BUREAU OF INDIAN STANDARDS (Southern Regional Office) Our Ref: 60/CM 1 22 Jan 2014 Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I’s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 1786 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/VZBO. (E. Devendar) Sc.G & DDGS HITSD -- E. DEVENDAR Scientist G & Deputy Director General (South) Bureau of Indian Standards Southern Regional Office IV Cross Road, C.I.T. Campus Tharamani, Chennai - 600 113 Email: [email protected]Phone: 044 - 2254 2365 Fax: 044 - 2254 1087
Transcript
BUREAU OF INDIAN STANDARDS
(Southern Regional Office)
Our Ref: 60/CM 1 22 Jan 2014
Subject: Preparation & Review of Product Manuals for Product
Certification
This has reference to CMD-I’s circular CMD-1/31 dated 11 Nov 2013 on
the above subject.
In this connection, the draft Product Manual in respect of IS 1786 allotted to SRO has been prepared. The same is attached herewith for
hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days.
Please find enclosed the following draft certification manual :
HIGH STRENGTH DEFORMED STEEL BARS AND WIRES FOR CONCRETE
REINFORCEMENT AS PER IS 1786:2008
Kindly examine the draft product certification manual and forward your comments on the draft manuals.
Last date for comments: ------ 2014.
Comments, if any, may please be made in the format as given below and mailed to VBO at the following email id: [email protected]
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 table.
DRAFT
CERTIFICATION OF
DEFORMED STEEL BARS AND
FOR CONCRETE REINFORCEMENT AS
PER IS 1786:2008
BUREAU OF INDIAN STANDARDS
9 BAHADUR
Doc. No. VZBO/1786/Draft Manual
DRAFT MANUAL FOR
CERTIFICATION OF HIGH STRENGTH
DEFORMED STEEL BARS AND WIRES
FOR CONCRETE REINFORCEMENT AS
PER IS 1786:2008
(FIRST ISSUE)
BUREAU OF INDIAN STANDARDSMANAK BHAWAN
BAHADUR SHAH ZAFAR MARG
NEW DELH1–I10002
VZBO/1786/Draft Manual
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HIGH STRENGTH
WIRES
FOR CONCRETE REINFORCEMENT AS
BUREAU OF INDIAN STANDARDS
MARG
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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 “High Strength
Deformed Steel Bars And Wires For Concrete Reinforcement”. It elaborates principle raw materials, manufacturing processes and desired controls, involved inspection and testing as needed to 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, needed to 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.
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TABLE OF CONTENTS
Section No/
Para No Title Page no
0 Amendment Sheet 3
0 Foreword 4
Section 1.0 Product Description 6
Para 1.1. Latest Indian Standard Number with Product Title and Number of Amendments
6
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 7
Section 3.0 Manufacturing Process and In- Process Quality Controls 7
Para 3.1 Manufacturing Process 7&8
Para 3.2 Infrastructure for production 9
Section 4.0 Certification criteria 10
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 10 & 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
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 --------- List of Test Equipments
Appendix-C --------- Scheme of Testing and Inspection
Appendix-D --------- Grouping Guidelines
SECTION – I
1.0. Description of product:
High strength deformed bars are steel
bars which are provided with lugs,
ribs, projection or deformation on the
surface and are produced in form of cold
twisted deformed / Thermo Mechanically
Treated/ Micro alloyed bars. These bars
are extensively used for reinforcement
purposes in a construction. Due to ribs
or projections on the surface, these steel
bars minimize slippage in concrete and
increase the bond between two materials
i.e. between cement concrete and steel bars.
1.1. Latest Indian Standard Number with Product Title and Number of Amendments:
• Latest Standard: IS 1786:2008
• Title: High Strength Deformed Steel Bars and Wires for concrete Reinforcement
• No. of Amendments: 02
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:
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IS No. Title
228 (Part 1 to 24) Methods of chemical analysis of steels 1387:1993 General requirements for the supply of metallurgical materials (second revision) 1599:1985 Method for bend test (second revision) 1608 :2005 Metabollic materials- Tensile Testing at ambient temperature (third revision) 2062:2006 Hot rolled medium and high tensile structural Steel (seventh revision) 2770(Part 1): Methods of testing bond in 1967 reinforced concrete : part 1 Pull-out test 9417: 1989 Recommendation for welding cold-worked steel bars for reinforcement concrete construction (First revision)
1.3 Check-list for submission of an application for grant of
licence: Please see Appendix A
SECTION – II
2.0 Raw Materials The bars/wires shall be manufactured from properly identified heats of mould cast, continuously cast steel or rolled semis i.e from cast Billets or Ingots.
