ASBESTOS CEMENT PRESSURE PIPES AND JOINTS · CMD-III/1592/1 Manual - 6 - Section I 1. Description of Product Asbestos cement (AC) pressure pipe is used primarily for potable water,

CMD-III/1592/1 Manual

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BUREAU OF INDIAN STANDARDS (Eastern Region Office, Kolkata)

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref: DDGE/22/IS 1592 Dated: 20 Feb 2014 Sub: Draft manual for IS 1592 This has reference to CMD circular CMD:1/31 dated:11 Nov 2013 on the above subject. In this connection, please find enclosed the draft product certification manuals as per details below: ASBESTOS CEMENT PRESSURE PIPES AND JOINTS Kindly examine the draft product certification manual and forward your comments on the draft to ERO at [email protected] , in the format given below:

Sl no Clause no/page no Comments

Last date for comments: 05 March 2014. (Product Certification Officer) ERO


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Doc No: CMD-III/1592/1 Manual Date of Issue:

MANUAL FOR CERTIFICATION OF

ASBESTOS CEMENT PRESSURE PIPES AND JOINTS AS PER IS 1592

(FIRST ISSUE )

BUREAU OF INDIAN STANDARDS MANAK BHAWAN, 9, BAHADUR SHAH ZAFAR

MARG, NEW DELHI – 110002


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FOREWORD The product certification scheme of the Bureau of Indian Standards, now under Bureau of Indian standards Act 1986, is in operation for more than four decades covering a wide variety of products. The wide experience in the area has brought a fair amount of rationalization in the certification process. This has resulted in the formulation of the Operation Manual for Product Certification (referred to as OMPC in this manual) prescribing rules and practices generally applicable to all products. Product related rules/guide lines are periodically issued to cover the specific requirements of different products. Still, in view of the wide spread of the certification operations, differences are found in the application of these guidelines in the BIS certification offices in different parts of the country. Therefore, it has been decided to bring out Sectoral manuals as guideline documents covering certification requirements of specific products/group of products. This Manual, one in the series, has been prepared to ensure uniformity in the certification practices in respect of ASBESTOS CEMENT PRESSURE PIPES AND JOINTS covered by IS 1592. This manual is strictly an internal document intended for use by the certification marks officers of BIS. In this manual, some useful information relating to the product characteristics, a few design aspects, limitations and constraints in its use, which is considered useful to the user, are included in a brief manner. This manual takes into consideration the generally acceptable practices.


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Table of Contents Section I Product Description Page

1 Description of Product(s) 5 2 Latest Indian Standard Number with Product Title and Number of Amendments 5 3 List of referred Indian Standards for raw materials / components and test methods 5 4 Check-list for submission of an application for grant of licence 6

Section II Raw Materials / Components

5 List of important Raw Materials / components, including those which are required to conform to the relevant Indian Standards 6

Section III Manufacturing Process and In-process Quality Controls 6 Description of Manufacturing Process(es) 7 7 Infrastructure for production 7

Section IV Certification Criteria

8 Identification of Critical Requirements of the Indian Standard 7 9 Scheme of Testing and Inspection 8 10 Marking Fee Rates 8 11 Grouping Guidelines, if any 8 12 Guidelines for writing Scope of Licence 8 13 Guidelines for Inclusion of new Varieties 8

14 Sample size, including guidelines for drawal of separate samples when samples are required to be sent to different labs for testing 8

15 Manner of Sealing of Sample(s) 8

16 Whether remnants of sample(s) are returnable / non-returnable, to be scrapped / used, to be deshaped before disposal In case of safety items), any other precaution required for dealing with remnants

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17 Procedure to be followed for destroying / deshaping / recycling the product that does not meet the quality parameters during regular production 9

