COVERED ELECTRODES FOR MILD STEEL WIRE … · D.1 Copper sulphate solution or D.2 Copper tin...

Doc No: CMD/280/Draft Manual

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DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS

Our Ref.CRO 22 / BPBO 19 Dec 2013 Please find enclosed the following draft certification manual : COVERED ELECTRODES FOR MILD STEEL WIRE FOR GENERAL ENGINEERING PURPOSES AS PER IS 280 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 30 Dec 2013. Comments, if any, may please be made in the format as given below and mailed to BPBO (Bhopal) at the following email id: hbplbo.bis

Sl. No.

Name of RO / BO

Clause/ Sub‐clause

Paragraph / Figure / Table

Type of comment (General / Technical / Editorial)

Comments Proposed Change

Note: Separate sheets may be attached incase comments are lengthy and cannot be incorporated in the


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DRAFT MANUAL FOR CERTIFICATION OF COVERED ELECTRODES FOR MILD

STEEL WIRE FOR GENERAL ENGINEERING PURPOSES AS PER IS

280

(FIRST ISSUE)

BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH

ZAFAR MARG, NEW DELHI – 110002


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Amendment Sheet S.No. Amendment No Reference no Date of Issue Date of implementation


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FOREWORD The present manual attempts in highlighting various requirements and providing handy and significant information related to “Mild Steel Wire for General Engineering Purposes”. It elaborates principle raw materials, manufacturing processes and desired controls, involved inspection and testing as need be practiced by BIS licencees and further monitoring thereof expected to be exercised by BIS Inspecting Officials during planned visits to those units and monitoring of BIS Certification Marks activities. Different tests as contained in relevant standards and referred standards thereof need be carried out at the licensee’s laboratory by the visiting officer with knowledge and background possessed by the individual. Since such inspecting officers come from different educational and technical background and may not be experienced or even having basic knowledge in the relevant field or product category, such documentation of sectoral manual aims in providing basic inputs and all essential aspects with the expectation of bringing uniformity of vision and enabling adoption of rational practices by concerned BIS officials during their visits for inspections to such sector as well as follow up actions.

TABLE OF CONTENTS


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Section No/ Para No

Title Page no

0 Amendment Sheet 2 0 Foreword 3 Section 1.0 Product Description 6-7 Para 1.1. Latest Indian Standard Number with Product Title and

Number of Amendments 7

Para 1.2 List of referred Indian Standards 7 Para 1.3 Check-list for submission of an application for grant

of licence 7

Section 2.0 Raw materials/ Components 8 Section 3.0 Manufacturing Process and In- Process Quality

Controls 9

Para 3.1 Manufacturing Process 9 Para 3.2 Infrastructure for production 9 Section 4.0 Certification criteria 10-11 Para 4.1 Identification of Critical Requirements of the Indian

Standard 10

Para 4.2 Scheme of Testing and Inspection 10 Para 4.3 Marking fee Rates 10 Para 4.4 Grouping guidelines 10 Para 4.5 Guidelines for writing Scope of Licence 10 Para 4.6 Guidelines for inclusion of new varieties 10 Para 4.7 Sample size required to be sent to independent lab for

testing 10

Para 4.8 Manner of sealing of samples 11 Para 4.9 Procedure of disposal of remnants of Tested Samples 11 Para 4.10 Procedure to be followed if sample does not meet the

specified norm as per Indian Standard during regular production

11

Section 5.0 Inspection and Testing 12-13 Para 5.1 Packing Material for packing/dispatch of samples 12 Para 5.2 List of test equipment/ Facilities with requirement and

frequency of Calibration 12

Para 5.3 Status of Test Facilities in BIS labs/OSLs 12 Para 5.4 Grant of Licence 12 Para 5.5 Details of tests to be carried out in the factory 12


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Appendix-A --------- Check list for submission of an Application for Grant of Licence Appendix-B --------- Flow Chart Appendix-C --------- List of Manufacturing Machinery Appendix-D --------- Scheme of Testing and Inspection

SECTION – I


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1.0. Description of product: Mild steel, also called plain-carbon steel, is the most common form of steel because its price is relatively low while it provides material properties that are acceptable for many applications Plain carbon steel contains approximately 0.05–0.3% carbon making it malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap and malleable. It is often used when large quantities of steel are needed, for example as structural steel. Mild steel wire are obtained from wire rod, generally in round, half round, square, hexagonal, flat or of any other section including grooved section, characterized by the fact that it has been subjected to cold drawing through a die or by other mechanical means. 1.1. Latest Indian Standard Number with Product Title and Number of Amendments: Latest Standard: IS 280:2006 Title: Mild Steel Wire for General Engineering Purposes No. of Amendments: 01

