Wooden Flush Door Shutters (Cellular and Hollow Core Type), Part 1: Plywood Face Panels

IS 2191 Part 1 - Scope: Key Specifications & Tables

Scope Summary

• Covers flush doors: sizes, thickness, and dimensional allowances.
• Applies modular sizing: width and height in multiples of 100 mm.
• Door frame and shutter dimensions include allowances for rebates, clearances, and floor finishes.

Key Dimensions & Allowances (Fig. 1 Reference)

Thickness of Shutters (Nominal)

Notes

• D = Door, S = Single shutter, T = Double shutter.
• Allowances: 60 mm for frame, 40 mm floor finish, 5 mm clearance all around, 15 mm rebate.
• Standard door frames per IS 4021-1983 and IS 4351-1976.
• Rounding off test values as per IS 2-1960.

flowchart LR
    A[Modular Width (Mw)] --> B[Overall Width = Mw - 10 mm]
    B --> C[Width of Shutter = Mw - 100 mm]
    D[Modular Height (MH)] --> E[Overall Height = MH - 10 mm]
    E --> F[Height of Shutter = MH - 95 mm]
    G[

IS 2191 Part 1 - Key Specifications for Door Sizes

1. Door Size Designation

• Designation format:
  Width (in 100 mm modules) + Door Type + Height (in modules)
  e.g., 8 DS 20 means 800 mm width, Single Shutter (DS), height module 20.

2. Standard Modular Sizes (Table 2)

*DT = Double shutter; combined width of two shutters.

3. Thickness of Shutters (Nominal)

4. Dimensional Allowances (Fig. 1)

• Door frame rebate thickness: 45 mm
• Allowance for frame, floor finish, clearance:
  • Frame: 60 mm
  • Floor finish: 40 mm
  • Clearance all round: 5 mm
  • Rebate for shutter: 15 mm
• Formulas:

Overall height of door frame = MH - 10 mm

IS 2191 Part 1 - Key Specifications & Tables for Types of Wooden Flush Doors

1. Types of Wooden Flush Door Shutters (Clause 3.1 & Table 1)

• CD: Cellular Decorative
• CN: Cellular Non-decorative
• HD: Hollow Decorative
• HN: Hollow Non-decorative

2. Thickness of Shutters (Clause 2.045)

3. Dimensional Allowances (Clause 2.045 & Fig. 1)

• Door Frame Thickness (minus rebate): 45 mm
• Allowances:
  • Door frame: 60 mm
  • Floor finish: 40 mm
  • Clearance all round: 5 mm
  • Rebate all round: 15 mm
• Dimensions:

MH = Modular Height, Mw = Modular Width of door opening

4. Type Tests (Clause 9.4)

• Performed as per IS 4020-1967
• Required on at least 3 samples (Clause 1.1)
• Applies only to specific door design, not routine tests

flowchart LR
    A[Door Opening Dimensions] --> B(Modular Width Mw, Modular Height MH)
    B --> C[Calculate

IS 2191 Part 1 - Key Specifications for Materials (Doors & Frames)

1. Door Sizes & Designations (Clause 2.045)

• Door size designation: Width and height in modules of 100 mm (e.g., 8 DS 20 means 800 mm width, 2000 mm height).
• Types:
  • D = Door
  • S = Single shutter
  • T = Double shutter

2. Thickness of Shutters (Nominal)

3. Dimensional Allowances (Fig. 1 Summary)

• Door frame rebate thickness: 45 mm
• Overall height of door frame: MH - 10 mm
• Height of shutter: MH - 95 mm
• Width of shutter: MW - 100 mm
• Overall width of door frame: MW - 10 mm
• Clearances:
  • 60 mm allowance for door frames
  • 40 mm for floor finish
  • 5 mm clearance all round
  • 15 mm rebate all round for shutter into frame

4. Reference Standards for Frames

• Timber door/window frames: IS 4021-1983, IS 4351-1976
• Steel door frames: IS 4351 (first revision)

Diagram: Door Dimensions (Simplified)

flowchart TD
    A[Modular Width (MW)] -->|MW - 100 mm| B[Shutter Width]
    A -->|MW - 10 mm| C[Overall Frame Width]
    D[Modular Height (MH)] -->|MH - 95 mm| E[Shutter Height]
    D -->|MH - 10 mm| F[Overall Frame Height]
    E --> G[Shutter Thickness: 25, 30 or 35 mm]

Summary: Use modular sizing with allowances for frame, clearance, and rebate. Choose shutter

IS 2191 Part 1: Face Panels and Veneers Key Points

Face Veneers (Clause 5.4 & 5.4.1)

• Commercial face veneers for flush door shutters must meet IS 303-1975 requirements for BWP grade plywood.
• Thickness of decorative veneers: 0.5 mm minimum.
• Thickness of commercial veneers: 0.5 mm to 1.5 mm.
• Thickness of decorative veneers: 0.5 mm to 1.0 mm.

