Doc: STI-210/5
December 2015
केन ् य मुहर वभाग 2
हमारा संदभ: सीएमडी 2/16:210
22 12 2015
वषय : भूरे लोहे क ढलाइयां व शि ट (पांचवां पुनर #ण) (आई एस 210:2009)के लए पर #ण
और /नर #ण क योजना, एसट आई Doc:STI/210/5,3दसंबर 2015
स म
ा धकार
वारा अनुमो!दत,भूरे लोहे क ढलाइयां व शि ट (पांचवां पुनर #ण) (आई एस
210:2009)के %लए पर
ण और *नर
ण क+ योजना, एसट आई Doc:STI/210/5,!दसंबर 2015 संल2न
है ।
( वी के 6डयड
ुं ी )
वै8ा*नक एफ
6मुख (सीएमडी 2)
सभी#े:ीय/शाखा काया;लय< को प=रचा लत
*त%ल:प : आई ट एसको बीआईएस वेबसाइट/इं<ानेट पर अपलोड करने के %लए
Doc: STI-210/5
December 2015
Central Marks Department-2
Ref : / CMD-2/ 16: IS 210
22 12 2015
Subject : Scheme of Testing & Inspection , STI Doc: STI/210/5 , December 2015 for Grey
Iron Castings as per IS 210 : 2009 (Fifth Revision)
Please find enclosed Scheme of Testing &Inspection , STI Doc: STI/210/5 , December 2015 for
Grey Iron Castings as per IS 210 : 2009 (Fifth Revision) duly approved by Competent
Authority.
( V K Diundi)
Sc F (CMD-2)
Head (CMD-2)
All ROs / BOs
Copy to : ITS for uploading in BIS website.
Doc: STI-210/5
December 2015
SCHEME OF TESTING AND INSPECTION
FOR CERTIFICATION OF GREY IRON CASTINGS
ACCORDING TO IS: 210 : 2009
(Fifth Revision)
1. LABORATORY
A laboratory shall be maintained which shall be suitably equipped and staffed, where the
tests shall be carried out in accordance with the methods given in the specification.
1.1 All the testing instruments/ measuring equipment are required to be brought under
calibration control, as per frequency to be decided depending upon the usage.Records of such
checks/ calibration shall be maintained
2. TEST RECORDS
All records of tests and analysis shall be kept in suitable forms including in Electronic format
approved by the Bureau.
NOTE: The existing forms etc., as being maintained by the manufacturers may be retained.
These forms, however, shall contain all the information required for operating this Scheme of
Testing and Inspection.
2.1 Copies of any records or charts that may be required by BIS shall be made available at
any time on request.
2.2 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 (Pt.I) to IS 397(part 4)]
2.3 In addition, effort should be made to gradually introduce a Quality Management System
in accordance with IS/ISO 9001.
3. STANDARD MARK
The Standard mark as given in column one of the first schedule of the license is specified for
the grades of grey iron castings specified in IS 210:2009
.
3.1 TEST CERTIFICATE
For each consignment of BIS certified material conforming to IS210 : 2009, there shall be a
test certificate which shall contain the Standard mark, cast number, grade designation and the
corresponding test results (as given in Annexure I).
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December 2015
4. MARKING
The cast number, manufacturer’s name or trade mark shall also be indicated on the castings.
In the case of the small castings where such marking on casting are not possible, the packing
for such castings shall be marked with the information.
5. LEVELS OF CONTROL
Inspection and tests at various levels of control (Table 1) shall be carried out on the whole
production of the factory covered by this Scheme and appropriate records maintained in
accordance with para 2 above. All the production which conforms to the standard and
covered by this license shall be marked with the BIS Standard Mark.
5.1 CAST NUMBER
For the purpose of this scheme, one melt shall represent one cast number. A group of castings
when castings are subjected to heat treatment and heat treated together under the same
condition would represent a heat treatment batch.
5.2 METHOD OF MANUFACTURE AND SUPPLY OF MATERIAL
The castings shall be made by any process that will produce castings complying with the
requirements of IS 210:2009 and shall be in accordance with the pattern or working drawing
as supplied by the purchaser. Supply of grey iron casting shall be as laid down in IS 1387.
5.2.1 Appropriate records shall be maintained in order to ensure the consistency of quality of
castings. For this purpose, records shall be maintained to indicate the control on raw material
and processing as given in 5.2.2 and 5.2.3.
5.2.2 RAW MATERIAL CONTROL
Chemical analysis of pig iron or scrap being used to produce castings for each consignment
produced with.
5.2.3 PROCESS CONTROL
(a) Tests for moisture content, permeability, green strength, shrinkage, etc. for conditioning
of sand;
(b) Weight of furnace feed, that is, quantity of pig iron, scrap, lime stone and other chemicals
for each melt;
(c) Proper control of temperature during melting;
(d) Provision of moulds with suitable runners, risers, gating, etc. and
(e) Proper control of hardness of moulds and cores.