Section V Inspection and Testing

18 Packing Material requirement (to be available in factory at all times) for Packing / Dispatch of Samples 9

19 List of required Test Equipment / Facilities with requirement and frequency of Calibration 9

20 Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS labs / OSLs 9

21 Whether Grant of Licence will be based on: 9 � Factory testing basis or � Independent testing basis or � Mixed (factory testing basis plus independent testing of some raw materials) 9

22 Details of Tests to be carried out in the Factory in case of: � Applicant Samples / Verification Samples � Surveillance / Market Samples

� Raw Material Samples to be got tested, if any


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Section I 1. Description of Product Asbestos cement (AC) pressure pipe is used primarily for potable water, as well as for sewer force mains and industrial effluent and process piping. This manual covers requirements relating to plain ended asbestos cement pipes and joints intended for use under pressure; it defines certain conditions of manufacture, classification, characteristics and acceptance tests applicable to these products. Asbestos cement building pipes and pipe fittings, gutters and gutter fittings and roofing fittings are covered by IS 1626. Asbestos cement pipes and fittings for sewerage and drainage are covered by IS 6908 ‘Specification for asbestos cement pipes and fittings for sewerage and drainage. 2. Latest Indian Standard Number with Product Title and Number of Amendments IS 1592 : 2003 - Specification for Asbestos Cement Pressure Pipes and Joints (Fourth Revision) Number of Amendments – 2 3. List of referred Indian Standards for raw materials / components and test methods The list of referred Indian Standards are given below: IS 269:2013 Specification for 33 Grade ordinary Portland Cement ((fifth revision) IS 455:1989 Specification for Portland slag cement (fourth revision) IS 1344:1981 Specification for Calcined Clay Pozzolana (second revision) IS 1489 Specification for Portland Pozzolana cement: (Part 1): 1991 Fly ash based (third revision) (Part 2): 1991 Calcined Clay based (third revision) IS 3812 Pulverized Fuel Ash (Part 1): 2013 - For Use as Pozzolana in Cement, Cement Mortar and Concrete (third revision) (Part 2): 2013 For Use as Admixture in Cement Mortar and Concrete (third revision) IS 5382:1985 Specification for rubber sealing rings for gas mains, water mains and sewers (first revision) IS 5913:2003 Methods of test for asbestos cement products (second revision) IS 6530:1972 Code of practice for laying of asbestos cement pressure pipes IS 7639:1975 Methods of sampIing for asbestos cement products


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IS 8041:1990 Specification for rapid hardening Portland cement (second revision) IS 8112:2013 Specification for 43 grade ordinary Portland cement (second revision) IS 8794:1988 Specification for cast iron detachable joints for use with asbestos cement pressure pipes (first revision) IS 11767: 2005 Recommendations For Cleaning Of Premises And Plants Using Asbestos Fibres (first revision) IS 11768 : 1986 Recommendations For Disposal Of Asbestos Waste Material IS 11769 (Part 1): 1987 Guidelines for safe use of products containing asbestos: Part 1 Asbestos cement products IS 12081 (Part 2) : 1987 Recommendations for pictorial warning signs and precautionary notices for asbestos and products containing asbestos: Part 2 Asbestos and its products IS 12269:2013 Specification for 53 grade ordinary Portland cement (first revision) IS 12330:1988 Specification for Sulphate resisting Portland cement

4. Check-list for submission of an application for grant of licence As per Annexure I Section II: Raw Materials / Components 5. List of important Raw Materials / components, including those which are required to

conform to the relevant Indian Standards

i) Asbestos fibre ii) Cement: -

a) 33 grade ordinary Portland cement conforming to IS 269 b) 43 grade ordinary Portland cement conforming to IS 8112 c) 53 grade ordinary Portland cement conforming to IS 12269 d) Rapid hardening Pontland cement conforming to IS 8041 e) Portland slag cement conforming to IS 455 f) Portland Pozzolana cement conforming to either 1S 1489 (Part 1) or IS 1489 (Part 2) g) Sulphate resisting Portand cement conforming to IS 12330.

