wooden flush door shutters (solid core type): Part 1 Plywood face panels

IS 2202 Part 1: Scope & Key Specifications Summary

Scope:

• Covers plywood, block boards, particle boards, and timber door shutters.
• Incorporates related IS standards (Annex A) such as IS 303 (plywood), IS 401 (timber preservation), IS 707 (timber glossary), IS 710 (marine plywood), IS 1328 (veneered plywood), IS 4021 (timber door/window frames), etc.
• Applies to testing, manufacturing, and quality control of wood-based door shutters.

Key Provisions:

• Referenced Standards:
  See Annex A for related IS codes essential for definitions, materials, testing, and specifications.

• Type Tests (Clause 10.1.2):
  Includes tests for:

  • Dimensions & squareness
  • Flatness (general & local)
  • Impact indentation
  • Flexure & edge loading
  • Shock resistance & buckling
  • Slamming, misuse, humidity variation
  • End immersion, knife, glue adhesion, screw withdrawal

• Sampling (Clause 12.2.1):
  Number of specimens for dimensional and flatness tests per Table 4 (not provided here).

• Standard Mark (Clause 14.2.1):
  Use governed by BIS Act 1986; license details from BIS.

Important Reference Table (Annex A excerpt):

This standard ensures quality and performance of wood-based door shutters through comprehensive testing and adherence to referenced IS codes.

IS 2202 (Part 1): 1999 – References Summary

This part of IS 2202 refers extensively to other Indian Standards (IS) for definitions, materials, testing, and specifications related to timber and wood-based products.

Key Referenced Standards (Annex A, Clause 2.1)

Important Notes:

• Definitions: Use IS 10428, IS 707 for timber and door-related terminology.
• Material Specs: Plywood, block boards, particle boards, and fibreboards are covered under IS 303, 710, 1328, 3087, 12406.
• Testing Methods: IS 1708 (Part 1) for moisture content and mechanical properties.
• Finishing & Preservation: IS 2338 (Part I) and IS 401 provide guidelines.
• Marking & Licensing: Clause 14.2.1 governs use of Standard Mark under BIS

IS 2202 (Part 1) - Definitions & References Summary

• Definitions: As per Clause 2.1, definitions used in IS 2202 (Part 1) refer primarily to:

  • IS 10428: Glossary of terms relating to doors
  • IS 707: Glossary of terms applicable to timber technology and utilization
  • IS 12406: Glossary of terms relating to medium density fibreboard

• Key Referenced Standards (Annex A): These provide specifications and test methods related to timber, plywood, particle boards, door frames, locks, and finishing. Examples include:

  • IS 303: Specification for plywood for general purposes
  • IS 401: Code of practice for preservation of timber
  • IS 710: Specification for marine plywood
  • IS 1708 (Part 1): Method of testing moisture content in timber
  • IS 2209: Specification for mortice locks

• Type Tests (Clause 10.1.2): Essential tests for product approval include:

  • Dimensions & squareness
  • Flexure and impact indentation
  • Shock resistance and buckling
  • Glue adhesion and screw withdrawal

Summary Table of Key Definitions Sources

Important Notes:

• Always check the latest editions of referenced IS standards.
• Definitions ensure uniform interpretation across timber and door-related products.
• Type tests ensure compliance with mechanical and durability requirements.

flowchart TD
    A[IS 2202 (Part 1) Definitions] --> B[IS 10428 (Doors Glossary)]
    A --> C[IS 707 (Timber Glossary)]
    A --> D[IS 12406 (MDF Glossary)]
    A --> E[Annex A - Referenced Standards]
    E --> F[Plywood, Particle Boards, Locks, Frames]
    A --> G[Type Tests]
    G --> H[Dimensions, Flexure, Impact, Adhesion]

For detailed formulas or tables, refer to respective IS standards mentioned above.

IS 2202 (Part 1): Nature of Construction - Key Points

1. Nature of Construction (Clause 4, Table 1)

Solid core flush door shutters are classified by core type and finish:

2. Dimensions of Flush Door Shutters (Clause 5.1, Table 2)

• Modular sizes: Width & height in multiples of 100 mm.
• Brackets indicate height if door opening is from finished floor level.
• Allowances: 60 mm for frame, 40 mm floor finish, 5 mm clearance, 15 mm rebate.

