Preformed Fillers for Expansion Joints in Concrete Pavements and Structures(non-extruding and resilient type) Part 3 Polymer Based

IS 1838 Part 3: Scope - Key Specifications & Tables

1. Tolerance on Dimensions (Clause 5.2)

2. Physical Requirements of Fillers (Table 1, Clause 6)

3. Marking (Clause 9.2)

• Each package may carry the BIS Certification Mark and the standard reference:
  IS 1838 (Part 3) : 2011

4. Rounding Off (General)

• Final values must be rounded as per IS 2:1960, retaining the same significant figures as specified.

Notes:

• Damaged filler pieces must be rejected.
• Fillers must be packed to prevent distortion or deterioration during transport.
• Refer to Annex A for installation guidance.

flowchart LR
    A[Start] --> B[Check Dimensions]
    B -->|Within Tolerance| C[Physical Tests]
    C --> D{Pass Tests?}
    D -->|Yes| E[Mark & Pack]
    D -->|No| F[Reject]

This summary ensures compliance with IS 1838 Part 3 regarding joint filler specifications and quality control.

IS 1838 Part 3: Key Specifications & Tables

1. Physical Requirements of Fillers (Table 1, Clause 6)

Damaged filler pieces must be rejected.

2. Dimensional Tolerances (Table 5.2, Clause 5.2)

• Length: ± 5 mm
• Width: +3 mm
• Thickness: ± 1.5 mm

3. Marking (Clause 9.2)

• Packages may carry the BIS Standard Mark for certification.

4. Rounding Off (IS 2:1960)

• Final test values should be rounded off maintaining the same significant figures as the specified values.

Summary Diagram: Filler Properties & Testing Flow

flowchart TD
    A[Preformed Joint Filler] --> B{Physical Tests per IS 10566}
    B --> C[Resistance to Handling]
    B --> D[Recovery ≥ 90%]
    B --> E[Compression Load 7-53 kgf/cm²]
    B --> F[Extrusion ≤ 6 mm]
    B --> G[Water Absorption ≤ 1%]
    B --> H[Density 100 ± 10 kg/m³]
    B --> I[Weathering - No Damage]
    I --> J[Meets Recovery, Compression, Extrusion]

This concise summary covers critical physical requirements, tolerances, marking, and testing methods per IS 1838

IS 1838 Part 3: Key Definitions & Specifications for Joint Fillers

1. Tolerances on Dimensions (Clause 5.2, Table 5.2)

2. Physical Requirements of Fillers (Clause 6, Table 1)

3. Packaging & Handling

• Fillers must be packed to avoid distortion, breakage, or property deterioration during transport.
• Damaged pieces must be rejected.

4. Rounding Off (Clause on Numerical Values)

• Follow IS 2:1960 for rounding test results to the same significant figures as specified values.

This concise summary covers critical definitions, tolerances, and physical criteria for joint fillers per IS 1838 Part 3. For detailed test procedures, refer to IS 10566.

IS 1838 Part 3: Material Requirements for Preformed Joint Fillers

Key Physical Requirements (Table 1, Clause 6)

Dimensional Tolerances (Clause 5.2)

Typical Dimensions (Clause 5.1)

Packaging & Marking (Clause 9.2)

• Fillers must be packed to avoid distortion or damage.
• BIS Certification Mark may be applied on each package.

flowchart TD
    A[Preformed Joint Filler] --> B[Physical Requirements]
    B --> C[Resistance to Handling]
    B --> D[Recovery ≥ 90%]
    B --> E[Compression 7-53 kgf/cm²]
    B --> F[Extrusion ≤ 6 mm]
    B --> G[Water Absorption ≤ 1%]
    B --> H[Density 100 ± 10 kg/m³]
    B --> I[Weathering Test]
    A --> J[Dimensional Tolerances

IS 1838 Part 3: Dimensions and Tolerances for Preformed Joint Fillers

Key Dimensions (Clause 5.1, Table 5.1)

• Alternative dimensions can be mutually agreed upon (ref: IS 10566 for measurement methods).

