BS594 1-2003

BS 594-1:2003
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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No reproduction or networking permitted without license from IHS
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BS 594-1:2003
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 Test Equipment Manufacturers Association
County Surveyors Society
Institution of Civil Engineers
Institution of Highways and Transportation
Mastic Asphalt Council Ltd.
Ministry of Defence UK Defence Standardization
Department for Transport Highways Agency
Quarry Products Association
Refined Bitumen Association
Road Surface Dressing Association
Scottish Office Roads Directorate
Society of Chemical Industry
TRL Transport Research Laboratory
United Kingdom Accreditation Service
This British Standard was

published under the authority
of the Standards Policy and
Strategy Committee
on 27 August 2003
BSI 27 August 2003
Amendments issued since publication

Amd. No.
Date
Comments
The following BSI references

relate to the work on this
British Standard:
Committee reference B/510/1
ISBN 0 580 42384 0

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First published April 1985

Second edition September 1992
Third edition December 2002
Fourth edition August 2003
BS 594-1:2003
Contents
Committees responsible
Foreword
Page
Inside front cover
ii
Introduction
1
2
3
4
5
6
7
8
Scope
Normative references
Terms and definitions
Constituent materials
Hot rolled asphalt mixtures
Mixing
Coated chippings for application to surface course surfaces
Sampling and testing
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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
18
22
Bibliography
23
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 Criteria for the stability of laboratory design asphalt
Table D.1 Limiting wheel-tracking requirements for site classifications
Table D.2 Classification of sites by traffic and stress condition
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BS 594-1:2003
Foreword
This British Standard has been prepared by Subcommittee B/510/1. It supersedes
BS 594-1:2002, which is withdrawn.
The previous edition of BS 594-1 introduced the following changes:
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.
This edition introduces 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.
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.
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 and ii,
pages 1 to 23 and a back cover.
The BSI copyright notice displayed in this document indicates when the
document was last issued.
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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.
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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 598-100:1987, 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.
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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.
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 3195-3 (EN 58), Methods for sampling petroleum products Part 3: Method for sampling bituminous
binders.
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 197-1, Cement Part 1: Composition, specifications and conformity criteria for common cements.
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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

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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
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
1
2
3
4
5
6
7
Bitumen
Lake asphalt-bitumen
Bitumen
Bitumen
Bitumen
30/45 pen
35 pen
40/60 pen
50 pen
70/100
70 pen
100/150
170
175
165
170
160
165
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 200C 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 above those
recommended in this table.)
4.2 Coarse aggregate

4.2.1 Type of coarse aggregate
Coarse aggregate shall be material substantially retained on a 2.36 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 conforming to BS 1047.
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.
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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 10 % fines value which indicates
aggregate strength.
4.2.2 Particle shape

The coarse aggregate shall conform to flakiness category FI35.
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 B.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
used.
For all other properties specified in BS EN 13043:2002, Clause 5 it is recommended that the No Requirement category is
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.
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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.
5.1.3 Composition of the mixture
The results of a mixture analysis shall be adjusted in accordance with BS 598-102:1996, Clause 6.
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.
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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.
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5.2.5 Composition of mixtures

The results of a mixture analysis shall be adjusted in accordance with BS 598-102:1996, Clause 6. 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 B.
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
20 mm
100
14 mm
100
10 mm
6.3 mm
90 to 100
100
100
90 to 100
90 to 100
90 to 100
50 to 80
90 to 100
65 to 100
65d
30 to 65
65 to 100
35 to 75
30 to
2 mm
30 to 50
30 to 50
30 to 50
25 to 39
25 to 39
0.500 mm
13 to 50
13 to 50
13 to 50
8 to 39
8 to 39
0.250 mm
6 to 31
6 to 31
6 to 31
4 to 26
4 to 26
0.063 mm
1 to 8
1 to 8
1 to 8
1 to 7
1 to 7
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
1.12 Mg/m3
7.1
7.1
7.1
6.3
6.3
Blastfurnace slag: bulk density
NOTE 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
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.