3. Dimensional Relations (Fig. 1)

• Thickness of door frame minus rebate = 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
• MH = Modular height; MW = Modular width of door opening

flowchart LR
    A[Modular Width (MW)] -->|MW - 100 mm| B[Width of Shutter]
    A -->|MW - 10 mm| C[Overall Width of Door Frame]
    D[Modular Height (MH)] -->|MH - 95 mm| E[Height of Shutter]
    D -->|MH - 10 mm| F[Overall Height of Door Frame]
   

IS 2202 Part 1: Sizes and Dimensions of Wooden Flush Door Shutters

1. Modular Sizes (Clause 5.1 & Table 2)

• Note: Values in brackets indicate height if door opening is measured from finished floor level.
• Designation meaning: First number = width in multiples of 100 mm; last number = height in multiples of 100 mm.
• Allowances:
  • 60 mm for door frames
  • 40 mm for floor finish
  • 5 mm clearance all around
  • 15 mm rebate all around
  • 5 mm gap from shutter bottom to finished floor

2. Thickness of Shutters (Clause 5.2 & Table 3)

• For sizes larger than 12 DT 21, thickness > 35 mm as agreed.

3. **Key Dimensional Relations (Fig.

IS 2202 Part 1 (1999) - Materials: Key Specifications & References

1. Referenced Indian Standards for Materials (Annex A, Clause 2.1)

Materials used in timber and wood-based products must comply with relevant IS codes:

2. Testing & Quality Control (Clause 10.1.2)

Type tests for materials include:

• Dimensions & squareness
• Flatness (general/local)
• Impact indentation
• Flexure & edge loading
• Shock resistance & buckling
• Slamming & misuse
• Varying humidity & end immersion
• Knife test, glue adhesion, screw withdrawal

3. Specimen Sampling (Clause 12.2.1)

Number of specimens for testing dimensions, flatness, and planeness follows Table 4 (not provided here; refer IS 2202 Part 1).

Summary Table: Material Standards & Tests

IS 2202 (Part 1) — Construction Details for Wooden Flush Door Shutters

1. Door Shutter Sizes (Clause 5.1, Table 2)

• Note: Values in brackets apply if door opening height is from finished floor level.
• Designation format: e.g., 8 DS 20 → 8 × 100 mm width, 20 × 100 mm height modules.

2. Thickness of Door Shutters (Clause 5.2, Table 3)

• For sizes > 12 DT 21, thickness > 35 mm as agreed.

3. Construction Types (Clause 4, Table 1)

IS 2202 Part 1 – Face Veneers and Finishing Key Points

Face Veneers (Clause 6.4 & 6.4.1)

• Commercial face veneers for flush door shutters must comply with IS 710 (marine grade plywood) quality and species per IS 303.
• Thickness requirements (Clause 1.5):
  • Commercial veneers: 0.5 mm to 1.5 mm
  • Decorative veneers: 0.4 mm to 1.0 mm
  • Combined thickness of both veneers ≥ 2.2 mm
• Veneers are glued under pressure on both faces of the core.
• Cross-bands grain direction is perpendicular to the core grain; face veneers are perpendicular to cross-bands.
• For blockboard cores with horizontal wooden strips, a 7-ply construction with 3-ply panels pressed on both sides is required.
• Decorative veneer thickness after finishing must be ≥ 0.4 mm.
• Avoid applying decorative veneer on a panel with veneer grain in the same direction; if unavoidable, sand existing veneer to maintain max thickness limits.

Summary Table: Veneer Thickness

Veneer Grain Orientation

flowchart LR
    Core[Core Grain Direction]
    CrossBands[Cross Bands Grain (⊥ to Core)]
    FaceVeneer[Face Veneer Grain (⊥ to Cross Bands)]

    Core --> CrossBands
    CrossBands --> FaceVeneer

This arrangement ensures dimensional stability and strength in flush door shutters.

