DRAFT PRODUCT MANUAL ON BLOCK BOARDS As per … · DRAFT PRODUCT MANUAL ON BLOCK BOARDS ... Each of...

DRAFT

PRODUCT MANUAL

ON

BLOCK BOARDS

As per IS 1659:2004

BUREAU OF INDIAN STANDARDS MANAK BHAWAN,

9, B.S. ZAFAR MARG, NEW DELHI-110 002

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Doc No. : DHBO/1659/Draft Manual

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Draft Product Manual for Block Boards as per IS 1659:2004

PREPARED BY : DHBO APPROVED BY :

Amendment Sheet:

To ensure that this Product Manual contains a complete record of Amendments, this Amendment sheet shall be maintained in the Product Manual.

Sl. No. Amendment No.

Reference No.

Date of Issue

Date of Implementation

Page No.


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BUREAU OF INDIAN STANDARDS



Foreword

This product manual contains the description, manufacturing and testing of Block Boards as per IS 1659:2004 (Fourth revision). Guidelines for Grant of BIS licence for an applicant is also described in this manual. Grouping guidelines, sample size for testing, information about laboratories where the product can be got tested for the purpose of Grant of Licence etc. are described in the manual for the easiness of new applicants as well as existing licensees.


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Table of Contents

Sl. No. Contents Title Page Nos.

Description of Product 6 Latest Indian Standard Number with Product title and number of Amendments

6

List of Referred ISS for Raw Materials/Components and Test Methods

7 1

Section I (Product Description)

Check list for submission of an application for GOL

7 to 10

2

Section II

(Raw Materials/Components)

Raw Materials/Components 12

Description of manufacturing process 14 3

Section III (Manufacturing Process and In-process Quality Controls) Infrastructure for production 15

Identification of critical requirements of the ISS

17

STI 18 to 23 Marking fee rate 24 Grouping guideline 24 Guideline for writing scope of licence 24 Guideline for inclusion of new varieties 25 Sample size 25 Manner of sealing the sample 25 Whether remnants of the sample are returnable/ non-returnable

25

4

Section IV (Certification Criteria)

Procedure to be followed for destroying the product that does not meet the quality parameters during regular production

25

Packing material requirement (to be available in factory at all times) for packing/dispatch of samples

27

List of required test requirements/facilities with requirement and frequency of calibration

27

Status of test facilities in BIS labs and OSL s with testing charges

27 to31

Approximate time required for testing by BIS labs/OSLs

32

GOL based on FT basis/IT basis/Mixed 32 Details of tests to be carried out in Factory 32

5

Section V (Inspection and testing)

CMD-III’s circular 33-34


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Section I: Product Description


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1. Description of Product

Block board is a board having a core made up of strips of wood, not exceeding 30 mm in width, which may or may not be glued together and the core is glued to two or more veneers, on either side with grain direction of core and veneers running at right angles to one another (Ref. Cl.3.1 of IS 1659:2004). IS 1659:2004 (Fourth revsion) covers the essential requirements of commercial and decorative block boards meant both for interior and exterior uses. As per IS 1659:2004, Block boards shall be of the following two grades: a) BWP Grade - Such block board may be used for bus bodies, railway coaches, prefabricated houses etc. where it is likely to be exposed to high humidity and for external use. b) MR Grade - Such block board may be used for interior use such as furniture, partition, paneling, ceiling etc. Each of the above grades shall be of the following two types: a) Decorative Type - These are block boards with decorative face veneers on one or both sides for use in high class furniture, paneling, interior decoration, partitions etc. b) Commercial Type - These are block boards with veneers of commercial timber on both sides and are used for ordinary furniture, table tops, partitions and paneling to be painted over flooring and seats of bus bodies, railway carriages etc.

