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    Methodology For Bitumen Mastic

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    Rohit Bali
    This document provides the methodology for laying 12mm thick bitumen mastic on bridge decks. It discusses: 1. The scope of laying mastic asphalt in a single layer before the wearing course on 20 bridges. 2. Details of mastic quantities required for bridges in Orissa and West Bengal totaling over 32,000 sqm. 3. The proposed job mix of bitumen, limestone powder, and coarse aggregate that was tested and determined to be the best mix.

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    Methodology For Bitumen Mastic

    Uploaded by

    Rohit Bali
    822 views6 pages
    This document provides the methodology for laying 12mm thick bitumen mastic on bridge decks. It discusses: 1. The scope of laying mastic asphalt in a single layer before the wearing course on 20 bridges. 2. Details of mastic quantities required for bridges in Orissa and West Bengal totaling over 32,000 sqm. 3. The proposed job mix of bitumen, limestone powder, and coarse aggregate that was tested and determined to be the best mix.

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    Methodology for Bitumen Mastic

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    This document provides the methodology for laying 12mm thick bitumen mastic on bridge decks. It discusses: 1. The scope of laying mastic asphalt in a single layer before the wearing course on 20 bridges. 2. Details of mastic quantities required for bridges in Orissa and West Bengal totaling over 32,000 sqm. 3. The proposed job mix of bitumen, limestone powder, and coarse aggregate that was tested and determined to be the best mix.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    822 views6 pages

    Methodology For Bitumen Mastic

    Uploaded by

    Rohit Bali
    This document provides the methodology for laying 12mm thick bitumen mastic on bridge decks. It discusses: 1. The scope of laying mastic asphalt in a single layer before the wearing course on 20 bridges. 2. Details of mastic quantities required for bridges in Orissa and West Bengal totaling over 32,000 sqm. 3. The proposed job mix of bitumen, limestone powder, and coarse aggregate that was tested and determined to be the best mix.

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    of 6

    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
    Bridge No.
    Qty. (m2)
    Fl-01
    333.3

    WEST BENGAL
    Bridge No. Qty. (m2)
    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

    Grand Total (Orissa + W.B.)

    Total

    6397.222

    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.
    1.
    2.
    3.

    Name of Machinery
    Mastic Cooker [1T/2T cap.]
    Hand Trolley.
    Hand Tools & Wire Brush

    Capacity
    2 Nos.
    3 Nos.
    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
    Bitumen

    Test to be
    Test
    Acceptance
    conducted
    Procedure
    criteria
    Penetration at 25 IS 1203
    20 40 mm
    deg. C ( in 1/100
    cm)

    Softening
    point IS 1205
    (Ring and Ball
    Method)

    Ductility
    at IS 1208
    o
    27 C(Minimum)
    Loss on heating IS 1212
    (Maximum)
    Solubility in CS2 IS 1216
    (Maximum)
    LIME

    Calcium

    IS 1195

    Frequency of test

    .One
    test
    at
    manufacturer s Lab
    for every 10T. One
    outside
    test
    for
    source
    approval
    from
    independent
    laboratory.
    o
    o
    One outside test for
    50 C to 90 C
    source approval
    from independent
    laboratory & One
    test for each lot of
    10T from
    manufacturers Lab.
    One outside test for
    10 cm
    source
    approval
    from
    independent
    laboratory
    One outside test for
    3%
    source
    approval
    from
    independent
    laboratory
    One outside test for
    99 %
    source
    approval
    from
    independent
    laboratory
    More
    than One outside test for

    Carbonate content
    Aggregat
    e

    Sieve
    Test

    80% by weight

    source
    approval
    from
    independent
    laboratory.
    Analysis MOST 500 As per MOST One test for every
    Section
    Table 500
    50 cu.m.

    II. Test Plan for In process products.


    Product
    Mastic

    Test to be
    Test
    conducted
    Procedure
    Hardness Number
    MOST
    515.3
    Thickness
    Visual

    Acceptance
    criteria
    MOST 515.3
    12 mm

    Frequency of test
    One Test for 1000
    M2 .
    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
    Bitumen 30/40]

    25 %

    B. Lime Stone Powder

    75%

    Mix B
    A. Bitumen as per IS 73 [Grade of
    Bitumen 30/40]

    25 %

    B. Lime Stone Powder

    50%

    C. Coarse Aggregate 6mm down

    25%

    Mix C
    A. Bitumen as per IS 73 [Grade of
    Bitumen 30/40]

    17 %

    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.

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