binder may be satisfactory is given in BS 812-113.
in less heavily trafficked roads. The purchaser should, where necessary, indicate
the minimum polished-stone value and maximum
A.4.2 Thickness
aggregate abrasion value required for the coarse
Basecourse and regulating course mixtures should aggregate and/or coated chippings, as appropriate.
be selected from Table 2 to suit the required
nominal layer thickness.

© BSI 11-1998 11
BS 594-1:1992

A.5.3 Composition of mixtures It may also need to be carried out if the aggregate
A.5.3.1 General grading changes materially during production.
When little or no variation has been indicated, a
Section 3 of this standard gives specifications for measure of consistency may be obtained by testing
two groups of wearing course mixtures. Both groups specimens, using plant-produced mixture
are of equal status and it is not intended that compacted in accordance with the procedure
preference be given to either group. in BS 598-107. The results obtained using such
The traditional recipe type wearing course mixtures material are not directly comparable with those
(see 3.3) have been very successful in most obtained on laboratory prepared specimens, so the

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


applications. However, on some roads where traffic values given in Table B.1 will not directly apply.
loadings have reached unprecedented levels, and as Therefore, periodic checks on the design should be
the range of constituent materials proposed for use carried out at mixing plants, even when fine
has greatly widened, some recipe mixtures have aggregate known to be reasonably consistent is
failed to perform consistently well, and have been used, to enable a producer to supply, with
replaced by designed mixtures. Purchasers having confidence, asphalt to a recent mix design in
proven materials sources and experience of the accordance with this specification, even when the
satisfactory use of recipe mixtures under the quantity of asphalt required is too small to justify
conditions applicable to their areas may wish to the full design procedure being carried out.
continue with their use, possibly with the additional
Attention is drawn to the limited experience with
resource of harder binders for roads where
type C designed mixtures. Problems may occur in
deformation may become a problem.
obtaining durable material of low permeability
A.5.3.2 Group 2 mixtures: design method because the harshness of this type of mixture makes
When there is little or no experience of the use of the compaction more difficult. The problem may be
proposed constituent materials (especially the fine overcome by increasing the binder content by up
aggregate), or where severe traffic loadings exist or to 1 % (m/m) of total mixture above the design
are anticipated, the design method is more suitable binder content, provided the criteria given in
than the recipe method, particularly for major Table B.1 are satisfied.
contracts involving high tonnages of wearing course In the case of 55/10 and 55/14 wearing course
material. mixtures, which are not chipped, 100 pen bitumen is
The mixture derived from laboratory procedure normally used where the mixes are laid on
described in BS 598-107 should satisfy the traffic secondary roads, housing estate roads, play areas
related criteria given in Table B.1. If the criteria are and similar sites. However, the use of 50 pen
not met, alternative sources of constituent bitumen is advised on high-stress sites used by
materials should be sought; normally a different heavy goods vehicles; this material may not be
fine aggregate and/or grade of binder will be suitable for hand laying. Mixtures
required. containing 100 pen bitumen have traditionally been
It is not yet possible to give specific guidance on known as “medium-temperature asphalt, MTA”, in
minimum flow values for each traffic category in view of their lower handling temperatures
Table B.1 compared with mixtures containing 50 pen
bitumen.
The mixtures derived from the use of the design
method in BS 598-107 are the result of tests on Enriched type R mixtures are particularly intended
laboratory prepared specimens, undertaken well in for use on lightly trafficked roads of sub-standard
advance of the works to determine an agreed construction where resistance to wheel track rutting
composition for contract purposes. Adequate time is less important than enhanced fatigue strength
should be allowed for this work. The laboratory and durability. They are also appropriate for better
design mix should be checked using aggregate from constructed, lightly trafficked roads, in areas which
the plant bins, or the aggregate feed in the case of a are colder and wetter than normal.
continuous plant.
In normal circumstances the laboratory design
procedure will be undertaken whenever a new
source of fine aggregate is used or proposed.