iii) Pulverized Fuel Ash — Specification Part 1 For Use As Pozzolana In Cement , Cement Mortar And Concrete as per IS 3812 (Part 1)


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iv) Specification for rubber sealing rings for gas mains, water mains and sewers as per

IS 5382

Section III: Manufacturing Process and In-process Quality Controls 6. Description of Manufacturing Process As per Annexure II 7. Infrastructure for production A typical list of manufacturing machinery is given below: -

a. Fibre Mill. b. Mixing Unit c. Pipe Forming Machine d. Pipe Calendaring Machine e. Pull of Unit f. Lifting Unit/Cranes g. Double Head Trimming Machine h. Vaccum Reservoir Tank i. Vaccum Pump j. Air Compressor k. Steel Mandrels l. Submersible Pump m. Water Pumps n. Curing Tanks of Suitable Capacity

Section IV: Certification Criteria 8. Identification of Critical Requirements of the Indian Standard The critical requirements are given below: -

a. Dimensions tolerances & Characteristics b. General Appearance & Finish c. Straightness Test (optional) d. Works Hydraulic Pressure Tightness Test e. Bursting Test f. Transverse Crushing Test g. Longitudinal Bending Test h. Joint Test i. Regulatory /Safety Requirements pertaining to Asbestos


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9. Scheme of Testing and Inspection As per DOC: STI/1592/6 January 2004

10. Marking Fee Rates The following rate of marking fee is applicable for a licencee: i) Rate of marking fee: Unit- 1 Tonne Rs.8.65 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 carried 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 licencee. 11. Grouping Guidelines, if any Not available.

12. Guidelines for writing Scope of Licence The Scope of grant of Licence should cover Nominal Size and Class.

13. Guidelines for Inclusion of new Varieties

Same as grant of Licence and as per guidelines envisaged in OMPC 2004

14. Sample size, including guidelines for drawal of separate samples when samples are

required to be sent to different labs for testing

Not Applicable as licence is operated on FT basis.

15. Manner of Sealing of Sample(s)


16. Whether remnants of sample(s) are returnable / non-returnable, to be scrapped / used, to be deshaped before disposal In case of safety items), any other precaution required for dealing with remnants



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17. Procedure to be followed for destroying / deshaping / recycling the product that

does not meet the quality parameters during regular production

If the BIS Standard Mark is available on the body of the pipe the same is to be removed by any suitable means

Waste material shall not be allowed to accumulate on the floor. All working areas should be kept clean by regular use of vacuum cleaner. Where vacuum cleaning is not practicable, the waste material shall be thoroughly wetted before removal, Cleaning shall be done in accordance with the provision laid down in IS 11767 : 2005. Broken pieces and off-cuts of asbestos cement material shall be collected and disposed of in a manner which does not generate dust. Loose swarf and dust collected from fabrication processes shall be wetted, where practicable, and placed in sealed impermeable bags and disposed of in accordance with the procedure given in IS 11768 : 1986. Section V: Inspection and Testing

18. Packing Material requirement (to be available in factory at all times) for Packing / Dispatch of Samples


19. List of required Test Equipment / Facilities with requirement and frequency of

Calibration

To be provided by CL

20. Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS labs / OSLs


21. Grant of Licence will be based on: Factory testing basis

22. Details of Tests to be carried out in the Factory in case of: The acceptance tests shall be carried out at the manufacturer’s works on pipes, coated or otherwise, sufficiently matured. The number of tests shall be as specified in IS 7639. Compulsory tests a) Works hydraulic pressure tightness test on all pipes (for methods of test see IS 5913). When nominal diameters exceed 1000 mm, this test may be replaced by a suitable method of control as agreed to between the purchaser and the manufacturer.