1.2 List of referred Indian Standards for raw materials/ components and test methods: The following standards contain provisions which through reference in this text, constitute provisions of this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision and parties to agreements based on this standard are encouraged to investigate the possibility Of applying the most recent editions of the standards indicated below: IS No. Title 228 (all parts) Methods for chemical analysis of steels 1387:1993 General requirements for the supply of metallurgical

materials (second revision) 1608:2005 Metallic materials — Tensile testing at ambient

temperature (third revision) 1755:1983 Method for wrapping test for metallic wire first

revision)


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1956 (Part 5): 1975 Glossary of terms relating to iron and steel: Part 5 Bright steel bar and steel wire

4826:1979 Hot-dipped galvanized coatings on round steel wires

(first revision) 4905:1968 Methods for random sampling 7887:1992 Mild steel wire rods for general engineering purposes

(first revision) 12753:1989 Electro galvanized coatings on round steel wire 1.3 Check-list for submission of an application for grant of licence: Please see Appendix-A

SECTION – II


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2.0 List of Major Raw Materials: A) Mild Steel wire rod conforming to IS 7887, B) For Annealed, cleaned and limed wire B.1 Dilute acids for pickling of steel, B.2 Hydrated lime. C) For Galvanized wire

C.1 Zinc ingots D) For Coppered wire

D.1 Copper sulphate solution or D.2 Copper tin sulphate solution

E) For Tinned wire E.1 Tin ingots

SECTION – III 3.0 Manufacturing Process and In-process Quality Controls:


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3.1 Manufacturing Process: A generalized flow chart with process controls points given at Appendix-B 3.2 Infrastructure for production: Please see Appendix-C

SECTION – IV


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4.0 Certification Criteria 4.1 Identification of Critical Requirements of the Indian Standard: (To be provided by a committee comprising the concerned officer from CMD, Member-Secretary of the concerned technical committee and an officer from central laboratory) 4.2 Scheme of Testing and Inspection: DOC: STI/280/R-1/7 September 2006 (Please see Appendix-D) 4.3. Marking fee Rates: Manufacturing Status of Industry

Minimum marking fee per year

Unit Rate

Large Scale Rs. 34,000/- 1 Tonne Rs.3/- for all units Small Scale Rs. 29,000/- 1 Tonne Rs.3/- for all units 4.4 Grouping guidelines: There is no grouping guidelines exists as on date to consider Grant of license/inclusion of new varieties for this product. 4.5 Guidelines for writing Scope of Licence: Scope of the license shall contain, diameter of the wire, condition of the wire as per table 2 of IS280:2006(Annealed or Soft or ¼ hard or ½ hard or hard drawn) and finishing as per Cl 10 of IS280:2006 (coated or uncoated); If coated with zinc i.e., galvanized the type of coating (Light or medium or heavy coat) as per IS 4826 or IS 12753 or any declared values shall be mentioned clearly. 4.6 Guidelines for inclusion of new varieties: There is no grouping guidelines exists as on date to consider Grant of license/inclusion of new varieties for this product. For getting a new variety included in the existing licence, a licensee is required to get the sample of each variety tested from BIS recognized laboratories. In case. Additional manufacturing and testing facilities are required to be declared for inclusion in the scope of the licence. 4.7 Sample size required to be sent to independent lab for testing: For Mechanical testing 4 meters of M S wire sample and for chemical testing 50 gm drilling is required. It shall be ensured that the size of the sample is adequate for testing (and retesting wherever needed) the requirements for which it is desired to be tested. The technical auditor shall anticipate all requirements of the laboratory on the basis of' the relevant Indian Standards and STI, and draw the required size of the sample. Counter samples of identical size shall be drawn and left with the applicant / licensee.


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4.8 Manner of sealing: 4.8.1 Sealing - The samples are properly tied and sealed with official seal, so that no substitution or tampering with the contents is possible subsequently. For the purpose of sealing, the technical auditor should always carry the brass seal. 4.8.2 Packing - The technical auditor shall take every precaution to ensure that the sealed samples are covered with polyethylene film tightly (to avoid samples contact with water). The drilling samples shall be packed in the Polyethylene pouches, further packed in wax coated envelop and sealed/signed. Wherever feasible, all original markings indicating the origin of the product would be removed / defaced from the sample with the objective of concealing the identity of the origin from the testing laboratory. 4.8.3 Labelling - The sample shall be labeled to indicate (a) Mild Steel Wire for General Engineering Purposes; (b) the relevant Indian Standard with its year (IS280:2006); (c) Size of the wire; (d) Type of coating (e) Condition of the wire as per Table 1;(f) Quantity of sample (4 meters + 50 gms); (g) batch No. /Control Unit No. /date of production; (h) Sample code. Labels shall be tagged on the Packing. 4.9 Procedure of disposal of remnants of Tested Samples: These remnant samples are non returnable and shall be disposed off. 4.10 Procedure to be followed if sample does not meet the specified norm as per Indian Standard during regular production: In case of sample does not meet the requirements specified in Indian standard, such control unit i.e. Batch/lot shall not be marked. Those rejected batches/lots shall be scrapped.

