Annexure - I

Page 1 of 4
GAMMON INDIA LIMITED
Job : 20 Bridges on Nh-60 @OR/WB/1
METHODOLOGY FOR LAYING OF BITUMEN MASTIC ON THE BRIDGE DECK

I. Scope:
Laying of 12mm thick Mastic Asphalt waterproof single layer on the bridge deck
before laying the Bituminous Concrete wearing course, shall be sufficiently plastic to
be poured in the place & compressed in required thickness.

II. Salient Features:

Details of Quantity of Bitumen Mastic for the different bridges are as follows:

ORISSA WEST BENGAL

Bridge No. Qty. (m2) Bridge No. Qty. (m2)
Fl-01 333.3 ROB-3 1555.418
Br-4/1 1200.42 FL-03 780.52
ROB-1 4472.65 Br-89/1A 2472.47
Br-17/1 1101.62 ROB-4 1588.815
Br-20/2 1558.57 Total 6397.222
Br-20/3 1101.62
Br-23/1 1425.19
Br-24/1 1200.42
Br-24/3 1262.17
Br-25/2 1200.42
Br-32/3 1262.17
Br-38/1 6657.788
Fl-02 771.9244
ROB-2 2317.679
Total 25865.94 Total 6397.222

Grand Total (Orissa + W.B.) 32263.16 M2

III. Material Source [Bitumen Mastic]:
The asphalt mastic is a mixture of asphalt cement (bitumen), Mineral aggregate &
mineral filler mixed at a temperature of 200 o C.

Materials for Bitumen Mastic:

A. Bitumen:
Source: M/s Mascot Industries, Howrah
Straight run 30/40 Penetration Grade bitumen satisfying the requirements of IS 73.
Physical Properties of Bitumen shall conform as follows:

S.No. Characteristics Requirement

1. Penetration at 25oC (in 1/100 cm) 20 to 40
2. Softening point (Ring and Ball Method) 50oC to 90oC
3. Ductility at 27oC(Minimum) 10 cm
4. Loss on heating (Maximum) 3%
5. Solubility in CS2 (Maximum) 99 %

B. Coarse Aggregate:
Source: Nilagiri /Soro [Balasore]
The nominal size, gradation of the coarse aggregate to be incorporated shall be of
6mm down Quarry dust passing through 6mm sieve & retaining on 75 micron.
Physical properties of 6mm down aggregate whose max. value of water absorption
shall be 1%.

C. Filler:
Source: Chibasa, Jharkand
Filler material shall be Limestone powder passing 75 micron sieve & shall have a
calcium carbonate content of not less than 80% by weight when determined in
accordance with IS:1195.

IV. Machine Power

S.No. Name of Machinery Capacity

1. Mastic Cooker [1T/2T cap.] 2 Nos.
2. Hand Trolley. 3 Nos.
3. Hand Tools & Wire Brush Lot
V. Man Power
Manpower for one Cooker

1] Mastic Cooker operator - 2 Nos

2] Mistry - 4 Nos
3] Unskilled Labour - 12 Nos.

VI. CONSTRUCTION METHODOLOGY:

A. PREPARATION OF THE BASE:

The Deck Surface shall have a true even and dry surface which has been slightly
coarsened by means of a stiff broom or wise brush and should be free from ridges
and hollows a steel trowel led finish is not desirable. The levels of the base should
be such that the specified thickness of bitumen mastic may be applied uniformly.
Also the Levels at the end side of the deck slab & in the centre shall be taken, and if
any variation occurs, appropriate corrective action shall be taken.

B. LAYING PROCEDURE:
i. Prime Coat:
Over the clean dry surface, the Prime / Tack coat shall be applied with
brush manually to enable Prime coat materials form a uniform layer covering
the bridge deck surface. A thickness of 3Kg – 3.5Kg / 10 M 2 shall be
maintained.
Prime coat shall be prepared by mixing 50% Bitumen & 50% Benzone oil /
Kerosene Oil.
Over the dry primer surface after 12 hours of prime coat, mastic bitumen
compound shall be laid over the prime coat.

ii. PREPARATION OF BITUMEN MASTIC:

Lime Powder shall be heated to a temperature of 170 oC to 200oC and
then the required amount of bitumen [heated to 170 o to 180oC] shall be added
to it. They shall be mixed and cooked in a mechanically agitated mixer called
mastic cooker for about 3 hours until the materials are thoroughly mixed.
During mixing, care shall be taken to ensure that the contents in the cooker at
no time are heated to a temperature exceeding 200 o C. After the mastic has
been prepared the requisite percentage of coarse aggregates shall be added
either during manufacture of the mastic.
 iii. Laying of Bitumen Mastic:
Bitumen mastic shall generally be laid in bays in one coat. It shall be spread
to the thickness of 12mm by means of suitable hand levels being used to
ensure accuracy. The bitumen mastic shall be of heavy wooden float and
shall be free from roughness and imperfections. If blowing occurs the bubbles
should be punchered and the area affected carefully made good while the
mastic is still hot.
It is laid Panel wise maintaining minimum Panel Area of 35 M 2.
Every Panel Edge shall be maintained a slope of 30 o for proper overlapping
with the adjoining layer..
Adjacent Edges shall be heated by blow Lamp for Proper Construction Joint.

VII. Quality Assurance:

I. Test Plan for Incoming Material.

Material Test to be Test Acceptance Frequency of test

conducted Procedure criteria
Bitumen Penetration at 25 IS 1203 20 – 40 mm .One test at
deg. C ( in 1/100 manufacturer’ s Lab
cm) for every 10T. One
outside test for
source approval
from independent
laboratory.
Softening point IS 1205 o o
50 C to 90 C One outside test for
(Ring and Ball source approval
Method) from independent
laboratory & One
test for each lot of
10T from
manufacturer’s Lab.
Ductility at IS 1208 10 cm One outside test for
o
27 C(Minimum) source approval
from independent
laboratory
Loss on heating IS 1212 3% One outside test for
(Maximum) source approval
from independent
laboratory
Solubility in CS2 IS 1216 99 % One outside test for
(Maximum) source approval
from independent
laboratory
LIME Calcium IS 1195 More than One outside test for
 Carbonate content 80% by weight
source approval
from independent
laboratory.
Aggregat Sieve Analysis MOST 500 As per MOST One test for every
e Test Section Table 500 50 cu.m.

II. Test Plan for In process products.

Product Test to be Test Acceptance Frequency of test

conducted Procedure criteria
Mastic Hardness Number MOST MOST 515.3 One Test for 1000
515.3 M2 .
Thickness Visual 12 mm One test for 35 M2

VIII. SAFETY PRECAUTIONS:

1. All work men shall be provided Mask & Hand gloves for carrying the
materials to the mixing location.
2. Proper care shall be taken while handling of Benzone oil & laying of prime
coat.
3. Safety shoes & Helmet shall be provided at the bridge location.
4. Safety Sign Boards shall be displayed at locations wherever necessary.
5. Traffic Diversion Boards shall be displayed at the required locations.
6. First Aid Kit shall be maintained in all the bridge locations

Annexure - II
 GAMMON INDIA LIMITED
Job : 20 Bridges on Nh-60 @OR/WB/1

PROPOSED JOB MIX FOR 12 mm Thk. MASTIC ASPHALT :-

Three samples were prepared jointly as per the following 3 mixes @Rajghat Q.C.Lab
on 20.02.04 in the presence of your Lab Personnel.

Mix – A
A. Bitumen as per IS 73 [Grade of 25 %
Bitumen 30/40]
B. Lime Stone Powder 75%

Mix – B
A. Bitumen as per IS 73 [Grade of 25 %
Bitumen 30/40]
B. Lime Stone Powder 50%
C. Coarse Aggregate 6mm down 25%

Mix – C
A. Bitumen as per IS 73 [Grade of 17 %
Bitumen 30/40]
B. Lime Stone Powder 58%
C. Coarse Aggregate 6mm down 25%

Note : -

Out of all these Mixes, Mix No. ‘B’ sample appears to be the “BEST” due to Flow
Quality, Uniform cohesion, Less air bubbles, better setting time, dent proof surface &
no surface cracking and therefore we request you to approve MIX No. ‘B’ to be used
in our Job.