Specification for Control Van for Fire Brigade Use

IS 957: Scope - Key Points & Specifications

Scope Overview:

• Applies to appliances with specified equipment and operational features.
• Emphasizes purchaser-supplier agreement on specific clauses (8.1, 9.2).
• Aligns with international standards and Indian field practices.
• Final test/analysis values must be rounded as per IS 2:1960.

Important Specifications & Tables

Additional Notes:

• Instruction Book(s) (Clause 7.1) must include:
  • Operating & maintenance procedures.
  • Illustrated spare parts list with reference numbers.

Rounding Off Rule (IS 2:1960)

• Round off final values to the same number of significant digits as specified.
• Ensures consistency in test result reporting.

flowchart LR
    A[Appliance Scope] --> B[Equipment List]
    B --> C[Clock]
    B --> D[Walkie-talkie Sets]
    B --> E[Loud Hailers]

IS 957: Road Performance Key Specifications & Formulas

1. Speed & Acceleration (Clause 2.2.1)

• Minimum road speed: 70 km/h on level road.
• Acceleration: Fully laden appliance must reach 65 km/h from standstill in ≤ 55 seconds through gears.

2. Load & Dimensions (Clause 4.1.1)

• Chassis load capacity: ≥ (Estimated max load + 250 kg).
• Wheelbase: ≥ 4.35 m.
• Overall width: ≥ 2.30 m.
• Turning circle: Preferably ≤ 20 m on either lock.
• Road clearance: ≥ 23 cm.

3. Testing Requirements (Clause 2.2.2)

• Braking test: To verify braking performance.
• Turning circle test: Confirm ≤ 20 m.
• Stability test: Tilting test in designed stowage condition.
• Electrical tests: As per Indian Electricity Rules.

4. Load for Road Tests

• Fuel tank full.
• Scheduled equipment in designed stowage.
• Specified crew or equivalent load.
• Test load = Estimated max load + 250 kg.

Summary Table

flowchart TD
    A[Start] --> B[Load + 250 kg]
    B --> C[Full fuel tank & equipment]
    C --> D[Acceleration test: 0 to 65 km/h ≤ 55 s]
    D --> E[Speed test: ≥ 70 km/h]
    E --> F[Braking test]
    F --> G[Turning circle test ≤ 20 m]
    G --> H[Stability test (tilting)]
    H --> I[Electrical test]
    I --> J[Certification]

This ensures compliance with IS 957 road performance criteria

IS 957: Materials and Corrosion Resistance - Key Points

1. Material Selection (Clauses 3.3 & 3.4)

• Water-contact parts: Must be made of corrosion-resisting materials (e.g., stainless steel, brass, copper alloys).
• Atmospheric exposure: Metal parts must be corrosion-resistant or suitably treated (e.g., galvanizing, painting).
• Nickel/Chromium plating:
  • No ferrous metals allowed as base.
  • Plating must be extra heavy quality for durability.

2. Corrosion Protection (Clause 6.2.3)

• Apply anticorrosion and priming coats before painting to protect metal surfaces.

3. Pressure Loss Limit (Clause 3.5)

• Maximum allowable pressure loss:
  [ \Delta P \leq 0.07 , \text{kg/cm}^2/\text{h} \quad \text{for first 12 hours} ]
• Working pressure ≤ 3.5 kg/cm².
• Anti-freezer provision mandatory for air/hydraulic brakes.

Summary Table: Corrosion-Resistant Materials

flowchart TD
    A[Water-contact parts] -->|Corrosion-resisting materials| B[Stainless steel, Brass]
    C[Atmospheric parts] -->|Corrosion-resistant or treated| D[Galvanized, Painted]
    E[Nickel/Chromium plating] -->|No ferrous base + extra heavy plating| F[Durable finish]

This ensures durability and compliance with IS 957 corrosion resistance requirements.

IS 957: Design and Construction - Key Points

IS 957 primarily covers specifications for ferrous metal fittings with emphasis on plating quality and material restrictions:

Material Specifications

• Clause 3.4:
  • Ferrous metals must not be used for nickel or chromium-plated fittings.
  • Plating must be of extra heavy quality for all such fittings.

