Post on 01-Nov-2019
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PRODUCT MANUAL ON
GYPSUM BUILDING PLASTER
PART I EXCLUDING PREMIXED LIGHT WEIGHT PLASTERS
IS 2547(Part I) - 1976
Bureau of Indian Standards
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FOREWORD
Gypsum Building Plaster is extensively in many countries for general building operations
and for the manufacture of preformed gypsum building products which have the specific
advantages of lightness and high fire resistance.
This Product Manual is intended to cover all elements needed for grant of a product
certification licence and its continued operation providing reference material that can be
used in all Regional / Branch Offices and by various applicants / licensees to ensure
coherence of practice and transparency.
TABLE OF CONTENTS
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SECTION CONTENT DETAIL PAGE NO
I PRODUCT DESCRIPTION 5
II RAW MATERIAL/COMPONENTS 6
III MANUFACTURING PROCESS & IN-PROCESS
QUALITY CONTROLS
7
IV CERTIFICATION CRITERIA 10
V INSPECTION AND TESTING 12
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PRODUCT DESCRIPTION
SECTION 1.1 DESCRIPTION OF PRODUCT
Gypsum Plasters are classified on the basis of their physical and chemical
properties. These possess a definite set of properties due to hydration of calcium
sulphate, anhydrous or hemihydrate, to form gypsum and are used in the
manufacture of gypsum building materials. Gypsum plaster shall be classified as follows: a) Plaster of paris, b) Retarded hemihydrate gypsum plaster: Type I — Under coat: a) Browning plaster, b) Metal lathing plaster, Type II — Final coat plaster: a) Finish plaster, b) Board finish plaster, c) Anhydrous gypsum plasters are for finishing only, and d) Keene’s plaster is for finishing only.
SECTION 1.2 LATEST INDIAN STANDARD WITH PRODUCT TITLE
AND NUMBER OF AMENDMENTS
IS Gypsum Building Plaster—SPECIFICATION
Part I Excluding Premixed Light Weight Plasters AMENDMENTS -2
SECTION 1.3 LIST OF REFERRED INDIAN STANDARDS FOR RAW
MATERIALS/COMPONENTS AND TEST METHODS
LIST OF REFERRED INDIAN STANDARDS
IS No. Title
2469:1976 Glossary of terms relating to gypsum.
1288:1982 Method of test for mineral gypsum and gypsum products.
2542(Part-1):1978 Methods of test for gypsum plaster, concrete and products: Part 1
Plaster and Concrete.
460(Part 1):1985 Specification for test sieves : Part 1 Wire Cloth test sieves.
SECTION 1.4
CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF
LICENCE
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KINDLY REFER ANNEX 1
RAW MATERIALS/ COMPONENTS
Gypsum is required which is calcined with wood or coal. No material is added to gypsum plasters except those which are necessary to control the setting, such as sodium citrate, break-drown products of keratin, potassium sulphate, sodium sulphate, alum and zinc sulphate; or working characteristics such as Alkyl-Aryl sulphonate; or to impart anti-corrosion such as nitrates and nitrites of alkali metals or fungicidal properties.
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MANUFACTURING PROCESS AND IN-PROCESS QUALITY
CONTROLS
Production Process Flow Chart
1. Best quality gypsum is picked from the market.
2. It is broken into small stones through lump crusher.
3. Small stone particles heated and calcined at per determined temp. Of approx 200˚C to
400˚C.
4. The mixture is cooled at specified temperature and passed through pulverized.
5. The sand particles. Dust and other impurities are removed from the mixture and pure
material is segregated.
6. The pure material is passed through various quality tests like reflectance. Purity setting
time and results are analyzed.
7. The material not conforming to standards is rejected and the pure material is packed in
HDPE bags with accurate weighment and stitch with stitching machines.
8. The packed material is store in moisture proof godown and dispatched to various locations
for sale.
