mastic asphalt, asphalt hot mix + grouting asphalt pavements

• MASTIC ASPHALT,
ASPHALT HOT MIX
+ GROUTING ASPHALT
PAVEMENTS

PROJECTS
FOAMGLAS Insulation Systems
®
1.
Mastic Asphalt
City-Galerie, Augsburg (D)
2. Commercial building Marché Bollaert,
Dunkerque (F)
3. Carrefour Supermarket in Ninove (B)
4. Delvita Supermarket, in Hradec Králové (CZ)
Asphalt Hot Mix (sheltered)
1. Coop Super Centre, Payerne (CH)
Grouting Asphalt pavements (exposed)
1. Post and Telecommunications Office
PTT Ouchy, Lausanne (CH)
2. Coop Centre Léman, Lausanne (CH)
3. Super U Shopping Centre, Lingolsheim (F)

5.2 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
Hot mix pavements as wearing surfaces
on FOAMGLAS ® compact insulation
systems are available in various
European countries as an alternative to insitu
concrete wearing slabs, pavements in
a bed of fine gravel or prefabricated slabs/
paving on spacer pads.
The following describes and illustrates the
main asphalt construction systems.
Mastic asphalt,
asphalt hot mix,
grouting asphalt pavements etc.
require a knowledge of materials and systems
which require the employment of
specialist companies.
The description of system solutions given
below does not claim to be complete and
is based on the relevant national regulations.
In general, with systems of this type, the
following factors:
- build-up of heat,
- stability and
- live loads under the effect of temperature
should be considered.
The placing of wearing surfaces and work
on the details is a business that must be
carried out by experts. As a manufacturer
of insulation materials, Pittsburgh Corning
wants to document by a wide selection of
projects its solid experience with the versatile
FOAMGLAS ® insulation products
and systems.
Erasmus University, Rotterdam (NL).
The case studies presented do not cover
all technical details, nor do they have any
validity for future liability claims in the
event of damage or system defects.
Transmission of forces and
choice of insulation
If dynamic forces are transmitted under a
pressure cone of ~45° on concrete load
distribution slabs with a mastic asphalt
wearing surface, the distribution effect for
mastic asphalt, rolled asphalt, asphalt hot
mix and grouting asphalt pavements is
much lower.
This means that greater layer thicknesses,
or else FOAMGLAS ® products with higher
compressive strengths, must be used to
obtain the same stress resistance.
To avoid the need for extra thicknesses of
the wearing course, FOAMGLAS ® types
S3 or F are normally used.
FOAMGLAS ®
141

5.2 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
142
Mastic asphalt/asphalt hot mix
pavement
Structural concrete
Primer (bitumen emulsion)
Hot bitumen or fine mastic asphalt (bituminous
mastic)
Thermal insulation, FOAMGLAS ® slabs,
fully bonded with hot bitumen and filled joints
Hot bitumen flood-coat or fine mastic asphalt
Bituminous waterproofing, two layers *)
Expanded metal or bar reinforcement if necessary
Mastic asphalt, one or more layer system;
thickness and number of layers depending on
the total thickness for pressure distribution
*) If mastic asphalt is installed above waterproofing
membranes, either special torch-on bitumen membranes
with upper reinforcement or with a metal
lining should be used, or temperature-resistant separating
layers provided which are resistant to the
installation temperatures of the mastic asphalt.
Note: The drawings provide information on the basic components
of the systems and do not exclude other construction
options. Depending on the specialist asphalt contractor
employed and on the conditions on site, additional separating
layers, such as non-woven fabrics, oil paper and reinforcement
mats, may be laid on top of the FOAMGLAS ®
insulation/waterproofing system.
Grouting asphalt pavement
Structural concrete
Primer (bitumen emulsion)
Hot bitumen
Thermal insulation, FOAMGLAS ® slabs,
fully bonded with hot bitumen and filled joints
Hot bitumen flood-coat
Bituminous waterproofing, two layers
Asphalt hot mix (installed by hand)
- Thickness depending on pressure distribution
from the supposed loading,
- Mechanically compacted with hand rollers or
with small machines, allowed for the load
limits of FOAMGLAS ® and
- Slurry seals applied using the vibration method
(grouting asphalt pavement)
FOAMGLAS ® Thermal Insulation
fo all construction solutions using
Mastic asphalt
Asphalt and asphalt hot mix
Grouting asphalt pavements

In contrast to in-situ concrete wearing slabs, mastic
asphalt, asphalt hot mix and grouting asphalt pavements
(asphalt hot mix stabilised with slurry seals) offer the following
advantages:
• quicker installation
• fast loadbearing ability (after just a few days)
• larger joint grid (every 8 - 12 m) or sometimes even
without joints.
What are the reasons for choosing
the FOAMGLAS ® Compact Roof system
in combination with mastic asphalt,
asphalt hot mix and grouting asphalt
wearing layers?
1. FOAMGLAS ® cellular glass is suitable for hot installation
and universally suitable for use with mastic
asphalt; cellular glass insulation does not deform, distort,
warp or shrink.
2. A compact build-up can be created – depending on the
system – without separating layers, so that there is no
risk of water infiltration.
3. The FOAMGLAS ® Compact Roof system combined
with mastic asphalt or asphalt forms the second waterproof
layer of the structure.
Roof-top car parks exposed to the weather and covered
parking decks are subjected to all sorts of different stresses.
In addition to mechanical loading from the vehicles,
there are also thermal stresses caused by fluctuations in
temperature.
Wearing courses which can bridge cracks therefore offer
a number of advantages. These systems should also have
a non-slip surface structure if they are subjected to external
stresses such as rain or snow.
In association with the compact FOAMGLAS ® insulation/
waterproofing system using hot bitumen, the loadbearing
concrete deck is protected against the effects of aggressive
de-icing products.
The airtight, fully adhered roof system also provides a
good barrier against odours, e.g. from exhaust gases, and
prevents the influx of oxygen in the event of a fire.
Practical experience in recent years, and consistent material
and system developments throughout Europe using
FOAMGLAS ® insulation and asphalt hot mix, or mastic
asphalt for traffic-related structures have led to the development
of efficient technologies which offer excellent
value for money. These will be described over the following
pages.
One of the most important factors here is sustained quality
assurance in the planning and workmanship of the insulating/waterproofing
layer to protect valuable concrete structures.
Thermal-insulation in association with different wearing
courses in sheltered and exposed structures is described.
• Mastic asphalt systems with or without reinforcement
• Variants using fine aggregate mastic asphalt
• Asphalt hot mix pavements
• Grouting asphalt pavements: asphalt hot mix with
slurry seals.
Lijnbaan, Rotterdam
FOAMGLAS ®
143

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
5.2.1 Mastic asphalt - composition
Medium-hard and hard road-building bitumen as specified
in DIN EN 12591 “Bitumen and bituminous binders -
Specifications for paving grade bitumens” are used to
produce mastic asphalt.
The properties of the mastic asphalt can be adjusted by
the use of additives (such as natural asphalt, polymers,
polymer-modified bitumen, brighteners, colour pigments,
fibres or wax) to meet a wide range of requirements.
Mastic asphalt is a void-free, dense mixture of filler
(stone dust), sand, chippings and bitumen.
The mineral compound is dense mixture. All mineral compound
must be resistant to frost and bad weather. The
binder content (bitumen) must be adjusted to the voids in
the mineral compound so that they are filled in the finished
layer.
MASTIC ASPHALT can be installed as a protective layer
and as a wearing course (superstructure).
FINE AGGREGATE MASTIC ASPHALT, is a dense, bituminous
mass, which can be poured when hot, made of
sand, filler and road-building bitumen, and is also used as
a subgrade pretreatment or basic waterproofing in
system build-ups.
MINERAL COMPOUNDS
Filler grain size less than 0.09 mm. Preferably
limestone dusts.
Sand grain size between 0.09 and 2.0 mm. A
distinction is made between natural and
crushed stone sand.
Chippings broken stone with at least 50% fractured
surfaces. The grain size is between 2.0
and 31.5 mm. For mastic asphalt, grain
sizes up to 11 mm are used.
Gravel unbroken natural stone with grain sizes
between 2.0 and 31.5 mm. Gravel from 2 to
8 mm is used.
As a rule, natural mineral compounds are used. Suitable
cast stone mineral compounds may also be used.
144
The following should be taken into account and
given in the specification as far as the composition
of the mastic asphalt is concerned:
the proposed use
local and climatic conditions
traffic loads and types of loading
insulated/uninsulated structures.
Properties and advantages
of mastic asphalt
• considerably reduces construction time, since it can
be used as soon as it has cooled
• is dense and waterproof, absorbs practically no
water and cannot expand or shrink.
• contains no water-soluble components; drainage
installations cannot become blocked by any products
which have leached out
• not sensitive to freezing and thawing cycles or
permanent moisture
• is visco-elastic and thus adapts without damage to
the slow movements in building components as
stresses are removed. The stresses caused by
changes in temperature are also absorbed.
• is wear-resistant and does not have any tendency to
form dust because bitumen is used as the binder
• is non-slip (R 13)
• does not contain any capillary pores, and so
osmotic processes cannot occur. Roots find no
nutrients in mastic asphalt
• is resistant to humus acids and aggressive water
• does not pollute water
• under DIN 4102 Fire behaviour of building materials
and components, is classified as building material
B1 – low flammability – and can even be safely
used in underground car parks as far as fire safety
considerations are concerned.
• special compositions can even be used on sloping
surfaces
• is an ideal pavement for heated outdoor decks, e.g.
ramps
• can be finished in a variety of colours
• can be installed largely independently of ambient
temperature
• does not require any curing time or compaction to
reach its final level of strength
• is a durable material and therefore economical
• can be recycled and safeguards the environment.

