GYPSUM BUILDING PLASTER PART I EXCLUDING …

1 1 | P a g e I S S U E N O 1 PRODUCT MANUAL ON GYPSUM BUILDING PLASTER part I EXCLUDING premixed light weight PLASTERS IS 2547( part I) - 1976 Bureau of Indian Standards 2 | P a g e I S S U E N O 1 AMENDMENT SHEET S NO AMENDMENT NO DATE PAGE NO CLAUSE NO 3 | P a g e I S S U E N O 1 FOREWORD GYPSUM BUILDING PLASTER is extensively in many countries for general BUILDING operations and for the manufacture of preformed GYPSUM BUILDING products which have the specific advantages of lightness and high fire resistance. This Product Manual is intended to cover all elements needed for grant of a product certification licence and its continued operation providing reference material that can be used in all Regional / Branch Offices and by various applicants / licensees to ensure coherence of practice and transparency.

2 TABLE OF CONTENTS 4 | P a g e I S S U E N O 1 SECTION CONTENT DETAIL PAGE NO I PRODUCT DESCRIPTION 5 II RAW MATERIAL/COMPONENTS 6 III MANUFACTURING PROCESS & IN-PROCESS QUALITY CONTROLS 7 IV CERTIFICATION CRITERIA 10 V INSPECTION AND TESTING 12 5 | P a g e I S S U E N O 1 PRODUCT DESCRIPTION SECTION DESCRIPTION OF PRODUCT GYPSUM Plasters are classified on the basis of their physical and chemical properties. These possess a definite set of properties due to hydration of calcium sulphate, anhydrous or hemihydrate, to form GYPSUM and are used in the manufacture of GYPSUM BUILDING materials. GYPSUM PLASTER shall be classified as follows: a) PLASTER of paris, b) Retarded hemihydrate GYPSUM PLASTER : Type I Under coat: a) Browning PLASTER , b) Metal lathing PLASTER , Type II Final coat PLASTER : a) Finish PLASTER , b) Board finish PLASTER , c) Anhydrous GYPSUM plasters are for finishing only, and d) Keene s PLASTER is for finishing only.

3 SECTION LATEST INDIAN STANDARD WITH PRODUCT TITLE AND NUMBER OF AMENDMENTS IS GYPSUM BUILDING PLASTER SPECIFICATION part I EXCLUDING premixed light weight Plasters AMENDMENTS -2 SECTION LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIALS/COMPONENTS AND TEST METHODS LIST OF REFERRED INDIAN STANDARDS IS No. Title 2469:1976 Glossary of terms relating to GYPSUM . 1288:1982 Method of test for mineral GYPSUM and GYPSUM products. 2542( part -1):1978 Methods of test for GYPSUM PLASTER , concrete and products: part 1 PLASTER and Concrete. 460( part 1):1985 Specification for test sieves : part 1 Wire Cloth test sieves.

4 SECTION CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE 6 | P a g e I S S U E N O 1 KINDLY REFER ANNEX 1 RAW MATERIALS/ COMPONENTS GYPSUM is required which is calcined with wood or coal. No material is added to GYPSUM plasters except those which are necessary to control the setting, such as sodium citrate, break-drown products of keratin, potassium sulphate, sodium sulphate, alum and zinc sulphate; or working characteristics such as Alkyl-Aryl sulphonate; or to impart anti-corrosion such as nitrates and nitrites of alkali metals or fungicidal properties. 7 | P a g e I S S U E N O 1 MANUFACTURING PROCESS AND IN-PROCESS QUALITY CONTROLS Production Process Flow Chart 1.

5 Best quality GYPSUM is picked from the market. 2. It is broken into small stones through lump crusher. 3. Small stone particles heated and calcined at per determined temp. Of approx 200 C to 400 C. 4. The mixture is cooled at specified temperature and passed through pulverized. 5. The sand particles. Dust and other impurities are removed from the mixture and pure material is segregated. 6. The pure material is passed through various quality tests like reflectance. Purity setting time and results are analyzed. 7. The material not conforming to standards is rejected and the pure material is packed in HDPE bags with accurate weighment and stitch with stitching machines.