SECTION 3.1 FLOW CHART OF MANUFACTURING PROCESS (TYPICAL)
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S.No. Machinery Capacity Number Remarks
1 Lump Crusher with electric motor 15 HP, RPM 960
5 MT/Hrs. One -
2
Elevator for transporting material with 3 HP Motor, RPM 960 (Crompton)
5 MT/Hrs. One -
3 Bhati ( Wood/coal fire with 5 HP motor, RPM 960
1 MT/90 Minute
Two -
4
Pulveriser 32" chamber with dust collector freedom hopper with motor 50 HP
1.5 MT/Hrs One -
5 Electric Weighing Machine
Range 0-150Kg,
L.C. 10 gm One
6 Stitching Machine - Two -
7 Trolley For loading 50 Bags Two -
8 Temperature Controller (Located on Bhati No. 1)
Range 0-600˚C, L.C. 1˚C
One
9 Temperature Controller (Located on Bhati No. 2)
Range 0-600˚C, L.C. 1˚C
One
10 Power Connection 11 KV One -
Note : Adequate Electric Power and Water supply is required
CERTIFICATION CRITERIA
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SECTION 4.1 CRITICAL REQUIREMENTS OF THE INDIAN STANDARD
To be provided by CMD
SECTION 4.2 SCHEME OF TESTING AND INSPECTION
DOC:STI/2547(Part-1)/1;February 2005. Please see ANNEX 2.
SECTION 4.3 MARKING FEE RATES
Description Value
Unit 1 MT
L S Marking Fee 52200
S S Marking Fee 44200
Slab 1 Rate 1.6
Slab 1 Qty All
Slab 2 Rate 0
Slab 2 Qty 0
Slab 3 Rate 0
Enforcement Date 20060701
Remarks
SECTION 4.4 GROUPING GUIDELINES:
Gypsum Building Plaster has been classified on the basis of hydration of its Calcium sulphate content.
SECTION 4.5 GUIDELINES FOR WRITING SCOPE OF LICENCE The scope of licence to declare :
Plaster of Paris B hemihydrate (Type A or type B),
Retarded Hemihydrate Gypsum plaster,
Anhydrous Gypsum Plaster or
Keene’s Plaster
SECTION 4.6 GUIDELINES FOR INCLUSION OF NEW VARIETIES Based on classification(Section 4.5) inclusion of each new variety to be on the basis of independent testing of
sample of each variety.
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SECTION 4.7 SAMPLES SIZE One composite sample of approx. 2Kg of each variety for complete testing.
SECTION 4.8 MANNER OF SEALING THE SAMPLE
Samples may be wrapped with suitable moisture proof packing
material, labeled and wax sealed or as an alternate code no and
signatures of IO may be marked with a permanent marker pen on
the product.
SECTION 4.9 REMNANTS ARE RETURNABLE/NON-RETURNABLE TO BE
SCRAPPED/USED OR TO BE DESHAPED DISPOSAL IN CASE
OF SAFETY ITEMS
Sample is normally consumed in testing and Remnants are not
returnable and may be suitably disposed off by the laboratory.
SECTION 4.10
PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/
RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY
PARAMETERS DURING REGULAR PRODUCTION
BIS Standard Mark to be marked only after ascertaining the quality
of the material after testing as per Indian standard and STI.
INSPECTION AND TESTING
SECTION 5.1 PACKING MATERIAL REQUIRED FOR PKG/DESPATCH OF
SAMPLE
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Any suitable material may be used for wrapping the sample to avoid moisture
and any damage during transit.
SECTION 5.2 LIST OF REQUIRED TEST EQUIPMENT/FACILITIES WITH
REQUIREMENT & FREQUENCY OF CALIBRATION
To be provided by CL
SECTION 5.3 STATUS OF TEST FACILITIES IN BIS LAB AND OSL WITH
TESTING CHARGES AND APPROXIMATE TIME REQUIRED
FOR TESTING
For latest information, please check the BIS web site www.bis.org.in
SECTION 5.4 WHETHER GRANT OF LICENCE WILL BE BASED ON
FACTORY TESTING BASIS---------------------------------------------No
INDEPENDENT TESTING BASIS--------------------------------------Yes
MIXED BASIS (FACTORY TESTING OF PRODUCT PLUS
INDEPENDENT TESTING OF SOME RAW MATERIALS)----------No
SECTION 5.5 DETAILS OF TESTS TO BE CARRIED OUT IN CASE OF
APPLICANT/VERIFICATION SAMPLES
• All tests
SURVEILLANCE SAMPLES
• All tests
• RAW MATERIAL SAMPLES TO BE GOT TESTED IF ANY --NIL