Handling
The mastic asphalt is transported to the building site in
heated dumpers in which the asphalt is kept at the appropriate
temperature.
Installation weight
Installation thicknesses of approx 3.0 cm per layer correspond
to installation weights between 50 kg/m 2 and 100 kg/m 2 .
Joints
Mastic asphalt can be laid without joints over large surfaces.
Structural joints must be taken over into the mastic
asphalt screed. They must be designed in accordance with
the stress upon them.
A distinction is made between the following types of joint:
- A movement joint is a joint in the screed that separates
it completely into two parts.
- A dummy joint is a joint in the screed which is cut into
the screed through half the screed thickness at most
- An edge joint is a joint which separates the screed
from adjoining installed building elements.
Load-bearing capacity
In assessing the load-bearing capacity of mastic asphalt, it
is the surface pressures applied rather than the total
weights that should be taken into consideration. Mastic
asphalt is able to absorb very high dynamic loads, i.e.
almost any traffic loading, without any damage.
With floating screeds, the permitted traffic loading also
depends on the load-bearing capacity of the insulating
layer.
Mastic asphalt is not sensitive to vibrations; it absorbs
vibrations over short distances.
Surface finish
With screeds, the surface of the mastic asphalt is abraded
with fine sand while it is still hot. This gives it a non-slip
surface even in damp or wet conditions. Further treatment
of the surface may be necessary for certain applications.
In the case of outdoor surfaces and mastic asphalt on traffic
areas, the mastic asphalt may be dressed with fine
chippings 1/3, or chippings 2/5 to 5/8 while still hot, to
increase the non-slip properties. The light coloured chippings
also reduce maximum surface temperatures.
Stability
Mastic asphalt is stable and can withstand high traffic
loads with no great deformation. As mastic asphalt grade
0/11 S in accordance with ZTV Asphalt-StB (Supplementary
Technical Contract Conditions for the construction
of asphalt road surfaces), it is suitable for
roads subject to particular stresses.
Composition
The composition is decided by the contractor, in accordance
with VOB/C DIN 18317 Road construction work,
asphalt superstructure layers and DIN 18354 Mastic
asphalt paving works.
The proposed purpose and the expected loading must be
taken into account and given in the specification.
For binder, base and wearing courses of traffic-accessed
areas within the remit of the Federal Ministry of Transport,
the requirements of ZTV Asphalt-StB, depending on the
mix types, contain information on grain size distribution,
and on the binder content, nature and type.
For screeds subject to particular stresses (industrial
screeds) as specified in DIN 18560-7, limit values for grain
size distribution are given in DIN 18560-1.
Torch-on bituminous waterproofing membranes
For waterproofing work under mastic asphalt, special
torch-on bituminous waterproofing membranes are used
(see DIN 18195-2 Waterproofing of buildings, materials)
torch-on bituminous waterproofing membranes with
upper reinforcement
torch-on bituminous waterproofing membranes with
metal lining.
FOAMGLAS ®
145

City-Galerie, Augsburg (D).
An ECE development project.
CASE STUDY Mastic asphalt - sheltered
146
The development, general planning,
building management, letting as well
as the centre management for the new,
glass-roofed shopping mall at Vogeltorplatz
in Augsburg were provided by
ECE Project Management, Hamburg.
The ECE group is Germany’s market
leader as far as shopping malls are concerned.
In numerous projects throughout
Europe, the ECE planners rely on
FOAMGLAS ® thermal insulation, which
provides recognized, economical system
solutions for both covered and exposed
parking areas. Because ECE runs many of
its shopping centres itself on a long term
basis, it is able to provide reliable data on
the cost efficiency of FOAMGLAS ® systems,
achieved through a combination of
durability and low maintenance costs.
The architectural highlights of the
City-Galerie Augsburg
Over 90 specialist stores present the right
combination of goods for this particular
location over a sales area of 25.000 m 2 .
The architecture of the City-Galerie is
characterized by high-quality materials and
the widespread use of glass.

5.2.1 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
The visual highlight is a gigantic glass
dome in the middle of the Galerie. The
new shopping mall has been greeted with
great enthusiasm by visitors, since it is
easily reached by car and by public transport.
Three parking levels above the shopping
centre (2 parking decks and 1 open area)
provide space for around 2.000 cars. From
the roof-top car park, the glass dome
offers a fascinating view of the activity in
the shopping mall, and provides bright natural
daylight inside.
FOAMGLAS ® thermal insulation was chosen
for the parking deck immediately
above the sales areas.
The rough concrete surface on the parking
deck is treated with a primer and the thermal
insulation is then installed.
Contractor: Hofmeister, Herford.
FOAMGLAS ®
FOAMGLAS ® S3 slabs laid fully
bonded and with filled joints on
the concrete deck using hot
bitumen.
A mastic asphalt covering layer
is applied on the top.
The completed mastic asphalt
covering layer.
Unrolling device for perfect, full
bonding of the waterproofing
membrane with an even application
pressure.
The waterproofing is applied in
two layers, with offset joints
and seams.
Glass fibre mat separating
layer and installation of reinforcement
...
Finally, the mastic asphalt surface
is applied in 2 layers.
147

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Other ECE projects using FOAMGLAS ® thermal insulation
GALERIA DOMINIKAÑSKA in Breslau (Wroclaw), Poland.
The shopping centre was built on 3 levels with a total retail
area of 30.000 m 2 and 2.500 m 2 of office space, and was
opened in August 2001.
The thermal insulation for the roof-top car parks and parking
decks (approx. 900 spaces) required the installation of
10.000 m 2 of 80 mm thick FOAMGLAS ® T4 slabs. The roofing
work was carried out by Hofmeister Roof Cooperation Ltd.
Planning: ECE architects in cooperation with Studio El
Edward Lach, Wroclaw.
GALERIA LÓDZKA in the town centre of Lodz, Poland.
The new retail attraction in the heart of the town of Lodz,
with 40.000 m 2 of shopping space, was opened in autumn
2002. The thermal insulation for the 17.000 m 2 of parking
(1400 spaces) was provided by 80 mm thick FOAMGLAS ® S3
slabs.
The ECE architects supervised the project, in cooperation
with the NOW Nowakowski-Owczarek-Wilkocki practice in
Lodz.
ÁRKÁD ÖRS VEZÉR TERE in Budapest, Hungary. The shopping
centre, with retail space covering 42.000 m 2 on 3 levels,
approx. 3.300 m 2 of offices and car parking, was opened in
2002.
148
The LINDEN-CENTER in Berlin (D) was completed in 1995 and
comprises 25.000 m 2 of retail space on three levels. 10.000 m 2
of parking space was thermally insulated using 80 mm thick
FOAMGLAS ® S3 slabs.
The ROTMAIN-CENTER in Bayreuth (D) was completed in
1997, and has 19.000 m 2 of retail space on 2 levels, plus parking
space. The thermal insulation is FOAMGLAS ® S3.
under construction
In the town centre of PÉCS (southern Hungary), the new
PÉCS ÁRKÁD is being built, with a retail area of 35.000 m 2 on
2 levels, plus parking. Topping out ceremony: June 2003.
50 mm thick FOAMGLAS ® S3 slabs were installed to provide
thermal insulation over an area of approx. 25.000 m 2 .
Architects, in cooperation with ECE project management:
Finta Studio Budapest, Dr. Jószef Finta, György Guczogi.
Shopping centres managed and built by ECE
with FOAMGLAS ® thermal insulation
Gesundbrunnen-Center, Berlin Linden-Center, Berlin
Stern-Center, Potsdam Lausitz-Center, Hoyerswerda
Allee-Center, Essen-Altenessen Allee Center, Remscheid
Rathaus-Center, Ludwigshafen Breuningerland, Sindelfingen
Rotmain-Center, Bayreuth City-Galerie, Augsburg
Ettlinger Tor, Karlsruhe Eastgate, Berlin Galeria
Dominikánska, Wroclaw (PL) Galeria Lódzka, Lodz (PL)
Galeria Vankova Brno (CZ) etc . . .
Project development, general planning and management:
ECE Projektmanagement GmbH & Co.KG
Heegbarg 30 D 22391 Hamburg
Telephone: +49-40-606 06-0 Internet: http://www.ece.de