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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
Percentage (m/m) of total aggregate

passing test sieve
20 mm
14 mm
10 mm
6.3 mm
2 mm
0.500 mm
0.250 mm
0.063 mm
Maximum percentage of aggregate
passing 2 mm and retained on
0.500 mm test sieves
Minimum target binder content
percentage (m/m) of total mixture
a
b
c
100
100
85 to 100 87 to 100
60 to 90
55 to 88
100
90 to 100 59 to 71
55 to 67
75 to 100 44 to 71
40 to 67
30 to 85
18 to 62
15 to 55
12.0 to 16.0 7.0 to 11.0 6.0 to 10.0
15
14
100
100
90 to 100
90 to 100
35 to 70
35 to 70
35 to 47
35 to 47
25 to 47
25 to 47
5 to 35
5 to 35
4.0 to 8.0
4.0 to 8.0
10
10
9.0
5.5
6.5
6.4
5.5

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

Column number
4/1
4/2
4/3
4/4
4/5
Designationa
0% 0/2
30% 0/14
35% 0/14
55% 0/10
55% 0/14
25
40
45 or 50
40
45
Percentage (m/m) of total

aggregate passing test sieve
20 mm
14 mm
10 mm
6.3 mm
2 mm
0.500 mm
0.250 mm
0.063 mm
Minimum target binder content
percentage (m/m) of total mixture
NOTE
100
87 to 100
55 to 88
50 to 62
20 to 45
15 to 35
6.0 to 10.0
6.4
100
100
90 to 100
90 to 100
35 to 70
35 to 70
32 to 44
32 to 44
15 to 35
15 to 35
5 to 35
5 to 35
4.0 to 8.0
4.0 to 8.0
5.5
5.5
There is no preferred mix for design type C.
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100
85 to 100
60 to 90
100
90 to 100
59 to 71
30 to 65
25 to 45
20 to 50
20 to 40
12.0 to 16.0 7.0 to 11.0
9.0
6.5
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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.
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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.
5.3.4 Composition of mixture

The results of a mixture analysis shall be adjusted in accordance with BS 598-102:1996, Clause 6. 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

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Table 6 Composition of recipe type F surface course mixtures

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
100
100
95 to 100
85 to 100
100
75 to 95
60 to 90
90 to 100
75 to 87
59 to 71
75 to 100
55 to 85
44 to 71
30 to 85
25 to 75
18 to 62
12.0 to 16.0 10.0 to 14.0
7.0 to 11.0
100
85 to 100
60 to 90
59 to 71
44 to 71
18 to 62
7.0 to 11.0
100
87 to 100
55 to 88
55 to 67
40 to 67
15 to 55
6.0 to 10.0
20
15
15
14
10.3
10.8
8.9
9.4
7.8
8.3
7.8
8.3
7.4
7.9
10.3
10.8
8.9
9.4
7.5
8.0
7.5
8.0
7.0
7.5
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
1.20 Mg/m3
9.3
8.2
8.2
7.9
1.12 Mg/m3
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
Percentage (m/m) of total

aggregate passing test sieve
20 mm
14 mm
10 mm
6.3 mm
2 mm
0.500 mm
0.250 mm
0.063 mm
Maximum percentage of
aggregate passing 2 mm and
retained on 0.500 mm test sieves
Binder content percentage
(m/m) of total mixture for:
Crushed rock or steel slag
Schedule 1A
Schedule 1B
Gravel
Schedule 2A
Schedule 2B
Binder content percentage
(m/m) of total mixture for:
Blastfurnace slag: bulk density
Schedule 3A
a
b
c
d
--`,``-`-`,,`,,`,`,,`---
Column number

The mixture designation numbers (e.g. 35% 0/14 in column 6/5) refer to the nominal coarse aggregate content of the mixture
Sand carpet.
Suitable for footpaths.
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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.
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
BVol = Bmass ----------b
where
Bmass is the binder content as a proportion of the total mixture by mass (%) added at the mixer;
b
is the density of the binder at 25 C in kilograms per cubic metre (kg/m3);
mix
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
pre-blended 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].
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 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;
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).
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 pre-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
Type
Grade
Maximum temperature at any stage

