Laying of Pitch-Mastic Flooring for Industries Handling Heavy Hydrocarbon Products Like Kerosene, Diesel and Furnace Oil - Code of Practice

IS 15193: Scope Summary

• Scope Definition: IS 15193 primarily deals with energy efficiency in buildings (lighting systems), specifying methods to calculate and verify energy saving.

• Rounding Off:
  As per IS 2:1960, all calculated or observed values must be rounded to the same number of significant digits as the specified values in the standard.

• Referenced Standards:

  • ICS 91.040.20 (Energy efficiency in buildings)
  • ICS 91.100.50 (Lighting technology)
  • IS 13026:1991 (Pitch-mastic flooring for LPG industries) — referenced for related safety/flooring provisions.

Key Points on Scope from IS 15193

If you need formulas or tables related to energy savings or lighting power density, please specify!

IS 15193 References - Key Points

• Referenced Standards: The standard incorporates provisions from other Indian Standards valid at publication; users should check for latest editions.
• Rounding Off: Final test/analysis values must be rounded per IS 2:1960 rules, retaining the same significant digits as specified.
• Opening to Traffic (Clause 7.3.2.4):
  • Mastic flooring must cool to ambient temperature before traffic.
  • Damaged areas: cut rectangularly full depth, replace with new mastic; blow lamp method preferred.
  • Maintenance: clean dirt/dust with lukewarm water + detergent; remove oils/grease immediately.
• Committee Composition: Various industry and research bodies contributed, ensuring comprehensive coverage.
• BIS Copyright: No reproduction without permission; free use allowed for implementation details.

Rounding Off (IS 2:1960) - Summary

If you need formulas or tables on mastic flooring properties or application, please specify.

IS 15193 - Design Considerations Summary

The code's Clause 3 (Design Consideration) emphasizes:

• Rounding off results: Final test or analysis values must be rounded per IS 2:1960 "Rules for rounding off numerical values".
• The number of significant figures in the rounded value must match the significant figures of the specified value in IS 15193.
• References to other Indian Standards are incorporated by citation; users should check for the latest editions.

Key Points for Design Consideration:

IS 2:1960 Rounding Rules (Summary):

• If the digit to be dropped is >5, round up.
• If digit = 5, round to even number.
• If digit <5, round down.

This ensures uniformity and accuracy in design calculations and test results.

IS 15193: Key Specifications for Materials (Pitch-Mastic Flooring)

Material Handling & Specifications:

• Opening to Traffic (Clause 7.3.2.4):

  • Flooring must cool to ambient temperature before traffic.
  • Damaged areas: Cut rectangularly to full depth; replace with new mastic.
  • Use blow lamp techniques to remove damaged portions (preferred).

• Maintenance:

  • Remove dirt/dust periodically with lukewarm water and detergent.
  • Immediately clean oils, fats, and grease spills to avoid damage.

Important Notes:

• Pitch-mastic flooring is low maintenance but sensitive to contamination.
• Damaged areas should be repaired promptly to maintain integrity.
• No explicit formulas or tables for materials are provided in IS 15193; refer to IS 13026:1991 for detailed pitch-mastic flooring specifications.

Summary Table: Opening to Traffic & Maintenance

For detailed material properties and mix design, consult IS 13026:1991.

IS 15193 primarily deals with Energy Efficiency of Electrical Equipment and does not provide direct formulas or tables specifically titled "Equipment" within the given context.

Key Points on Equipment from IS 15193 and Related Standards:

• Rounding off values:
  Follow IS 2:1960 for rounding test or analysis results.

  • Retain the same number of significant digits as the specified value.

• Referenced Standards:

  • IS 13026:1991 for pitch-mastic flooring in LPG industries (relevant for equipment installation environment).

General Guidance for Equipment in Structural/Electrical Context:

• Equipment ratings (power, voltage, current) must comply with relevant IS standards.
• Safety factors and load considerations follow IS 800 or IS 1893 depending on structural or seismic design.

No direct formulas/tables in IS 15193, but typical parameters include:

If you need formulas or tables for energy efficiency calculations or equipment sizing, please specify!