Marché Bollaert, Dunkerque (F).
Parking deck with FOAMGLAS ® insulation,
fine aggregate mastic asphalt and reinforced
mastic asphalt surface
CASE STUDY Mastic asphalt - sheltered
Structure,
from bottom to top
Structural concrete
Primer (bitumen
emulsion)
Fine aggregate mastic
asphalt
(bituminous mastic)
Thermal insulation
FOAMGLAS ® F slabs
Flood-coat of fine
aggregate mastic asphalt
(bituminous mastic)
Separating layer made
from glass fibre mat,
100 g/m 2
Expanded metal
Mastic asphalt
For the Marché Bollaert, Rue des
Fusilliers Marins, at the Bassin de l’arrière
Port docks, 3.400 m2 of covered car
parking was constructed in the new building.
Insulation work
A bituminous primer was applied to the
clean, dust-free concrete deck.
Sufficient quantities of fine aggregate
mastic asphalt (bituminous mastic) were
poured onto the concrete deck and the
FOAMGLAS ® F slabs were fully bonded in
the mastic mass. The insulating slabs
were laid staggered. Pressing the slabs
diagonally against the elements that had
already been laid ensured the joints were
completely filled. Any excess mastic
pressed out of the joints was removed on
the top side of the insulation with a spatula,
or evenly distributed.
A variant of this installation technique is to
immerse a short and long side of the insu-
Thermal insulation of the parking deck
was required; this was provided using
FOAMGLAS ® F slabs, 50 mm thick, in a
combined bituminous mastic and mastic
asphalt wearing course.
lation slab in the poured bituminous mastic
and then to push it diagonally into place. In
this case too, any mastic emerging on the
top is smoothed off with a spatula.
Fine aggregate mastic asphalt (bituminous
mastic) was used above and below the
cellular glass insulation. It acts as a base,
a levelling layer, as flood-coat and basic
waterproofing.
FOAMGLAS ®
149

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Mastic asphalt applications
Where installing waterproofing against
water without hydrostatic head, the use of
fine aggregate mastic asphalt, which is
filler poor compared to mastic asphalt, is
recommended. It can be installed in one
layer between 7 and 15 mm thick, or two
layers between 12 and 20 mm thick. Fine
aggregate mastic asphalt (bituminous
mastic) is suitable for use on horizontal or
slightly sloping surfaces and helps to level
unevenness in the concrete deck.
Fine aggregate mastic asphalt (bituminous
mastic) also offers excellent mechanical
protection of the cellular glass. The layer
can be walked on after it has cooled. Work
teams of subsequent contractors can
work without risk to damage this waterproofing
layer or the cellular glass.
The following vehicle-accessible mastic
asphalt layer is installed over a separating
layer made from glass fibre mat 100 g/m 2
and an expanded metal grid.
The following photographs illustrate the work
required to install a pressure-distributing
wearing course system:
Flood-coating the FOAMGLAS ® insulation
with fine aggregate mastic asphalt (bituminous
mastic), approx. 10 mm thick.
Bituminous mastic withstands the installation
temperatures of mastic asphalt.
150
Insulation/waterproofing
system consisting of:
- Rough concrete deck
with bituminous primer
- Fine aggregate mastic
asphalt (bituminous
mastic)
- FOAMGLAS ® F slabs
- Flood-coat made from
fine aggregate mastic
asphalt (bituminous
mastic), providing a
waterproofing function.
A glass fibre mat 100 g/m 2
is laid loose with
10 cm overlapping.
The following expanded
metal grid is also installed
loose, with overlaps.
The grids are joined in the
overlap area.
The hot mastic asphalt is
then placed in sections.
The dumper container
full of mastic asphalt
can be seen in the
background.

MARCHÉ BOLLAERT, DUNKEQUE (F)
+
Installation of mastic asphalt
on the expanded metal grid
approx. 3 cm thick.
The build-up of layers on top
of the FOAMGLAS ® insulation
and bituminous mastic
flood-coat:
- Glass fibre mat
- Expanded metal grid
reinforcement
- Mastic asphalt.
Detail showing work
at the edge.
Daily work output
1. l Insulation + fine aggregate mastic
asphalt (bituminous mastic)
• Fine aggregate mastic asphalt:
8 tonnes
• 2 teams of 3 people each
- 1 workman for the installation of
the insulation material
- 1 person for pouring the mastic
asphalt
- 1 assistant for the material transport
and cleaning up afterwards
Surface area: → 270 - 340 m 2
2. l Non-woven fibre, expanded metal
+ mastic asphalt wearing course
Surface area: → 250 - 270 m 2
Technical data
Project:
Marché Bollaert
Rue des Fusilliers Marins
F - Dunkerque 59
New construction, sheltered parking
deck
Contractor:
SMAC Aciéroïd
F - Dunkerque 59
Building inspection:
SOCOTEC
Thermal insulation:
FOAMGLAS ® F slabs, 5 cm thick
Technical consultant, thermal
insulation:
Pittsburgh Corning FRANCE
François Bécquaert
5, rue Saarinen - SILIC 125
F - 94523 RUNGIS CEDEX
Tel.: +33 1 56 34 70 00
Fax: +33 1 56 34 70 01
E-mail: info@foamglas.fr
Surface area: 3.400 m2 Construction date: 2000
FOAMGLAS ®
151

Carrefour Supermarket in Ninove (B).
Roof-top car park refurbishment with mastic asphalt;
Asphaltco System - with UBAtc certification.
CASE STUDY Special mastic asphalt - exposed
After careful removal of the
old road surface asphalt, the
rough concrete deck was
cleaned, pretreated with a
bituminous primer and
weatherproofed with a fully
adhered bituminous torch-on
waterproofing.
152
ATG 1884
Since the takeover of the GB supermarkets
and Lunch Garden Restaurants in
Belgium, the Carrefour wholesale chain
has been investing in the refurbishment of
roof-top car parks. A refurbishment plan
was prepared, for example, for the supermarket
in Ninove which specified the conversion
of the uninsulated roof-top car
park into a thermally insulated structure,
using FOAMGLAS ® slabs and special mastic
asphalt.
The contract for the execution of the work
was awarded to Asphaltco; this company
has been working very successfully with
FOAMGLAS ® cellular glass since 1981,
having installed over 75.000 m2 of thermally
insulated roof-top car parks, including
many projects for the former GB Group.
The Asphaltco roof system using
FOAMGLAS ® thermal insulation and mastic
asphalt has the technical approval since
decades, in accordance with current building
regulations.
The most time-consuming activity within
this refurbishment project was the removal
of the road asphalt applied directly onto
the concrete deck. Because the concrete
structure was not designed to take heavy
machinery, the asphalt had to be torn up
using small hammer drills and Bobcat
compact shovel loaders meter by meter
and then removed.
An additional problem was the fact that
the supermarket was to remain open for
business, without restrictions, during the
demolition and building works. Because
parts of the soffit boards on the ceiling
regularly dropped off as a result of the
drilling work, nets had to be provided
under the ceilings inside the store to protect
the clients.
After the old surface had been completely
removed, the concrete deck was thoroughly
cleaned and treated with a bituminous
primer (cover: approx. 300 g/m 2 ).

5.2.1 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
Laying the FOAMGLAS ® S3 slabs, 5 cm thick, fully bonded in
hot bitumen. The slabs are laid directly on the basic weatherproofing
of the structural deck and ...
Next a torch-on V4 waterproofing sheet
was fully adhered to the concrete deck as
basic weatherproofing.
This was followed by the FOAMGLAS ®
insulation, fully bonded with hot bitumen
and with filled joints, sealed with a hot
bitumen flood-coat. Further work was carried
out as listed in the next column.
The compressive strength of the
FOAMGLAS ® S3 slabs (factory standard
1.00 N/mm 2 ) is sufficient for use by cars
and light delivery vans, i.e. up to an axle
load of 2 tonnes. It is also adequate for
site traffic, since no heavy machinery is
used for compaction during the installation
of mastic asphalt and the work is carried
out in sections. However, care should
be taken not to drive over the thermally
insulated areas with the boiler/dumper
truck, or building protection slabs should
be provided in transport areas.
Roof system
... flood-coated with hot bitumen on the top.
Concrete deck
Bitumen primer
Basic weatherproofing, torch-on waterproofing, type V4 membranes
Thermal insulation, FOAMGLAS ® S3 slabs, 5 cm thick, fully adhered
with hot bitumen, filled joints
Hot bitumen flood-coat
2 layers polyester fibre mats with inserts, 170 g/m 2
V4 torch-on waterproofing sheet, laid loose with torched overlappings
Ascoflex waterproofing sheet ES 4P, fully adhered by torch
2 layers polyester fibre mats with inserts, 170 g/m 2
Special mastic asphalt (quality HD), applied in 2 layers of 3 cm each,
dressed with sand.
In contrast to systems with a compact
asphalt build-up with no moisture migration
(such as System Reinartz Asphalt),
with this system, the asphalt wearing
course is installed on a separating layer
above the FOAMGLAS ® insulation.
Therefore this system may not be resistant
to water infiltration in the long term,
like the Reinartz Asphalt AG system.
FOAMGLAS ®
153

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Photos to be read
from top to bottom.
154
Technical data
Project:
Carrefour Supermarket
B - NINOVE
Refurbishment of an
exposed roof-top car park
with mastic asphalt
Contractor:
Asphaltco
Vilvoordelaan 92
B - 1830 MACHELEN
Tel.: +32 2/251.84.00
Fax: +32 2/252.48.00
Thermal insulation:
FOAMGLAS ® S3 slabs,
5 cm thick
Technical consultant,
thermal insulation:
Pittsburgh Corning Europe SA
Joris Mellebeek
Chaussée de Louvain, 431
B - 1380 LASNE
Tel.: +32 2/352 31 82
Fax: +32 2/353 15 99
Surface area:
9.500 m2 Year of refurbishment:
2001
Applying the hot bitumen flood-coat onto
the FOAMGLAS ® insulation.
On the right of the photo: the next layers of
the system, 2 layers of polyester fibre mats
and the loose-laid V4 bituminous torch-on
waterproofing.
The V4 torch-on waterproofing is laid loose
on the polyester non-woven fibre and only
torched at the overlappings.
At the edge of the roof, cellular glass angle
fillets are bonded at the parapet and the
waterproofing membranes are taken up
over them.
The Ascoflex roofing sheet, a PYP bitumen
torch-on membrane, is applied by torch to
the lower, loose-laid V4 waterproofing.
The finished roofing system.
Above the waterproofing, polyester fibre
mats are unrolled in such a way that the layers
are doubled over.
The subsequent mastic asphalt layers must
be placed above waterproofing sheets
either on heat-resistant separating layers
(as here), or on heat-resistant bituminous
waterproofing membranes (with inserted
upper reinforcement).

