product manual on decorative thermosetting … · decorative thermosetting synthetic resin bonded...

BUREAU OF INDIAN STANDARDS

PRODUCT QUALITY MANUAL

DECORATIVE THERMOSETTING

SYNTHETIC RESIN BONDED LAMINATED SHEETS

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DOC NO. BIS/PQM/DLS DATE: NOV 2013

PREPARED BY PAGE NO APPROVED BY S.K.SINGH, Sc D & ALOK SINGH, Sc D, ABO of 45

PRODUCT MANUAL ON

DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS





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AMENDMENT SHEET

To ensure that each copy of the Product Quality Manual contains a complete record of Amendments, this Amendment page should be updated by controlled copy holders with each set





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of revised/new pages of the Product Quality Manual. An acknowledgment slip will be sent alongwith revised/new pages of Product Quality Manual for signature and return by all holders of controlled copies.

Amendment No Date of Issue Section/Page/Clause No

Reason for Change





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FOREWORD

Product Certification Scheme of the Bureau of Indian Standards , now under BIS Act 1986 , is in operation for about 5 decades covering a wide variety of products. The wide experience in the area has brought a fair amount of rationalization in the certification process. This has resulted in the formulation of the Operation Manual for Product Certification (referred to as OMPC in this manual) prescribing rules and practices generally applicable to all products. Product related rules/guide lines are periodically issued to cover the specific requirements of different products. Still, in view of the wide spread of the certification operations, differences are found in the application of these guidelines in the BIS certification offices in different parts of the country. Therefore, it has been decided to bring out Sectoral manuals as guideline documents covering certification requirements of specific products/group of products. This Manual, one in the series, has been prepared to ensure uniformity in the certification practices in respect of DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS

covered by IS 2046. (referred to as ‘standard’ or ‘specification’ or ‘IS 2046’ in this manual) under the BIS Product Certification Scheme. This standard prescribes the requirements and the methods of sampling and test for decorative laminated sheets (HPL) classified according to their performance and main recommended fields of application and provides also for materials of special characteristics, for example post formability or defined reaction to fire. They are intended for interior applications.





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This manual takes into consideration the generally acceptable practices.

THIS MANUAL IF FOR GUIDANCE ONLY AND SHOULD HOWEVER DO NOT TREAT SUCH DOCUMENT AS REPLACEMENT FOR REFERRED STANDARDS OR THAT OF RELEVANT SCHEME FOR TESTING AND INSPECTION (STI). STANDARDS AND OTHER DOCUMENTS ( STI ETC.) REFERRED ARE AS APPLICABLE AT THE TIME OF PREPARATION OF MANUAL HOWEVER, LATEST, STANDARDS/OTHER DOCUMENTS AS IMPLEMENTED SHALL BE REFERRED.

This manual is based on the Indian Standard IS 2046, the OMPC, and the guidelines specific to Laminated Sheets issued from time to time. It is intended to assist the certification personnel in understanding and appreciating the various requirements of the product as prescribed in IS 2046 and other related standards. This manual is not a substitute for the standards, OMPC and the guidelines mentioned above, to which reference may be made in case of doubt or any conflict and for complete information. At the time of writing this manual, IS 2046:1995 was in force. Therefore, although based on IS 2046:1995, the standard is referred to as IS 2046 without reference to the year of publication, so that any revisions to the manual as a result of further revisions in the standards becomes convenient.

TABLE OF CONTENTS

SI. NO. Section Contents Page no.

1 1 Product Description 5

2 2 Raw materials 6

3 3 Manufacturing Process

7-8

4 4 Certification Criteria 9-11

5 5 Inspection and Testing 12





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6 Annex 1 Check List for Application

14-27

7 Annex 2 Scheme of Testing and Inspection

28-33





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SECTION NO. 1

1.1 DESCRIPTION OF PRODUCT

DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS

1.2 LATEST INDIAN STANDARD NO WITH PRODUCT TITLE AND NUMBER OF AMENDMENTS

IS 2046:1995 (Reaffirmed 2005) Amendment No. 1- Decorative Thermosetting Synthetic Resin Bonded Laminated Sheets

1.3 LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIAL/ COMPONENTS AND TEST METHODS

IS No. Title

1998:1962 Methods of test for thermosetting synthetic resin bonded laminated sheets.

