CENTRAL MARKS DEPARTMENT-III

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1 CENTRAL MARKS DEPARTMENT-III Our Ref: CMD-III/16: Subject: Implementation of revised IS 814:2004 Covered electrodes for manual metal arc welding of carbon and carbon manganese steel and revised STI: Doc STI/814/7. IS 814:1991 has been revised and published as IS 814:2004. In the revised specification following changes have been made: a) Semi-basic type of covering has been included. b) Chemical analysis of basic and semi-basic classification has been provided. c) Percentage elongation for O designating digit has been included. Consequent upon revision of IS 814, STI has been revised (copy enclosed). Due to this revision, there is no change in the manufacturing and testing facilities. It is proposed that: i) Revised IS 814:2004 and STI be implemented w.e.f. 1 st February ii) iii) iv) BOs to inform the licensees about the revised STI and endorse the same in the licenses where basic and semi-basic type covering and O designating digit for percentage elongation has not been covered in the license. In case of licenses where basic and semi-basic type covering and O designating digit for percentage elongation is covered in the licenses, the licenses be advised to give an undertaking that their product conforms to revised specification. On receipt of this undertaking and acceptance of STI, necessary endorsement be made in the licenses. In such cases, periodic visits may be arranged at the earliest to verify the provision of revised standard and to draw samples for independent t4esting to check the conformity of product through independent testing. All pending applications be processed as per revised specification w.e.f. 1 st February 2005, and where test reports have been received as per the earlier specification, additional requirements be got tested before grant of license. Submitted for approval please. Encl: As above. Sd/- (C.K. Veda) DCM-III DDGM Sd -

2 SCHEME OF TESTING AND INSPECTION FOR CERTIFIACTION OF COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANGANESE STEEL ACCORDING TO IS 814:2004 (SIXTH REVISION) 1. LABORATORY: A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 2. TEST RECORDS: All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. 2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 3. 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) 2003, IS 397 (Part 2): 2003 and IS 397 (Part 3):2003]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS: ISO as appropriate to the activities of the organization. 4. STANDARD MARK: The Standard Mark, as given in Column (1) of the First Schedule of the license shall be printed on the body of the container and on any other packaging unit. Where paper packing cases or wrappers are used the Standard Mark shall be applied in such a manner that it cannot be misused. 4.1 OTHER MARKING: In addition the bundle or carton of electrodes shall be clearly marked with the following information: i) Classification as per clause 5 of IS 814:2004; ii) Manufacturer s name or recognized trade mark, if any; iii) Trade name and brief description of the electrodes; iv) Size and quantity of electrodes; v) Batch No. vi) Recommended current range; polarity and open circuit voltage; vii) Recommendations for special storage conditions and redrying temperature

3 viii) Date of manufacture; ix) A cautionary note on safety during welding; x) Made in India, if required; and xi) License number (CM/L.) Note 1: As agreed to between the manufacturer and the purchaser, brand name/ classification shall be printed on all the electrodes. Note 2: If the licensee wanted to mentioned any other information which is not related to IS specification, should preferably use separate label or demarcation for the same. 5. LEVELS OF CONTROL: The tests, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this scheme and appropriate records and charts maintained in accordance with paragraph 2.0 above. All the production which conforms to the Indian Standard and covered by the license shall be marked with certification mark of the Bureau. 5.1 BATCH: For the purpose of this scheme a batch is defined as a lot of covered electrodes manufactured in a day on each extruder of one size, classification produced from coating identified by a dry mix or more than one dry mix of controlled chemical composition and core wire identified by a heat number of controlled chemical composition (Refer Cl. 8.2 of IS 814:2004). 5.2 TEST PAD: Weld pad for checking electrode properties shall prepared as recommended in Annex-F, G & H of IS 814: INITIAL TESTS: The initial tests shall be carried out once in a year on each type (classification) of electrodes manufactured during one operative year Whenever there is a change in basic material or production condition, the initial tests shall be carried out before the production is marked. 5.4 PERIODIC CHECK TESTS: The periodic check test shall be carried out once in a month on each type (classification) of electrodes manufactured during the month. When the production of a type of electrodes after stoppage of production for more than six months is restarted, the periodic check test shall be conducted. The electrodes manufactured thereof shall be dispatched only after conformity of test results. 5.5 In case any size of electrodes fails to satisfy periodic check test, two further test specimens shall be prepared using electrodes drawn from the counter samples (electrodes from the same batch). If any samples fail in any of the retests, the marking of that size of electrodes shall be suspended. Causes of failure shall be investigated and necessary corrective measures shall be undertaken. Fresh samples from the products manufactured thereafter shall be tested for initial test and if the samples meet the requirements of the specification the marking may be resumed.