2. Latest Indian Standard Number with Product title and number of Amendments

IS 1659:2004 Block Boards-Specification No. of Amendments: 02


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3. List of Referred Indian Standards for Raw Materials/Components and Test

Methods

a) IS 303:1989-Specification for plywood for general purposes (third revision)

b) IS 401:2001- Preservation of timber-Code of practice (fourth revision) c) IS 707:1976- Glossary of terms applicable for timber technology and utilization (second revison) d) IS 848:1974- Specification for synthetic resin adhesives for plywood (phenolic and aminoplastic) (first revision) e) IS 1141:1993- Code of practice for seasoning of timber (second revision) f) IS 1328:1996- Specification for veneered decorative plywood (third revision) g) IS 7638:1999- Wood/Lignocellulosic based panel products-Methods of sampling (second revision)

4. Check-List for submission of an application for grant of licence

a) Check list for application to be submitted by applicant to BIS while applying for BIS licence


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b) List of documents to be attached with application


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Section II: Raw Materials/Components


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1. Raw Materials/Components (Ref: Cl. 5 of IS 1659:2004) a) Timber :

Any suitable species of timber may be used for block board manufacture. A list of species for manufacture of block board is given in Annex B of IS 1659:2004 for guidance only. For ECO-Mark only species of wood from sources other than natural forests such as wood from rubber, cashew industrial and social forestry plantations etc. and shade trees from tea and coffee estates, shall be used for the manufacture of block board.

Face Veneers for Decorative Type of Block Boards: The species of timber for the decorative face veneer in decorative type of block board shall be specified by the purchaser while placing the order. The species of timber commonly used for face veneers of decorative type of block boards is given in Annex C of IS 1659:2004 for guidance only. For ECO-Mark only species of wood from sources other than natural forests such as wood from rubber, cashew industrial and social forestry plantations etc. and shade trees from tea and coffee estates shall be used.

b) Adhesives :

The adhesives used for bonding purposes shall be the BWP type conforming to IS 848 for BWP Grade block boards. For MR Grade block boards, the adhesives shall be MR type conforming to IS 848.

Note: The compliance of Cl. 5 of STI (Doc: STI/1659/5 Oct 2004) shall be ensured.


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Section III: Manufacturing Process and In-process Quality Controls


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1. Description of manufacturing process

A typical flow chart indicating manufacturing process is depicted below:

* The compliance of Cl. 6 “Manufacture” of IS 1659:2004 shall be ensured.


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Timber

Sawing

Seasoning

Board Preparation

Spreading of Glue (Confirming to IS 848)

Assembly

Prepressing

Hot Pressing

Trimming

Sanding

Preservative Treatment (As per Cl. 6.1 of IS 1659:2004)

Drying

Gaping

Marking as per STI & Despatch

Testing as per STI

Destroyed/ may be

Re-worked & sold as Non-ISI OK

NOT OK



2. Infrastructure for production A Unit may need following machineries in manufacturing the Block Boards: a) Boiler b) Resin kettle c) Peeling machine d) Hand chopping e) Paddle chopping f) Glue Mixer g) Glue Spreader h) Aluminium Plate i) D.D Saw j) Sanding Machine k) Generator l) Seasoning Chamber m) Preservative treatment tank n) Assembly table o) Dryer p) Band Saw q) Generator r) Rip Saw s) Wood Plainer t) Cutter u) Hot Press f) Aluminum Plate Stand with Fan


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Section IV: Certification Criteria


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1. Identification of critical requirements of the Indi an Standard

(To be identified by CMD)


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2. Scheme of Testing and Inspection:


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3. Marking fee rate: The following rate of marking fee is applicable for a licence:

i) Rate of marking fee: Unit – One Sq. meter Rs. 0.36 for all units

ii) Minimum marking fee Rs. 29000 (for Small Scale Industries) /Rs.34000 (for Large Scale Industries) for one operative year payable in advance which will be caried to next renewals.

iii) Actual marking fee for the first nine months of the operative period calculated on unit rate basis on the production marked or the minimum marking fee whichever is higher shall be payable by the licensee.

4. Grouping Guideline (if any):

i) No guidelines prescribed as yet. ii) Proposed grouping guidelines is enclosed at page 35. CMD may please examine the proposal.

5. Guideline for writing scope of licence:

Scope of licence may be written as: “Recommended Grant of Licence for use of Standard Mark on Block Boards, Grade- MR/BWP,Type-COM/DEC as per IS 1659:2004 (Upto Amd. 2)”


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6. Guidelines for inclusion of new varieties:

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.

