BUREAU OF INDIAN STANDARDS CENTRAL MARKS DEPARTMENT-III

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1 BUREAU OF INDIAN STANDARDS CENTRAL MARKS DEPARTMENT-III Our Ref:CMD-III/16: Subject: Implementation of revised IS 12427:2001 Hexagon head transmission tower bolts and revised STI, Doc:STI/12427/2 May IS 12427:1988 has been revised and published as IS 12427:2001. In the revision, following major changes have been made. a) The range of sizes has been enlarged to cover sizes upto M24; b) The range of nominal lengths has been extended upto M24; c) The use of property classes 5.8 and 8.8 are also permitted subject to the agreement between the manufacturers and the users; and d) The length size combinations have been suitably extended. Consequent upon revision of IS 12427, the STI has been revised as Doc:STI/12427/2 May 2003 (enclosed). In this STI, latest referred standards have been incorporated. Due to revision of IS 12427, no change is required in the existing manufacturing and testing facilities. It is proposed that: a) The revised STI be implemented by 15 July b) All pending applications be processed as per revised IS 12427:2001. BOs may inform the licensees under their jurisdiction accordingly and ensure implementation of revised IS 12427:2001 and revised STI by the stipulated date. Submitted for approval please. D&H(CMD-III) DDGM Sd/- (C.K. Veda) Director (CMD-III)

2 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF HEXAGON HEAD TRANSMISSION TOWER BOLTS ACCORDING TO IS 12427:2001 (First 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 1):1972 and IS 397 (Part 2):1985]. and IS 397(Part 3): In addition, effort should be made to gradually introduce a Quality Management System in accordance with IS/ISO 9000 series 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 a metal plate or on a tag/label and shall be applied on the cardboard box or the gunny packing or may be marked through stencil provided always that the bolts in the box or gunny bags conforms to every requirement of the specification. 4.1 MARKING: In addition the following markings shall be provided on the package/gunny bags. a) Name or trade mark of the manufacturer; b) Designation, quantity and size; c) Batch or code No. or date of manufacture to trace back the production of batch; and d) License number (CM/L.).

3 4.2 All bolts conforming to specification shall be marked with the Manufacturer s identification symbol on the top of surface of the bolt head either embossed or indented so that dimensions and manner of marking are in accordance with clause 11.2 of the specification. The identification symbol T for transmission tower bolt may also be marked on the head. 5. LEVELS OF CONTROL: The tests, as indicated in Table 1, 2 and 3 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 Standards and covered by the license shall be marked with certification mark of the Bureau CONTROL UNIT: All the bolts of same property class and designation manufactured during a day shall constitute a control unit. 5.2 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. 6.0 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. 7.0 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. 8.0 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. 8.1 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.

4 9.0 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. 9.1 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.

5 IS 12427:2001 HEXAGON HEAD TRANSMISSION TOWER BOLTS TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Cl. TEST DETAILS Test Method No. of Samples LEVELS OF CONTROL Frequency Remarks Clause Reference 6.1 Material 4 & IS 1367 (Pt.3) Table Nuts (if supplied with bolts) 5.2 Washers 5.2 IS 12427:2001 IS Dimensions 3.1 & 3.2 IS Table 1 :2004 & Table 2, Fig Thread Requirement One Each consignment. The test is required only for those fasteners which are not subjected to tensile test. If the material is supported by suitable test certificate regarding conformity of material, no further testing is required in the factory. IS Please see table 2 No testing is required in case these are marked with BIS standard mark. IS 4218 (Pt.1 to 4) Please see table 3. As per sampling plan given below (see note 3) As per sampling plan given below (see note 3) The existing frequency for dimensional verification would be applicable only when firm is having adequate system of checking the dimensions and inspection at a frequency of 15 minutes/30 minutes for each operation. In case of failure the production should be stopped and setting of the machine should be rectified so as to produce all subsequent product within the tolerance.

6 IS 12427:2001 HEXAGON HEAD TRANSMISSION TOWER BOLTS TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Cl. TEST DETAILS Test Method No. Samples of LEVELS OF CONTROL Frequency Remarks Clause Reference 6. Test for Mechanical properties. (i) Tensile strength. (a) % Elongation. (b) Yield stress (ii) Proof load test. (iii) Tensile Strength under wedge loading. (iv) Impact test. (v) Head soundness (vi) Shear strength. (vii) Hardness (viii) Decarburisation (ix) Retempering test. 5 to 7 IS 1367 (Pt.3) Table & 8.2 IS 1367 (Pt.3) * 8.6* * 6.2 IS 12427: IS 1367 (Pt.3) Two samples for each characteristics Two Three Three Each control unit. Every heat treatment batch In case of any failure twice the number of samples shall be drawn from the same control unit/heat treatment batch and tested for the characteristics for which the failure has occurred. In case of any further failure the control unit/batch under reference shall be rejected and not marked with BIS standard mark. 7.1 Galvanising IS 1367 (Pt.13) Sampling plan as per note 4 given below. 7.3 Passivation. IS 12427:2001 All Visual only. 8.0 Surface discontinuities. IS 1367 (Pt.9)/ Sec.1) All

7 * Tests under these clauses are required to be carried out on full size bolts only. Note 1: The above tests are as per test programme which is recommended for in-process control. Note 2: For applicability of test to a property class, reference may be made to Table 5 of IS 1367 (Pt.3):2002. Note 3. Sampling plan based on IS 2614:1969 Lot Size Sample Size Acceptance Number Upto to to to Over Note 4 Sampling plan for galvanizing test (Ref: IS 1367 (Part 13). Total Number of Fasteners in batch Number of test samples Upto and including upto and including Over

8 IS 12427:2001 HEXAGON HEAD TRANSMISSION TOWER BOLTS (Cl. 5.1) TABLE 2 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Doc:STI/12427/2 Cl. TEST DETAILS Test Method No. of Samples LEVELS OF CONTROL Frequency Remarks Clause Reference 5.1 a) Material 4 & IS 1367 (Pt.6) Table 4 One Each consignment. If the material is supported by suitable test certificate regarding conformity of the material, no further testing is required. b) c) Dimension & Tolerance Threads & Tolerance 3 & IS Table 1 IS 1367 (Pt.3) Annex A IS IS 1367 (Pt.2) IS 4218 (Pt.2) IS 4218 (Pt.4) As per sampling plan given at Note 3 under Table 1 of this STI d) Mechanical Properties i) Proof Load Table 5 IS 1367 (Pt.6) & 8.1 One Each control unit. ii) Hardness Table 5 IS 1367 (Pt.6) & 8.2 Three samples per heat treatment batch. General Surface discontinuity Hot dip Galvanizing IS 1367 (Pt.10) IS 1367 (Pt.13) Every ½ hour samples are to be checked As per sampling plan given at Note 4 (Under Table 1 of this STI).

9 IS 12427:2001 HEXAGON HEAD TRANSMISSION TOWER BOLTS (Cl. 5.1) TABLE 2 LEVELS OF CONTROL (Para 5 of the Scheme of Testing and Inspection) Cl. TEST DETAILS Test Method No. of Samples LEVELS OF CONTROL Frequency Remarks Clause Reference 5.2 Workmanship 2.2 IS 2016 Each Washer Dimensions 4.1 & 4.2 Five Washers Every hour 7.2 Galvanizing IS 4759 Sampling plan as given in Note 4 under Table 1 of this STI. 7.3 Passivation IS 12427:2001 All Visual check