SECTION – V 5.0 Inspection and Testing 5.1 Packing Material: The following material should always be available with the firm for packing, sealing and dispatch of samples:


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Wax coated plain envelops, Polyethylene pouches, Polyethylene covers, Thread, Sealing wax, Candle, Match box, Gum, Stapler, Sealing tape, etc. 5.2 List of test equipment/ Facilities with requirement and frequency of Calibration: (To be prepared / provided by Central Laboratory) 5.3 Status of Test Facilities in BIS labs/OSLs: Technical auditor shall ensure status of laboratory and availability of testing facilities at the time of visit from BIS intranet. 5.3.1 Testing Charges: (To be provided by Central Laboratory) 5.3.2 Approximate time required for testing by BIS labs/OSLs: (To be provided by Central Laboratory) 5.4 Grant of Licence: Grant of licence would be on the basis on independent testing. 5.5 Details of tests to be carried out in the factory: 5.5.1 In case of Applicant/Verification samples:

a) Chemical Composition (Clause 6) b) Size (Clause 7) c) Mechanical tests (Clause 9) d) Coating tests (Clause 11) e) Freedom from Defects (Clause 13)

5.5.2 In case of Surveillance samples: Technical auditor shall conduct maximum possible tests in order to bring out any deficiencies in test equipment/testing procedures and testing personnel as well as for spot establishment of quality of product 5.5.3 In case of Market samples: The laboratory shall conduct maximum possible tests in order to asses’ quality of the product. 5.5.4: In case of Raw Material: Mild steel wire rod sample shall conform the specifications mentioned IS 7887:1992.


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APPENDIX-A

CHECK-LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION

SCHEME OF BIS

The following check-list is required to be submitted with all the applications for grant of BIS licence under the Product Certification Scheme of BIS. Please tick (√) in the relevant box. Whether applied under: Simplified Procedure Normal Procedure


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Note: Refer BIS website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence.

No. Check-point Requirement Observations Page No.

General Is the application form completely filled? Name &

Address

Is the name and address of applicant (manufacturing unit applying for licence) same in the application as given in the attached document of Central/State Government

a. Has it been indicated whether the applicant is a large scale or small scale unit?

b. In case the applicant is a small scale unit, does the applicant hold valid Registration Certificate from the Local / State authority or from a Chartered Accountant, and is the certificate attached.

Status of Applicant (Manufacturing Unit)

c. Has it been indicated whether the applicant is a Public Sector or a Private Sector company?

a. Has applicant recorded the applicable Indian Standard with correct title of the Standard?

IS No. & Varieties

b. Where applicable, has applicant mentioned designation, grade, type, variety, size, etc., of the product for which the BIS licence is sought?

a. Where applicable, has the applicant provided information regarding earlier BIS licence(s) held by them and / or cancelled in the past?

History

b. Where applicable, has the applicant provided information regarding BIS licences currently held by them?

a. Is the application signed by the CEO of the applicant?

Signature

b. In case the application is signed by a person other than the CEO, is the application signed by the authorized signatory of the applicant and his authorization is attached by the authorized signatory?

Machinery a. Does applicant possess requisite manufacturing infrastructure to manufacture the


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product as per the Indian Standard? b. Is installed capacity of production indicated in the application?

c. Does applicant have all machineries installed as per manufacturing process at the applicant’s manufacturing premises?

d. If answer to ‘c’ above is no, does the applicant outsource any of its manufacturing processes and possesses valid agreement(s) with other manufacturing units for the outsourced processes and traceability of material, thus produced, etc.?

e. If answer to‘d’ above is yes, does the applicant has any control over such outsourced activity? Are these outsourced process will ensure testing the quality of final product for all requirements at the applicant's manufacturing premises?

a. Does applicant possesses requisite test facilities in-house as per the relevant Indian Standard at its factory address?

b. Are valid calibration certificates for relevant test equipment attached are complete and valid at least 3 months after the date of recording?