7. Sample size: For Grant of Licence under Normal Procedure, the following samples to be drawn: 1. One block board of full size 2. Resin: 5 litres 3. Face veneer & Cross band: 02 pieces each of suitable size for testing species, thickness, uniformity of thickness and Moisture content. 4. Core strips: 02 pieces of suitable size for testing species,width and Moisture content 5. Edge strips: 02 pieces of suitable size for testing species and width

8. Manner of sealing the sample: Coded & signed with a permanent marker and wrapped in a thick poly bag.

9. Whether remnants of the sample are returnable/non-returnable:

Returnable

10. Procedure to be followed for destroying the product that does not meet the quality parameters during regular production: In case of sample does not meet the requirements specified in Indian Standard, such control unit shall not be marked. Since the product is not covered under Mandatory Certification, hence rejected control unit may be either destroyed or re-worked and sold as Non-ISI.


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Section V: Inspection and testing


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1. Packing material requirement (to be available in factory at all times) for packing/dispatch of samples:

Thick poly bag of the size of the block board. Cans & clothes for packaging of resin.

2. List of required test equipments/facilities with requirement and frequency of calibration: (To be decided by Central Lab, Sahibabad)

The list of testing equipments required for IS 1659:2004 circulated by CMD-III vide their circular (Ref: CMD-III/IS 1659/1 dated 24.01.2008) is enclosed at page 33 and 34.

3. Status of test facilities in BIS labs and OSLs with testing charges :

Technical Auditor shall ensure status of laboratory, availability of testing facilities and testing charges at the time of visit from BIS Intranet.

List of BIS Laboratories (As on 13.12.2013)

Date :- 13/12/2013

Lab Quantity Lab

Type Testing

Facility Remarks

IS Number :- IS 1659 - 0 : 1990 BNBOL 2 nos. Mech N

EROL 2 nos. Mech P Except Edge straightness, Squareness

SROL 1 No. Mech P excluding load,type&mycological tests

IS Number :- IS 1659 - 0 : 2004

CL One board of full size

Mech P

IS No. Testing Charges Remarks IS 1659 : 1990 Rs 600/-

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility


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List of Outside Recognized Laboratories (As on 13.12.2013)

Sl No. Name of the Recognized Laboratory Lab Code Testing Charges

Remarks

IS Number :- IS 1659 - BLOCK BOARDS

1 Indian Plywood Industries Research & Training Inst B-65, Phase-VII, Industrial Area Mohali-160055 Punjab Contact : Dr. Pradeep K. Kushwaha, Officer -In-Charge Tel : 0172-2236130 Fax : 0172-5095875

9120435 Rs.4000/- Rs. 500/- extra to carry out on tests on dimensions & tolerances

2 Bharat Test House 454/2, 1st Floor, Timber Market, Azadpur Delhi-110033 Delhi Contact : Mr. Rajiv Gupta, CEO Tel : 011-27672629 Fax : 011-27681204

8118506 Rs.5366/- for MR Grade, Rs.6494/- for BWP Grade [10% discount to BIS]

3 International Testing Centre 86, Industrial Area, Phase-1 Panchkula-134109 Haryana Contact : Sh. K. R. Gupta, CEO Tel : 0172-2565825 Fax : 0172-2561543

9108716 Rs 2000/-


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4 Choksi Laboratotries Limited 6/3 Manoramaganj Indore-452001 Madhya Pradesh Contact : Shri Sunil Choksi Tel : 0731-2490593 Fax : 0731-2490593

8100106 BIS Testing Charges Suspended w.e.f. 30.09.2013

5 Cali-Labs Pvt Ltd HX-83, E-7, Arera Colony Bhopal-462016 Madhya Pradesh Contact : Shri V.G. Narula, Director Tel : 0755-4218014,2468583 Fax : 0755-2461836

8118116 BIS testing charges

6 Gujarat Test House Plot No.292, Road No.4, GIDC Kathwada Ahmedabad-382430 Gujarat Contact : Shri A.N. Barua, CEO Tel : 09825063601 Fax : 079-22168817