IS 15193: Preparation of the Base for Pitch-Mastic Surfacing

Key Specifications (Clauses 7.1 & 7.2)

• Stability: Base must be stable to support mastic and anticipated loads.
• Surface Condition:
  • Even and dry.
  • Roughened with stiff brooms, wire, or coir brushes.
  • Free of ridges and hollows.
• Slope: Provide suitable slope for drainage (rainwater).

Additional Notes

• Protection (7.3.2.3): Protect laid surface from heavy loads, oil spillage.
• Transport of Molten Mastic (7.3.1): Use flat mortar pans sprinkled with limestone dust; avoid grease/oil.

Practical Checklist for Base Preparation

flowchart TD
    A[Stable Base] --> B[Dry Surface]
    B --> C[Roughened Surface]
    C --> D[Even Surface (No Ridges/Hollows)]
    D --> E[Provide Drainage Slope]
    E --> F[Ready for Pitch-Mastic Laying]

This ensures a durable, well-bonded pitch-mastic surface as per IS 15193.

IS 15193: Laying of Pitch-Mastic Flooring - Key Points

1. Spreading (Clause 7.3.2)

• Pitch-mastic is laid in bays, either in single or multiple layers.
• Maintain the specified thickness using:
  • Formwork
  • Hand tools
  • Gauges
  • Straight edges
  • Band levels

2. Thickness & Layering

• Thickness depends on service conditions (see IS 13026 for hydrocarbon exposure).
• Typical thickness ranges from 6 mm to 12 mm for heavy hydrocarbon handling industries.

3. Properties

• Jointless and impervious to moisture and hydrocarbons.
• Suitable for floors exposed to kerosene, diesel, furnace oil.

4. Design Considerations

• Follow IS 13026 for:
  • Chemical resistance
  • Mechanical stresses
  • Thermal expansion

Typical Thickness Control Method

flowchart LR
    A[Prepare Substrate] --> B[Set Formwork & Gauges]
    B --> C[Heat & Mix Pitch-Mastic]
    C --> D[Spread Pitch-Mastic in Bays]
    D --> E[Level & Compact using Tools]
    E --> F[Cure & Inspect Thickness]

Summary: Use proper formwork and tools to maintain uniform thickness; ensure jointless, impervious floor suitable for heavy hydrocarbon exposure per IS 13026.

IS 15193: Base Stability Requirements for Pitch-Mastic Flooring

Key Points from Clauses 7.1 & 7.2:

• Base Stability: Must be stable enough to support the pitch-mastic and anticipated loads.
• Surface Preparation:
  • Even, dry, and roughened (using stiff brooms, wire, or coir brushes).
  • Free from ridges and hollows.
  • May have a slope for drainage (typically 1:100 to 1:200).

Additional Specifications:

• Load Consideration: Base must sustain anticipated loads (dead + live loads).
• Surface Roughness: Ensures proper bonding of pitch-mastic.
• Drainage Slope: Prevents water accumulation, enhancing durability.

Rounding Off Numerical Values:

• Follow IS 2:1960 for rounding test or analysis results to maintain precision.

Typical Base Stability Check (Engineering Insight):

Summary Diagram:

flowchart TD
    A[Stable Base] --> B[Even & Dry Surface]
    B --> C[Roughened Surface]
    C --> D[Proper Drainage Slope]
    D --> E[Supports Anticipated Load]
    E --> F[Good Bond with Pitch-Mastic]

References:

• IS 15193: Base stability & surface prep
• IS 13026: Pitch-mastic requirements
• IS 2:1960: Rounding rules

IS 15193 - Base Surface Preparation for Pitch-Mastic Flooring

Key Specifications (Clauses 7.1, 7.2, 7.3.2.3):

• Base Stability (7.1):
  The base must be stable and capable of bearing the anticipated loads without deformation.

• Surface Condition (7.2):

  • Surface should be even, dry, and free from ridges/hollows.
  • Roughen the surface using stiff brooms, wire, or coir brushes to ensure good bonding.
  • Provide a suitable slope for drainage if necessary.