CARREFOUR SUPERMARKET IN NINOVE (B)
Filling the wheelbarrows with mastic
asphalt from boiler/dumper fitted with
mixer and thermometer.
The mastic asphalt layer is applied in 2 layers
with a total thickness of 60 mm.
The mastic asphalt covering is installed in
sections on tear-resistant polyester fibre
mats laid in 2 layers.
To give a good non-slip finish, sand is then
sprinkled on the mastic asphalt while it is
still hot. In the foreground, you can see the
hand-roller, which weighs 50 kg.
After cooling, the sand is pressed in using
the roller. Excess sand is brushed off for use
later. Finally, the movement joints are filled
with a polymer bitumen mastic.
Notes on the Asphaltco System (ATG 1884)
(taken from the approval certificate)
1. Object of the certification
The mastic asphalt system is installed on site and consists of a polymer
bitumen waterproofing, separating layer and mastic asphalt.
If there is a concrete deck, a basic waterproofing membrane is fully
adhered to the deck for the weatherproofing of the building; in the case of
structures with thermal insulation, the waterproofing is applied loose -
with torched overlappings - on top of the insulation.
The waterproofing is also laid loose if there are construction joints in the
structural concrete. Bearing structures or insulation layers should have a
minimum slope of 1.5 to max. 5% in order to avoid ponding of water.
No waterproofing membrane is laid on access ramps. The waterproofing
of ramps is not part of this certification. The roof system is designed for
moving and stationary cars and vans (maximum axle load 2 tonnes).
2. Building materials
2.1 l Ascoflex ES waterproofing
The Ascoflex ES 4P and ES 4AP waterproofing membranes are made from
polymer bitumen with polyester reinforcement.
The type ES 4AP is used on upstands, parapets, abutments and is protected
with chippings on the upper side.
2.2 l Additives - mastic asphalt
A distinction is made between 2 types of mastic asphalt: type HD (heavy
duty), to which pure TRINIDAD natural bitumen has been added, and type
2, which is modified with APP plastomers.
Type 1 is used for the top layer, whilst
Type 2 is installed as a waterproofing layer on access ramps.
The binder content in each case depends on the proportion of voids in the
mineral compound matrix.
TRINIDAD bitumen or APP plastomers are only added when the mixer
tanker drives to the site. The materials are mixed during transport from the
factory to the site. A stirring time of at least 1 hour is necessary, and this
must be taken into consideration when the additives are added. If the
transport route is less than 1 hour, the mixing must be continued on site.
2.3 l Thermal insulation
Cellular glass - FOAMGLAS ® S3 - is used for thermal insulation; the minimum
thickness is 40 mm.
FOAMGLAS ®
155

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
2.4 l Separating layers
A distinction is made between 2 types of separating layers, depending on
where they are used:
• Polyester fibre mats with a minimum weight of 170 g/m 2 , which are
laid as a separating layer between the Ascoflex waterproofing membrane
and the mastic asphalt and between the insulating layer and the
loose-laid Ascoflex membrane
and
• Glass fibre mat of 50 gr/m 2 , which is used as a separating layer over
construction joints; it is laid between the Ascoflex membrane and the
two layers of elastomer waterproofing in a thickness of 1.5 mm.
2.5 l Reinforcement of the mastic asphalt above
construction joints
The reinforcement consists of a steel mesh 50 x 50 x 5 mm, 600 mm wide
(length ± 2.0 m).
2.6 l Synthetic-resin-based adhesion primer
This coating resin is only used on ramps as a primer.
It is different from normal primers in that it does not contain any bitumen.
2.7 l Placing of mastic asphalt
2 layers of polyester fibre mats 170 gr/m2 are installed above the thermal
insulation and waterproofing. The first layer of HD (heavy duty) mastic
asphalt is laid on this in a thickness of 30 ± 5 mm.
The mastic asphalt is applied in sections, with a sheet width of 2.5 to 5 m
and provided with dummy joints (± 2 cm wide) between the sections.
The second layer of mastic asphalt is sprinkled with sand to improve the
non-slip finish. The sand sprinkled onto the surface is pressed in after cooling
using a hand roller (weight 50 kg). Excess sand is brushed off for use
later. Finally, the movement joints are filled with a polymer bitumen joint
filler.
156
Making the construction joints
A separating layer made from a glass fibre
mat is laid above the thermal insulation and
Ascoflex waterproofing, followed by further
elastomer bitumen waterproofing strips and
separating layers alternately.
A steel reinforcement mat is incorporated
into the first layer of mastic asphalt in the
area above the construction joint over a
width of 60 cm.
The approx. 2 cm wide joints in the mastic
asphalt to both sides of the construction
joint are filled with a polymer bitumen joint
filler.

Delvita Supermarket, in Hradec Králové (CZ).
Roof-top car park with mastic asphalt.
CASE STUDY Special mastic asphalt - exposed
The internationally successful retail
chain Delhaize, which has major market
shares in Belgium and the USA in the
high-class food sector, is also investing in
new supermarkets in eastern Europe.
Another store in the Delhaize chain has now
been opened under the name DELVITA, in
Hradec Králové in the Czech Republic.
A top-quality range of products and easy,
convenient shopping are obvious ways of
increasing customer loyalty as far as
Delhaize is concerned. For this reason, rooftop
parking is provided in most Delhaize
supermarkets. These car parks are generally
well-used and are required to meet
extremely high traffic safety standards
combined with low levels of maintenance.
Many years of experience throughout
Europe with the FOAMGLAS ® roof-top car
park system convinced the Delhaize planners,
who have built many of their roof top
car parks on the same principle, to opt for
this system once again.
Build-up of the roof,
from bottom to top
- Concrete deck made from
prefabricated slabs and
in-situ concrete slabs
- Screed to falls with bituminous primer
- Fine aggregate mastic asphalt
(bituminous mastic) 5 mm
- FOAMGLAS ® S3 slabs, fully
adhered with hot bitumen 100 mm
- Hot bitumen flood-coat 2 mm
- Bituminous torch-on waterproofing,
type Isoflam PS 5, 5S 5.5 mm
- Mastic asphalt wearing course,
2-layers sprinkled with sand 80 mm
FOAMGLAS ®
FOAMGLAS ® S3 slabs,
100 mm thick, are fully
bonded with hot bitumen,
joints filled.
FOAMGLAS ® insulation slabs are installed quickly and efficiently onto the
level concrete deck.
The insulating slabs are laid in sections and the hot bitumen flood-coat,
required for the subsequent application of a torch-on waterproofing layer, is
spread on at the same time.
157

5.2.1 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Delivery and installation
of the mastic asphalt
pavement, 8 cm thick,
in 2 layers,
on a separating layer.
158
Technical data
Project:
DELVITA (Delhaize)
Hradec Králové (CZ)
Architect:
Hájek • Hradec Králové (CZ)
General contractor:
Fospol (CZ)
Contractor:
Novác - Slavonia
Thermal insulation:
FOAMGLAS ® S3 slabs
Technical consultant,
thermal insulation:
AZ Flex
Zelenkova 533/3
CR-142 00 Praha 4 – Czechia
Contact: Jan Vychytil
Tel. : +420 2 41011631
Fax : +420 2 41011630
foamglas@azflex.cz
www.foamglas.cz
Finally, to improve the non-slip finish, the mastic asphalt surface is sprinkled
with sand.