7109836 Rs. 4,500/-

7 Indian Plywood Industries Research & Training Inst (IPITRI) Post Bag No.2273, Tumkur Road Bangalore-560022 Karnataka Contact : Dr. C.N. Pandey, Director Tel : 080-28394231,32,33 Fax : 80-28396361

6107135 Rs.4000/- and Rs.500/- extra for tests on dimensions and tolerances


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8 National Test House (NR) Kamla Nehru Nagar Ghaziabad-201001 Uttar Pradesh Contact : The Director Tel : 0120-2789493 Fax : 0120-2789883, 13

8101304 Rs.8000/- Renewal deferred

9 Hindustaan Test House 80-HSIIDC, 2nd Floor, Industrial Area, Ambala Cantt-133001 Haryana Contact : Ms. Rachna Nayyar, CEO Tel : 09355002828 Fax : 0171-2698089

9122136 Rs.6150/- with water resistence (MR); Rs.6850/- with water resistance(BWP)

(20% discount for BIS on the given charges)

10 Indian Plywood Industries Research & Training Institute IPIRTI, Kolkata 2/2, Biren Roy Road (West), Sarsuna, Kolkata-700061 Contact : Sh. Amitava Sil(Officer-In-Charge) Tel : 91-033-24983120 Fax : 91-033-24983120

5125335 Rs.4,000/- Rs.500/- extra to carry out test on dimensions and tolerance

11 National Test House (NWR) E 763, Road No.9F-1 VKI Area Jaipur-302019 Rajasthan Contact : Sh.Rakesh Saini, Scientist In-charge Tel : 0141-2332057,58 Fax : 0141-2330074

8122904 Rs.8000/-


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12 M/s CIMEC Technologies Private Ltd. 23/H, Meldi Estate, Near Gota Railway Crossing Gota, Ahmedabad-382424 Gujarat Contact : Shri. Veer Singh, Director Tel : 079-64102053 Fax :

7127606 BIS Testing Charges

13 M/s United Solutions Private Limited C-245, Village: Allour, Bhadla Road, Khanna Distt.- Ludhiana Ludhiana-141402 Contact : Shri Manoj Kumar, Managing Director Tel : 09417010448 Fax : 01628-238108

9126706 BIS Testing charges


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4. Approximate time required for testing by BIS labs/OSLs : (To be decided by Central Lab, Sahibabad)

5. Whether grant of licence will be based on: Factory testing basis X Independent testing basis √ Mixed (Factory testing basis plus Independent testing basis ) X

6. Details of tests to be carried out in the factory in case of : � Applicant sample/verification sample-

All possible Routine tests like Defects and finish, Dimensions & Tolerances, Variation in thickness,Adhesion of plies, MOR,MOE,Spot test etc.

� Surveillance sample- All possible Routine tests like Defects and finish, Dimensions & Tolerances, Variation in thickness,Adhesion of plies, MOR,MOE,Spot test etc.

� Market sample- The laboratory shall conduct maximum possible test in order to assess quality of the product.

� Raw material samplesto be got tested , if any-

Compliance of Cl. 5.0 of STI (Ref: Doc. STI/1659/5 Oct 2004) and Cl.5 & 6 of IS 1659:2004 shall be ensured.


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ANNEXURE of CLAUSE 2 OF SECTION 5


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ANNEXURE of CLAUSE 4 OF SECTION 4

PROPOSED GROUPING GUIDELINES FOR IS 1659:2004

1. The Block Boards may be grouped under two categories as shown below:

Group Grade & Type 1 BWP-DEC and BWP-COM 2 MR-DEC and MR-COM

2. Since Grade-BWP Type- DEC being the most superior grade, for covering all grades & types under the licence, BWP-DEC variety may be drawn for Independent Testing. 3. However while considering grant of licence /inclusion of additional variety, it will be ensured that the applicant/licensee has got the complete manufacturing and testing facilities for varieties to be covered in the licence. 4. During operation of the licence in an operative period, BO shall ensure that all designation & grades covered in the licence are tested in factory and drawn for Independent testing on rotation. The above grouping guidelines may be considered for finalization by CMD.

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