Face Panel Specifications (Clause 6.5 & 6.5.1)

• Minimum plywood thickness for face panel:
  • Cellular core shutters: ≥ 3 mm
  • Hollow core shutters: ≥ 6 mm (except 25 mm thick doors where 4 mm allowed)
• Two-ply face skin (cross-band + face veneer) allowed only for cellular core shutters with combined thickness ≥ 4 mm.
• When applying decorative veneer over existing veneer:
  • Sand existing veneer so total thickness ≤ max specified.
  • Decorative veneer thickness ≥ 0.5 mm.

Summary Table of Thicknesses

flowchart TD
    A[Face Panel] --> B{Core Type}
    B -->|Cellular Core| C[Face Panel ≥ 3 mm]
    B -->|Hollow Core| D[Face Panel ≥ 6 mm]
    D --> E{Door Thickness}
    E -->|25 mm| F[Face Panel ≥ 4 mm]
    E -->|Others| D
    C --> G[Two-ply Face Skin Allowed]
    G --> H[Cross-band + Face Veneer ≥ 4 mm]
    A --> I[Face Veneers]
    I --> J[Commercial: 0.5 -

IS 2191 Part 1 (1983) covers Construction of concrete piles, focusing on cast-in-situ piles.

Key Specifications & Construction Guidelines:

• Pile Diameter: Typically ranges from 300 mm to 600 mm.
• Pile Length: As per design, depending on soil strata.
• Reinforcement: Minimum cover of 40 mm for piles in soil.
• Concrete Grade: Minimum M20 grade concrete recommended.
• Boring Methods: Use rotary or percussion boring; avoid soil disturbance.
• Cleaning: Clean borehole before concreting to remove loose soil.
• Concreting: Use tremie pipe or direct pouring to avoid segregation.
• Curing: Proper curing for at least 7 days to achieve strength.

Typical Formula for Pile Capacity (Approximate):

[ Q_u = Q_s + Q_b ]

Where:

• (Q_u) = Ultimate pile capacity
• (Q_s = ) Skin friction resistance
• (Q_b = ) End bearing resistance

Skin friction (for cohesive soil):

[ Q_s = \pi d L f_s ]

Where:

• (d) = Pile diameter
• (L) = Length of pile in soil
• (f_s) = Unit skin friction from soil tests

flowchart TD
    A[Start Construction] --> B[Borehole Drilling]
    B --> C[Cleaning Borehole]
    C --> D[Reinforcement Placement]
    D --> E[Concreting (Tremie Method)]
    E --> F[Curing]
    F --> G[Load Testing]

For detailed tables and soil parameters, refer to IS 2911 (Pile Foundations) and soil investigation reports.

IS 2191 Part 1: Workmanship and Finish - Key Points

• Reference Standards for Finish:

  • Commercial Type: IS 303-1975
  • Decorative Type: IS 1328-1970

• Locks Preparation (Clause 7.1):

  • Shutters shall be shop-prepared for mortice locks/latches only if ordered.
  • Wood blocks for lock fixing should match max lock size per IS 2209-1976.

• Inspection Criteria (Clause 2.3.1):

  • Check dimensions (Clauses 4.1, 4.2, 4.3).
  • Check workmanship & finish (Clause 8).

• Acceptance Sampling (Clause 2.4.2):

  • Lot conformity depends on permissible failure limits in Table 3 (IS 2191 Part 1).
  • Number of defective shutters must not exceed limits in Table 3, Column 3.

Typical Table 3 Format (Permissible Number of Defects)

(Exact values per IS 2191 Part 1 Table 3)

Summary Diagram: Workmanship & Finish Quality Control Flow

flowchart TD
    A[Select Shutters] --> B[Inspect Dimensions]
    B --> C[Inspect Workmanship & Finish]
    C --> D{Defects within Limits?}
    D -- Yes --> E[Lot Accepted]
    D -- No --> F[Lot Rejected]

In brief: Follow IS 303/1328 for finish, prepare lock blocks per IS 2209, inspect per IS 2191 clauses, and accept lots based on defect limits in Table 3.

IS 2191 Part 1 — Marking Requirements

Key Marking Specifications (Clause 11.1 & 12.1)

Each shutter must be legibly and indelibly marked on any edge with:

• a) Manufacturer's name or trade-mark
• f) Species of timber (if ECO Marked)
• g) Criteria for ECO Mark labelling

Use of Standard Mark (Clause 11.1.1)

• The shutter may bear the BIS Standard Mark, indicating compliance with IS 2191 under BIS supervision.
• The Standard Mark ensures:
  • Production under strict inspection and quality control.
  • Continuous conformity checks by BIS.
• Licensing conditions for the Standard Mark are governed by the Bureau of Indian Standards Act, 1986.

Additional Notes

• Marking must be indelible and legible.
• Marking location: any edge of the shutter.