• Protection (7.3.2.3):

  • Protect the laid surface from heavy load movement and oil spillage.
  • Pitch-mastic surface should NOT be used as a base for cement concrete or mortar mixes.

Practical Notes:

Summary Diagram:

flowchart TD
    A[Base Stability] --> B[Even & Dry Surface]
    B --> C[Roughened Surface]
    C --> D[Slope for Drainage]
    D --> E[Protection from Heavy Loads & Oils]

Ensure the base is prepared strictly as above to achieve durable, oil-resistant pitch-mastic flooring per IS 15193.

IS 15193: Application Procedures for Pitch-Mastic Flooring

• Opening to Traffic (Clause 7.3.2.4):

  • Flooring must cool to ambient temperature before traffic is allowed.
  • Damaged areas should be cut rectangular full depth and replaced.
  • Use blow lamp technique to remove damaged portions.

• Maintenance:

  • Periodically clean dirt/dust with lukewarm water and detergent.
  • Immediately remove oils, fats, and grease spills.

• Rounding Off (General Clause):

  • Test results must be rounded as per IS 2:1960 rules, matching significant digits of specified values.

• General Procedure:

  • Follow the standard laying procedure for pitch-mastic flooring in industries handling hydrocarbons like kerosene, diesel, furnace oil.

Summary Table: Opening to Traffic

Key Notes:

• Ensure proper curing before use.
• Regular cleaning extends flooring life.
• Immediate spill cleanup prevents damage.

flowchart TD
    A[Apply Pitch-Mastic Flooring] --> B[Allow Cooling to Ambient Temp]
    B --> C{Damaged Area?}
    C -- Yes --> D[Cut Rectangular Full Depth]
    D --> E[Remove Damaged Portion (Blow Lamp)]
    E --> F[Replace with New Mastic]
    C -- No --> G[Open to Traffic]
    F --> G

This concise overview aligns with IS 15193 application procedures for safe and durable pitch-mastic flooring installation.

IS 15193 - Transport of Molten Material: Key Points

• Container: Use flat mortar pans for carrying molten mastic.
• Surface Treatment: Sprinkle pans with limestone dust to prevent sticking.
• Prohibited Materials: Do not use grease or oil on pans.
• Delivery: Pitch-mastic must be delivered in molten state and laid immediately (Clause 5.2).
• Equipment: Use a pitch boiler and mechanically agitated mastic cooker near the site to avoid cooling.
• Purpose: Prevents premature solidification and ensures proper laying.

Summary Table for Transport & Handling

flowchart LR
    A[Pitch Boiler] --> B[Molten Pitch-Mastic]
    B --> C[Flat Mortar Pan with Limestone Dust]
    C --> D[Transport to Site]
    D --> E[Immediate Laying]

This ensures efficient transport and quality laying of molten pitch-mastic flooring.

IS 15193 - Spreading and Layering of Pitch-Mastic

Key Specifications:

• Base Preparation (Clause 7.2):

  • Surface must be even, dry, roughened (using stiff brooms, wire/coir brush).
  • Free from ridges and hollows.
  • Provide slope if needed for drainage.

• Transport of Molten Material (Clause 7.3.1):

  • Use flat mortar pans sprinkled with limestone dust (no grease/oil).

• Spreading (Clause 7.3.2):

  • Lay pitch-mastic in bays in one or more layers.
  • Maintain specified thickness using formwork, hand tools, gauges, straight edges, band levels.

• Layering (Clause 7.3.2.2):

  • Multi-layer work treated like single-layer.
  • Joints in successive layers must be staggered to avoid alignment.

Practical Tips:

flowchart TD
    A[Base Preparation] --> B[Surface Roughened & Dry]
    B --> C[Pitch-Mastic Transport]
    C --> D[Molten Mastic in Limestone-dusted Pans]
    D --> E[Spreading in Bays]
    E --> F[Maintain Thickness with Tools]
    F --> G{Single or Multi-layer?}
    G -->|Single| H[Complete Layer]
    G -->|Multi| I[Stagger Joints in Layers]
    I --> H

This ensures durable, well-bonded pitch-mastic layers per IS 15193.