References:

• IS 2202 Part 1 Clause 6.4, 6.4.1, 1.5
• IS 710 (Marine Grade Plywood)
• IS 303 (Veneer Species & Quality)

IS 2202 Part 1: Manufacturing Requirements Summary

Key Type Tests (Clause 10.1.2)

• Dimensions & squareness
• General flatness
• Local planeness
• Impact indentation
• Flexure
• Edge loading
• Shock resistance
• Buckling
• Slamming
• Misuse
• Varying humidity
• End immersion
• Knife
• Glue adhesion
• Screw withdrawal

Sampling & Conformity (Clause 12.2.3, Table 4)

• For lots ≤ 25, sample size is mutually agreed.
• Impact and screw withdrawal tests require testing on production of 1000 shutters of same size/type.

Notes

• The lot is conforming if defective samples ≤ permissible number.
• Refer to IS 10428, IS 707 for definitions.
• Follow latest editions of referenced standards.

flowchart TD
    A[Manufacturing] --> B[Type Tests]
    B --> C[Dimension & Squareness]
    B --> D[Impact Indentation]
    B --> E[Flexure Test]
    B --> F[Screw Withdrawal]
    B --> G[Other Tests]
    A --> H[Sampling & Conformity]
    H --> I[Sample Size per Lot Size]
    H --> J[Permissible Defectives]
    H --> K[Acceptance/Rejection]

This ensures product quality per IS 2202 Part 1 manufacturing standards.

IS 2202 (Part 1) - Classification of Tests

1. Types of Tests

• Type Tests (Product Approval):
  These are comprehensive tests to validate product quality and performance before approval.
  Includes:

  • Dimensions & Squareness
  • General Flatness
  • Local Planeness
  • Impact Indentation
  • Flexure
  • Edge Loading
  • Shock Resistance
  • Buckling
  • Slamming
  • Misuse
  • Varying Humidity
  • End Immersion
  • Knife
  • Glue Adhesion
  • Screw Withdrawal

• Acceptance Tests (Product Identification):
  Conducted on batches to ensure conformity with approved product standards.
  Includes:

  • Dimensions & Squareness
  • General Flatness
  • Local Planeness
  • Slamming
  • End Immersion
  • Knife
  • Glue Adhesion

2. Key Specifications

• Clause 11.9.1:
  Any one test from 11.9.2 or 11.9.3 shall be used for acceptance.

Summary Table

This classification ensures rigorous quality control through detailed type testing and routine acceptance testing for ongoing production.

IS 2202 Part 1: Test Methods & Performance Criteria Summary

1. Type Tests (Clause 10.1.2)

These ensure product approval and include:

• Dimensions & squareness
• General flatness & local planeness
• Impact indentation
• Flexure & edge loading
• Shock resistance & buckling
• Slamming test
• Misuse test
• Varying humidity
• End immersion
• Knife test
• Glue adhesion
• Screw withdrawal

2. Acceptance Tests (Clause 10.1.1)

For product identification, tests include:

• Dimensions & squareness
• General flatness & local planeness
• Slamming test
• End immersion
• Knife test
• Glue adhesion

3. Test Quantity (Clause 12.2.2)

Number of shutters tested for knife, glue adhesion, slamming, and end immersion tests follows Column 4 of Table 4 (refer IS 2202 Part 1 Table 4 for exact quantities).

Key Notes:

• Slamming Test: Checks resistance to repeated impact.
• Knife Test: Assesses surface resistance to cutting.
• Glue Adhesion Test: Measures bond strength of glued joints.
• End Immersion Test: Evaluates water resistance on edges.

Typical Test Specification Table (Example):

*Refer IS 2202 Part 1 Table 4 for exact sample numbers.

flowchart LR
    A[Start: Product Sample] --> B{Type or Acceptance Test?}
    B -->|Type Test| C[Perform all 15 tests]
    B -->|Acceptance Test| D[Perform 7 specified tests]
    C --> E[Evaluate Results]
    D --> E
    E --> F{Pass Criteria Met?}
    F -->|Yes| G[

IS 2202 Part 1: Sampling and Criteria for Conformity

Key Specifications from Clause 12.2 & 12.3:

• Sample Size and Defective Limits (Table 4):

• For lot size ≤ 25, sample size is mutually agreed between manufacturer and purchaser.