Tolerances on Average Dimensions (Clause 5.2, Table 5.2)

Additional Specifications

• Rounding off of test/analysis results should follow IS 2:1960.
• Physical properties must comply with Column 3 of Table 1 (tested per IS 10566).
• Fillers must be packed to avoid distortion or damage during transport.
• Installation guidance is in Annex A.

flowchart TD
    A[Preformed Joint Filler] --> B[Dimensions]
    B --> C[Length: 1800 or 2200 mm]
    B --> D[Width: 900 or 1100 mm]
    B --> E[Thickness: 8 to 50 mm]
    A --> F[Tolerances]
    F --> G[Length ±5 mm]
    F --> H[Width +3 mm]
    F --> I[Thickness ±1.5 mm]
    A --> J[Physical Requirements per IS 10566]
    A --> K[Packing to avoid damage]

This summary ensures compliance with IS 1838 Part 3 for filler dimensions and tolerances.

IS 1838 Part 3: Physical Requirements of Preformed Joint Fillers

Key Specifications (Clause 6, Table 1)

Dimensional Tolerances (Clauses 5.1 & 5.2)

Packaging

• Fillers must be packed to avoid distortion, breakage, or property deterioration during transport.

Summary Diagram

flowchart LR
    A[Preformed Joint Filler] --> B[Physical Properties]
    B --> C[Resistance to Handling: No damage]
    B --> D[Recovery ≥ 90%]
    B --> E[Compression 7-53 kgf/cm²]
    B --> F[Extrusion ≤ 6 mm]
    B --> G[Water Absorption ≤ 1%]
    B --> H[Density 100 ± 10 kg/m³]
    B --> I[Weathering: No damage + meets other criteria]

Note: Refer to IS 10566 for detailed test procedures. Damaged fillers must be rejected.

IS 1838 Part 3: Sampling and Testing Key Points

Sampling (Clause 10.1 & 10.2)

• Number of Samples:
  • 1 representative sample per 100 m² of material with the same thickness.
  • Sampling must be random.
• Sample Size:
  • Each sample must yield five test pieces of 100 mm × 100 mm.
• Acceptance Criteria:
  • All five test pieces must meet dimensional and physical requirements for the lot to be accepted.

Physical Requirements of Fillers (Table 1, Clause 6)

Notes:

• Damaged filler pieces must be rejected.
• Final test values should be rounded per IS 2:1960 rules.

flowchart TD
    A[Sampling] --> B[1 sample per 100 m²]
    B --> C[Cut 5 test pieces (100x100 mm)]
    C --> D{All 5 pass physical & dimensional tests?}
    D -- Yes --> E[Lot Accepted]
    D -- No --> F[Lot Rejected]

This ensures quality control per IS 1838 Part 3 requirements.

IS 1838 Part 3: Packaging and Marking Key Points

1. Marking Requirements (Clause 9.1 & 9.2)

• Packages must be marked with:
  • Manufacturer's name or trade-mark
  • Dimensions
  • Type of filler
• Optionally, the BIS Certification Mark (Standard Mark) may be included on each package.

2. Packaging Specifications (Clause 1.5)

• Preformed joint fillers must be packed to prevent distortion, breakage, or property deterioration during transportation.
• Refer to Annex A for installation guidance.

3. Dimension Tolerances (Clause 5.2)

4. Physical Requirements of Fillers (Table 1, Clause 6)

flowchart TD
    A[Packaging] --> B[Marking]
    B --> C[Manufacturer Name]
    B --> D[Dimensions]
    B --> E[Type of Filler]
    A --> F[Protection]
    F --> G[No distortion]
    F --> H[No breakage]
    F --> I[No property deterioration]

This summary ensures compliance with IS 1838 Part 3 packaging and marking requirements for preformed joint fillers.

IS 1838 Part 3: Installation Guidelines & Key Specifications for Preformed Joint Fillers

1. Physical Requirements (Table 1)

2. Typical Dimensions (Clause 5.1)

Dimensions may be mutually agreed upon.

3. Installation Highlights (Annex A & Clause 1.3)

• Handling: Fillers must be packed to avoid distortion or damage during transport.
• Use as Shuttering: Fillers can act as shuttering on one side of expansion joints, secured by MS bolts spaced ~1m apart, later removed and grouted.
• Installation Steps:
  • Place filler strip in joint gap.
  • Remove top strip if polymer-based.
  • Complete joint treatment with plaster/tiling (floor) or finishing (wall).