Base (roadbase) or binder course
Surface course
Bitumen
Bitumen
Bitumen
Bitumen
--`,``-`-`,,`,,`,`,,`---
1
2
3
4
5
6
7
30/45
35 pen
40/60
50 pen
70/100
70 pen
100/150
175
170
165
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.
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 594-2:2002, 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 20 mm chippings or 50 g/kg
for 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 933-2.
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
8/14 mm size
100
90 to 100
0 to 25
0 to 4
0 to 2
100
90 to 100
0 to 25
0 to 4
0 to 2
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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.
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 3195-3 (EN 58), 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).
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 mixtures
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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BS 594-1:2003
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 PSVdeclared 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
AAVdeclared 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.
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.
--`,``-`-`,,`,,`,`,,`---
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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 high-stress 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.
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 Criteria for the stability of laboratory design asphalt
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
8a
3 to
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.
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.
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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 598-107:1990, 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.
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 4987-1:2003, 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
18
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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 598-100:1987, 6.3.
At least six 200 mm diameter cores and six 150 mm diameter cores should be cut from the trial area with
pre-coated chippings; at least six 150 mm diameter cores should be cut from the trial area without
pre-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 pre-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 pre-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 598-104:1989, Clause 4. The density of the compacted hot rolled asphalt without pre-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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19
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BS 594-1:2003
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.
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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.
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.
Table D.1 Limiting wheel-tracking requirements for site classifications
Classification
No.
Test temperature
Maximum wheel-tracking
Description
C
0
1
2
Lightly stressed sites not requiring specific

design for deformation resistance.
Not required
Moderate to heavily stressed sites requiring
high rut resistance.
45
Very heavily stressed sites requiring very high
rut resistance.
60
20

Rate
Rut depth
mm/h
mm
Not required
Not required
2.0
4.0
5.0
7.0
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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
Not for Resale
A
Motorway (main line)
B
Dual carriageway (all purpose) non-event sections
D
Dual carriageway (all purpose) minor junctions
C
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
501- 1 001- 1 501- 2 001- 2 501- 3 001- 4 001- 5 001- Over

1 000 1 500 2 000 2 500 3 000 4 000 5 000 6 000 6 001
0
0
0
0
1
1
1
1
2
2
2
2
21
BS 594-1:2003
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BS 594-1:2003
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);
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d) any additional relevant information, including recommendations for early trafficking (see BS 594-2).
22

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BS 594-1:2003
Bibliography
Standards publications
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.
BSI 27 August 2003

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[2] HIGHWAYS AGENCY. Notes for Guidance to the Specification for Highway Works.
London: The Stationery Office.
23
Not for Resale
BS 594-1:2003
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Hot rolled asphalt for

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Committees responsible for this

This British Standard was

Amendments issued since publication

The following BSI references

ISBN 0 580 42384 0

Copyright British Standards Institution

Not for Resale

First published April 1985

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

Table 1 Designation of binders and recommended storage temperatures

BSI 27 August 2003

ii British Standards Institution

BSI 27 August 2003

BSI 27 August 2003

BS EN 932 (all parts), Tests for general properties of aggregates.

3 Terms and definitions

Copyright British Standards Institution

BSI 27 August 2003

Table 1 Designation of binders and recommended storage temperatures

4.2 Coarse aggregate

BSI 27 August 2003

4.2.2 Particle shape

4.3 Fine aggregate

4.3.2 Fines content

For guidance on fines quality see PD 6682-2.

4.4 Added filler

5 Hot rolled asphalt mixtures

4 British Standards Institution

BSI 27 August 2003

5.1.1.3 Added filler

5.2.4 Target binder content

Design proposals should be verified in accordance with Annex B.

BSI 27 August 2003

5.2.5 Composition of mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total aggregate

Binder content percentage (m/m) of

Blastfurnace slag: bulk density

Preferred mix (see Foreword).

Copyright British Standards Institution

BSI 27 August 2003

Table 3 Composition of design type F surface course mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total aggregate

Preferred mix (see Foreword).

Table 4 Composition of design type C surface course mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total

There is no preferred mix for design type C.

BSI 27 August 2003

5.3 Group 3: surface course recipe mixtures

5.3.4 Composition of mixture

Advice on mixture schedules is given in Annex A.

Table 5 Table deleted

Copyright British Standards Institution

BSI 27 August 2003

Table 6 Composition of recipe type F surface course mixtures

Nominal layer thickness (mm)

Percentage (m/m) of total