Code of practice for laying bitumen mastic flooring

Scope of IS 1196 - Specification for Bitumen Mastic Flooring

Key Points:

• Purpose: Specifies materials, construction, and performance requirements for bitumen mastic floor finishes.
• Service Conditions: Flooring thickness and type depend on traffic and wear:

• Chemical Susceptibility: Bitumen mastic reacts differently to chemicals (see Table 1 below):

• Design & Planning Considerations: Include traffic type, load, temperature, base condition, surface finish, and special requirements.

Summary Diagram:

graph TD
A[Bitumen Mastic Flooring] --> B[Service Conditions]
B --> C[Light Duty: 15-20 mm]
B --> D[Medium Duty: 20-25 mm]
B --> E[Heavy Duty: 25-30+ mm]
A --> F[Chemical Susceptibility]
F --> G[Acids, Alcohols: Special Grades]
F --> H[Alkalis: Depends on concentration/temp]
F --> I[Oils & Fats: Attack]
F --> J[Hot Water: Use High Temp Grade]
A --> K[Design Considerations]
K --> L[Traffic Type & Load]
K --> M[Temperature Range]
K --> N[Base & Surface Condition]

**Use IS

IS 1196: Definitions & Key Specifications Summary

1. Definitions

• Refer to IS 334-1965 for all definitions related to bitumen mastic flooring.

2. Susceptibility of Bitumen Mastic to Chemical & Temperature Attack (Table 1, Clause 4.1.2)

3. Thickness Recommendations for Bitumen Mastic Flooring (Table 2, Clause 4.2)

4. Design Considerations (Clause 3.1)

• Assess: function, traffic type, wheeled loads, load nature, temperature extremes, surface finish, base condition, concrete screed, underlay, site constraints, and special needs.

5. Rounding Off Values

• Follow IS 2-1960 for rounding numerical results to match specified significant figures.

flowchart TD
    A[Function & Traffic] --> B[Load & Wheel Type]
    B --> C[Temperature Range]
    C --> D[Base & Screed Condition]
    D --> E[Select Mastic Grade & Thickness]
    E -->

IS 1196: Necessary Information for Planning Bitumen Mastic Flooring

Key Information to Collect (Clause 3.1):

• Function of flooring (e.g., industrial, commercial).
• Traffic type: light, medium, heavy.
• Wheeled conveyors: load, speed, wheel type & width.
• Standing loads: weight, bearing area.
• Temperature range: max & min exposure.
• Surface finish required.
• Base condition: age, type, condition.
• Concrete screed: type & thickness.
• Underlay/separating layer if any.
• Site constraints: space for plant, storage, hoisting.
• Special requirements (chemical resistance, hygiene, etc.).

Thickness Recommendations (Clause 4.2, Table 2):

Chemical & Temperature Susceptibility (Clause 4.1.2, Table 1):

• Acids & vegetable extracts: Normal grades attacked; use special grades for dilute acids.
• Alcoholic liquors: Normal grades attacked; special grades needed in breweries.
• Alkalis: Low concentration safe; high concentration & >38°C harmful.
• Brine & sulphates: Generally unaffected.
• Oils, fats, greases: Attack bitumen mastic; avoid or use protective layers.
• Hot water exposure: Use high-temperature grade to avoid cracking.

Repair Joint Detail (Clause 9.2.2):

• Cut back edge ≥ 75 mm to half thickness for lapped joint in two-coat restoration.

This data ensures proper selection, design, and durability of bitumen mastic flooring per IS 1196.

flowchart TD
    A[Collect Necessary Info] --> B{Traffic Type}
    B --> C[Light]
    B --> D[Medium]
    B --> E[Heavy]
    A --> F[Chemical Exposure]
    A --> G[

IS 1196: Design Considerations for Bitumen Mastic Flooring

1. Key Design Inputs (Clause 3.1)

• Function of flooring
• Traffic type: light, medium, heavy
• Wheeled conveyor loads, wheel/tyre types & widths
• Standing loads & bearing area
• Temperature range (max/min)
• Surface finish type
• Base condition & age
• Concrete screed type & thickness
• Underlay/separating layer details
• Space for plant, storage, hoisting
• Special requirements