Design and Construction

• Clause 8.1:
  • Design and construction details require mutual agreement between purchaser and supplier/manufacturer.
  • This ensures customization to specific needs while adhering to the standard.

General Guidelines

• The standard aligns with international practices and Indian field conditions.
• Test results and calculations must be rounded off per IS 2:1960 to maintain consistency.

Summary Table: Material & Plating

For detailed design formulas or construction methods, IS 957 refers to coordination with other standards and purchaser requirements rather than prescribing fixed formulas.

flowchart LR
    A[Start: Design Requirement] --> B{Material Selection}
    B -->|Ferrous Metal| C[Not Allowed for Plated Fittings]
    B -->|Non-Ferrous Metal| D[Allowed]
    D --> E[Apply Extra Heavy Nickel/Chromium Plating]
    E --> F[Design & Construction Agreement]
    F --> G[Final Product]

Note: For precise design parameters, consult related IS codes or manufacturer guidelines.

IS 957: Body Work and Stowage - Key Specifications

1. Body Construction (Clause 5.1.3)

• Frame: Steel framework.
• Exterior: Aluminium sheets.
• Interior Panelling: Good quality teak wood.
• Flooring: Aluminium chequered sheet.
• Insulation: Optional insulating material between inner and outer coverings.

2. Load & Dimensions (Clause 4.1.1)

• Chassis Load Capacity: ≥ (Estimated max load + 250 kg).
• Wheelbase: ≥ 4.35 m.
• Overall Width: ≥ 2.30 m.
• Road Clearance: ≥ 23 cm.
• Turning Circle: Preferably ≤ 20 m on either lock.

3. Lockers & Racks (Clause 5.1.2)

• Height: 1.5 to 1.8 m from ground.
• Must be weather-proof and self-draining.
• Doors open safely without hazard.
• Supports/stays releasable by one person.
• Designed for functional use and pleasing appearance.

Summary Table:

flowchart TD
    A[Steel Frame] --> B[Aluminium Outer Sheet]
    B --> C[Teak Wood Inner Panelling]
    C --> D[Aluminium Chequered Flooring]
    E[Load Capacity] --> F[Max Load + 250 kg]
    G[Lockers & Racks] --> H[Height 1.5-1.8 m]
    H --> I[Weather-proof & Self-draining]
    I --> J[Safe Door Operation]

This ensures safety, durability, and ergonomic access for equipment and personnel.

IS 957 – Painting and Finishing: Key Points

• Clause 6.2.3: Apply necessary anticorrosion and priming coats before final painting to ensure durability.

• Clause 6.2.4: Painting and phosphating must be suitable for tropical climates, implying:

  • Use of corrosion-resistant primers.
  • Weatherproof topcoats resistant to humidity and UV.

• Clause 6.2.1:

  • Interior compartments (driving, crew, lockers) painted cream.
  • Lockers finished with shadow board painting to indicate equipment positions.

Typical Painting Process (per IS 957 & good practice):

Important Specifications:

• Primer thickness: ~20-30 microns
• Top coat thickness: ~40-50 microns
• Color: Cream (interior), as per IS 5 (color standard)
• Phosphating: Ensures chemical bonding and corrosion resistance

flowchart TD
    A[Surface Preparation] --> B[Phosphating]
    B --> C[Primer Coat]
    C --> D[Intermediate Coat (optional)]
    D --> E[Top Coat (Weatherproof)]

Note: Final paint system must be agreed upon between purchaser and supplier (Clause 8.1). Always follow IS 2-1960 for rounding off test values.

IS 957: Key Specifications for Equipment on Fire Appliances

Schedule of Equipment (Appendix A, Clauses 4.1.1 & 7.3)

Additional Notes:

• All equipment must conform to relevant Indian Standards.
• Electrical equipment details are in Clause 4.4.
• Acceptance tests for electrical and extra equipment are covered under Clause 4.5.

