TITLE : BITUMEN MASTIC FLOORING

PROCEDURE NO :

WORK ORDER NO :

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 BITUMEN MASTIC FLOORING
1. OBJECTIVE
The purpose of this procedure for laying bitumen mastic flooring

2. PURPOSE
Bitumen mastic is dustless, odourless, jointless and impervious to the transmission of
moisture, either in liquid or vapour form. The surface can be easily cleaned and is also durable.

3. REFERENCE
IS 1196:1978, IS 1195:2002, IS 702:1988, Technical Specifications of Projects, Approved
Drawings, Approved Brand of product, Field Quality Plan, Manufacturer Data Sheet

4. SCOPE
This procedure covers the laying of bitumen mastic flooring.
This work procedure should not be considered for acid resistant bitumen mastic and
damp-proofing base.

5. EQUIPMENT/ INSTRUMENTS
Stove/Oven, Smoke Hood, Brush, Mixing Tools, Gloves, Goggles

6. RESPONSIBILITY
Primary Responsibility
Secondary
: Construction Manager,
: Section In-charge,
Engineer In charge of area,
Quality In-charge,
Safety Engineer

7. SAFETY
 Use Necessary PPE’s required for the job.
 Necessary barricading to be done at the job site.
 Fire extinguishers, fire buckets and other fire exhausting measures to be kept available
 Use certified company’s respirator when Applying the Bitumen.

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 8. MATERIAL SPECIFICATION
A. Bitumen
Bitumen grades shall be meeting the requirements specified in IS:702. The physical
properties of bitumen used in the manufacture of mastic-bitumen shall conform to the
requirements laid down in Table 1 when tested in accordance with the method of tests
specified in Table 1.

B. Coarse Aggregate
The coarse aggregate shall consist of clean igneous or calcareous or siliceous rock
obtained from natural deposits either directly or by crushing screening or other mechanical
process. It shall be free from dust as far as possible/practicable.

C. Fine Aggregate
The fine aggregate shall consist of naturally occurring lime stone or any other rock
ground to a grading as given in Table 2.

D. Filler

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 The filler shall consist of limestone rock crushed to tine powder with at least 85
percent passing 75-micron IS Sieve. The calcium-carbonate contents of filler material shall
not be less than 80 percent by mass.

9. WORK PROCEDURE

GRADE OF BITUMEN-MASTIC FLOORING:

 Grade 1 Special flooring
 Grade 2 Light duty flooring
 Grade 3 Medium duty flooring
 Grade 4 Industrial factory flooring

COMPOSITION
 The proportions of coarse aggregate retained on a 600-micron IS Sieve shall be in
accordance with Table 3, depending on the thickness of the finished floor.

 The composition of the remaining material shall then be calculated as a percentage

by mass of the bitumen-mastic excluding the material retained on a 600-micron IS
Sieve and shall fall within the Limits specified in Table 4.

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 SURFACE PREPARATION:
 The surface shall be cleaned to remove all dust, foreign matters, loose materials or
any deposits of contamination which could affect the bond between the surface and
the coating.
 Slight hacking of the base surface shall be done for bonding.
 Required level and slope shall be maintained for the base material.

TREATMENT OF BASE:
 Screed concrete not less than 25 mm thick shall be applied over base concrete.

MIXING:
 The fine aggregates shall be heated to a temperature of 170 to 205°C.
 Blocks of bitumen shall be broken to convenient size then be carefully melted.
 Coarse aggregate and filler material preferably dry shall be fed in successive portions
as per the required composition.
 After all the coarse aggregate has been incorporated, it shall be mixed continuously
for a period of not less than one hour before laying is begun.
 Mixing shall be continued until laying operation is completed, so as to maintain the
coarse aggregate in suspension.
 At no stage during the re-melting and mixing process, shall the temperature exceed
205°C.
LAYING:

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  When the material is sufficiently molten to be workable, it should be carried in flat
mortar pans, to the point of laying.
 Bitumen mastic should generally be laid in bays in one coat.
 It should be spread to the specified thickness by means of suitable hand tools,
gauges, straight edges and hand levels being used to ensure accuracy.
 The bitumen mastic should then be floated to a uniformly level surface by a heavy
wooden float and should be free from roughness and’ imperfections.
 If blowing occurs, the bubbles should be punctured and the area affected carefully
made good while the mastic is still hot.
 Two-coat work should be treated in a manner similar to that for single-coat work, but
care should be taken to arrange that the joints in successive layers are staggered.

SURFACE FINISH:
 Matt finish
o The surface should be rubbed in with sand during the final floating operation. The
sand should be clean and free from foreign matter.
o All surplus material should be removed after rubbing is completed.
 Polished Finish
o The surface should be finished with a float in a manner similar to that used for a
matt finish but without the use of an abrasive

10. ACCEPTANCE CRITERIA:

 The product used shall be approved.
 As per the instruction given in the approved construction drawings

11. Related Documents:

 Checklists/ Protocols/ Inspection reports
 Test certificates of the material used
 Data sheet of the product

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