4905:1968 Methods for random sampling (with Amendment No. 1)





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8543 (Part-4/ Methods of testing plastics: Part 4 Short term mechanical properties.

Sec 1):1984 Section 1 Determination of tensile properties.

13411:1992 Glass reinforced polyester dough moulding compounds

1.4 CHECK-LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE

Checklist as enclosed at Annexure 1 may be used for submission and recording of application for grant of licence.

SECTION NO. 2

2.1 LIST OF IMPORTANT RAW MATERIALS/ COMPONENTS INCLUDING THOSE WHICH ARE REQUIRED TO CONFORM TO THE RELEVANT INDIAN STANDARDS





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RAW MATERIAL WHETHER CONFORMITY REQUIRED AS PER IS

CONFORMING IS NO.

KRAFT PAPER NO -

BASE PAPER NO -

PHENOL NO -

FORMALDEHYDE NO -

METHANOL NO -

MELAMINE NO -

BOPP FILM NO





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SECTION NO. 3

3.1 DESCRIPTION OF MANUFACTURING PROCESS

A. Preparation of Adhesive (Glue)

i. Received Phenol, formaldehyde, Melamine, Methanol. ii. Melamine, formaldehyde & Phenol formaldehyde are mixed at ambient to 90oC temperature

respectively according to grade. iii. During manufacturing Viscosity is checked accordingly backing is given and material is discharge

from kettle. iv. Now, Resin stored in storage tank according to grade. v. The chemical will be ready for impregnation.

B. Processing of Kraft & Base Paper

i. Test on Paper Kraft & Base Paper for required width and GSM. ii. Pass Paper taken into Paper Impregnating Plant with Drying 110 oC to 150 oC.





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iii. Test on Impregnated Paper iv. Feedback provide to Impregnation plant for improvement.. v. Passed paper stored in Temperature and humidity Controlled Room at 25oC+2oC (40+5%Rh)

C. Assembly Section

i. BOPP film checked for thickness. ii. Wound on pay off and cut down to required size. iii. Pack of Kraft paper and one design Paper are assembled on the SS mould plate. Two such pack

separated by BOPP film are Sandwiched between the SS mould plates. The number of Kraft use in the pack depends upon the thickness of the sheet. HOT PRESS temperature set as 130oC to 140oC at 210 kg/cm² to 230 kg/cm² pressure.

iv. Under high temperature and pressure in the HOT PRESS the treated design paper and Kraft paper get bonded by resin are laminated to form one laminated sheets.

v. After above procedure check thickness and visual test. vi. Then FEEDBACK to be provide to Assembly Table. vii. Then Laminate sheets are cut into required size in a Shearing or Cutting machine. viii. Segregating of Sheet according to Thickness and design. ix. The cut sheets are then passed through sanding machine. x. The cut and sanded sheets are graded by visual test. xi. Now sheet are to be tested for complete testing as per IS. xii. Passed sheet are marked and packed in paper. xiii. Now Product Stored and Ready for Dispatch.

3.2 LIST OF MANUFACTURING MACHINES REQUIRED FOR PRODUCTION

Typical list of manufacturing machinery for manufacturing of Decorative thermosetting resin is given below:

Sl.No. Machinery Purpose

1 Boiler (Steam Boiler) To provide heat to press

2 Thermic Fluid Heater To provide heat to press

3 Generator For power backup

4 Air Compressor For operating hydraulic machines

5 Glue Kettles For resin manufacturing





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6 Cooling Tower For cooling of press

7 Design Paper Dryer (Impregnator) For impregnation of design paper

8 Kraft Paper Drier (Impregnator) For impregnation of Kraft paper

9 Hot Press digital temperature controller ,timer and pressure controller

For lamination

10 SS Plates of glossy/matt & sued finish To separate sheet & for desired finish

11 Shearing or Laminate Cutting Machine For cutting to size

12 Laminate Sanding Machine

Leveling

13 Weigh Scale For resin weighing

14 Temperature and humidity controlled storage room for Impregnated paper

For storing Impregnated paper

15 Effluent Treatment Plant (If resin is manufactured in-house)

For effluent treatment





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SECTION NO. 4

4.1 IDENTIFICATION OF CRTICAL REQUIREMENTS OF THE INDIAN STANDARD

As per CMD note dated 11 Nov 2013, the critical requirements of an Indian Standard shall be determined by a committee comprising the identified officer in the concerned CMD, member secretary of the concerned technical committee and an officer from Central laboratory.