Test Equipment & Calibration

c. If reply to ‘a’ above is no, does applicant have arrangement with a BIS recognized outside lab for testing of the requirements for which it does not possess test facilities in-house? Is the consent letter as attached by applicant in this regard in order? Note: Relaxation in in-house test facilities may be allowed on submission of proper justification for requirements which are obligatory to get tested and for which frequency of testing, as prescribed in the relevant scheme of testing and inspection (STI),is, normally, one month or more.

QC personnel Does the applicant employ qualified & experienced Quality Control (QC) personnel on permanent basis and possess documentary


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evidence to establish the same? Are the copies of the qualification certificates and appointment letters of the QC personnel are in order

Raw Materials and Components

Where ever requirements for raw materials/ components used in the manufacturing of the product are specified in the standard, do test reports/suppliers’ test certificates, as submitted by the applicant show that these requirements are met as per the standard?

Plant Layout Does copy of the plant (applicant manufacturing premises) layout clearly indicates locations of manufacturing machinery, laboratory, office, workshop, amenities, storage area, etc.?

a. Is the attached test report of in-house or from independent laboratory cover all requirements of the Indian Standard and is passing in such requirements?

Test Report(s)

b. In case the application is filed under “simplified Procedure” is the test report(s), in original, as submitted a) from BIS or its recognized laboratories? b) the test report is not older than one month from the date of submission of application, c) covers all the requirements of the standard, and d) passes in all such requirements.

Undertaking In case application is under simplified procedure, an undertaking shall be obtained from the applicant on his letter-head that the licence if granted against his application shall be put under Stop Marking by BIS if the verification sample(s) (any sample including the long duration test samples) drawn during visit of the BIS officer prior to grant of licence fail to conform to the requirements of relevant Indian Standards. The licensee shall take necessary corrective actions and inform the same to BIS along with fresh samples (of rating/size/variety which facilitates verification of corrective actions on the reported failures) manufactured after taking the corrective actions. The resumption of marking in such cases shall be allowed only on the basis of independent


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satisfactory Test Reports of the fresh samples offered (including long duration tests where failures were in long duration tests). In case the fresh sample drawn by BIS for independent testing fails, or the licensee does not inform corrective actions taken and does not offer improved samples within 1 month of the date of Stop Marking, the licence shall be processed for cancellation and no further chance would be given to the licensee

Application Fee

Has applicant paid requisite application fee of Rs. 1000/-, in equivalent US$ (Rs. 1000/- plus 12.36% tax for applicants from SAARC countries)?

Signature Is the application countersigned by the applicant’s Authorized Indian Representative?

a. Has ‘Nomination Form’ of ‘authorized Indian representative (AIR)’ in the prescribed format on the firm’s letter-head, duly signed by the authorized signatory of the applicant and the AIR or the authorized person of the company of the AIR, been submitted with the application?

b. Is the authorization to the signing authority to sign the ‘Nomination Form’ on behalf of the Indian Co. also submitted?

c. Is address of the AIR in the ‘Nomination Form’ complete and evidence of nationality, address proof, contact details like phone / fax numbers and e-mail address of the AIR submitted?

d. In case AIR is an Indian company, have copies of registration certificate and/or Memorandum of Articles along with authorization letter from top management of the Indian company in the name of a person acting as the AIR also been submitted with the application?

e. Has copy of Agreement between applicant and the Indian company / individual, nominated as the AIR, also been submitted?

Nomination

f. Are copies of valid RBI clearance certificate


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for Indian Office / Branch of the applicant or any other relevant document for establishment of its Office / Branch in India provided?

Language Are English translations of all the documents, which are in languages other than English, also available?

Preliminary Inspection / Visit Charges

Does the applicant undertake to bear inspection charges for all the inspections to be carried out by BIS at its premises before the grant of licence, including the arrangements and costs incidental thereto for travel and stay, visa, insurance, etc.?

Translation Facility

Does the applicant undertake to arrange, if required, services of translator (for translation in English) during the visits of BIS officers to its factory?

Agreement Does the applicant agree to sign a legally binding agreement with BIS in the prescribed format?

Indemnity Bond

Does the applicant agree to submit an Indemnity Bond to BIS in the prescribed format?

Performance Bank Guarantee

Does the applicant agree to furnish a Performance Bank Guarantee to BIS of US $ 10000/- (from a bank having its branch in India) in the prescribed format on the letter-head of the bank?