• Criteria for Conformity (Clause 12.3):
  A lot is conforming if the number of defective samples ≤ permissible defective number (Col 3 of Table 4).

• Testing Requirements (Clause 12.2.1 & 12.2.3):

  • Dimensions, squareness, flatness: sample size per Table 4.
  • Impact and screw withdrawal resistance tests: For every 1000 shutters of same size/type, test as per Clause 12.2.3.

Summary Formula:

[ \text{Lot conforms if } D \leq D_{max} ]

Where:

• (D) = Number of defective samples
• (D_{max}) = Permissible defective number from Table 4

This ensures quality control by statistically verifying sample conformity within defined limits.

IS 2202 Part 1: Requirements for ECO Mark (Clause 13 & 14)

Key Specifications:

• Source of Wood: Door shutters must be made from wood sourced only from non-natural forests such as:

  • Industrial/social forestry plantations
  • Shade trees from tea/coffee estates

• Quality & Performance: Must comply with IS 2202 Part 1 quality/performance and ECO Mark standards.

• Documentation for ECO Mark:

  • Manufacturer must submit a certificate/declaration to BIS.
  • Environmental consent clearance from State Pollution Control Board as per:
    • Water (Prevention & Control of Pollution) Act, 1974
    • Air (Prevention & Control of Pollution) Act, 1981
    • Environment (Protection) Act, 1986 (if applicable)

Marking Requirements (Clause 14.1):

Each shutter edge must be marked with:

• Manufacturer name/trade mark
• Construction type abbreviation (see Table 1)
• Modular or Non-modular size indication
• Designation per Table 2 or actual size (width × height)
• Thickness (see 5.2)
• Timber species (for ECO Mark)
• ECO Mark criteria label

Table Summary Extract (Marking)

Additional Notes:

• ECO Mark certification requires compliance with environmental laws and BIS standards.
• Refer to Table 4 (Clause 12.3) for permissible defective samples limits.
• Refer to Annex A for related IS standards on plywood, timber preservation, and testing.

flowchart LR
    A[Wood Source] --> B{Non-natural forest?}
    B -- Yes --> C[Manufacture Door Shutter]
    B -- No --> D[Reject for ECO Mark]
    C --> E[Quality & Performance Check]
    E --> F{Conforms to IS 2202 & ECO Mark?}
    F -- Yes --> G[Apply for ECO Mark]
    F -- No --> H[Reject]

IS 2202 Part 1: Marking and Labeling of Door Shutters

Key Marking Requirements (Clause 14.1)

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

• Manufacturer's name or trademark
• Abbreviation for shutter construction type (see Table 1)
• Size type: Modular or Non-modular
• Designation: Modular sizes as per Table 2; actual size (width × height) for non-modular, with door shutter designation from Table 2
• Thickness of door shutters (refer Clause 5.2)
• Species of timber (for ECO Marked products)
• ECO Mark criteria if applicable

Tables Summary

(Refer IS 2202 Part 1 for complete tables)

Additional Notes

• Standard Mark Usage (Clause 14.2.1): Governed by BIS Act, 1986; licensing required.
• Thickness Reference: Clause 5.2 defines thickness ranges (typically 30mm for flush shutters).
• ECO Mark: Specific timber species and environmental criteria must be indicated.

Diagram: Marking Placement on Shutter Edge

graph LR
A[Shutter Edge] --> B[Manufacturer's Name]
A --> C[Construction Abbreviation]
A --> D[Size Type & Designation]
A --> E[Thickness]
A --> F[Timber Species (ECO)]
A --> G[ECO Mark Criteria]

Summary: Proper marking ensures traceability, compliance with modular sizing, and environmental labeling per IS 2202 Part 1. Always cross-check with Tables 1 & 2 for correct abbreviations and size designations.