preformed fillers for expansion joints in concrete pavement and structure (non-extruding and resilient type) Part 2 CNSL Aldehyde resin and coconut pith - Specification

IS 1838 (Part 2) - Scope & Key Specifications Summary

• Scope:
  Covers hot applied sealing compounds for joints in concrete, including dimensional and performance criteria for fillers used in expansion joints in paving and structural construction.

• Key Specifications:

  • Compression (Clause 4.3):
    Load to compress specimen to 50% thickness:
    [ 0.7 \text{ to } 5.3 , \text{N/mm}^2 ]
    Mass loss after compression ≤ 5%.

  • Dimensions (Clause 5.1):
    Fillers must conform to dimensions specified in the contract/order.

• Rounding Off (Clause 0.5):
  Final test values rounded as per IS 2:1960, maintaining the same significant figures as the specified values.

Summary Table: Compression Requirements

flowchart LR
    A[Joint in Concrete] --> B[Hot Applied Sealing Compound]
    B --> C[Compression Test]
    C --> D[Load: 0.7 - 5.3 N/mm²]
    C --> E[Mass Loss ≤ 5%]
    B --> F[Dimension as per Contract]

This ensures sealing compounds meet mechanical and dimensional standards for durability and performance in concrete joints.

IS 1838 (Part 2) - 1984: Key Material Specifications & Formulas

Clause 4.3: Compression Test for Preformed Fillers

• Compression Load: 0.7 to 5.3 N/mm² to compress specimen to 50% thickness.
• Mass Loss: After compression, mass loss ≤ 5% of original mass.
• Reference Standard: IS 10566-1983 for test specimen preparation.

Clause 7.3: Testing Requirements

• Test 5 specimens for:
  • Physical properties (as per Clause 4).
  • Dimensional tolerances (see Clause 5).
• Lot acceptance if all specimens meet criteria.

Important Notes:

• Materials include bitumen-impregnated fibre fillers (Part 1).
• Hot-applied sealing compounds and resilient fillers are covered.
• Compression strength and durability under load are critical.

Summary Table for Compression Requirements

flowchart LR
    A[Specimen Preparation] --> B[Compression Test]
    B --> C{Load Applied}
    C -->|0.7 to 5.3 N/mm²| D[Thickness reduced to 50%]
    D --> E[Check Mass Loss]
    E -->|≤5%| F[Pass]
    E -->|>5%| G[Fail]

Use IS 10566-1983 for detailed specimen preparation and test procedures. This ensures compliance with IS 1838 (Part 2) standards.

IS 1838 Part 2 - Manufacture: Key Specifications

• Compression Test (Clause 4.3):

  • Load to compress specimen to 50% thickness: 0.7 to 5.3 N/mm² (per IS 10566-1983).
  • Post-compression mass loss: ≤ 5% of original mass.

• Rounding Off (General Clause):

  • Final test values must be rounded as per IS 2-1960.
  • Retain the same significant figures as specified values.

Summary Table: Compression Requirements

Notes:

• Compression test ensures material durability under load.
• Mass loss limit indicates chemical stability or binder retention.
• Follow IS 10566-1983 for detailed test procedure.

flowchart TD
    A[Specimen Preparation] --> B[Compression Test]
    B --> C{Load Applied}
    C -->|0.7 to 5.3 N/mm²| D[Thickness reduced to 50%]
    D --> E[Measure Mass Loss]
    E --> F{Mass Loss ≤ 5%?}
    F -->|Yes| G[Pass]
    F -->|No| H[Fail]

This ensures quality control during manufacture of sealing compounds and related materials per IS 1838 Part 2.

IS 1838 Part 2 (1984) – Key Properties & Specifications Summary

1. Compression Test (Clause 4.3)

• Compression Load: 0.7 to 5.3 N/mm² applied to compress specimen to 50% thickness.
• Mass Loss: After compression, mass loss must not exceed 5% of original mass.
• Reference: Test method per IS 10566-1983.

2. Rounding Off (General Clause)

• Follow IS 2-1960 for rounding numerical values.
• Retain the same number of significant digits as specified values.

3. Material Types Covered

• Preformed fillers for expansion joints (non-extruding, resilient).
• Hot-applied sealing compounds for concrete joints.
• Specifications for chemical materials like CNSL, phosphoric acid, paraformaldehyde, quick lime, and hydrated lime.

Summary Table: Compression Test Requirements

flowchart LR
    A[Specimen Preparation] --> B[Apply Compression Load (0.7-5.3 N/mm²)]
    B --> C[Reduce Thickness to 50%]
    C --> D[Measure Mass Loss]
    D --> E{Mass Loss ≤ 5%?}
    E -- Yes --> F[Pass]
    E -- No --> G[Fail]

This ensures the filler material's resilience and durability under compression in concrete joints.

IS 1838 Part 2 — Dimensions and Tolerances Summary

Key Tolerances (Clause 5.2)

• Thickness: +2.5 mm
• Depth: +5 mm
• Length: ±7.5 mm

Dimensions (Clause 5.1)

• Fillers' dimensions must conform to the contract or order specifications.

Rounding Off (Clause 0.5)

• Follow IS 2-1960 for rounding test or analysis results.
• Retain the same number of significant digits as specified values.