12 © BSI 11-1998
BS 594-1:1992

A.5.3.3 Group 3 mixtures: recipe method Traffic is categorized in terms of the estimated
As indicated in section 3, it is impossible to cover in average number of commercial vehicles per lane per
this standard all suitable aggregates, a few of which day during the year of laying. A commercial vehicle
require binder contents other than those given in is defined as a goods or public service vehicle of
section 3. If experience is lacking with a particular unladen weight exceeding 15 kN.
aggregate, and especially a fine aggregate, the Where intense canalization of commercial vehicles
recipe method should be used with caution. If the occurs, such as at approaches to traffic lights, where
mixture obtained using the recommended recipe is heavy vehicles are continually braking and
unsuitably brittle or soft, the use of either a softer or restarting, and where the rate of growth of traffic is
expected to be abnormally high, the design test
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

harder binder, or the design method (group 2),


should be considered. criteria should be based on the next higher traffic
Soluble binder contents should be related to the category.
climatic conditions and the volume of traffic. In the
B.2 Verification of design proposals
majority of cases mixtures conforming to
schedules 1A, 2A and 3A should be used. In cold, The design proposals submitted in accordance with
elevated, wet conditions, or for more lightly clause 11 of BS 598-107:1990 should be verified.
trafficked roads, mixtures conforming to This may be done by supervision or by further
schedules 1B, 2B and 3B will be more appropriate. testing. An exception may be made for small
contracts using material from a particular source
A.6 Storage of mixed materials where there is sufficient experience of the mixture
It is not possible, given the present state of for there to be confidence in the design submitted.
knowledge, to give specific guidance on extended Sufficiently large representative samples of the
storage of bituminous mixtures. Conditions of constituent materials should be taken to cover the
storage will affect the maximum storage period. requirements for the design, the verification and
any necessary repeat tests. Wherever possible the
Annex B (informative)
verification should be carried out as a joint exercise,
Recommendations for the application although verification is not always required when
of design test criteria the original design is undertaken at an
independently accredited laboratory.
B.1 Consideration of traffic conditions The supplier’s design proposals are acceptable for
When a rolled asphalt wearing course with stability if the verification results conform to
chippings is specified in accordance with 3.2, it is Table B.1, and for design binder content if the
desirable to ensure that the properties of the results of the verification tests are within ± 0.5 % of
asphalt are suitable for traffic conditions at the site the submitted proposal.
on which it is to be used. Table B.1 gives suggested Annex C (informative)
test criteria, measured at the target binder content,
for various levels of traffic.
Information to be provided by the
Table B.1 — Criteria for the stability of
purchaser and the supplier
laboratory design asphalt
C.1 Information to be provided by the
Traffic (in commercial vehicles Stability of complete purchaser with the enquiry or order
per lane per day) mix
kN
Where the purchaser wishes to select the
constituent materials and mix composition from the
Less than 1 500 3 to 8a options given in this Part of BS 594, the purchaser
1 500 to 6 000 4 to 8 should indicate the following information with the
over 6 000 6 to 10 enquiry or order:
NOTE 1 For stabilities up to 8.0 kN the maximum flow value a) description of course(s) (see annex A);
should be 5 mm. For stabilities in excess of 8.0 kN a maximum
flow of 7 mm is permissible. b) thickness of layer (see Table 2, Table 3,
NOTE 2 The stability values referred to should be obtained on Table 4, Table 5 and Table 6);
laboratory mixes. c) coarse aggregate content for each course
NOTE 3 The stability and flow values are those pertaining to (see Table 2, Table 3, Table 4, Table 5 and
the target binder content.
Table 6);
a
It may be necessary to restrict the upper limit where
d) type of coarse aggregate (see 2.2);
difficulties in the compaction of materials might occur. Type R
enriched mixes conforming to Table 5 are intended for use with e) type of fine aggregate (see 2.3);
this traffic category.

© BSI 11-1998 13
BS 594-1:1992

f) type and grade of binder for each course a) descriptions of course(s) (see annex A);
(see 2.1); b) type, source and size of coated chippings
g) composition for each course and design method (see Section 4);
or recipe method for wearing course (see Table 2, c) coarse aggregate content (see Table 2, Table 3,
Table 3, Table 4, Table 5 and Table 6); Table 4, Table 5 and Table 6);
h) whether additional requirements are specified d) type and source of coarse aggregate (see 2.2);
for coated chippings (see section 4);
e) type and source of fine aggregate (see 2.3);
i) any additional relevant information
f) type and grade of binder (see 2.1);
(see BS 594-2).