2. Chemical & Temperature Susceptibility (Table 1, Clause 4.1.2)

3. Recommended Thickness of Bitumen Mastic (Table 2, Clause 4.2)

Summary Diagram: Design Inputs & Selection Flow

flowchart TD
    A[Start: Flooring Design

IS 1196: Materials and Specifications for Bitumen Mastic Flooring

1. Chemical Susceptibility of Bitumen Mastic (Table 1)

2. Recommended Thickness of Bitumen Mastic (Table 2)

3. Key Specifications (Clause 3.1)

• Consider function, traffic type, wheeled loads, load bearing area
• Temperature range exposure
• Surface finish type
• Base condition and concrete screed thickness
• Underlay/separating layer presence
• Space for plant, storage, and special requirements

4. Repair Specification (Clause 9.2.2)

• For two-coat restoration, cut back edge ≥75 mm to half mastic thickness to form a lapped joint.

This summary aids in selecting appropriate bitumen mastic grades, thickness, and repair methods per IS 1196 for durable, chemically resistant flooring.

IS 1196 - Equipment for Bitumen Mastic Flooring

Key Specifications & Equipment Details (Clause 6.1)

• Equipment includes:
  • Bitumen boiler (to melt bitumen)
  • Mechanically agitated mixer (mastic cooker)
  • Accessories for handling and application
• Setup: Equipment should be placed near the work site to prevent cooling of molten bitumen mastic.

Important Tables

Table 1: Susceptibility of Bitumen Mastic to Chemical & Temperature Attack (Clause 4.1.2)

Table 2: Recommended Thickness of Bitumen Mastic (Clause 4.2)

Design Considerations (Clause 3.1)

• Function of flooring
• Traffic type (light/medium/heavy)
• Loads, wheel types, and speeds
• Load bearing area
• Temperature extremes
• Surface finish type
• Base condition & screed thickness
• Underlay/separating layers
• Space for equipment & storage
• Special requirements

flow

IS 1196: Key Construction Specifications for Bitumen Mastic Flooring

1. Susceptibility to Chemical & Temperature Attack (Table 1, Clause 4.1.2)

2. Thickness of Bitumen Mastic (Table 2, Clause 4.2)

3. Construction Considerations (Clause 3.1)

• Assess function, traffic type, load, temperature range.
• Evaluate base condition, screed type/thickness.
• Plan for storage, plant space, and special requirements.

4. Repair Guidelines (Clause 9.2.2)

• Cut back edges at least 75 mm to half mastic thickness for lapped joints during repairs.

Summary Diagram: Bitumen Mastic Flooring Construction Flow

flowchart TD
    A[Assess Site & Requirements] --> B[Select Bitumen Grade]
    B --> C[Determine Thickness per Service]
    C --> D[Prepare Base & Screed]
    D --> E[Heat & Mix Bitumen Mastic]
    E --> F[Apply Flooring Layer]
    F --> G[Curing & Finishing]
    G --> H[Maintenance & Repairs]

Note: Use special bitumen grades for chemical resistance and high temperatures. Thickness varies by wear and impact severity. Proper planning ensures durability.

Inspection Key Points (IS 1196 - Clause 8.1)

During and after laying bitumen mastic flooring, inspect:

• Base Condition: Ensure it is sound and free from irregularities.
• Surface & Underlay: Check for smoothness and correct placement.
• Cleanliness: Plant and materials must be clean, especially for re-melting.
• Mixture Temperature: Confirm correct temperature before laying.
• Dust Use: Use appropriate dust to prevent sticking in buckets.
• Blows Repair: Fill all air pockets or 'blows' immediately.
• Thickness: Maintain uniform thickness as per specifications.
• Tailings: Remove all leftover asphalt.
• Finished Level & Finish: Verify level and surface finish conformity.
• Decorative Patterns: Ensure correct pattern application if specified.

Thickness Recommendations (Clause 4.2 - Table 2)

Susceptibility to Chemical & Temperature Attack (Clause 4.1.2 - Table 1)

• Acids & Alcohols: Normal grades attacked; use special grades if needed.
• Alkalis: Low concentration safe; high temp/concentration harmful.
• Brine & Salts: Generally unaffected.
• Oils & Fats: Attack mastic; avoid or protect.
• Hot Water: Use high-temp grade if frequent exposure.