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December 2015
5.3 CHEMICAL COMPOSITION
The chemical analysis may be carried out either on a finished casting or a test bar
representing each heat/cast as per the discretion of manufacturer/purchaser.
5.4 MICROSTRUCTURE
Where so required, the microstructure of grey iron castings and location for taking the sample
shall be as agreed to between the purchaser and the manufacturer.
5.5 WORKMANSHIP AND FINISH
The casting shall be accurately moulded in accordance with the pattern or working drawings
supplied by the purchaser with the addition of such letters, figures or marks as may be
specified.
5.5.1 The tolerances on all important dimensions shall be as per purchaser’s drawings. When
not specified, tolerances specified in IS 5519 shall apply.
5.5.2 Drawings pertaining to each pattern shall be made available to BIS bythe licensee. If
there is any change, that should also be made available to BIS.
5.6 FREEDOM FROM DEFECTS
The castings shall be sound, clean and free from porosity, blow holes, hard spots, cold shuts,
distortion, sand and slag inclusions and other harmful defects. They shall be well dressed and
fettled and shall be readily machinable.
5.6.1 No welding or repairs shall be carried out without the prior permission of the purchaser.
Welding referred to here includes fusion welding in accordance with the common foundry
practice. The method of repair by welding (See IS 5139) and subsequent stress-relieving shall
be as agreed to between the purchaser and the manufacturer.
5.7 HEAT TREATMENT
Castings are generally supplied without having any heat treatment. However, if required by
the purchaser, the heat treatment may be carried out in accordance with 2 of IS 13655.
5.8 TEST BARS:
5.8.1 FREQUENCY OF TESTING -The number of tests required for each melt or batch of
castings shall be as per specified under clause 12.2 and Table 1 of IS 210:2009.
5.8.2 TENSILE TEST -The two tensile test bars of dimensions as given in clause 13 and14
of the specification shall be cast for each heat. These shall be separately cast at the same time
and from the same melt and suitably marked to identify them with the casting they represent.
When castings are subjected to heat treatment, the test bars shall be heat treated together with
the casting they represent. The machined tensile test piece shall conform to the dimensions in
Fig. 1 and Table 2 of the specification. From each of those test bars, one bar shall be tested
and the remaining bar shall be reserved for the purpose of retest. Tensile test shall be carried
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out as per clause 14 of the specification and tensile properties shall conform to Table 3 of the
specification.
5.9HARDNESS TEST-Brinell hardness test shall be carried out as per IS 1500. The
hardness values for different grades of grey iron castings shall be as specified in Table 3 of IS
210:2009.
5.9.1 Hardness test shall be carried out at specific points on the castings. These specific
points shall be such that they are amenable for hardness checking in routine procedure.
5.10 TRANSVERSE TEST- If required, the transverse test may be carried out in accordance
with the method given in Annex.E of the specification. The minimum test requirements shall
be agreed upon at the time of enquiry and order.
5.11 HYDROSTATIC TEST- If specified at the time of enquiry and order the castings may
be tested for the hydrostatic test pressure. The requirements for the test pressure shall be
mutually agreed to between the purchaser and the manufacturer.
5.12 RETESTS – In case of failure of any test piece showing obvious casting defects, the
results of the test may be discarded and a further test made.
5.12.1 If any sound test piece fails, two further tests shall be made, should either of these test
pieces fail, the castings represented shall not comply with the requirements of the
specification.
5.12.2 In the absence of further separately cast test bars, the manufacturer shall have the
option of submitting test bars, sectioned from an agreed position in the castings. The
requirements of the test shall be as agreed to between the purchaser and the manufacturer.
However, the guidance may be obtained from Annex.A of the specification.
6. In respect of all other clauses of the specification, the factory will maintain appropriate
controls and checks to ensure that their product conforms to the various requirements of the
specification.
7. REJECTION
Records shall be maintained for a reasonable time from which information relating to the
rejection of material on the basis of tests, which do not conform to IS:210-2009 shall be
available. Such rejected material shall not be mixed up with that which conforms to the
specification.
8. SAMPLES
The licensee shall supply, free of charge, the samples required in accordance with
Regulations of the bureau of Indian Standards from his factory or godown. BIS shall pay for
the samples taken by it from the open market.
9. REPLACEMENT
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Whenever a complaint is received soon after the goods with Certification Mark have been
purchased and used and if there is adequate evidence that the goods have not been misused,
defective goods shall be replaced 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 conformity of the product to the Standard shall be with BIS.