SECTION – III
3.0 Manufacturing Process and In-process Quality Controls: (Please see
Annexure A of IS 1786:2008
3.1 Rebars are rolled from billets that are obtained from a furnace. Billets can be produced either from iron-ore through the blast furnace converter route, or by melting scraps and refining the same in the furnace. When billets are produced from scrap, they are known as re-rollables. IS : 1786 allows manufacture of billets for reinforcing steel by open hearth, electric, duplex, basic-oxygen or a combination of these processes. Higher strength is imparted to rebars either by post rolling process or by adopting additional measures during manufacturing of billets. Rebars are generally rolled in round section. Ribs are indented on the surface of the deformed rebars or wires during the process of rolling. The prime objective of such deformation is the enhancement of bonding with concrete by mechanical interlocking.
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The high yield strength was first imparted to the rebars by raising carbon as well as manganese contents, and to a great extent, by cold twisting. The cold twisted deformed (CTD) bars are produced by cold working process, which is basically a mechanical process. It involves stretching and twisting of mild steel, beyond the yield plateau, and subsequently releasing the load. Thermo mechanical treatment is an advanced heat treatment process in which hot bars coming out of last rolling mill stand are rapidly quenched through a series of water jets. Rapid quenching provides intensive cooling of surface resulting in the bars having hardened surface with hot core. The rebars are then allowed to cool in ambient conditions. During the course of such slow cooling,the heat released from core tempers the hardened surface while core is turned in to ferrite-pearlite aggregate composition. TMT process thus changes the structure of material to a composite structure of ductile ferrite-pearlite composition with tough surface rim of tempered martensite providing an optimum combination of high strength, ductility, bendability and other desirable properties.
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3.2 Typical infrastructure for production
S. No Name of the machinery
1 Pusher
2 Furnace for billet reheating (Coal /Oil fired)
3 Coal Pulverizing unit
4 Roughing Mill unit
5 Intermediate Mill unit
6 Finishing Mill Unit
7 TMT Box
8 Pinch Roll
9 Rotary Sheering
10 Cooling Bed
11 Conveyors
12 Cold Shearing Machines
13 Lathe Machines
14 Compressors
15 Power Transformers
16 Weigh Bridge
Note : The above list is only indicative and typical. The manufacturers may use machineries
other than those specified above.
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SECTION – IV
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/1786/R-1/10, July 2013 (Please see Annexure-C
4.3. Marking fee Rates:
Manufacturing
Status of Industry
Minimum marking fee
per year Unit Unit rate
Large Scale Rs. 34000/- 1 Metric Ton Rs. 3/-
Small Scale Rs. 29000/- 1 Metric Ton Rs. 3/-
4.4 Grouping guidelines: Please see Appendix-D.
4.5 Guidelines for writing Scope of Licence: Scope of the licence shall contain Size & Grade of the bars & wires.
4.6 Guidelines for inclusion of new varieties: Please see Appendix-D 4.7 Sample size required to be sent to independent lab for testing:
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.
However, for chemical testing minimum 50gm of drill chips is required to carry out complete testing including requirement of nitrogen. In case of instrumental method i.e.
spectrophotometer a cut piece of minimum 2 cm2 is required.
4.8 Manner of sealing:
4.8.1 Packing: For packing drill chips the technical auditor shall keep sample in zip locking polythene bags and shall be packed in wax coated plain envelop either with stapler or gum. Thereafter, these envelop shall be tied with thread in order to ensure that the sample is packed in a durable packing material to withstand hazards during handling and transportation. Samples for testing physical properties can be cut to a suitable length and bundled.