Summary Table for Marking Information

If you need sampling or conformity criteria, refer to Appendix B (Clause 10.1) for detailed procedures.

IS 2191 Part 1: Tests - Key Points

1. Number of Tests (Clause 2.3 / B-2.3)

• Specifies the minimum number of tests required for product conformity.
• Tests include type tests, routine tests, and acceptance tests.
• Number depends on batch size and test type.

2. Type Tests (Clause 9.4)

• Performed as per IS 4020-1967 for flush doors.
• Validate performance of a specific door design.
• Not mandatory for every batch; done initially or on design change.

3. Sampling and Criteria for Conformity (Clause 10.1 / Appendix B)

• Sampling follows statistical methods for batch acceptance.
• Results rounded per IS 2-1960:
  • Round test results to the same decimal places as specified values.
• Acceptance criteria based on number of defective samples allowed.

4. Rounding Off (Clause 0.5)

• Final test results must be rounded off as per IS 2-1960.
• Ensures uniformity in reporting test data.

Summary Table: Test Types and Purpose

flowchart TD
    A[Start] --> B{Test Type?}
    B -->|Type Test| C[Perform IS 4020-1967 tests]
    B -->|Routine Test| D[Test every batch]
    B -->|Acceptance Test| E[Sample batch as per Appendix B]
    C --> F[Validate design]
    D --> F[Check production quality]
    E --> F[Decide batch conformity]
    F --> G[Round off results per IS 2-1960]
    G --> H[Pass/Fail decision]

For detailed test procedures and sampling plans, refer to Appendix B and **IS 4020

IS 2191 Part 1: Sampling and Criteria for Conformity (Appendix B)

Key Points from Clause 10.1 and Table 3 (Clause 2.2)

• For lot size ≤ 25, sample size is mutually agreed.
• Permissible number of defectives indicates the maximum allowable defective shutters in the sample for the lot to be accepted.
• Sub-sample size refers to the number of samples selected for specific tests within the sample.

Criterion for Conformity (Clause B-2.4)

• A lot is accepted if the number of defectives found in the sample does not exceed the permissible number.
• If defectives exceed permissible limits, the lot is rejected or subjected to further inspection.

Summary:

• Use Table 3 to determine sample size based on lot size.
• Check defectives against permissible limits.
• Sampling ensures quality conformity before acceptance.

flowchart TD
    A[Start: Lot Size] --> B{Lot Size}
    B -->|≤ 25| C[Sample size as agreed]
    B -->|26 to 50| D[Sample size = 8, Permissible defectives = 0]
    B -->|51 to 100| E[Sample size = 13, Permissible defectives = 1]
    B -->|101 to 150| F[Sample size = 20, Permissible defectives = 1]
    B -->|151 to 300| G[Sample size = 32, Permissible defectives

IS 2191 Part 1 - Species of Timber Suitable for Manufacture

Key Points from Clause 5.1.2 & Appendix A:

• Group 1: Suitable for core and cross-bands only (mainly coniferous & softwoods).
• Group 2: Suitable for frame, core, and cross-bands (non-coniferous hardwoods).
• Species marked with * and all sapwood must be preservative treated before assembly.

Important Specifications:

Examples from Appendix A:

Treatment Note (Clause 5.1.5):

• Species with * and sapwood require preservative treatment (e.g., brush/spray).
• Ensures durability and protection against decay and insects.

Summary Diagram:

graph TD
A[Timber for Flush Door Manufacture] --> B[Group 1: Core & Cross-bands]
A --> C[Group 2: Frame, Core & Cross-bands]
B --> D[Coniferous & Softwoods]
C --> E[Non-coniferous Hardwoods]
E --> F[Treated Species (*) & Sapwood]

**Use Group 1 species for core/cross-bands, Group 2 for

IS 2191 Part 1: Sampling and Acceptance Tests

Key Specifications from Appendix B (Clause 10.1):

1. Sampling Plan (Table 3):

• Note: For lots ≤ 25, sampling is mutually agreed between purchaser and seller.

2. Acceptance Criteria:

• The lot is accepted if the number of defective shutters in the sample does not exceed the permissible number.
• Sub-sample size refers to the number of units tested for specific tests within the sample.

3. Type Tests (Clause 9.4):

• Performed as per IS 4020-1967 for flush doors.
• Type tests apply only to specific designs, not routine testing.

Summary Diagram:

flowchart TD
    A[Lot Size] --> B{Determine Sample Size}
    B -->|26-50| C[Sample=8, Defectives=0, Sub=1]
    B -->|51-100| D[Sample=13, Defectives=1, Sub=2]
    B -->|101-150| E[Sample=20, Defectives=1, Sub=2]
    B -->|151-300| F[Sample=32, Defectives=1, Sub=3]
    B -->|301-500| G[Sample=50, Defectives=2, Sub=4]
    B -->|>500| H[Sample=80, Defectives=2, Sub=5]
    I[Lot ≤ 25] --> J[Sampling as agreed]