Reference:

• IS 957-1967 for Fire Fighting Appliances – General Requirements.
• IS 1032-1957 for Public Address Equipment specifications.

flowchart LR
    A[Fire Appliance] --> B[Rear Compartment]
    B --> C[Clock]
    B --> D[Walkie-talkie sets (4)]
    B --> E[Loud hailers (2)]
    B --> F[Binoculars]
    B --> G[Fire Alarm Receiver]
    B --> H[VHF Radio Telephone]
    B --> I[Revolving Chair]
    A --> J[Cab Roof]
    J --> K[Public Address Loudspeakers (2)]

This ensures communication, alert, and operational readiness as per IS 957.

IS 957: Acceptance Tests Summary

Key Acceptance Tests (Clause 8.1 & 2.2)

• Acceleration & Performance Test: Verify compliance with Clause 2.2.1 (e.g., acceleration time, speed).
• Braking Test: Check requirements under Clauses 2.2.2 & 2.2.3.
• Turning Circle Test: Confirm turning radius as per Clause 4.1.1.
• Stability Test: Conduct tilting test ensuring stability in designed stowage condition.
• Electrical Tests: Test all switchgear, instruments, and wiring per Indian Electricity Rules.

Test Conditions (Note)

• Fuel tank full.
• Scheduled equipment in designed stowage or agreed test load.
• Specified crew on board or equivalent load.
• Road tests with load = max estimated load + 250 kg.

Rounding Off (Clause 0.5)

• Use IS 2-1960 for rounding test results.
• Retain significant figures equal to those in the standard's specified values.

Typical Test Load Calculation

flowchart TD
    A[Start Acceptance Tests] --> B{Test Type}
    B -->|Acceleration & Performance| C[Check Clause 2.2.1]
    B -->|Braking| D[Check Clauses 2.2.2 & 2.2.3]
    B -->|Turning Circle| E[Check Clause 4.1.1]
    B -->|Stability| F[Tilting Test]
    B -->|Electrical| G[Switchgear & Wiring Tests]
    C & D & E & F & G --> H[Evaluate Results]
    H --> I{Results within Tolerance?}
    I -->|Yes| J[Accept Appliance]
    I -->|No| K[Reject / Re-test]

Note: Tests can be conducted at manufacturer’s works, fire brigade, or mutually agreed location.

For detailed equipment specs, refer Appendix A of IS 957.

IS 957: Manufacturer's Certificate and Guarantee

Key Specifications from IS 957:

• Clause 9.1:
  The manufacturer must provide a certificate confirming the appliance conforms fully to IS 957.

• Clause 9.1.1:
  If the appliance bears the ISI Certification Mark, a separate manufacturer's certificate is not required as the mark itself certifies compliance.

• Clause 9.2:
  The manufacturer shall guarantee:

  • Material quality
  • Workmanship
  • Operation of the appliance
    The guarantee period is as mutually agreed between purchaser and supplier.

Additional Testing Requirements (Related to Guarantee):

• Braking Test: Verify compliance with clauses 2.2.2 & 2.2.3
• Turning Circle Test: Verify compliance with clause 4.1.1
• Stability Test: Tilting test in designed stowage condition
• Electrical Tests: Switchgear, instruments, wiring per Indian Electricity Rules

Summary Table:

flowchart TD
    A[Manufacturer] --> B[Certificate of Conformance]
    B --> C{ISI Mark Present?}
    C -- Yes --> D[No separate certificate needed]
    C -- No --> E[Certificate mandatory]
    A --> F[Guarantee: Material, Workmanship, Operation]
    F --> G[Period as agreed with purchaser]

This ensures compliance, quality assurance, and clarity on responsibilities as per IS 957.

IS 957 – Marking Specifications for Control Vans

According to Clause 10.1 of IS 957, each control van must be clearly and permanently marked with:

• Manufacturer's name or trade-mark
• Reference: "IS 957"
• Year of manufacture

Additionally, Clause 10.1.1 permits the use of the ISI Certification Mark, which indicates compliance with the standard under ISI's quality control and inspection system.

Important Notes:

• The ISI mark usage is governed by the Indian Standards Institution (Certification Marks) Act.
• Marking ensures traceability and quality assurance.
• Final test values should be rounded per IS 2:1960 (see Clause 0.5).

Summary Table for Marking Requirements

This marking ensures product authenticity and adherence to IS 957 quality norms.