5.2.2 Asphalt hot mix
5.2.2 Asphalt hot mix,
sheltered areas
In contrast to mastic asphalt, which
requires no compaction, normal asphalt
hot mix is applied as a load-distribution
base and wearing course on the
FOAMGLAS ® insulation/waterproofing system,
generally in 2 layers.
In addition to the weight permitted for the
bearing structure, it should also be noted
that compaction must be carried out in
various stages and that only certain rollers
and bitumen finishers/carriageway levellers
are suitable for use on FOAMGLAS ® .
The grain size of the asphalt hot mix,
which is installed hot and is low-density, is
similar to that of road-building compounds.
The rolled asphalt is used on roofed parking
decks and on ramps.
In contrast to “grouting asphalt pavement”,
described below, no slurry seals
are sintered into the top surface.
For exposed, vehicle-access surfaces,
rolled asphalt consolidated with slurry
seals is used as grouting asphalt pavements,
e.g. in Switzerland and France (see
System Description, Chapter 5.2.3).
Parking deck system using
FOAMGLAS ® thermal insulation
with asphalt hot mix
This parking deck system consists of the
following layers, from bottom to top:
• Structural concrete
• Bituminous primer
• FOAMGLAS ® thermal insulation
• Bituminous waterproofing with
polyester reinforcement, 2 layers
• Asphalt hot mix (rolled asphalt),
installed in 2 layers.
Application and permitted usage
The system is suitable for the new construction
and refurbishment of sheltered,
vehicle-accessed decks.
On the assumption that the structural
deck is made from concrete, the roof system
is allowed for the driving and parking
of vehicles up to a maximum axle load of
2 tonnes.
FOAMGLAS ®
159

Swiss building projects using asphalt hot mix
CASE STUDY Rolled asphalt, sheltered
Execution of the asphalting
works on a FOAMGLAS ®
insulation/waterproofing
system
Structural concrete
Bituminous primer
Thermal insulation
FOAMGLAS ® S3 slabs,
applied with hot bitumen
fully bonded with filled
joints
2 layers bituminous
waterproofing with
polyester reinforcement
Asphalt hot mix pavement
(rolled asphalt) -
applied in 2 layers and
mechanically compacted.
160
Construction of a Coop Super Centre in Payerne with a
thermally insulated parking deck for lightweight vehicles
The following describes the steps
involved in the installation of asphalt
hot mix in 2 layers on the FOAMGLAS ®
compact system for a sheltered car park
building.
FOAMGLAS ® S3 slabs were used.
The steps are the same for traffic-accessed
areas that are exposed to the weather.
An efficient method
of installation
Good site organisation is essential for the
fast installation of the insulation material.
The palettes with the insulation material
are distributed over the surface of the parking
deck – covering approx. 5.600 m 2 – in
such a way that the transport distances
are kept to a minimum for the laying team.
Before it is possible for suitable shovel
dozers to drive over the completed insulation/waterproofing
build-up, an asphalt
course is installed first of all by hand as
pathway for transport purposes; this is protected
using suitable protective boarding.
Before using double rollers or suitable
bitumen finishers/carriageway levellers on
FOAMGLAS ® insulation, please contact
the roller manufacturer and Pittsburgh
Corning to check their suitability from the
point of view of loading.
After pre-treatment of the concrete deck
with a bituminous primer, FOAMGLAS ® S3
slabs are applied using the well-proven
compact roof method.
This comprises full bonding, with filled
joints, using hot bitumen.
On the top side of the insulation, a waterproofing
membrane with polyester reinforcement
is applied using the pour and roll
method with overlapping.
After this, a second layer of high-quality
bituminous torch-on waterproofing with
polyester reinforcement is torch-applied, at
right angles to the first.

5.2.2 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
Delivery of the asphalt hot mix and manual installation at the
first stage.
First of all, an asphalt pathway is laid by hand across the
parking deck. It is used as an access road for the machinery
that is used afterwards.
Spreading out the hot mix with a rake.
Compacting the asphalt mix with a double roller – a light
piece of machinery operated without any vibration.
In areas that are difficult to reach, a plate compressor is used
with a static pressure under the plate of < 15 kPa.
161
FOAMGLAS ®
Test drive with the 4-tonne shovel dozer on the road track
with the 1st layer of asphalt, covered with additional protective
boarding.

5.2.2 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
The mixture for a second lane is supplied with the shovel
dozer and distributed. The red marking in the foreground is
the guide for the width of the next strip.
Spreading the mix out by hand. In the access area, the first
pathway is widened to create a turning area for the
machines.
Installation of the 2nd layer of asphalting by machine. No loaddistributing,
protective planking is needed on the 2nd layer.
162
An adhesive bridge is sprayed on between the 1st and 2nd
asphalt layer. The picture shows the spray pump.
The 2nd layer of asphalt hot mix can be installed automatically,
with remote control, using the bitumen finishers.
The picture shows the different layers:
FOAMGLAS ® insulation with two layers of waterproofing
1st layer of asphalt with protective planking for the installation of the
Second layer of asphalt.

Examples of completed projects using asphalt hot mix
Parking deck with FOAMGLAS ® thermal insulation at the Coop Signy Centre, Nyon (CH).
Service deck with FOAMGLAS ® thermal insulation at the PTT, Montreux (CH).
Service deck with FOAMGLAS ® thermal insulation at the law court, Tribunal Fédéral, Lausanne (CH).
FOAMGLAS ®
163

5.2.3 Grouting asphalt pavements
164
5.2.3 Grouting asphalt pavements
As a category, grouting asphalt pavements include wearing layers made from special
types of asphalt hot mix, which are applied hot and lightly compacted with a roller, and
then stabilised with a slurry seal. Although they differ from region to region, these pavements
are also known as “grouting asphalt pavements”.
Modern grouting asphalt pavements 1) are more elastic than concrete and have higher
strengths than asphalt concrete 2) .
Grouting asphalt pavement is an asphalt hot mix covering with a specific grain composition
and characterized by voids within its cross-section which are filled with latex cement
slurry using a vibration process.
In terms of behaviour, i.e. shape retention and the load-distribution effect, grouting
asphalt pavement can be classified as being between a concrete load distribution slab
and a hot mix wearing course and is therefore also suitable (in contrast to the hot mix
wearing course) for use on surfaces that are exposed to the sun.
The resistance to frost and to de-icing products is good to very good.
The linear thermal expansion and pH value are similar to concrete.
1) , 2) see definitions on page 165
FOAMGLAS ® roof-top car park with grouting asphalt pavement. The voids in the asphalt hot
mix are filled with a latex cement slurry which is spread out using a double roller. Surplus
slurry is spread over the surface using a broom or rubber lipped spreading tool.

5.2.3 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
FOAMGLAS ® roof-top car park;
Construction: Weiss + Appetito AG, Postfach, CH 3210 Kerzers.
Material structure of the
asphalt hot mix before the
slurry seal is vibrated in.
1) Grouting asphalt pavement:
a definition
A grouting asphalt pavement is a dense, homogenous
building material with a good-quality
structure. The voids in the asphalt hot mix are
almost 100% filled with slurry seals. The total
porosity is approximately 5.6% by volume,
which is around 50% less than concrete.
The hot mix is also described as the supporting
matrix and the latex cement slurry as a slurry
seal. To take the slurry seal, the supporting
matrix has a void content of approx. 16 - 20%.
The grain composition has been specially developed
for the grouting asphalt pavement and only
contains a small proportion of fines. The grain
sizes of the supporting matrix must be matched to the required pavement thickness.
The grading is discontinuous, varying between 0 - 8 and 0 - 32 mm.
Depending on the plastics used, pavement thicknesses of 25 - 90 mm are possible.
Pavements up to 90 mm thick can be grouted in one work stage. The slurry seal
consists of cement, quartz sand, plasticizers and water. Coloured slurry seals are
available.
2) Asphalt concrete: a definition
Asphalt concrete is the mixture of chippings and sand with a bitumen binder.
Depending on the fineness of the aggregates, asphalt concrete is used for all sorts
of different applications, such as road-building and for the production of various
surfaces (application example: wearing course of vehicle-accessed underground
car park decks).
Roof-top car park build-up,
from bottom to top (*)
- Concrete deck
- Bituminous primer
- FOAMGLAS ® thermal insulation,
using the compact roof method
- Polymer-modified bituminous waterproofing
membrane (2 layers), or
1 layer waterproofing membrane plus
1 layer mastic asphalt
- Grouting asphalt pavement, i.e.
asphalt hot mix with slurry seal
(*) This is the standard build-up. Depending
on the specialist asphalt contractor and
the specific project situation, additional
separating layers made from fibre mats,
oil-impregnated paper and reinforcing
mats may be inserted on top of the
FOAMGLAS ® insulation/waterproofing
system.
FOAMGLAS ®
165

