DRAFT PRODUCT MANUAL ON PLYWOOD FOR GENERAL … · 2018-12-10 · draft product manual on plywood...

DRAFT

PRODUCT MANUAL

ON

PLYWOOD FOR GENERAL PURPOSES

As per IS 303:1989

BUREAU OF INDIAN STANDARDS MANAK BHAWAN,

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

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Doc No. : DHBO/303/Draft Manual

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Draft Product Manual for Plywood for General Purposes as per IS 303:1989

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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Foreword

This product manual contains the description, manufacturing and testing of Plywood for General Purposes (Third Revision) as per IS 303:1989.

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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BUREAU OF INDIAN STANDARDS



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 24 Marking fee rate 25 Grouping guideline 25 Guideline for writing scope of licence 25 Guideline for inclusion of new varieties 26 Sample size 26 Manner of sealing the sample 26 Whether remnants of the sample are returnable/ non-returnable

26

4

Section IV (Certification Criteria)

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

26

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

28

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

28

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

28 to 33

Approximate time required for testing by BIS labs/OSLs

33

GOL based on FT basis/IT basis/Mixed 33 Details of tests to be carried out in Factory 33

5

Section V (Inspection and testing)

CMD-III’s circular 34-35


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Section I: Product Description


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1. Description of Product

Plywood is a panel formed of three or more layers of veneer glued together, usually with the grain of adjacent veneers running at right angles to each other (Ref: IS 707). IS 303:1989 (third revision) covers the requirements of different grades and types of plywood used for general purposes. As per IS 303:1989 (third revision), Plywood for general purposes shall be the following two grades, depending upon the bond strength developed by the adhesive used for bonding the veneers:

a) Boiling water resistant or BWR Grade b) Moisture resistant or MR Grade

Moreover, plywood for general purposes shall be classified into three types, namely, AA, AB and BB based on the quality of the two surfaces, namely, A and B in terms of general permissible defects. The type of plywood, shall, therefore, be designated by the kind of surfaces of the panels The better quality surface shall be called ‘face’ and the opposite side shall be called ‘back’.If the face and the back are of the same quality, they are not distinguished. The type of plywood shall denote first the quality of face followed by the quality of back. For example, Type AA shall have both surfaces of quality A, Type AB shall have face of quality A and the back of quality B and Type BB shall have both the surfaces of quality B.

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

IS 303:1989 Plywood for General Purposes No. of Amendments: 06


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

Test Methods

a) IS 707:1976 - Glossary of terms applicable to timber and timber products (second revision)

b) IS 848:1974 - Specification for synthetic resin adhesives for plywood( phenolic and aminoplastic )(first revision)

c) IS 1508:1972 - Specification for extenders for use in synthetic resin adhesive

(urea-formaldehyde ) for plywood (first revision )

d) IS 1734 (Part 1) : 1983 -Methods of test for plywood :Part 1 Determination of density and moisture ‘(second revision)

e) IS 1734 (Part 4) : 1983 - Methods of test for plywood :Part 4 Determination of glue shear strength (second revision)

f) IS 1734 (Part 6) : 1983 - Methods of test for plywood :Determination of water resistance

g) IS 1734 (Part 7) : 1983 - Methods of test for plywood :Part 7 Mycological test (second revision)

h) IS 7638: 1975 - Methods of sampling of plywood

i) IS 12049:1987 - Dimension and tolerances relating to wood based panel materials

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. 6 of IS 303:1989) a) Timber :

Any species of timber may be used for plywood manufacture. However, a list of species, for the manufacture of plywood is given in Annex B of IS 303:1989 for guidance.

b) Adhesive : The adhesive used for bonding the veneers in different grades of plywood shall be the corresponding type of adhesive as specified in IS 848:1974. Extenders conforming to IS 1508:1972 may be used with the synthetic resin adhesive ( aminoresins ). However, synthetic resin adhesives (aminoresin) when extended by more than 25 percent shall contain suitable preservative chemicals in sufficient concentration to satisfy the mycological test described in Cl. 11.2.2 of IS 303:1989

Note: The compliance of Cl.5 of STI (Doc: STI/303/6 June 2006) 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.7 “Manufacture” of IS 303:1989 shall be ensured.