Summary Diagram of Inspection Process

flowchart TD
    A[Start Inspection] --> B{Check Base Condition}
    B --> C[Irregularities?]
    C -->|Yes| D[Correct Base]
    C -->|No| E[Check Underlay]
    E --> F[Mixture Temperature]
    F --> G[Use Correct Dust]
    G --> H[Check Thickness]
    H --> I[Remove Tailings]
    I --> J[Verify Finish & Pattern]
    J --> K[Complete Inspection]

Note: Follow IS 2-1960 rounding rules

IS 1196: Maintenance and Repairs Key Points

Repair Specifications (Clause 9.2.2)

• When restoring two-coat bitumen mastic flooring:
  • Cut back the perimeter edge at least 75 mm wide.
  • Cut to half the total thickness of the mastic.
  • This forms a lapped joint ensuring proper adhesion and continuity.

Chemical Susceptibility (Table 1)

• Normal bitumen mastic is attacked by:
  • Acids (special grades needed for dilute acid resistance).
  • Certain alcoholic liquors (special grades for breweries/distilleries).
  • Alkalis above 38°C and high concentration.
  • Oils, fats, greases, syrups, molasses.
• Resistant to:
  • Brine (NaCl, CaCl₂), sulphate salts.
  • Water unless frequently hot; use high-temp grade if exposed.

Thickness Recommendations (Table 2)

Maintenance Tips

• Ensure clean, dry surfaces before repair.
• Use compatible bitumen mastic grades as per chemical exposure.
• For repairs, maintain lapped joints for durability.
• Consider metal armouring in dairy or heavy impact areas to prevent indentation.

flowchart LR
    A[Damaged Area] --> B[Cut Back Edge ≥ 75 mm]
    B --> C[Cut Depth = 1/2 Thickness]
    C --> D[Lapped Joint Formation]
    D --> E[Apply New Mastic Coat]
    E --> F[Finish & Cure]

This ensures durable repairs conforming to IS 1196 standards.

IS 1196: Safety and Handling Precautions for Bitumen Mastic Flooring

Key Specifications & Precautions

• Chemical Susceptibility (Table 1):
  Bitumen mastic can be attacked by:

  • Acids (normal grades attacked; special grades needed for dilute acids)
  • Alcoholic liquors (special grades for breweries/distilleries)
  • Alkalis (high concentration & >38°C affect mastic)
  • Oils, fats, greases (attack mastic)
  • Hot water (frequent contact causes cracking; use high-temp grade)
  • Radioactive materials (special grades required)
  • Dairy areas: metal armouring recommended where churns/milk cans handled to prevent indentation and fat accumulation.

• Thickness Recommendations (Table 2):

  Service Condition	Type of Flooring	Thickness (mm)
  Medium wear (foot traffic)	Light duty	15 to 20
  Severe abrasion (continuous foot traffic)	Medium duty	20 to 25
  Severe abrasion + impact	Heavy duty	25 to 30+

Handling Precautions

• Use special grades for chemical resistance as per environment.
• Avoid exposure to high temperature alkalis and hot water unless specified.
• Maintain hygiene and cleaning to prevent fat/oil attack.
• Plan considering traffic type, load, temperature, and base condition (Clause 3.1).

flowchart TD
    A[Assess Environment] --> B{Chemical Exposure?}
    B -- Yes --> C[Select Special Grade Mastic]
    B -- No --> D[Normal Grade Mastic]
    A --> E{Traffic Type?}
    E -- Light --> F[Use 15-20 mm Thickness]
    E -- Medium --> G[Use 20-25 mm Thickness]
    E -- Heavy --> H[Use 25-30+ mm Thickness]
    C & D --> I[Apply Flooring]
    I --> J[Maintain Hygiene & Avoid Hot Water]

Summary: Choose bitumen mastic grade based on chemical exposure and use thickness per traffic severity. Follow hygiene and temperature precautions to ensure durability.