5.2.3 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
Material characteristic values
There are no standardised characteristic
values for grouting asphalt pavement as
there are for concrete.
To guarantee a perfect grouting asphalt
pavement, however, the characteristic values
given in the next column should be
maintained 1) . The values must be proved in
materials tests at a temperature of +20 °C.
166
Asphalt hot mix (supporting matrix)
Void content 16 - 20 %
Pure bitumen content (Bitumen 80/100) 3 - 3.5 %
Grain composition for a thickness of 45 - 90 mm 0 - 22 mm
in suitable discontinuous grain grading
Slurry seals
Synthetic resin solids content
in relation to PC content > 10 %
PC content > 600 kg/m 2
Water-cement factor < 0.5
Compressive strength after 28 days
(cube compressive strength) 25 - 35 N/mm 2
Bending tensile strength after 28 days 5 - 6 N/mm 2
Modulus of elasticity 11 - 13 kN/mm 2
Coefficient of thermal expansion 14 x 10-6 m/m °K
Capillary water absorption A5 (at 60°C) 16 - 18 % by vol.
Total porosity Av 29 - 33 % by vol.
Cavity difference LG 13 - 15 % by vol.
Dry bulk density Rd 1.7 - 1.85 kg/dm 3
Resistance to frost/de-icing products
according to D-R (SN 640’461) > 80 WFT-L %
Grouting asphalt pavement
The grouting capability must be guaranteed at + 28°C
with falling temperatures.
Minimum degree of grouting of the void content 98 %
Requirement for cracking tolerances
(only cracks > 0.2 mm) 2 m/100 m 2
in the system
Compressive strength after 28 days
(cylinder compressive strength ø 115 mm) > 6 N/mm 2
Bending tensile strength after 28 days > 2.8 N/mm 2
Modulus of elasticity > 3 N/mm 2
Coefficient of thermal expansion 16 x 10-6 m/m °K
Capillary water absorption A5 (at 60°C) < 4 % by vol.
Total porosity Av < 6 % by vol.
Cavity difference LG < 2.0 % by vol.
Dry bulk density Rd 2.3 - 2.4 kg/dm 3
Resistance to frost/de-icing products
in accordance with SN 640’461
purely visually, weathering over entire drill core
(ø 115 mm) minimal > 60 WFT-L %
1) Source: Knobel Kislig + Partner AG, consulting engineers, CH - Bern

Notes on construction
The placing and treatment of grouting
asphalt pavements need to meet the
toughest of requirements.
When producing the individual components,
all batch proportioning must be carried
out with absolute precision.
Formation of joints
Joints are required in large surfaces and
around the exteriour. Because grouting
asphalt pavements are less rigid in their
behaviour than concrete, joints can be
spaced more widely apart.
Depending on the ambient temperature,
grouting asphalt pavements should be
separated by expansion joints every 8 to
12 m. The ratio of the side lengths of the
jointed surface sections should be less
than 1.5. The joints can be cut later, but
the slabs must be subdivided no more
than 24-48 hours after the installation of
the grouting asphalt pavement.
When dividing the joints, care should be
taken to ensure that there are no joint
intersections within driving lanes where
possible.
Joint formation in grouting asphalt pavement.
The cut joints can be filled with various
mastic fillers. Depending on viscosity and
temperature-related behaviour of the filler,
the stability of the sides of the joints can
be improved.
Larger distances between the joints will
give a 30 - 50% reduction in joint length
overall, which saves time and money.
Curing
The freshly installed grouting asphalt
pavement must be cured by means of
suitable measures to be proposed by the
contractor. If the surface is exposed to
strong sunlight and high outside temperatures,
additional measures must be taken
to protect the fresh surface (e.g. covering
with white fibre matting or jute and keeping
moist at all times).
Principles for the
dimensioning of
the wearing course
Measurement results show that at +20°C
the transmission of force, or the introduction
of compressive stresses into the cellular
glass insulation material reaches its
maximum.
The thickness of the wearing slab is therefore
calculated on the basis of the material
characteristic values at +20°C and
according to the calculation of stresses
using Westergaard’s theory or dimensioning
using the punching cone method.
In the temperature range from -20°C to
+20°C, a failure/fracture of the grouting
asphalt pavement is the first thing to
occur. Cellular glass is therefore capable
of bearing loads up to the limit of failure of
the wearing surface.
At +40°C, no cracks were found in the cellular
glass after the failure of the grouting
asphalt pavement.
FOAMGLAS ®
Cross-section, grouting
asphalt pavement.
167

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
H. Kislig, Peter Knobel:
Grouting asphalt pavement.
Use as wearing slab on
thermally insulated roof top
car parks.
Schweizer Ingenieur und
Architekt Nr. 4, January 1996.
The report is available in
German from Pittsburgh
Corning.
168
At temperatures >5°C, grouting asphalt
pavements show a striking reduction in Emoduli,
and in bending and compressive
strengths. Here, the use of high-compressive
strength FOAMGLAS ® S3 slabs as a
substrate has an extremely beneficial
effect.
The grouting asphalt pavement changes
from the elastic to the visco-elastic state.
The viscosity of the bitumen and also, to a
lesser extent, the flexible behaviour of the
plastic components in the slurry seal
become crucially important. High local
stresses are reduced and extreme peaks
in stress occur much less frequently
because of the visco-elastic behaviour of
the grouting asphalt pavement and a
transfer of the loading within the structure
of the pavement.
Extensive tests have shown that the peak
loads at the edges and corners determined
using Westergaard’s theory do not
occur, which means that there is no harmful
overloading in the cellular glass thermal
insulation.
Grouting asphalt pavement has the ideal
properties for use as a wearing course and
can meet high standards in terms of
strength.
Choosing the right FOAMGLAS ® type
TYPE OF USE FG ® T4 FG ® S3 FG ® F
Car use
- low level of use ⌧ ⌧
- special use,
high levl of use ⌧
Pedestrian/
terrace use ⌧ ⌧ ⌧
Performance limits
Grouting asphalt pavements on thermally
insulated roof-top car parks can be driven
over by cars, light commercial vehicles
and occasionally by emergency rescue
vehicles, furniture trucks, etc. Additional
protective measures must be provided if
point loads are applied through the supports
of transfer lifts/inclined lifts, scaffolds,
vehicle hoists, etc..
If applied on a stiff subgrade, grouting
asphalt pavements can be installed in
areas with high special loads. However,
temperature-related strengths must also
be taken into consideration in such cases.
Detailed investigations into the behaviour
of grouting asphalt pavements used as
wearing slabs on thermally insulated rooftop
car parks are provided in the study
produced by H. Kislig, Peter Knobel (Bern),
published under the title “Vermörtelungsbelag”
[Grouting asphalt pavement]
in the Schweizer Ingenieur und
Architekt Nr. 4, 1996.
The report is available in German from
Pittsburgh Corning.
In Switzerland, excellent results have
been achieved with BITUZIM ® , manufactured
by Weiss + Appetito AG,
Postfach, CH 3210 Kerzers.
The insulation material should be laid on
the concrete deck in a single layer at least
50 mm thick.

Installation of grouting asphalt pavement on
a compact roof structure using FOAMGLAS ® S3 slabs
FOAMGLAS ®
169

Refurbishment project at the Post and
Telecommunications Office PTT Ouchy, Lausanne (CH).
CASE STUDY Grouting asphalt pavement, exposed
170
New roof-top car park system: grouting asphalt pavement
as a wearing slab on FOAMGLAS ® insulation
The old roof structure in the PTT Ouchy
Post and Telecommunications Office
was showing major damage,
and leaks and complete
water penetration
of the build-up indicated
that a fundamental refurbishment
was required.
Large quantities of building
rubble had to be
removed at considerable
expense, and the parking
area could not be used
for 3 months.
The owner’s planning
office chose waterproof,
high compressive strength FOAMGLAS ®
Compact Roof with a Bituzim ® asphalt
pavement (otherwise known as a grouting
asphalt pavement) for the refurbishment.
The installation of the system is described
below, step by step.
Hot bitumen was poured onto the concrete
deck prepared with primer, and
FOAMGLAS ® S3 insulation slabs were laid
staggered with hot bitumen. Compact
bonding with the subgrade was achieved
by pushing the slabs together diagonally,
along with water- and vapourproof filling
of the joints.
Refurbished roof with thermal insulation.
Excess bitumen emerging at the sides
was scraped off with an insulation slab.
The insulation slabs can be laid and the
waterproofing can be applied in sections
with parallel working teams, depending on
the size of the site.

5.2.3 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
The 1st layer of bituminous waterproofing membrane is
applied by pour and roll.
The waterproofing membrane is bonded with seam and joint
overlap. The quality of the adhesion must be monitored.
A high-quality bituminous torch-on waterproofing is applied,
offset from the 1st layer.
The Pittsburgh Corning representative is on hand to assist
the contractors at any time for site meetings and intermediate
acceptances.
f
e
g
Sequence of layers within the roof build-up: [a] Structural concrete; [b]
FOAMGLAS ® insulation with waterproofing; [c] Oil-impregnated paper;
[d] Fibre mat; [e] 1st layer asphalt hot mix; [f] Reinforcing mesh; [g] 2nd
layer asphalt hot mix to take the slurry seal.
171
FOAMGLAS ®
The 1st layer of asphalt hot mix is installed manually on the separating
layers made from oil-impregnated paper and fibre matting. In the background
light compaction of the surface is beginning to be carried out
with a roller.
c
d
b
a

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
The 2nd layer of asphalt hot mix is applied to a reinforcement
mesh with a light bitumen finisher/carriageway leveller and
compacted.
The hot mix is installed manually at the edges. Compaction
of the 2nd layer can be carried out using heavier machines
than for the 1st layer.
Detail of the drain gutter recommended by Pittsburgh
Corning with elastomer flange and the two separating layers
(oil-impregnated paper and fibre mat).
172
The hardened wearing slab with cement slurry seal: the
Bituzim ® grouting asphalt pavement (Weiss + Appetito AG).
Producing dummy joints in the grouting asphalt pavement to
avoid uncontrolled crack formation. The joints are then
sealed with mastic filler.
Completed roof surface with grouting asphalt pavement.
FOAMGLAS ® thermal insulation guarantees long-term performance,
excellent protection for the building and energy
savings in line with Swiss Minergie requirements.