4.2 SCHEME OF TESTING AND INSPECTION

The applicable Scheme of Testing and Inspection is DOC:STI/2046/4, JUNE 1999 and the same is enclosed at Annexure-2. However, latest STI may be confirmed and downloaded from BIS website.

4.3 MARKING FEE RATES

The marking fee applicable is as follows:

Unit- 1 Sq. metres

Rs 0.60 per unit for All Units





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Minimum marking fee for large scale units : Rs 123000

Minimum marking fee for small scale units : Rs 111000

Effective from 01/07/2006

However, latest MF may be confirmed and downloaded from BIS website.

4.4 GROUPING GUIDELINES

Each type (Type S/ Type P or Type F) and Class based on three Index Numbers as per 4.1 or Alphabetical Classification as per Table 1 (namely CGS/CGF/HDS/HDF/HGS/HGF/HGP/VGS/VGF/VGP and VLS) of IS 2046 shall be treated as different variety. Based on the manufacturing process and applications, thickness can be grouped into following three groups:

Group I – 0.5 mm to 3.0 mm

Group II - 3.5 mm to 5.0 mm

Group III - > 5.0 mm





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Size of sheets (L x W) may be restricted based on maximum size of the sheets that can be manufactured on the press available with the firm. For considering grant of licence/ inclusion of additional varieties, one sample of each type and class and each thickness group as mentioned above shall be tested in independent testing.

4.5 GUIDELINES FOR WRITING SCOPE OF LICENCE

Scope of the Licence should cover the following:

A) Name of the product – Decorative thermosetting Synthetic Resin Bonded Laminated Sheets

B) Type of Material : Standard Type Decorative Laminated Sheets (Type S) or Postformable Type Decorative Laminated Sheets (Type P) or Decorative Laminated Sheets having defined reaction to Fire (Type F)

C) Index numbers for specifying HPL Properties as follows:

i) Index 1, Resistance to Surface wear ii) Index 2, Resistance to impact by small ball diameter iii) Index 3, Resistance to Scratching

D) Thickness of sheet in mm E) Size {upto L(mm) x W(mm)}

As an alternate to (B) and (C) above, equivalent Alphabetical Classification as per Table 1 of IS 2046 (namely CGS/CGF/HDS/HDF/HGS/HGF/HGP/VGS/VGF/VGP and VLS) may be specified if material falls directly into above classes.

4.6 GUIDELINES FOR INCLUSION OF NEW VARIETIES





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Grouping guidelines as mentioned at item 4.4 above shall be followed. Samples may be drawn by the BIS Officer (under normal procedure ) for independent testing or got tested by the licensee himself (under simplified procedure) from BIS recognized Outside lab. No testing of raw materials is required. Availability of additional manufacturing and testing facilities shall be ensured.

4.7 SAMPLE SIZE

Normally, one full sheet of size 2440 mm x 1220 mm is adequate for testing. However as there are only two BIS recognized labs, and sample may be required to be sent a long distance through transport, two sheets may be drawn and sent for independent testing to avoid damage during transit.

4.8 MANNER OF SEALING OF SAMPLE

Sheets may be rolled in coil form and covered with kraft paper then tied with proper thread/ rope and wax sealed at the knot. A label containing sample details, code no and signatures of IO may also be affixed over the packing of the sheet.

4.9 ABOUT REMNANTS SAMPLE

As most of the sheet will be consumed in the testing, remnants are not required to be returned to the manufacturers. Laboratory to retain, handle and scrap the samples as per their established procedure.

4.10 PROCEDURE TO BE FOLLOWED FOR DESTROYING/ DESHAPING/ RECYCLING THE PRODUCTS THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION





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Non conforming products may be scrapped or sold as commercial grade depending on its condition. As the product is not easily biodegradable, direct disposal as waste product in open areas to be avoided.

SECTION NO. 5 INSPECTION AND TESTING

5.1 PACKING MATERIAL REQUIREMENT

For sealing of samples, sealing wax, strong thread, blank yellow labels, candle, match box, permanent marker is required. No specific packing materials are required for packing and sealing of samples. However, for sending sealed samples through transport, rolled sheets may be covered with kraft paper and then repacked in cylindrical corrugated close fitting boxes. Manufacturer should have arrangement for such packing.