Quick Reference Table

Notes:

• These tolerances ensure proper fit and performance of fillers in construction joints.
• Always verify contract/order for any special dimension requirements.
• Rounding rules ensure consistency in reporting test results.

flowchart LR
    A[Contract/Order] --> B[Specify Dimensions]
    B --> C[Manufacture Fillers]
    C --> D[Apply Tolerances]
    D --> E[Thickness +2.5 mm]
    D --> F[Depth +5 mm]
    D --> G[Length ±7.5 mm]
    E & F & G --> H[Final Product]

This concise guide helps maintain dimensional accuracy and quality control as per IS 1838 Part 2.

IS 1838 Part 2: Marking and Packaging Key Points

• Clause 6.1: Marking Requirements

  • Packages must be marked with:
    • Manufacturer's name or trademark (if any)
    • Size of the product

• Clause 6.2: BIS Certification Marking

  • Products may carry the BIS Standard Mark to indicate conformity.

Additional Notes:

• No specific formulas or tables are provided in these clauses.
• Marking ensures traceability and size identification.
• Packaging should protect the product and maintain marking legibility.
• Rounding off numerical values should follow IS rounding rules (usually nearest whole number or decimal place as per product requirement).

Summary Table for Marking:

If you need packaging specifications or sealing compound details, please specify the exact clause or part.

IS 1838 Part 2 - Sampling and Testing Key Points

Sampling

• Number of Samples (Clause 7.1):

  • One representative sample per 100 m² of material of the same thickness.
  • Sampling must be random to ensure representativeness.

• Sample Size (Clause 7.2):

  • Each sample must be large enough to produce five test pieces of 100 mm x 100 mm.

Testing and Evaluation

• Compression Test (Clause 4.3):
  • Compress specimen to 50% of original thickness.
  • Required load range: 0.7 to 5.3 N/mm².
  • Mass loss after compression should not exceed 5%.

Rounding Off Results

• Follow IS 2-1960 for rounding off test results.
• Retain the same number of significant figures as the specified value.

Summary Table

flowchart TD
    A[Sampling] --> B[Select 1 sample per 100 m²]
    B --> C[Sample size: Enough for 5 pieces 100x100 mm]
    C --> D[Compression Test]
    D --> E[Compress to 50% thickness]
    E --> F[Load between 0.7 - 5.3 N/mm²]
    F --> G[Mass loss ≤ 5%]
    G --> H[Round off results as per IS 2-1960]

This ensures consistent, reliable testing and compliance with IS 1838 Part 2.

IS 1838 Part 2 – Certification and Standard Mark (Clause 6.2 & 6.2.1)

• Standard Mark Usage:
  The Standard Mark is a certification mark granted by BIS under the Bureau of Indian Standards Act, 1986. It signifies compliance with the relevant Indian Standard.

• Licensing Conditions:
  Manufacturers or producers must obtain a license from BIS to use the Standard Mark. This license is granted based on compliance with the product specifications and quality control requirements.

• Key Points:

  • The Standard Mark indicates conformity to IS 1838 Part 2.
  • Use of the mark is strictly regulated by BIS rules and licensing agreements.
  • Details on licensing procedures, conditions, and fees are available directly from BIS.

• No explicit formulas or tables are provided in Clause 6.2 or 6.2.1 for certification marking.

For practical purposes, always consult the latest BIS licensing handbook or contact BIS for detailed application and compliance requirements.

IS 1838 Part 2 - Application and Usage Guidelines: Key Points

• Compression Test (Clause 4.3):

  • Load to compress specimen to 50% thickness: 0.7 to 5.3 N/mm² (per IS 10566-1983).
  • After compression, mass loss must be ≤ 5% of original mass.

• Rounding Off Numerical Values:

  • Follow IS 2-1960 for rounding rules.
  • Retain the same number of significant digits as specified values.

• Material Specifications:

  • Hot applied sealing compounds for concrete joints must meet compression and mass loss criteria.
  • Related materials: cashewnut shell liquid (CNSL), paraformaldehyde, quick lime, hydrated lime (chemical industry grade).

Summary Table: Compression Test Limits

flowchart LR
    A[Sealing Compound Sample] --> B[Compression Test]
    B --> C{Load Applied}
    C -->|0.7-5.3 N/mm²| D[Thickness reduced to 50%]
    D --> E[Check Mass Loss]
    E -->|≤ 5% mass loss| F[Pass]
    E -->|> 5% mass loss| G[Fail]

Note: Always verify material compliance with IS 1838 Part 2 and related IS codes for specific applications.

IS 1838 Part 2 - Key References & Specifications Summary

• Compression Test (Clause 4.3):

  • Load to compress specimen to 50% thickness: 0.7 to 5.3 N/mm² (per IS 10566-1983).
  • Post-compression mass loss: ≤ 5%.

• Rounding Rules (IS:2-1960):

  • Final test/calculated values must be rounded off to the same significant figures as specified in the standard.

• Related Specifications Referenced:

  • Hot applied sealing compounds for concrete joints (first revision).
  • Cashewnut Shell Liquid (CNSL) specification (revised).
  • Paraformaldehyde specification.
  • Quick lime and hydrated lime for chemical industries (Part 2 Hydrated lime, second revision).
  • Safety code for phosphoric acid.
  • Test methods for preformed fillers for expansion joints.

Rounding Off (IS 2-1960) Example:

flowchart LR
    A[Test Specimen] --> B[Compression Load Applied]
    B --> C{Load = 0.7 to 5.3 N/mm²?}
    C -- Yes --> D[Specimen compressed to 50% thickness]
    D --> E[Mass loss ≤ 5%?]
    E -- Yes --> F[Pass]
    E -- No --> G[Fail]
    C -- No --> G

This ensures sealing compounds meet mechanical and durability criteria per IS 1838 Part 2.