Roof-top car park for the Coop Centre Léman,
Bussigny-Lausanne (CH).
CASE STUDY Grouting asphalt pavement, exposed
On the Coop Centre
Léman (CH) project,
various construction details
are of interest, as examples,
in relation to the
Bituzim ® wearing course
and the incorporation of the
latex cement slurry using
vibration equipment.
Detailed illustrations
Installation of the slurry seal using vibration equipment.
Expansion joint profile for
the area around a door
threshold.
Design of the construction
joint adjoining rising masonry.
FOAMGLAS ® roof-top car park with Bituzim ® wearing course;
construction: Weiss + Appetito AG, 3210 Kerzers - Switzerland.
FOAMGLAS ®
Construction joint with
replaceable expansion joint
strip, which is pressed into
the metal profile after completion
of the asphalt surface.
173

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Grouting asphalt pavement
BITUZIM ®
made by Weiss+Appetito - Switzerland
BITUZIM ® is a bituminous hot mix asphalt combined with
cement concrete. This mixture produces flexibility and stability.
BITUZIM ® grouting asphalt pavement used in a structure
with FOAMGLAS ® thermal insulation is an industrial surface
which is suitable for thermally insulated roof-top car
parks and service decks, both inside and outside.
• For light to heavy loading, can be adapted to any type
of use and design.
FOAMGLAS ® S cellular glass is used for medium-level
loading, and F is suitable for heavy loads.
• The load distribution and wearing system, which is
independent from the waterproofing and supported by
a high compressive strength insulation layer, offers the
best guarantees for a long service life.
• No deformations under load, even in positions
exposed to the sun. Can be installed and used quickly.
• Reasonably priced and low-maintenance.
174
Systems
BITUZIM ® - Technical Data
BITUZIM ® - Classico
For Stress Category I, interior areas, without specific thermal
stresses (effects of direct sunlight), max. course thickness
40 mm, all appropriate types of mineral compound
matrix using normal bitumen 80/100 and BITUZIM-1 latex
cement slurry.
BITUZIM ® - Robusto
For Stress Category I - III, interior and exterior areas, without
special thermal stresses (effects of direct sunlight),
max. course thickness 100 mm, all appropriate types of
mineral compound matrix using normal bitumen 80/100
and BITUZIM-3 latex cement slurry.
BITUZIM ® - Forte
For Stress Category I - III, interior and exterior areas, with
important thermal stresses (effects of direct sunlight),
max. course thickness 100 mm, all appropriate types of
mineral compound matrix using KMB plastic-modified bitumen
and BITUZIM-3 latex cement slurry.
Grain size in mm 0-11 0-16 0-22
Waterproof ✔ ✔ ✔
Resistant to frost/de-icing products ✔ ✔ ✔
Resistant to oils/fuels ✔ ✔ ✔
Permeable to water vapour ✔ ✔ ✔
Fire retardant ✔ ✔ ✔
Compressive strength* N/mm 2 > 4.0 > 4.5 > 5.0
Bending tensile strength* N/mm 2 > 2.0 > 2.5 > 2.8
Abrasion resistance* in mm 1.8 1.8 1.7
Average impact resistance* N/mm 2 8.0 10.0 12.0
Resistance to slipping as required
Deformation should be allowed for at higher temperatures through the choice of
the most appropriate system.
Colour light grey
Ready for use (light use) after 2 days
Ready for use (full) after 10 days
* valid for BITUZIM-3 latex cement slurry EMPA- and LPM-tested

Reference projects
BITUZIM ® grouting asphalt pavement, uninsulated and
with FOAMGLAS ® thermal insulation
Bischofszell, warehouse • Uster, square in front of the
armoury • Bätterkinden, warehouse • Bern, reloading centre
• Bürglen OW, MMM car park • Frenkendorf, container
rep. centre • Liestal, armoury • Lucerne, Jelmoli car park •
Bellinzona, PAE’s • Cadenazzo, warehouse • Olten, SBB
warehouse • Stettlen, workshop • Würenlingen, manufacturing
unit • Bern, PW hall • Döttingen, warehouse •
Echallens Lausanne, roof-top car park • Glarus, multi-purpose
hall • Jegenstorf, PW hall • Lausanne, Migros roof-top
car park • Sion, warehouse, roof-top car park • Zug, Casino
car park • Belp, PW hall • Bern, warehouse • Bern, Höhe
petrol station • Bremgarten, warehouse • Fällanden, Bosch
factory yard • Geneva, garage • Geneva, PTT exposed traffic-accessed
area • Ostermundigen,
Zentweg car park
• Saxon, fruit and vegetable
warehouse • Bern, Holenacker
car park • Bümpliz,
warehouse • Cham, Neudorf
car park • Hettiswil,
warehouse • Laupen, garage
• Le Sépey, roof-top car park
• Lyss reloading centre •
Lyss, car park and ramp •
Aigle, warehouse • Belp,
operating building • Bern,
Coop reloading centre • Bern, warehouse • Jegenstorf,
indoor parking • Kerzers, vegetable trading building •
Nänikon, factory building • Nyon, warehouse •
Ostermundigen, Coop indoor parking • Schönenwerd, Bally
warehouse • Schönenwerd, production unit • Sembrancher,
maintenance centre • Sion,Televerbier hall • Bern Betlehem,
car park for old people’s home • Bolligen, Dorfmärit car park
• Niederbottigen, PTT head office • Sion, factory unit •
Wädenswil, roof-top car park • Wangen a.A., warehouse •
Aarberg, ZRA warehouse • Bern, Losinger factory yard •
Bern, PTT Schanzen post office • Hasle- Rüegsau, Coop car
park • Monthey Le Cotterd, car park • Bern administration
building, car park • Bern, station car park • Schöhnbühl,
Shoppyland car park • Sion, car park • Bern, SBB (Swiss
Federal Railways) • Bern, SIB (Swiss Institute for Bio
Information Technology) • Bern, v. Graffenried AG •
Niederscherli centre • Uster, Florahof drinks unit • Bäretswil,
Grob centre • Schönried, single-family house in Brückmatte •
Sion, factory unit • Volketswil, production unit • Basel, reloading
centre • Bex, factory unit • Bex, production unit •
Burgdorf, car park • Dotzigen, sales premises, warehouse •
Morges, factory unit • Niederscherli, car park • Renens, car
park • Renens, SBS Bank, inner courtyard • Sion, Batterie
Oerlikon, traffic-accessed area • Aarberg, sugar factory
warehouse • Bern, roof-top car park • Bern, roof-top car
park of Flachdachbau AG • Bern,Arge parking deck • Bern,
Fussauto AG industrial building • Burgdorf, indoor parking
Mäder AG • Neuchâtel, A. Muller SA, craft operation •
Renens, SBS computer centre • Schmitten, Xiro AG • Bern,
parking deck, restaurant tower block • Burgdorf, new building
of Ivers Lee AG • Langnau, square in front of armoury
• Neuchâtel, A. Muller SA industrial building •
Niederwangen, Merz & Benteli AG factory • Thun, Frutiger
AG business premises • Bern, Shell petrol station • Bern,
AFB Bern car park • Bern, indoor parking BHG Stapfenstr.
• Bern-Bümpliz, Shell petrol station • Burgdorf, ESA reloading
centre • Pregassona, Tobler AG reloading centre •
Signau, Coop warehouse • Solothurn, car park for Schweizerische
Volksbank • Bern,
Coop Bern indoor parking •
Bern, Techno Park, ramp •
Münchenbuchsee, Schwendimann,
indoor parking •
Neuchâtel, Coop roof-top
car park • Renens, Ciba-
Geigy • Schönbühl, Calenica
ramp • Wangen a.A., Conbau
AG parking • Bern, Meliger
Immobilien administration
building • Bern, Bund indoor
parking • Biel, Rolex car park
• Deitingen, Astrada AG, multi-purpose hall • Münchenbuchsee,
Coop indoor parking •Schönbühl, truck reloading
centre, Migros Bern • Aigle, Gétaz-Romang SA, depot •
Assens, Coop Garden Centre • Lausanne, car park PTT
Lausanne • Bern, Stuag AG parking deck • Bern, ASB Bern,
hangar • Conthey, Gétaz-Romang SA hall • Grancy, Coop
outlet, Setimac SA • Lausanne, traffic-accessed area, Coop,
Av. Grancy • Lausanne, Dentan Georges SA car park •
Stans, Alfred Müller AG shop • Bolligen, factory building,
Glas Trösch • Bützberg, factory building, Grisberger AG • Le
Sentier, Roth Daniel SA, vehicle-accessed terrace •
Neuchâtel, Police car park • Biel, Migros Bielerhof • Köniz,
Coop Stapfenmärit • Lausanne, Winterthur Versicherung
car park • Lausanne-Ouchy, Dentan Georges SA car park •
Aarberg, ZRA warehouse 2nd floor • Bern, SRG parking
deck • Frutigen, Hydrotechnik AG ramp • Murten, Coop
car park ramp • Nebikon, Galliker AG rebuilding, warehouse
• Crissier, Coop Léman Centre • Lausanne, roof-top
car park Coop und Brico Centre • Bern, Haag Streit AG car
park • • •
FOAMGLAS ®
175