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Timber

Peeling/Reeling/Clipping

Drying

Veneer Preparation (Rotary cut/Sliced)

Spreading of Glue (Confirming to IS 848)

Assembly

Prepressing

Hot Pressing

Trimming

Sanding

Preservative Treatment (As per Cl. 7.1.1 of IS 303:1989)

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 plywood for general purposes:

a) Boiler b) Resin kettle c) Peeling machine d) Hand chopping e) Paddle chopping f) Glue Mixer g) Glue Spreader h) Aluminum 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. 0.17 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 36. 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 Plywood for General Purposes, Grade- BWR/MR, Type-AA/AB/BB as per IS 303:1989 (Upto Amd. 6)”


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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 plywood of full size 2. Resin: 5 litres 3. Core veneer & Face veneer : 02 pieces each of suitable size for testing species, thickness, uniformity of thickness and Moisture content. Routine sample: One plywood of full size

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 plywood 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 303:1989 circulated by CMD-III vide their circular (Ref: CMD-III/IS 303/1 dated 24.01.2008) is enclosed at page 34 and 35

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 303 - 0 : 1989

CL One sheet of full size

Mech C

BNBOL 2 NOS. Mech N

EROL 2 NOS. Mech P Except Edge Straightness, Squareness

NROL 2 NOS. Mech P except Tensile, MOR/MOE

SROL 2 NOS. Mech P Excl type test & mycological test

IS No. Testing Charges Remarks IS 303 : 1989

Rs 1725/- + Adhesive,if reqired (IS:848)

Refer test charges for IS 848)

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 303 - PLYWOOD FOR

GENERAL PURPOSES 1 National Test House (WR)

Plot No. F-10, MIDC, Andheri (East) Mumbai-400093 Maharashtra Contact : Dr. S.K.Kulshrestha , Sc. 'SD' Tel : 022-28327276,52341 Fax : 022-28341767

7107604 Rs. 9000/-

2 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

3 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.9000/-


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(As on 13.12.2013) 4 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.1,400/- Rs.500/- extra to carry out test on dimensions and tolerances

5 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.4900/- (20% discount for BIS on the given charges)

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

8101304 Rs.9000/- Renewal deferred

7 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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(As on 13.12.2013)

8 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.1400/- and Rs.500/- extra for tests on dimensions and tolerances

9 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.1400/- Rs. 500/- extra to carry out on tests on dimensions & tolerances

10 Quality Marking & Testing Laboratory M.P. Laghu Udyog Nigam Limited, Pologround Indl Estate INDORE-452015 Madhya Pradesh Contact : Shri P.K.Sharma, General Manager Tel : 0731-2421010, 03 Fax : 0731-2421003

8100304 Rs.1560/-

11 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. 1,725/-


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List of Outside Recognized Laboratories (As on 13.12.2013)

12 Cali-Labs Pvt Ltd HX-83, E-7, Arera Colony

8118116 Rs.3500/-

Bhopal-462016,Madhya Pradesh Contact : Shri V.G. Narula, Director Tel : 0755-4218014,2468583 Fax : 0755-2461836

13 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

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

9108716 BIS testng charges

15 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.3490/- [10% discount to BIS]

16 Shriram Institute For Industrial Research, 14-15, Sadarmangla Industrial Area,Whitefield Road, Bangalore-560048,Karnataka Contact : Dr. A. Radhakrishna, Joint Director Tel : 080-28410165-167,172 Fax : 080-28410189

6104206 Rs.7500/- (Included w.e.f. 09.03.2013)


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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 × Independent testing basis √ Mixed (Factory testing basis plus Independent testing basis) ×

6. Details of tests to be carried out in the factory in case of :

� Applicant sample/verification sample- All possible Routine tests like Visual defects and finish, Dimensions and tolerances, moisture content ,Static bending strength test etc.

� Surveillance samples All possible Routine tests like Visual defects and finish, Dimensions and tolerances, moisture content ,Static bending strength etc.

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

� Raw material- Compliance of Cl. 5.0 of STI (Ref: Doc. STI/303/6 June 2006) and Cl.6 & 7 of IS 303:1989 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 303:1989

1. The plywood for General purposes may be grouped under two categories as shown below:

Group Grade & Type 1 BWR-AA, BWR-AB and BWR-BB 2 MR-AA, MR-AB and MR-BB

2. Since Grade-BWR Type- AA being the most superior grade, for covering all grades & types under the licence, BWR-AA 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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