APPENDIX-B

Raw material (wire rod) conforming to specifications as per

IS7887:1992

Wire Drawing of required size (Soft / ½ hard / ¼ hard / hard drawn)

Wire Drawing of required size (Annealed /Soft / ½ hard / ¼ hard /

hard drawn)


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APPENDIX-C

S No

Name of Machine/Qty. Capacity Make Date of purchase

Quantity

1 Wire Drawing Machine with dies of required sizes of wire

2 Cutting / Shearing Machines

3 Coiler and Decoilers 4 Annealing furnace (If required)

Coating as Required

Dimension check, mechanical properties check

Pass

Rejected- Scraped / Recycled

Pass

fail

Coating check as per Cl 11 of IS280:2006

Rejected- Scraped / Recycled

fail

Pass

Marking and packing as per

IS280:2006


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5 Crucibles for Melting of Zinc or Tin metal for Galvanizing or Tinning of wire respectively (If required)

6 Arrangements for pickling and lime washing (If required)

APPENDIX-D DOC/STI/280/R-1/7, September 2006

SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF

MILD STEEL WIRE FOR GENERAL ENGINEERING PURPOSES ACCORDING TO IS 280:2006

(Fourth Revision)


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1. LABORATORY – A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification.

2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau.

2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained.

2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request.

3. QUALITY CONTROL – It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part I):2003, IS 397(Part 2):2003 and IS 397(Part 3):2003].

3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9001.

4. STANDARD MARK – The Standard Mark, a s g i v e n i n Column (1) of the First Schedule of the licence, is specified for the various categories of mild steel wires covered in IS 280:2006.

4.1 For each consignment of BIS certified material conforming to IS 280:2006 there shall be a test certificate which shall contain the BIS Standard Mark, the cast/lot number and the corresponding test results (as given in Annex I).

4.2 MARKING AND BUNDLING - Each coil of wire shall be suitably bound and fastened compactly and a metal tag attached to it should bear the following particulars:

a) Name of the manufacturer or trade mark; and b) Finish; c) Size of wire; d) Lot number; and e) Licence number (CM/L…….). 5.1 LEVELS OF CONTROL - The tests, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production of the


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factory which is covered by this scheme and appropriate records and charts maintained in accordance with paragraph 2.0 above. All the production which conforms to the Indian Standards and covered by the licence shall be marked with certification mark of the Bureau 5.2 If the tested material received do not carry the cast number or any other identification mark, it shall be marked for identification. In case of mix up, one sample for every 10 tonnes or part thereof of unidentified tested wire rods shall be tested for chemical analysis.

5.3 On the basis of tests and inspection, the decision regarding conformity or otherwise of the control unit to a given requirement shall be made.

5.4 In respect of all other clauses of the specification and all stages of manufacture the factory shall maintain appropriate control to ensure that the product conform to the requirements of these clauses.

6.0 REJECTIONS - A separate record shall be maintained giving information

relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no circumstances be stored together with those conforming to the specification.

7.0 SAMPLES - The licensee shall supply, free of charge, the samples required

in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory or godowns. The Bureau shall pay

for the samples taken by it from the open market. 8.1 REPLACEMENT- whenever a complaint is received soon after the goods with Standard marks have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods are replaced free of cost by the licensee in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with the Bureau. The firm shall have own complaint investigation system as per IS 15400.

8.2 In the event of any damages caused by the goods bearing the standard Marks, or claim being filed by the consumers against BIS Standard mark and not “ conforming to” the relevant Indian Standard, entire liability arising out of such non-conforming product shall be of licensee and BIS shall not in any way be responsible in


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such cases. 9.1 STOP MARKING - The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau.

9.2 The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of marking shall also be sent to the Bureau.

10.0 PRODUCTION DATA -The licensee shall send to BIS as per the enclosed

proforma- 1 to be authenticated by a Chartered Accountant a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence.

. Table 1……

IS 280:2006

MILD STEEL WIRE FOR GENERAL ENGINEERING PURPOSES

TABLE 1 LEVELS OF CONTROL

(Para 5 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL Cl. Requirement Test Methods

Clause Reference

No. of

Lot Size

Fre- quency

Remarks

6. Chemical Composition

Relevant part of IS 228 or any other established instrumental/chemical method

Each consignment of raw

Material used shall be supported by test certificate

from the supplier of steel.

Also refer clause5.1 of STI.


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7 & 8

Dimensions and tolerances

7&8 IS 280:2006 Table 1

Each coil

9.1 Tensile Test IS 1608 Every fifth coil 9.2 Wrapping Test IS 1755 -do- 9.3 Bend Test 9.3 IS 280:2006 -do- 11 Coating Test

Zinc coating Electro galvanizing

IS 4826 IS 12753

-do-

13 Freedom from Defects

Adequate inspection to ensure the quality

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