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4.8.2 Labeling: The sample shall be labeled to indicate a) Name of the product as High Strength Deformed Steel Bars for Concrete Reinforcement ; b) The relevant Indian Standard with its year (1786:2008); c) Designation of the product; d) Quantity of sample; e) Heat/Cast Number f) Declared values i.e. Grade & Size of the sample.
4.8.3 Sealing: The sample shall be properly sealed with official seal and signed by technical auditor and the representative of applicant/licensee (if he demands) 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.
4.9 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. heat/lot shall not be marked. Those rejected lots/heats shall be scrapped or recycled.
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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:
Wax coated plain envelopes, Zip locking polythene bags, Thread, Sealing wax, Candle, Match box, Gum, Stapler, Transparent sealing tape etc. 5.2 List of test equipment/ Facilities with requirement and frequency of
Calibration: (please see Appendix –B)
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 both independent testing and factory testing.
5.5 Details of tests to be carried out in the factory:
The following parameters are to be carried out in factory testing:
a. Requirements for Bond as per clause 5.2 of IS 1786:2008 b. Dimension and Nominal Mass as per clause 7 of IS 1786: 2008. c. Freedom from defects as per clause 4.3.1 of IS 1786 : 2008 d. Physical properties as per clause 8 of IS 1786 : 2008 e. Chemical Composition as per clause 4.2 of IS 1786 : 2008
5.5.1 In case of Applicant/Verification samples:
In addition to the tests described in 5.5 a) Requirement for Bond as per clause 5.7 of IS 1786 : 2008
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: As per ISS declared.
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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
Note: Refer BIS website or details of “Simplified Procedure” and Normal Procedure
S.no Check-
point Requirement
Obs
erva
tions
Pg.
No.
1 General Is the application form completely filled?
2 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
3
Status of Applicant
(Manufacturing
Unit)
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.
c. Has it been indicated whether the applicant is a Public Sector or a Private Sector company?
4 IS No. & Varieties
a. Has applicant recorded the applicable Indian Standard with correct title of the Standard?
b. Where applicable, has applicant mentioned designation, grade, type, variety, size, etc., of the product for which the BIS licence is sought?
5 History
a. Where applicable, has the applicant provided information
regarding earlier BIS licence(s) held by them and / or
cancelled in the past?
b. Where applicable, has the applicant provided information
regarding BIS licences currently held by them?
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6 Signature
a. Is the application signed by the CEO of the applicant?
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?
7 Machinery
a. Does applicant possess requisite manufacturing infrastructure to manufacture the 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?
8
Test Equipment
& Calibration
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?
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.
9 QC
personnel
Does the applicant employ qualified & experienced Quality Control (QC) personnel on permanent basis and possess documentary evidence to establish the same? Are the copies of the qualification certificates and appointment letters of the QC personnel are in order.
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10
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?
11 Plant
Layout
Does copy of the plant (applicant manufacturing premises) layout clearly indicates locations of manufacturing machinery, laboratory, office, workshop, amenities, storage area, etc.?
12
Test Report(s)
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?
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.
13 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 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.
14 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)?
15 Signature Is the application countersigned by the applicant’s Authorized Indian Representative?
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16 Nomination
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?
f. Are copies of valid RBI clearance certificate for Indian Office / Branch of the applicant or any other relevant document for establishment of its Office / Branch in India provided?
17 Language Are English translations of all the documents, which are in languages other than English, also available?
18
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.?
19 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?
20 Agreement Does the applicant agree to sign a legally binding agreement with BIS in the prescribed format?
21 Indemnity Bond
Does the applicant agree to submit an Indemnity Bond to BIS in the prescribed format?
22
Perform ance 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?
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APPENDIX -B
DOC No. CMD-III/IS 1786/1 Date :
RECOMMENDED LIST OF TEST EQUIPMENT
FOR HIGH STRENGTH DEFORMED STEEL BARS AND WIRES FOR
CONCRETE REINFORCEMENTAS PER IS 1786:2008
Sl No. Test Equipment/Chemicals & identification
Numbers (Where applicable)
Least Count &
Range (where applicable)
Test used
with
clause
1. Universal Tensile Testing Machine (UTM)
a) Capacity Minimum 400 KN
b)Higher capacity of UTM may be used for
other grade FE550 and sizes.