4. Summary Diagram: Installation Procedure

flowchart TD
    A[Prepare joint gap] --> B[Place preformed filler strip]
    B --> C{Is polymer-based?}
    C -- Yes --> D[Remove top strip]
    C -- No --> E[Proceed]
    D --> E
    E --> F[Secure with MS bolts if used as shuttering]
    F --> G[Pour concrete / grout holes after bolt removal]
    G --> H[Finish joint with plaster/tiling]

IS 1838 Part 3 - Annex A: Typical Laying Procedure

Key Specifications & Procedure Highlights

• Sample Size (Clause 10.2):

  • Each sample must yield five test pieces of 100 mm × 100 mm.
  • All five must meet dimensional & physical requirements per IS 10566 for acceptance.

• Physical Requirements (Clause 1.5):

  • Fillers must conform to Column 3 of Table 1 (IS 1838 Part 3) tested by IS 10566 methods.

• Laying Procedure (Annex A, Clause 1.3):

  • Fillers can be used as shuttering on one side of the expansion joint by abutting the cast member.
  • Use MS bolts at ~1 m intervals to hold shuttering; bolts removed post-casting and holes grouted with cement mortar.
  • Preformed polymer-based fillers must be packed to avoid distortion or damage during transport.

• Typical Dimensions (Clause 5.1, Table 5.1):

• Installation Steps (Fig. 1 & 2):
  • Place filler strip, remove top strip after placement.
  • Complete joint treatment for horizontal (floor) and vertical (wall) surfaces.
  • Use filler as shuttering for column members secured with bolts (Fig. 2).

Summary Diagram (Mermaid.js)

flowchart TD
    A[Prepare Surface] --> B[Place Preformed Filler]
    B --> C{Use as Shuttering?}
    C -->|Yes| D[Secure with MS Bolts @1m]
    C -->|No| E[Direct Placement]
    D --> F[Pour Concrete]
    E --> F
    F --> G[Remove Bolts & Grout Holes]
    G --> H[Finish Joint Treatment]

References:

• IS 1838 Part 3 (2011)
• IS 10566 (Physical Testing of Joint Fillers)

IS 1838 (Part 3) - Annex B: Committee Composition

Annex B lists the composition of the Building Construction Practices Sectional Committee, CED 13, responsible for this standard's formulation.

Key Points:

• Committee Members: Representatives from government departments, research institutes, industry bodies, and experts in personal capacity.
• Organizations include:
  • Bhabha Atomic Research Centre, Mumbai
  • Central Building Research Institute, Roorkee
  • Central Public Works Department, New Delhi
  • Indian Buildings Congress, New Delhi
  • Structural Engineering Research Centre (CSIR), Chennai
  • The Institution of Engineers (India), Kolkata
  • BIS Directorate General (Member Secretary: Shri S. Arun Kumar)
• Chairman: Shri D. S. Sachdev
• Each organization has primary and alternate representatives.

No formulas or tables are provided in Annex B, as it is solely for committee details.

For sample size in testing (Clause 10.2):

• Sample size: Material sufficient for five test pieces of 100 mm × 100 mm.
• Acceptance criteria: All five test pieces must meet dimensional and physical requirements.

Summary Diagram of Committee Structure:

graph TD
    A[Building Construction Practices Sectional Committee, CED 13]
    A --> B[Government Departments]
    A --> C[Research Institutes]
    A --> D[Industry Bodies]
    A --> E[Experts in Personal Capacity]
    B --> B1[CPWD, New Delhi]
    B --> B2[Military Engineering Services]
    C --> C1[CSIR - SERC Chennai]
    C --> C2[CBRI Roorkee]
    D --> D1[Indian Buildings Congress]
    D --> D2[Confederation of Construction Products]
    E --> E1[Shri D. S. Sachdev (Chairman)]
    E --> E2[Shri S. Arun Kumar (Member Secretary)]

Note: Annex B is administrative; technical details and formulas are in other clauses/annexes of IS 1838 Part 3.