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b) Hydraulic pressure bursting test for all diameters (for method of test see IS 5913 and for number of samples sees IS 7639). c) Transverse crushing test for all diameters (for method of test see IS 5913 and for number of samples see IS 7639). d) Longitudinal bending test (for methods of test see IS 5913 and for number of samples see IS 7639). Test limited to pipes of 150 mm diameter and less. Optional tests at purchaser’s request a) Hydraulic pressure bursting non-immersed test to be done at random at the purchasers’ store (for method of test see IS 5913 and for number of samples see IS 7639). b) Line test to be done as per 11.6 of 1S 6530 on 100 m length of laid pipeline for at least each size ordered above 5000 m’. This is to be done at random at factory of origin.

� Applicant Samples / Verification Samples – Full test including raw materials � Surveillance - Full test as licence is operated on FT basis

� Market Samples – Customer Feedback to be obtained

� Raw Material Samples to be got tested – Cement/Fly ash as per the raw materials used by

the manufacture.


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Annexure -1


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Annexure –II


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The manufacturing process of the Ac pressure pipes consists of following steps:

Asbestos fibres are brought in impermeable bags and will be stored in enclosed area. To avoid fugitive emission asbestos fibre bags will be transported to the works by container mode. There will be no manual handling and opening of the asbestos bags. The raw asbestos contained in bags is put into the fibre Mill. There will be automatic bag openers at the mixing stage.

The Fibre mill is the closed and water to an extent of 25% is added. Fibre mill grinds the material, open the asbestos from the bundle and water prevents any emissions from emanating from the unit. The ground wet material is conveyed through screw on to a weighing platform. Weighed quantity of material is added to the Turbo Mixer.

In the turbo mixer, 20kg of asbestos and 400kg of water is mixed to make into slurry. This operation takes 5-10 minutes. The turbo mixer is a closed unit. The mixer slurry is later pumped into a U mixer. Two U-mixers have been provided so that one acts as a stand by. In the U-mixer, about 150 kg of cement is added to the asbestos-water slurry. The mixer thus becomes Fibre-Cement slurry. The U-mixers are closed units. This mix is then poured on the forming mandrel which has a perforated mandrel containing cloth wrapping. The Fibre-Cement slurry is poured around the mandrel. The mandrel is continuously under vacuum thus eliminating any chances of emissions. Water is separated from the slurry during pipe formation which is re-circulated to the Turbo-Mixer.

Once the pipe is formed, the mandrel is conveyed by over head pneumatic crane into the Callendaring Machine. In the Callendaring Machine the formed pipe is subjected to roller pressure which presses the pipes to increase the density of pipe. The mandrel is then conveyed to Pull Off Machine where the pipe is separated from the mandrel. The mandrel is sent back to the forming machine. The pipe is wet and is allowed to set for 8 to 10 hours and then cured in a tank of water.

The dried pipes are placed in the curing tanks where the pipes are kept submerged under water for 3 weeks. The curing water is no replaced but topped everyday. Only a case the settled sediments are high the water is decanted and reused and settled solids are removed. After curing the pipes are removed from the tanks and cut to required length. Generally, the pipes are manufactured in the standard length of 4 m. The pipe is hydraulic tested. The test is done for each and every pipe manufactured. Random samples of pipe for others testing is required as per ISI norms. Dust extraction system with Bag filters will be connected to the Fibre Mill, Turbo-mixer and U-mixer. The entire solid waste generated including process rejects, dust from bag filters and empty asbestos bag will be reused in the manufacturing process. A schematic diagram of the process is presented in the following figure.


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Process Flow Chart

Fibre

Fibre Mill

Water

Wet Fibre ISI Marked Cement

Water Turbo Mixer Slurry Pump

U Mixer - 1 U Mixer - 2

Forming Machine

Drying Curing Cutting Testing Stock

Yard

Water

Callendering Machine Pull Off

Documents

ASBESTOS CEMENT PRESSURE PIPES AND JOINTS · CMD-III/1592/1 Manual - 6 - Section I 1. Description of Product Asbestos cement (AC) pressure pipe is used primarily for potable water,