4 6.0 QUALITY CONTROL TESTS: Weld deposit from each batch of electrodes shall be analysed for chemical composition and the results obtained shall be within the manufacturers acceptance limit. 6.1 The manufacturer shall declare the range of chemical composition of weld metal for each classification and brand of electrodes. 7.0 RAW MATERIAL TESTS: Routine analysis of each consignment of raw materials received in the factory shall be carried out and appropriate records maintained. 7.1 IN PROCESS CONTROL: In respect of all other clauses of the specification the factory will maintain appropriate control and checks to ensure that their product conforms to the various requirements of this specification. 8.0 PACKING AND STORAGE: Electrodes shall be packed and stored as per clause 11 of IS 814: REJECTIONS: A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no circumstances be stored together with that conforming to the specification 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 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 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.

5 12.0 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 specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau 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 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant or by the manufacturer by giving an affidavit/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 license. Table 1.

6 IS: 814 : 2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Doc:STI/814/7 TEST DETAILS Clause Requirements Test Method Clause Reference No. of Samples LEVELS OF CONTROL Lot Size Remarks 6. Core Wire for electrodes. 6 IS 814 One One sample from each cast or every 20 coils whichever is Parent metal for test pieces. less IS 814 One Each consignment If the material covered under BIS Certification Scheme, no further testing is required. -do- 3. Coating ingredients As per company standard One -do- In case accompanied with manufacturer s test certificate, no further testing is required. 7. Dimensions a) Diameter 7.1 IS 814 One Every half an hour b) Length 7.1 -do- One Every half an hour. Maximum, minimum diameter of each coil of the wire should be recorded. c) Bare length of electrodes d) Concentricity of flux covering with core wire & do- One sample of each type & size Every hour 7.3 -do- -do- Every half an hour Sample tests to determine robustness, resistance to withstand normal conditions of handling and use and ability to burn or fire evenly should be carried out by the Inspecting officer during his visit. 5.2 Coating ratio 5.2 Annex B -do- -do- -do-

7 IS 814 : 2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Doc:STI/814/7 TEST DETAILS Clause Requirements Test Method Clause Reference 8.3 Initial Tests 8.3 IS 814 No. of Samples LEVELS OF CONTROL Lot Size Remarks a) All weld metal mechanical tests for tensile and Impact 9.1 -do- One sample from each type b) Butt weld bend tests do- Once in a year. (Please refer el. 5.3 of the Scheme) c) Running performance test 9.3 -do- d) Increased metal 9.4 -dorecovery tests (for electrodes claiming recovery 110% and above) e) Diffusible hydrogen 9.5 -doestimation test (for hydrogen controlled electrodes) f) Radiographic quality 9.6 -dotest (for radiographic quality electrodes) 7. Periodic check test 8.4 -do- a) All weld metal mechanical tests for tensile and impact b) Running Performance test 9.1 -do- One sample from each type Once in a month 9.3 -do- -do- -do- (Please refer cl. 5.4 of the Scheme) 8.5 Quality control test 8.5 -do- One batch of electrodes Each batch (Please refer cl.6 of the Scheme)

8 IS 814 : 2004 COVERED ELECTRODES FOR MANUAL METAL ARC WELDING OF CARBON AND CARBON MANAGANESE STEEL TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Doc:STI/814/7 TEST DETAILS Clause Requirements Test Method Clause Reference No. of Samples LEVELS OF CONTROL Lot Size Remarks 8.6 Additional tests 8.6 IS 814 Subject to agreement with the manufacturer. The purchaser may request for additional tests to be made or certification to be provided for each batch of electrodes supplied. If so, the tests and batch definition shall be agreed between the purchaser and the manufacturer. 11. Packing and storage 11 -do- One Once in a shift carton of each size 13. Marking 13 -do- -do- Each Carton (Please refer cl.4 of the Scheme)