L.C. – 1.0KN; for
the grades Fe 415
up to sizes 32mm
outside diameter
& Fe500 up to
sizes 16mm
outside diameter.
2. Bend & Re-bend tests Mandrels for different
sizes as per ISS
3. Hot water bath for re-bend test 4. Vernier calipers L.C.- 0.02mm 5. Steel scales L.C. 1mm 6. Extensometer L.C.-0.01mm 7. Measuring tapes 8. Protactor L.C.- one degree 9. Mercury Barometer L.C.- 0.1cm 10. Drilling machine for drilling samples for
chemical tests
11. Hot plate 12. Weighing scale (Electronic or physical
Necessary Glassware & other chemicals as per IS 1786 shall be made available.
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APPENDIX -C
SCHEME OF TESTING AND
INSPECTION FOR CERTIFICATION OF HIGH STRENGTH DEFORMED STEEL BARS AND
WIRES FOR CONCRETE
REINFORCEMENT ACCORDING
TO IS 1786:2008
(Fourth Revision) 1.0 LABORATORY A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the standard shall be carried out in accordance with the methods given in the standard.
2.0 TEST RECORDS
2.1 All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. 2.2 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.3 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 2.4 The frequency of periodic calibration of tensile testing machine shall preferably be once in six months and in any case not less than once in a year.
3.0 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), to IS 397(Part
4)]. In addition, effort should be made to gradually introduce a Quality
Management System in accordance with IS/ISO 9001.
4.0 STANDARD MARK- The Standard Mark, as given in Column(1) of the First Schedule of the license, is specified for high strength deformed steel bars and wires for concrete reinforcement and shall be marked on the product provided the materials marked conform to all the applicable requirements of the standard.
4.1 Identification and Marking-
4.1.1 The manufacturer or supplier shall have ingots, billets and bars or bundles of bars/wires marked in such a way that all finished bars/wires can be traced to the cast from which they were made. Every facility shall be given to the purchaser or his authorized representative for tracing the bars/wires to the cast from which they were made.
4.2 For each bundle/coil of bars/wires a tag shall be attached indicating cast/lot
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number, grade and size. 4.3 All bars/wires should be identifiable by marks/brands introduced during rolling which indicate the name of the manufacturer or their brand name.
4.4 Identification marks like brand name, trade-mark etc, that are introduced during rolling shall be designed and located in such a manner that the performance in use of the bar is not affected.
5.0 TEST CERTIFICATE- For each consignment of BIS certified material conforming to IS 1786:2008, there shall be a test certificate which shall contain the Standard Mark, the cast/lot number, grade, size and corresponding test results (as given in Annexure 1).
6.0 LEVELS OF CONTROL
6.1 Inspection and tests at various levels of control specified in Table1 shall be carried
out on all quantities of steel covered by this Scheme and appropriate records and charts
maintained in accordance with Para 2 and 3 above. All the production which conforms to
the Indian Standards and covered by the license shall be marked with certification mark
of the Bureau.
6.2 Routine Inspection and Testing- All material shall be subjected to routine
inspection and testing by the manufacturer or supplier in accordance with the standard
and a record of the test results of material conforming to the standard shall be kept by the
manufacturer or the supplier. The records shall be available for inspection by the
purchaser or his representative.
7.0 RAW MATERIAL- High-strength deformed steel bars and wires shall have the chemical composition in accordance with the requirements specified in clause 4.2 of the standard.
7.1 The location on the finished product from where the test samples are to be taken and the procedure for the preparation of the test pieces from test samples shall be in accordance with clause 9.1 of the standard.
8.0 RE-TEST- If any one of the test pieces first selected fails to conform to any of the tests as given in the standard, two further samples shall be selected for testing in respect of each failure. Should the test pieces from both these additional samples pass, the material represented by the test samples shall be deemed as fit to be covered under BIS Certification Marks Scheme.
8.1 The licensee shall also verify the deformation pattern of the high strength deformed steel bars and wires on the production line preferably at an interval of one hour at each twisting machine against the registered design. Proper records shall be maintained for this.