6 8. The packed material is store in moisture proof godown and dispatched to various locations for sale. SECTION FLOW CHART OF MANUFACTURING PROCESS (TYPICAL) 8 | P a g e I S S U E N O 1 SECTION INFRASTRUCTURE FOR PRODUCTION Manufacturing Machinery 9 | P a g e I S S U E N O 1 Machinery Capacity Number Remarks 1 Lump Crusher with electric motor 15 HP, RPM 960 5 MT/Hrs. One - 2 Elevator for transporting material with 3 HP Motor, RPM 960 (Crompton) 5 MT/Hrs. One - 3 Bhati ( Wood/coal fire with 5 HP motor, RPM 960 1 MT/90 Minute Two - 4 Pulveriser 32" chamber with dust collector freedom hopper with motor 50 HP MT/Hrs One - 5 Electric Weighing Machine Range 0-150Kg, 10 gm One 6 Stitching Machine - Two - 7 Trolley For loading 50 Bags Two - 8 Temperature Controller (Located on Bhati No.))

7 1) Range 0-600 C, 1 C One 9 Temperature Controller (Located on Bhati No. 2) Range 0-600 C, 1 C One 10 Power Connection 11 KV One - Note : Adequate Electric Power and Water supply is required CERTIFICATION CRITERIA 10 | P a g e I S S U E N O 1 SECTION CRITICAL REQUIREMENTS OF THE INDIAN STANDARD To be provided by CMD SECTION SCHEME OF TESTING AND INSPECTION DOC:STI/2547( part -1)/1;February 2005. Please see ANNEX 2. SECTION MARKING FEE RATES Description Value Unit 1 MT L S Marking Fee 52200 S S Marking Fee 44200 Slab 1 Rate Slab 1 Qty All Slab 2 Rate 0 Slab 2 Qty 0 Slab 3 Rate 0 Enforcement Date 20060701 Remarks SECTION GROUPING GUIDELINES: GYPSUM BUILDING PLASTER has been classified on the basis of hydration of its Calcium sulphate content.

8 SECTION GUIDELINES FOR WRITING SCOPE OF LICENCE The scope of licence to declare : PLASTER of Paris B hemihydrate (Type A or type B), Retarded Hemihydrate GYPSUM PLASTER , Anhydrous GYPSUM PLASTER or Keene s PLASTER SECTION GUIDELINES FOR INCLUSION OF NEW VARIETIES Based on classification(Section ) inclusion of each new variety to be on the basis of independent testing of sample of each variety. 11 | P a g e I S S U E N O 1 SECTION SAMPLES SIZE One composite sample of approx. 2Kg of each variety for complete testing. SECTION MANNER OF SEALING THE SAMPLE Samples may be wrapped with suitable moisture proof packing material, labeled and wax sealed or as an alternate code no and signatures of IO may be marked with a permanent marker pen on the product.

9 SECTION REMNANTS ARE RETURNABLE/NON-RETURNABLE TO BE SCRAPPED/USED OR TO BE DESHAPED DISPOSAL IN CASE OF SAFETY ITEMS Sample is normally consumed in testing and Remnants are not returnable and may be suitably disposed off by the laboratory. SECTION PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/ RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION BIS Standard Mark to be marked only after ascertaining the quality of the material after testing as per Indian standard and STI. INSPECTION AND TESTING SECTION PACKING MATERIAL REQUIRED FOR PKG/DESPATCH OF SAMPLE 12 | P a g e I S S U E N O 1 Any suitable material may be used for wrapping the sample to avoid moisture and any damage during transit.

10 SECTION LIST OF REQUIRED TEST EQUIPMENT/FACILITIES WITH REQUIREMENT & FREQUENCY OF CALIBRATION To be provided by CL SECTION STATUS OF TEST FACILITIES IN BIS LAB AND OSL WITH TESTING CHARGES AND APPROXIMATE TIME REQUIRED FOR TESTING For latest information, please check the BIS web site SECTION WHETHER GRANT OF LICENCE WILL BE BASED ON FACTORY TESTING BASIS----------------------------------- ----------No INDEPENDENT TESTING BASIS----------------------------------- ---Yes MIXED BASIS (FACTORY TESTING OF PRODUCT PLUS INDEPENDENT TESTING OF SOME RAW MATERIALS)----------No SECTION DETAILS OF TESTS TO BE CARRIED OUT IN CASE OF APPLICANT/VERIFICATION SAMPLES All tests SURVEILLANCE SAMPLES All tests RAW MATERIAL SAMPLES TO BE GOT TESTED IF ANY --NIL 13 | P a g e I S S U E N O 1 CHECKLIST 14 | P a g e I S S U E N O 1 15 | P a g e I S S U E N O 1 16 | P a g e I S S U E N O 1 17 | P a g e I S S U E N O 1 18 | P a g e I S S U E N O 1