5.2 LIST OF REQUIRED TEST EQUIPMENT/ FACILITIES WITH REQUIREMENTS AND FREQUENCY OF CALIBRATION

As per note a) of typical framework of Product Manual, the list of test equipment is to be prepared /provided by CL.





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5.3 STATUS OF TEST FACILITIES IN BIS LAB AND OSL & APPROXIMATE TESTING TIME REQUIRED

Testing facilities are not available in the BIS labs. Please visit the BIS website www.bis.org.in for latest list of BIS recognized outside lab and their testing charges.

Total testing time will depend availability of conditioning chambers with the lab. For concurrent testing of various tests as per IS 2046:1995, minimum three conditioning chambers are required. If all the tests are run concurrently, maximum testing time for complete testing would be 10 days. Thus, depending on the work load and availability of infrastructure and human resources, laboratory should expedite the test reports preferably within 3 weeks (21 days).

5.4 BASIS OF GRANT OF LICENCE:

In this standard, a large number of tests with different conditioning temperatures and humidity and durations have been specified. There are two BIS recognized outside labs. As most of the tests are to be carried out after conditioning of samples in standard test conditions and large numbers of tests with different durations are involved, licence to be considered on the basis of independent testing.

5.5 DETAILS OF TESTS TO BE CARRIED OUT IN THE FACTORY

5.5.1 DURING PRELIMINARY INSPECTION/ VERIFICATION VISITS





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As most of the tests are to be carried out after conditioning of samples in standard test conditions, only following tests may be carried out during preliminary inspection/ verification visits

i) Colour and Pattern ii) Surface Finish iii) Thickness iv) Length and Width of a full size laminate v) Appearance

a) Surface defects - Spot, dirt etc - Fibres, hairs, scratches - Accumulated (combinations) of surface defects

b) Edge defects c) Broken corners d) Sanding defects e) Warping (Flatness) f) Straightness of edge g) Squareness of the laminates

vi) Resistance to Staining for Group 3 test materials as per test procedure M-5.1, Procedure A

5.5.2 SURVEILLANCE/ MARKET SAMPLES

During the surveillance visit all the tests as mentioned at 5.5.1 above may be carried out in the factory. However, surveillance and market samples may be tested for all tests, whichever applicable, as per ISS in the independent laboratory.

5.5.3 RAW MATERIALS

In this Indian Standard, no specific requirements have been specified for any of the raw materials. Hence no testing of raw materials is called for grant of licence and operation of licence.





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ANNEX 1

CHECK-LIST FOR SCRUTINY OF APPLICATIONS AT THE COUNTER (to be checked at the time of receipt of Application)

Sl.

No.

REQUIREMENT YES /

NO 1. Whether the application form is as per BIS standard format and filled completely with no

column left as blank?

2. Whether the application is signed and stamped?

3. Whether the application is accompanied with requisite fee (DD or evidence of transfer through

RTGS)?

4. Whether the application is accompanied with check list?

5. Whether the application is accompanied by all documents as per “the list of documents to be

attached”? (Please see Annex A, Annex A-1, Annex A-2, Annex A-3 and Annex B)

6. In case the application is under "simplified procedure", is the test report attached with

application and is not older than one month from date of submission of application?

Notes:

1. If the application is found to be complete, it shall be recorded and acknowledgement issued to the applicant across the counter.

2. If the application is found to be incomplete or deficient, the deficiencies shall be clearly communicated to the applicant in writing and acknowledgement obtained across the counter.

3. The application shall, then, be marked to the Head of the Branch Office, immediately.





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ANNEX A-1

CM/PF/ 305 (First Revision) March 1997

DECLARATION REGARDING MANUFACTURING MACHINERY

1. Application No._____________________________________________________

2. Name/Address______________________________________________________

Date

Machinery

Make

Capacity

Number

Remarks





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Changes





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CM/PF/ 305 (First Revision) March 1997

MANUFACTURINGMACHINERY DECLARATION

I hereby declare that the machinery of which details are given overleaf is owned by me are actually installed in the premises.* Sign of Firm’s Representative Name_____________________________ Designation________________________ Date______________________________

I have checked and found that machinery of which details are given overleaf was available during my inspection. Sign of BIS I.O.

Name_____________________________ Designation________________________ Date of Verification





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*I also declare that in case of grant of licence, I will send prior intimation to BIS whenever any machinery is taken out of the premises of the firm due to any reason.