9.0 REJECTIONS -A separate record shall be maintained giving information relating to
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the rejection of the production not conforming to the requirements of the standard and the
method of its disposal. Such material shall in no circumstances be stored together with
that conforming to the standard.
10.0 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.
11.0 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 or their components are replaced or repaired 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 should have own complaint investigation system as per IS/ISO 10002.
11.1 In the event of any damages caused by the goods bearing the Standard Mark, 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 such cases.
12.0 DELIVERY, INSPECTION AND TESTING FACILITIES- Unless otherwise
specified, general requirements relating to the supply of material, inspection and testing shall be as mentioned in clause 12 of IS 1786.
13.0 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 standard or the testing equipment goes out of order. The marking may
be resumed as soon as the defects/deficiencies/inadequacies are removed under
intimation to Bureau. 13.1 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 markings shall also be sent to the Bureau.
14.0 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 license.
Table 1………
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Doc: STI/1786/PP/6 January 2013
IS 1786: 2008
HIGH STRENGTH DEFORMED STEEL BARS AND WIRES
FOR CONCRETE REINFORCEMENT TABLE 1 LEVELS OF CONTROL
(Clause 6 of the Scheme of Testing & Inspection)
TEST DETAILS LEVELS OF CONTROL
Sr. Requirements Test Method No. Lot Frequency Remarks Samp
No. Clause Reference
Chemical Composition
les Size
3 One heat Each heat of 100 tonnes
capacity or more
Three samples should be drawn from the
beginning, middle and end of teeming
1 a) Ladle Analysis 4.2 IS 1786:2008 2 One heat Each heat of less than
100.
One from the beginning and the other from the
end of the teeming.
b) Check Analysis 4.2 IS 1786:2008 1 100 tonnes or
less from the
same cast
Each Cast
Freedom from 2. defects.
4.3.1 &4.3.2
IS 1786:2008 Adequate inspection to ensure each item to
be free from surface defects.
Deformation and 3. Surface
Characteristics
5.2 to 5.6
IS 1786:2008
1 Every days Production
Each size
rolled.
Pull- out test 5.7 &
4. 8.3
NominalSize,
Cross sectional
IS 1786:2008 IS 2770(Part 1)
i) The frequency of bond strength test as required in 5.7 shall be as agreed to between the
Manufacturer and the purchaser/testing authority or adequate inspection to ensure each item
to be within the limits of the standard. ii) Pull out test shall be done in addition to 5.2 for approval of new or amended geometry for
the first time.
area, Mass,
Dimension and
5. Tolerences
6&7 Table 1 &2
IS 1786:2008 Adequate inspection to ensure each item to be within the limits of the standard.
Table 1 continues…..
Doc.No. VZBO/1786/Draft Manual
Page 23 of 26
Doc: STI/1786/PP/6 January 2013
IS 1786: 2008 HIGH STRENGTH DEFORMED STEEL BARS AND WIRES
FOR CONCRETE REINFORCEMENT TABLE 1 LEVELS OF CONTROL
(Clause 6 of the Scheme of Testing & Inspection)
TEST DETAILS LEVELS OF CONTROL Remarks Sr.
No.
Requirements Test Method No of
Samples
Lot Size Frequency
Clause
Reference
6.
Mechanical
st
8.1 & 9.2
IS 1786:2008 IS 1608
3
2
For cast above 100
tonnes
For cast
below 100
tonnes
Each cast
A separate test shall be made from each type of
finished bars and for each variation in size.
properties
Tensile Te
7.
Bend Test
8.2 & 9.3
IS 1786:2008
IS 1599
-do-
-do-
-do-
8.
Rebend test
9.4
IS 1786:2008
-do-
-do-
-do-
Doc. No. VZBO/1786/Draft Manual
Page 24of 26
ANNEXURE I (Clause 5 of the Scheme of Testing & Inspection)
XYZ IRON AND STEEL COMPANY
(REGISTERED FACTORY ADDRESS)
Doc: STI/1786/PP/6 January 2013
Standard
Mark
TEST CERTIFICATE FOR HIGH STRENGTH DEFORMED STEEL BARS AND WIRES FOR CONCRETE REINFORCEMENT
TEST CERTIFICATE NO. DATE:
M/s
We certify that the material described below fully conforms to IS: 1786-2008. Chemical composition and mechanical properties of the
product as tested in accordance with the Scheme of Testing and Inspection contained and attached with the document for ISI
Certification Marks License No.CM/L- are as indicated against each requirements. (PLEASE REFER TO IS 1786:2008 FOR DETAILS OF SPECIFICATION REQUIREMENTS)
TEST RESULTS
Order No.