10. STOP MARKING
The marking of the product shall be suspended under intimation to BIS, if, at any time, there
is some difficulty in maintaining the conformity of the product to the specification, or the
testing equipment goes out of order, or if directed to do so by BIS for any reason. The
marking may be resumed as soon as the defects are removed or when BIS gives the
permission to do so. The information regarding resumption of marking shall also be sent to
BIS.
11. Production Data
The licensee shall send to BIS as per the enclosed proforma to be authenticated by a Charted
Accountant and by the manufacturer by giving an undertaking, a statement of quantity
produced, marked and exported by him and the trade value thereof at the end of each
operative year of the licence.
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IS 210: 2009
SPECIFICATION FOR
GREY IRON CASTINGS
TABLE 1 LEVELS OF CONTROL
(Para 5 of the Scheme of Testing and Inspection)
CLAUSE
TEST DETAILS
REQUIREMENT
TEST M ETHOD
CLAUSE
9
10
Microstructure, if
required
Freedom from Defects
14&15
Tensile Test
16
Hardness Test
17
18
Transverse Test, if
required
Hydrostatic Test
7.2
Castings Dimensions
LEVEL OF CONTROL
NO. OF
LOT SIZE
FREQUENCY
SAMPLES
REMARKS
REFERNCE
Table 2 & 3 of IS 210 and IS
1608
Table 3
IS 210
IS 1500
Annex E
IS 210
IS 210
Adequate inspection as per the agreement with the
purchaser
10 % of
One
Each cast/heat
castings
cast/heat
One
One
Each cast/heat
cast/heat
25% of
One
Each cast/heat
Castings
cast/heat
One
One
Each cast/heat
cast/heat
The minimum test requirement and the
frequency shall be as agreed to between
the purchaser and the manufacturer.
Two
One
Each cast/heat
cast/heat
See Cl 5.6 of
STI
See Cl 5.8.2 of
STI
See Cl 5.9 of
STI
See Cl 5.10 of
STI
See Cl 5.11 of
STI
Dimensions
measured shall
be within the
tolerance
limits specified
in IS
5519 as well as
purchaser’s
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requirements.
If any failure
are observed
in any of the
samples, all
the pieces for
the day shall
be checked for
conformity
to the drawing
values.
Only
those castings
which strictly
conform to the
tolerance shall
be marked and
other shall be
segregated,
rejected
and
recorded.
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December 2015
PROFORMA FOR OBTAINING PRODUCTION DETAILS
(Period to be covered by the Report being……….. to ……………)*
Name of Licensee
CM/L No.
Name of Articles(s):
IS No.
Grade/type/Size/Variety/Class/ Rating
1.1 Brand/Trade/Name(s) of BIS Certification Marked Products
2. Total production of the article(s) licensed for certification
marking
2.1 Total production of the article(s) conforming to Indian standard
3. Production covered with BIS Certification Mark and its approximate value
a) Quantity
b) Value Rs.
3.1 Brand Name used on production covered under BIS Certification Mark
3.2 Calculation of marking fee on Unit-rate basis: Marking Fee per unit
a) Unit
b) Quantity covered with BIS Certification Mark
c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on
quantity given in (b)
4. Quantity not covered with BIS
Certification Mark. If any, and the reasons
for such non-coverage
4.1 Brand Name under which non certified goods were sold
5. Quantity Exported with BIS Standard
Mark and its value
5.1 Brand Name under which BIS
Certified goods are exported
5. Authentication by Chartered Accountant
*Information to be filled up by BO before forwarding to the licensee.
Note: In case a clause is not applicable, suitable remarks may be given against it.
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ANNEXURE I
(Para 3.1 of the Scheme of Testing and inspection)
XYZ ___________________ COMPANY Standard Mark
(Registered office Address and works address)
TEST CERTIFICATE FOR GREY IRON CASTINGS
TEST CERTIFICATE No.___________________________________ DATE
To M/s_____________________________________________________________________
It is certified that the material described below fully conforms to IS:210-2009. Mechanicalproperties of the product, as tested in accordance with the Scheme
of Testing and Inspectioncontained in the BIS Certification marks License No.CM/L _______________ are as indicatedbelow against each order No. etc.
(PLEASE REFER TO IS:210-1993 FOR DETAILS OF SPECIFICATION REQUIREMENTS)
Order
No.
&
Date
Heat
Number/Cast
Number
Quantity
Number
of
castings
Tonnes
Tensile
Strength
Hardness
M Pa
HB
Transverse
Test
Micro Structure
Hydrostatic
Test
Note: The material supplied conforms to the specified tolerances.
REMARKS
SHIPPING ADVICE NO.
SIGNATURE:
WAGON NOS.
DESIGNATION:
FOR XYZ IRON AND STEEL COMPANY
(It is suggested that size A-4 paper (210 x 297 mm) be used for this Test Certificate)
Grade
Remarks