ANNEX A-2

CM/PF/ 306

(Second Revision) May 2001

TEST EQUIPMENT DECLARATION

No entry to be crossed

1. Application No.__________________

3. Name/Address_____________________

_____________________

_____________________

_____________________

S. No.

Test Equipment/Chemicals & Identification Number (where applicable)

Least Count & Range (where applicable)

Valid Calibration (where required) Yes/No

Test used in with clause reference

Remarks

(Indicate No. of Eqpt.)





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Date

CM/PF/ 306

(Second Revision) May 2001





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TEST EQUIPMENT DECLARATION

I hereby declare that the test equipment of which details are given overleaf by me are actually installed in the premises.* I also declare that in case of grant of licence, I will send prior intimation to BIS whenever any equipment is taken out of the premises of the firm due to any reason. Sign of Firm’s Representative Name_____________________________ Designation________________________ Date______________________________

I have checked and found that test equipment of which details are given overleaf was available during my inspection. Sign of BIS I.O.

Name_____________________________ Designation________________________ Date of Verification





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CHECK-LIST FOR SCRUTINY OF APPLICATIONS BY CONCERNED OFFICER IN THE BO

(To be checked at the time of receipt of Application)

Sl.

No.

REQUIREMENT YES /

NO 1. Whether the application is complete in all respects, including the availability of requisite

infrastructure for manufacturing and testing as per the Indian Standard? (Please see Check-

2. Whether the test report(s) attached with the application has / have been submitted within the

specified time norms (applicable in case of simplified procedure)?

3. Whether the test report(s) is / are from BIS or BIS recognized laboratory(ies) only?

4. Whether the test report(s) show conformity of the sample(s) tested to the relevant Indian

Standard(s)?

5. Whether all the requirements as per the relevant Indian Standard(s) have been tested?

6. Whether, in case of application under the Foreign Manufacturers’ Certification Scheme,

additional requirements, as given in Annex C, have been checked and found

Note - After scrutiny of the application, the concerned Officer shall communicate the deficiencies, if any, to the applicant and also indicate the date on which the preliminary / verification inspection is proposed to be carried out, clearly indicating that all deficiencies shall have to be completed by the applicant within the stipulated period in order to enable the BIS officer to verify the same during the preliminary / verification inspection.





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LIST OF DOCUMENTS TO BE ATTACHED WITH APPLICATION

No. Title of Document Page 1 Check-list (Please see Annex B) 2 In case the application is filed under “simplified Procedure”, the test report(s) in

original from BIS

or its recognized laboratories for all the requirements of the product and, where

3 Document of Central/State Government (e.g. Registration Certificate, Memorandum of Articles,

etc) authenticating the address and purpose of the establishment of the

4 In case the applicant applies as SSI unit, copy of valid Registration Certificate from the Local /

5 In case the application is signed by the authorized signatory of the applicant, authorization letter

6 Process Flow-chart covering all processes of manufacture (from raw material to finished product

stage), including details of in-process controls at each stage, even for those

7 Complete list of manufacturing machinery, clearly indicating the name of the machinery, the

8 In case some of the manufacturing processes are outsourced, provide details of such processes

and the controls exercised by you before receipt of such material/components,





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9 Complete list of testing facilities, clearly indicating the name of the equipment, the test for which it

is used (mention clause No. of the Indian Standard), range / least count / accuracy of the test

equipment, calibration status and quantity in Annex A-2.

10 Copies of calibration certificates of testing equipment valid at least till 3 months of acceptance of

11 Where applicable, ‘consent letter’ from BIS recognized laboratory (for requirements which have

got to be and / or are proposed to be got tested from outside lab for which the

12 Plant Layout clearly indicating location of manufacturing machinery, lab, office, workshop,

13 Appointment letter of QC personnel indicating names, experience, qualifications, date of

14 Copy each of the test reports/suppliers’ test certificates for each of the raw materials /

15 Copy of in-house or independent test report for the product covering all requirements as per the

16 In case application is under simplified procedure, an undertaking from the applicant on his letter-

head (see Annex A-3) that the licence if granted to him shall be put under Stop Marking by BIS

if the verification sample(s) drawn during verification visit of the BIS officer prior to grant of





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ANNEX A-3

(Sl. No. 16 on the List of Documents)

UNDERTAKING BY APPLICANT APPLYING UNDER SIMPLIFIED PROCEDURE

(To be submitted on the letter head by CEO/Authorized Signatory to concerned Head of the Branch office along with the Application and other documents)

The Director and Head

BIS

____________

Dear sir

I, -----------------( name of person), ----------------------( designation) have applied for a licence to you for use of BIS standard mark on --------------------(name of product) being manufactured at our factory at -------

-----( give address).