Date
Nom
inal
Size
Cast/
Heat
No.
Qua
ntity
MT
Date of Testing
CHEMICAL
ANALYSIS
MECHANICAL PROPERTIES
Grade
of
Steel
Remark
C
%
S
%
P
%
S
&
P
%
C
E
%
Strength ening
elements
%
Alloy ing
elem
ents
%
Nitro gen
conte
nt
%
0.2%
Proof
Stress/
YS
N/mm2
min
0.2%
Proof
Stress/
YS
N/mm2
max
Tensile
strength
N/mm2
TS/
YS
ratio
Elongation
%
Total
elongation
at
maximum
force
%
Bend
Test
Rebend
Test
REMARKS SHIPPING ADVICE NO.
WAGONS NOS.
The material supplied conforms to the standard rolling and mass tolerances.
(It is suggested that size and paper (210x297) mm be used CHIEF METALURGIST/LAB MANAGER
for this Test Certificates) For XYZ IRON AND STEEL COMPANY.
The material supplied conforms to the standard rolling and mass tolerances. REMARKS SHIPPING ADVICE NO.
WAGONS NOS. (It is suggested that size and paper (210x297) mm be used CHIEF METALURGIST/LAB MANAGER
for this Test Certificates) For XYZ IRON AND STEEL COMPANY
Page 25 of 26
Doc.No. VZBO/1786/Draft Manual
APPENDIX –D BUREAU OF INDIAN STANDARDS
(Central Marks Department-III)
Ref: CMD-III/16:1786 31122012
Subject: Grouping guidelines for High strength deformed steel bars and wires for concrete reinforcement as per IS 1786: 2008 for grant of license and inclusions.
1) IS 1786:2008 for "High strength Deformed Bars and Wires for Concrete reinforcement" covers the following: i) Nominal sizes for bars/wires:4, 5, 6, 8, 10, 12, 16,20,25,28,32,36,40,45 and 50mm; and ii) Strength Grades a)Fe 415, Fe 415D, Fe 415S; b) Fe 500, Fe 500D, Fe 500S; c) Fe 550, Fe 550D; and d) Fe 600.
2) In order to consider grant of license and inclusion of additional varieties in the existing license, the following sampling plan shall be followed
Grouping of Sizes:
Group 1 : Sizes from 4mm to 6mm. Group 2 : Sizes from 8mm to 32mm. Group 3 : Sizes from 36mm to 50mm.
Grouping of Strength Grades:
Group 1 : Grade Fe 415, Fe 415D& Fe 415S; Group 2 : Grade Fe 500, Fe 500D & Fe 500S; Group 3 : Grade Fe 550& Fe 550D; and Group4 : Grade Fe 600.
a) One sample of highest size and maximum strength grade from each group shall be tested for all requirements of the specification, in order to cover the complete range of sizes and grades of that group. For example, if a sample of bar/wire of size 6mm and grade Fe 415S is / tested for all the requirements of the specification, then bar/wire sizes from 4mm up to and including 6mm having grades Fe 415, Fe 415D and Fe 415S shall be considered for grant of license/inclusion.
b) Similarly, in case one sample of a size and a strength grade other than the highest of a group is tested for all the requirements of the specification, then the bar/wire of that size and also of lower sizes in that group, and lower strength grades including the strength grade tested shall also be considered for Grant of license/inclusion.
c)While considering Grant of license /inclusion of additional varieties, it shall be ensured that the applicant/licensee has got the complete manufacturing and testing facilities for all the sizes and grades, to be covered as per existing guidelines of OMPC for grant of license and
inclusion of additional varieties.
d) During operation of license, BO shall ensure that all the sizes/grades covered in the license are tested in rotation. e) In case of change of process, the grouping guidelines as above shall be followed.