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


g) composition for each course and design method
C.2 Information to be provided by the supplier or recipe method for wearing course (see Table 2,
with the quotation Table 3, Table 4, Table 5 and Table 6);
The following information should be provided by the h) any additional relevant information
supplier with the quotation, particularly where the (see BS 594-2).
purchaser has left the choice of the options to the
supplier after giving the details of the construction
to be carried out:

14 © BSI 11-1998
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

blank
15
BS 594-1:1992

List of references (see 1.2)

Normative references

BSI standards publications


BRITISH STANDARDS INSTITUTION, London

BS 63, Road aggregates.

Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI


BS 63-1:1987, Specification for single-sized aggregate for general purposes.
BS 410:1986, Specification for test sieves.
BS 598, Sampling and examination of bituminous mixtures for roads and other paved areas.
BS 598-100:1987, Methods for sampling for analysis.
BS 598-101:1987, Methods for preparatory treatments of samples for analysis.
BS 598-102:1989, Analytical test methods.
BS 598-107:1990, Method of test for the determination of the composition of design wearing course rolled
asphalt.
BS 598-108:1990, Methods for determination of the condition of the binder on coated chippings and for
measurement of the rate of spread of coated chippings.
BS 598-109:1990, Methods for the assessment of the compaction performance of a roller and recommended
procedures for the measurement of the temperature of bituminous mixtures.
BS 812, Testing aggregates.
BS 812-1:1975, Methods for determination of particle size and shape.
BS 812-2:1975, Methods for determination of physical properties.
BS 812-100:1990, General requirements for apparatus and calibration.
BS 812-101:1984, Guide to sampling and testing aggregates.
BS 812-102:1989, Methods for sampling.
BS 812-103, Method for determination of particle size distribution.
BS 812-103.1:1985, Sieve tests.
BS 812-103.2:1989, Sedimentation test.
BS 812-105, Methods for determination of particle shape.
BS 812-105.1:1989, Flakiness index.
BS 812-105.2:1990, Elongation index of coarse aggregate.
BS 812-106:1985, Method for determination of shell content in coarse aggregate.
BS 812-109:1990, Methods for determination of moisture content.
BS 812-110:1990, Methods for determination of aggregate crushing value.
BS 812-111:1990, Methods for determination of ten per cent fines value (TFV).
BS 812-112:1990, Method for determination of aggregate impact value (AIV).
BS 812-113:1990, Method for determination of aggregate abrasion value (AAV).
BS 812-114:1989, Method for determination of the polished-stone value.
BS 812-117:1988, Method for determination of water-soluble chloride salts.
BS 812-118:1988, Methods for determination of sulphate content.
BS 812-119:1985, Method for determination of acid-soluble material in fine aggregate.
BS 812-120:1989, Method for testing and classifying drying shrinkage of aggregates in concrete.
BS 812-121:1989, Method for determination of soundness.
BS 812-124:1988, Method for determination of frost-heave.
BS 1047:1983, Specification for air-cooled blastfurnace slag aggregate for use in construction.
BS 3690, Bitumens for building and civil engineering.

16 © BSI 11-1998
BS 594-1:1992

BS 3690-1:1989, Specification for bitumens for roads and other paved areas.
BS 3690-3:1990, Specification for mixtures of bitumen with pitch, tar and Trinidad lake asphalt.
BS 6100, Glossary of building and civil engineering terms.

Informative references

BSI standards publications


BRITISH STANDARDS INSTITUTION, London

BS 594, Hot rolled asphalt for roads and other paved areas.
BS 594-2:1992, Specification for transport, laying and compaction of rolled asphalt.
Licensed Copy: Giorgio Cavalieri, ALSTOM, 15-Mar-01, Uncontrolled Copy. © BSI

© BSI 11-1998
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