I give an undertaking that the licence if granted against his application shall be put under Stop Marking by BIS if the verification sample(s) drawn during verification visit of the BIS officer prior to grant of licence fail to conform to the Indian Standard.

In such a case, I shall take necessary corrective actions and inform the same to BIS within 15 days along with offering fresh lot of products manufactured after taking corrective actions, from which samples (of rating/size/variety which facilitates verification of corrective actions on the reported failures) shall be drawn by BIS for independent testing .

I agree that the resumption of marking in such cases shall be allowed only on the basis of independent satisfactory Test Reports of the fresh samples offered (including long duration tests where failures were in long duration tests). In case the fresh sample drawn by BIS for independent testing fails, or the licensee does not inform corrective actions taken and does not offer improved samples within 15 days of the date of Stop Marking, the licence shall be processed for cancellation without any further chance to me

Date:





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(Name)

(Designation) (Seal)

Annex B

CHECK-LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS

WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS

The following check-list is required to be submitted with all the applications for grant of BIS licence under the Product Certification Scheme of BIS. Please tick (√) in the relevant box.

Whether applied under: Simplified Procedure Normal Procedure

Note: Refer BIS website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence.

No. Check-point Requirement Observations

Page

No. General Is the application form completely filled? 1. Name

&

Is the name and address of applicant (manufacturing unit

applying for licence) same in the application as

2. Status of

Applicant

a. Has it been indicated whether the applicant is a large scale or

b. In case the applicant is a small scale unit, does the applicant

hold valid Registration Certificate from the Local / State





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(Manufacturing

Unit)

c. Has it been indicated whether the applicant is a Public Sector

3. IS No. &

Varieties

a. Has applicant recorded the applicable Indian Standard with

b. Where applicable, has applicant mentioned designation,

grade, type, variety, size, etc., of the product for

5. History a. Where applicable, has the applicant provided information

regarding earlier BIS licence(s) held by them

b. Where applicable, has the applicant provided information

6. Signature a. Is the application signed by the CEO of the applicant?

b. In case the application is signed by a person other than the

CEO, is the application signed by the authorized signatory of

7. Machinery a. Does applicant possess requisite manufacturing infrastructure

b. Is installed capacity of production indicated in the application?

c. Does applicant have all machineries installed as per

manufacturing process at the applicant’s

d. If answer to ‘c’ above is no, does the applicant outsource any

of its manufacturing processes and possesses valid

e. If answer to ‘d’ above is yes, does the applicant has any

control over such outsourced activity? Are these outsourced

8. Test Equipment

&

a. Does applicant possesses requisite test facilities in-house as

b. Are valid calibration certificates for relevant test equipment

attached are complete and valid at least 3 months





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Calibration c. If reply to ‘a’ above is no, does applicant have arrangement

with a BIS recognized outside lab for testing of the

requirements for which it does not possess test facilities in-

house? Is the consent letter as attached by applicant in this

9. QC personnel Does the applicant employ qualified & experienced Quality

Control (QC) personnel on permanent basis and possess

10. Raw Materials

and

Components

Where ever requirements for raw materials/ components used in

the manufacturing of the product are specified in the standard, do

11. Plant Layout Does copy of the plant (applicant manufacturing premises) layout

clearly indicates locations of manufacturing

13. Test Report(s) a. Is the attached test report of in-house or from independent

laboratory cover all requirements of the Indian

b. In case the application is filed under “simplified Procedure” is

the test report(s), in original, as submitted a) from BIS or its

recognized laboratories? b) the test report is not





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14 Undertaking In case application is under simplified procedure, an undertaking

shall be obtained from the applicant on his letter-head that the

licence if granted against his application shall be put under Stop

Marking by BIS if the verification sample(s) (any sample including

the long duration test samples) drawn during visit of the BIS

officer prior to grant of licence fail to conform to the requirements

of relevant Indian Standards. The licensee shall take necessary





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Annex C

ADDITIONAL REQUIREMENTS FOR APPLICANTS UNDER

FOREIGN MANUFACTURERS’ CERTIFICATION SCHEME OF BIS

Sl.