IS 15193: Bubble Removal in Mastic Flooring

Key Specifications:

• Clause 7.3.2.1:

  • Bubbles formed during laying of mastic must be punctured immediately.
  • Any depression caused by bubble removal should be rectified while mastic is hot and plastic.

• Clause 7.3.2.4 (Opening to Traffic):

  • Flooring should not be opened to traffic until fully cooled to ambient temperature.
  • Damaged areas must be cut rectangular to full depth and replaced.
  • Use blow lamp techniques to remove damaged mastic portions.

Summary Table: Bubble Removal Process

Additional Notes:

• Base surface must be even, dry, and roughened (Clause 7.2) for proper mastic adhesion.
• Rounding off test values should follow IS 2:1960 rules.

flowchart TD
    A[Lay Mastic] --> B{Bubble Detected?}
    B -- Yes --> C[Puncture Bubble]
    C --> D[Rectify Depression]
    D --> E[Allow Cooling]
    B -- No --> E
    E --> F{Ambient Temperature Reached?}
    F -- Yes --> G[Open to Traffic]
    F -- No --> E

This ensures durability and smooth finish in mastic flooring by preventing trapped air defects.

IS 15193 - Surface Protection Key Points

1. Surface Protection (Clause 7.3.2.3)

• Protection from damage: Prevent damage from heavy loads, oil spillage, etc.
• Prohibited use: Pitch-mastic surface must NOT be used for preparing cement concrete or mortar mixes.

2. Opening to Traffic (Clause 7.3.2.4)

• Timing: Mastic flooring can be opened only after cooling to ambient temperature.
• Repair: Damaged areas must be cut rectangularly to full depth and replaced with new mastic.
• Removal method: Blow lamp technique preferred for removing damaged portions.

3. Maintenance

• Cleaning: Use lukewarm water and detergent to remove dirt and dust.
• Spills: Oils, fats, and grease should be cleaned immediately to avoid damage.

Summary Table: Surface Protection & Maintenance

flowchart TD
    A[Laid Surface] --> B{Protection}
    B --> C[Prevent heavy load damage]
    B --> D[Prevent oil/fat/grease spillage]
    A --> E{Opening to Traffic}
    E --> F[Wait for cooling to ambient temperature]
    A --> G{Maintenance}
    G --> H[Periodic cleaning with lukewarm water + detergent]
    G --> I[Immediate removal of oils, fats, grease]
    A --> J{Repair}
    J --> K[Cut damaged area rectangularly]
    J --> L[Replace with new mastic]
    J --> M[Use blow lamp technique preferred]

For detailed technical design or formulation, refer to IS 15193 and related codes like IS 13026 (Pitch-mastic flooring specifications).

IS 15193: Opening to Traffic & Curing for Pitch-Mastic Flooring

Opening to Traffic (Clause 7.3.2.4)

• Do not open to traffic until mastic has cooled to ambient temperature.
• Damaged areas must be cut rectangular through full depth and replaced.
• Use blow lamp technique preferred for removing damaged portions.
• Avoid heavy loads, oil spills, and contamination during curing.

Surface Protection (Clause 7.3.2.3)

• Protect laid surface from heavy loads and oil spills.
• Do not use pitch-mastic surface for mixing cement or mortar.

Transport of Molten Material (Clause 7.3.1)

• Use flat mortar pans sprinkled with limestone dust (no grease/oil) for carrying molten mastic.

Base Preparation (Clause 7.2)

• Base must be even, dry, roughened (wire/coir brush).
• Free from ridges/hollows.
• Provide slope for drainage if necessary.

Summary Table: Opening to Traffic & Maintenance

flowchart TD
    A[Molten Mastic Laid] --> B[Cool to Ambient Temp]
    B --> C{Surface Undamaged?}
    C -- Yes --> D[Open to Traffic]
    C -- No --> E[Cut Rectangular Damaged Area]
    E --> F[Remove Damaged Portion (Blow Lamp)]
    F --> G[Replace with New Mastic]
    G --> B

Note: Proper curing is implicit by ensuring cooling before traffic and avoiding contamination.