Super U Shopping centre, Lingolsheim (F)
CASE STUDY Grouting asphalt pavement, exposed
Super U Shopping Centre, in Lingolsheim (F) with FOAMGLAS ® thermal insulation and grouting asphalt pavement as wearing slab.
In France too, grouting asphalt pavements laid on high
compressive strength FOAMGLAS ® insulation have
proved successful in many building developments.
Effective thermal insulation, compact waterproofing on a
bitumen base in combination with a tough yet light load
distribution slab made from grouting asphalt pavement
provides the required structural solution for thermally insulated
roof-top car parks and service decks on shopping
centres, office developments, residential complexes, etc.
Installation of the insulation slabs
The water- and vapour-proof cellular glass insulation slabs
can be installed without any additional vapour barrier.
- The works should normally be carried out at temperatures
> +5°C.
- The state and evenness of the structural concrete
must be examined beforehand and if necessary, levelling
and repair work must be carried out in accordance
with guidelines. As regards evenness, for example,
the requirement is max. 5 mm over 10 cm. The substrate
should normally be dry.
- After application of a bituminous primer, a layer of mastic
asphalt (bituminous mastic) is applied hot. After
this, the insulation slabs are fully bonded to the deck
with hot bitumen, with joints filled.
- The slabs are installed with staggered joints.
176
- To achieve full bonding, with filled joints, sufficient
bitumen must be used.
- The rate of bitumen consumption varies between
5 and 6 kg/m 2 , depending on the evenness of the substrate.
- With the hot bitumen pour and dip technique, care must
be taken to ensure that the joints are filled properly.
Waterproofing
After the insulation slabs have been placed in position, the
waterproofing is applied in two layers.
The 1st layer of bituminous waterproofing is either
applied by the pour and roll method directly onto the insulation
material, or applied by torch for a torch-on membrane
after previously applying a hot bitumen flood-coat.

5.2.3 Mastic asphalt, asphalt hot mix and
grouting asphalt pavements
The 2nd layer of waterproofing can either
be applied using the pour and roll method,
or in case of a torch-on membrane type,
be torched on.
The waterproofing membranes used in
this project are marked with a longitudinal
dotted line in the overlap area. The membranes
should be offset so that there is no
bulging or extra thickness as a result of
quadruple overlaps at the seams and
joints. The corners should be bevelled off
at 45°.
When the waterproofing membranes are
torched on, the proper adhesion of the
joints/seams must be checked:
- a small bead of bitumen should
emerge at the edges;
- if there is no bitumen bead, proper
seam adhesion should be checked,
using a spatula, for example.
Site traffic
When the work is carried out, traffic
across the waterproofing should be kept
to a minimum. If it is necessary, a surface
protection should be provided.
To protect the waterproofing, machinery
and vehicles should be operated on protective
layers until the load distribution
slab/ wearing course is installed.
Site traffic from other trades is only advisable
after the installation of the first layer
of asphalt hot mix/grouting asphalt pavement.
The waterproofing is protected in 1 or 2
layers using asphalt hot mix or the grouting
asphalt pavement. The thickness of
each layer should not exceed 6 cm.
The open-pored asphalt hot mix can be installed
using one of the following 3 methods:
with a bitumen finisher, a vibrating screed
or manually.
The choice of installation equipment
depends on the size and geometry of the
surfaces to be covered and the permitted
working loads on the bearing structure.
Note: If a bitumen finisher is used,
vibration mode is not switched on.
Compaction is carried out with a double
roller in accordance with, for example,
standard NF P98-736. Equipment is operated
solely in static mode, rather than
vibration mode. In the areas that cannot
be accessed by the rollers, a plate compactor
can also be used.
Formation of joints
• 2 cm wide joints at edges and
abutments.
• 0.5 - 1 cm wide joints to divide the
area into sections.
• Sections without joints up to ~ 200 m 2 .
If necessary, the joints to divide the area
(dummy joints or construction joints) can
be cut later to a depth of ~1.5 cm.
FOAMGLAS ®
Double rollers, e.g. Ammann
rollers, are suitable for compacting
the asphalt hot mix.
A plate compactor is used in
the areas that cannot be
accessed by the rollers.
177

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Vibrating in the slurry seal with the plate compactor.
Application of the slurry seal
The slurry seal is applied after the asphalt hot mix has
cooled down.
It is either mixed in situ using an electric mixing machine
or delivered to the site ready-mixed in concrete tankers.
The latex cement slurry is spread over the asphalt surface
and vibrated in with rollers. Excess slurry is spread out
with a broom, or rubber-lipped spreading tool and scraped
off.
At higher outside temperatures, the grouting asphalt pavement
should be protected directly after setting with a tarpaulin
cover, or by other suitable means to stop it drying
too quickly and prevent the formation of cracks.
Additional surface treatment
Various surface treatments such as
- roughening
- smoothing, coating
- sealing, impregnating can be carried out.
If grout is to be removed from the surface, this can be
done after the slurry has hardened (at least 7 days). A
range of techniques can be used here, e.g. jet blasting
with steel scrap, sand blasting or water-sand blasting.
Readiness for use
The surface is ready for use after application of the slurry
seal:
- after 24 hours, for pedestrian-accessed surfaces
- after 5 days, for vehicle-accessed surfaces.
178
Advantages of the surface
visually attractive,
as it is largely joint free
excellent sound insulation
good grip, non-slip
non-combustible
good chemical resistance.

SUPER U SHOPPING CENTRE, LINGOLSHEIM (F).
Roof surface before application of the slurry seal.
Mixing the slurry seal.
Application of the slurry seal. Spreading and vibrating in the slurry seal.
Spreading and vibrating in of the slurry seal on the roof-top
car park and access ramp.
Finished surface on FOAMGLAS ® thermal insulation before
the addition of a special surface treatment.
FOAMGLAS ®
179

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
Detailed illustrations
Roof edge
Pedestrian-accessed edge with concrete angle quoin and hand rails
180
Structural concrete deck
Bituminous primer
Thermal insulation, FOAMGLAS ® F slabs,
fully bonded with hot bitumen
Joints filled with hot bitumen
1st layer bituminous waterproofing
2nd layer bituminous torch-on
waterproofing
Asphalt hot mix as load-distributing
wearing slab with slurry seal
Primer, adhesive bridge
’ Upstand joint
Support bracket 0.25 x 0.25
Edge protection element, bonded onto
wearing course
Kerb stone with wooden buffer
Roof edge parapet
Structural concrete
A Concrete beam
B Structural concrete deck
Bituminous primer
Thermal insulation, FOAMGLAS ® F slabs,
fully bonded with hot bitumen and filled
joints
Concrete kerb stone
1st layer bituminous waterproofing
2nd layer bituminous torch-on
waterproofing
Asphalt hot mix load-distributing wearing
slab with slurry seal
Bituminous waterproofing
Bituminous torch-on waterproofing
Concrete kerb stone, edge protection
Upstand joint
Roof edge parapet
Edge protection element, bonded onto
wearing course

Detailed illustration
Drain with grating
Structural concrete deck
Bituminous primer
Thermal insulation, FOAMGLAS ® F slabs, fully
bonded with hot bitumen and filled joints
’ Insulation material cut to shape to take
drain fitting
Drain fitting (funnel + connection pipe)
1st layer bituminous waterproofing
’ Reinforcing strip, bituminous waterproofing
2nd layer bituminous torch-on waterproofing
Asphalt hot mix load-distributing wearing slab
with slurry seal
Drain (frame + grating)
Direction of fall
Drain pipe
FOAMGLAS ®
181

5.2.3 Mastic asphalt, asphalt hot mix and grouting asphalt pavements
182
Completed car park in rue Delacroix, Le Mans (F).
ADVANTAGES OF THE SYSTEM
Simple construction. Limited number of layers.
Extremely high compressive strength of insulation material
without deformation, e.g. FOAMGLAS ® F with 1,7 N/mm 2 .
Well-proven FOAMGLAS ® Compact Roof system with full
bonding.
High-quality, reinforced waterproofing.
Low-weight construction.
Finished height: slimline construction with cellular glass
insulation thickness for optimum thermal performance
Almost no joints in the wearing course (only construction
joints).
Ready to use shortly after completion – in the week following
installation.
Bedding on deformation-free FOAMGLAS ® insulation layer
means surface is free from cracks in the long term
Coloured surfaces offer additional design opportunities.
The fall can be created in the insulation material
(FOAMGLAS ® TAPERED ® slabs).
No additional vapour barrier necessary.
Technical advice and on-site instruction provided.
FOAMGLAS ® cellular glass insulation fully bonded with hot bitumen
and filled joints
Waterproofing membrane, 1st layer applied by pour and roll;
2nd layer of bituminous waterproofing torched on
Application of the asphalt hot mix
Compaction of the asphalt hot mix
Application of the slurry seal (latex cement slurry)
Vibrating in of the slurry seal.