No.

Check-point Requirement Yes

Not

Applica15. Application Fee

Has applicant paid requisite application fee of Rs. 1000/-, in

equivalent US$ (Rs. 1000/- plus 12.36% tax for applicants from

16. Signature Is the application countersigned by the applicant’s Authorized Indian

17. Nomination a. Has ‘Nomination Form’ of ‘authorized Indian representative (AIR)’

in the prescribed format on the firm’s letter-head, duly signed by

the authorized signatory of the applicant and the AIR or the

b. Is the authorization to the signing authority to sign the ‘Nomination

c. Is address of the AIR in the ‘Nomination Form’ complete and

evidence of nationality, address proof, contact details like phone /

d. In case AIR is an Indian company, have copies of registration

certificate and/or Memorandum of Articles along with authorization

letter from top management of the Indian company in the name

e. Has copy of Agreement between applicant and the Indian

company / individual, nominated as the AIR, also been

f. Are copies of valid RBI clearance certificate for Indian Office /

Branch of the applicant or any other relevant document for





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18. Language Are English translations of all the documents, which are in languages

19. Preliminary

Inspection /

Visit Charges

Does the applicant undertake to bear inspection charges for all the

inspections to be carried out by BIS at its premises before the grant of

20. Translation

Facility

Does the applicant undertake to arrange, if required, services of

translator (for translation in English) during the visits of BIS officers to

21. Agreement Does the applicant agree to sign a legally binding agreement with BIS

22. Indemnity Bond

Does the applicant agree to submit an Indemnity Bond to BIS in the

prescribed format?

23. Performance

Bank Guarantee

Does the applicant agree to furnish a Performance Bank Guarantee

to BIS of US $ 10000/- (from a bank having its branch in India) in





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ANNEX 2

Doc:STI/2046/4 June 1999





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SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED

LAMINATED SHEETS

ACCORDING TO IS 2046:1995 (First Revision)

1. LABORATORY: A laboratory shall be maintained which shall be suitably equipped and staffed, where different test given in the specification shall be carried out in accordance with the methods given in the specification.

1.1 All testing apparatus shall be periodically checked and calibrated and records of such checks/calibration shall be maintained.

2.0 TEST RECORDS: All records of tests and inspection shall be kept in suitable forms approved by the Bureau.

2.1 Copies of any record and other connected papers that may be required by the Bureau shall be made available at any time on request.

3.0 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):1972, IS 397 (Part 2):1985 and IS 397(Part 3):1980].

3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with the quality system modules as per IS/ISO 9001 or IS/ISO 9002 or IS/ISO 9003 as appropriate to the activities of the organization.

4.0 STANDARD MARK: The standard mark(s) as given in column (1) of the First Schedule of the license shall be printed on the label applied to each Sheet and the covering carton, provided always that the materials in the Sheet to which the Mark is thus applied conforms to every requirement of the specification.

5.0 MARKING: The following information shall also be marked legibly and indelibly on the Decorative thermosetting synthetic resin Bonded indicated sheets:

a) Name of the material;





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b) Name of the manufacture and recognized trade mark, if any;

c) Type and class of the material

d) Month and year of manufacture;

e) Batch number/code number/Control unit number

f) Size and thickness of sheets;

g) ‘Made in India’ (if required)

h) License No.(CM/L……….)

6.0 PACKING: The material shall be packed as per clause 7.1 of IS 2046:1995.

7.0 CONTROL UNIT: For the purpose of this scheme, the total quantity of laminated sheets similar in regard to type/class and produced on the same day shall constitute a control unit.

7.1 On the basis of test results, the decision regarding conformity or otherwise of a control unit to a given requirement shall be made.

8.0 LEVELS OF CONTROL: The tests as indicated in Table 1 and at levels of control specified therein shall be carried out on the whole production of the factory covered by the scheme and appropriate records and charts maintained in accordance with clause 2.0 above. All the production which conforms to the Indian Standard and covered by this license shall be marked with Certification Mark of the Bureau.

9.0 In respect of all other clauses of the specification and at all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the requirements of those clauses.

10.0 RAW MATERIALS: It is recommended that the resins used for the production of decorative sheets shall be tested for the requirements of specific gravity, pH and its consistency and appropriate test records shall be maintained for the tests carried out.





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10.1 It is also recommended that craft papers, tissue papers and design papers shall be accepted for manufacturing decorative sheets only after visual observation for the manufacturing defects, if any, and for the improper size of the papers.

11.0 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 case be stored together with that conforming to the specification.

12.0 SAMPLES: The licensee shall supply, free of charge, the samples required in accordance with Bureau of Indian Standard (Certification) Regulations, 1988, as subsequently amended, from his factory or godowns. The Bureau shall pay for the samples taken by it from the open market.

13.0 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 are 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 the conformity of the product to the Indian Standard shall be with the Bureau.

13.1 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.

14.0 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.





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15.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed proforma to be authenticated by a Chartered Accountant 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.


DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS IS 2046:1995 (First Revision)

TABLE 1 LEVELS OF CONTROL

(Clause 8 of the Scheme of Testing and Inspection)

TEST DETAILS LEVELS OF CONTROL

Remarks Clause Requirements Test Method No. of

Samples

Frequency Clause

Reference

5.1

Colour and Pattern

5.1

IS 2046:1995

One

Each

5.2

Surface finish and reverse side/bonding.

5.2.1

-do-

-do-

-do-

5.3

Thickness

5.3.1

-do-

Two from

-do-

5.4

Appearance





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5.4.1

Surface defects.

5.4.1

-do-

5% subject

to a

minimum 5

-do-

5.4.1.1

Spot, dirt and similar

5.4.1.1

-do-

-do-

-do-

5.4.1.2

Fibres, heirs, scratches

5.4.1.2

-do-

-do-

-do-

5.4.1.3

Accumulated

(combinations) of surface

5.4.1.3

-do-

-do-

-do-

5.4.2

Edge defect.

5.4.2

-do-

-do-

-do-

5.4.3

Broken corners.

5.4.3

-do-

-do-

-do-

5.4.4

Sanding Defects

5.4.4

IS 2046:1995

5.4.5

Warping

5.4.5

-do-

-do-

-do-


IS 2046: 1995

DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS (First Revision)




Remarks Clause Requirements Test Method No. of

Samples

Frequency Clause

Reference





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5.4.6

Length and Width.

5.4.6

IS 2046:1995

Two

from

Each control unit

5.4.7

Straightness of Edges

5.4.7

-do-

-do-

-do-

5.4.8

Squareness of the

5.4.8

-do-

-do-

-do-

5.5 &

Properly Requirements.

i)

Resistance to surface wear.

Annex C

-do-

One

Once in three days*

ii)

Resistance to immersion in

Annex D

-do-

-do-

Once in a day*

iii)

Resistance to Dry heat.

Annex E

-do-

-do-

Once in a week*

iv)

Dimensional stability at

Annex F

-do-

-do-

-do-

v)

dimensional stability at

Annex G

-do-

-do-

Once in two weeks*

vi)

Resistance to impact by

Annex H

-do-

-do-

Once in two weeks*

vii)

Resistance to impact by

Annex J

-do-

-do-

-do-

viii)

Resistance to cracking.

Annex K

IS 2046:1995

One

Every alternate day*


IS 2046: 1995

DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS (First Revision)








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Clause Requirements Test Method No. of

Samples

Frequency Remarks Clause

Reference

ix)

Resistance to scratching.

Annex L

-do-

-do-

Once a week*

x)

Resistance to staining

Annex M

-do-

-do-

Once a day*

xi)

Resistance to colour

change.

Annex N

Alternate

IS 2046:1995

One

Once in six

months**

xii)

Resistance to cigarette

burns.

Annex P

Alternate

-do-

-do-

Once a week*

xiii)

Formability.

Annex R

-do-

-do-

-do-

xv)

Resistance to steam.

Annex T

-do-

-do-

Once in three

xvi)

Resistance to crazing.

Annex W

-do-

-do-

-do-

xvii)

Resistance to Moisture.

Annex Y

-do-

-do-

-do-

xviii)

Flexural Modulers.

Annex F

-do-

-do-

-do-

xix)

Flexural strength.

-do-

-do-

-do-

-do-

xx)

Tensile Strength

IS 8543

(Pt.4/sec1):

1984

-do-

-do-

* Subject to the condition that all types/classes of laminates are covered in a month.

** Subject to the condition that all types/classes of laminates are covered in two years