Chemical Resistant Mortars, Part II: Resin type
1969 Edition

Overview of Resin-Based Chemical Resistant Mortars - Key Specifications

Summary of Physical Properties (Refer Table 1)

• Note: Bond strength tests must not fail below the stated thresholds.
• Retesting is mandated if the initial sample fails; failure of the second sample results in lot rejection (Clause 3.3).

Additional Information:

• Testing temperature maintained at 27°C ± 2°C.
• Amendment: Maximum batch size reduced from 1000 kg to 500 kg.
• Chemical resistance references available in IS:4443-1980 Table 1.

flowchart TD
    Sample[Lot Sample] --> Testing{Compliance with Tests?}
    Testing -- Yes --> Accept[Lot Accepted]
    Testing -- No --> Retest[Test Second Sample]
    Retest --> RetestResult{Pass?}
    RetestResult -- Yes --> Accept
    RetestResult -- No --> Reject[Lot Rejected]

Scope (Clauses 2.0 & 3.1)

• Defines criteria for resin-based chemical resistant mortars.
• Applicable resin types: Phenolic, Furane, Epoxy, Polyester.
• Testing conducted as per IS 4456 (Part I) - 1967 methods.
• Lot acceptance requires all test parameters to meet the values in Table 1.

Essential Physical Properties (Table 1)

Important Notes

• Bond strength test joints must not fail at or below the specified limits.
• Working time ensures sufficient handling period prior to setting.

Testing Workflow

flowchart TD
    LotSample[Sample Mortar Lot] --> Specimens[Prepare Test Specimens]
    Specimens --> WorkingTime[Test Working Time]
    Specimens --> Flexural[Test Flexural Strength]
    Specimens --> Compressive[Test Compressive Strength]
    Specimens --> Bond[Test Bond Strength]
    Specimens --> Absorption[Test Absorption]
    WorkingTime --> Check{All Tests Passed?}
    Flexural --> Check
    Compressive --> Check
    Bond --> Check
    Absorption --> Check
    Check -- Yes --> Accept[Lot Accepted]
    Check -- No --> Reject[Lot Rejected]

Definitions (Clause 2.0)

• Establishes terminology specific to resin-based chemical resistant mortars within the standard.

Physical Property Requirements (Clause 3.1, Table 1)

General Criteria (Clauses 3.2 & 3.3)

• A lot is approved if all tests satisfy Table 1 requirements.
• Upon failure, a second sample is tested; failure again leads to rejection.

flowchart TD
    Sample[Sample from Lot] --> Test{Test per Table 1}
    Test -- Pass --> Accept[Lot Approved]
    Test -- Fail --> Retest[Test Second Sample]
    Retest -- Pass --> Accept
    Retest -- Fail --> Reject[Lot Rejected]

Physical Properties (Table 1 Summary)

• Bond strength tests require joints not to fail below specified values.
• Retesting is compulsory if the initial sample is non-compliant; failure of the retest leads to lot rejection.

Packaging and Catalyst Information (Clause 3.3)

• Catalysts may be blended with fillers or provided separately.
• Packaging configurations differ by resin type:
  • Phenolic and Furane: Two-component packs (resin and filler)
  • Epoxy: Three-component packs (resin, hardener, filler)
  • Polyester: Three or four-component packs

Chemical Resistance Reference

• Consult IS:4443-1980 Table 1 for chemical resistance data.

Physical Property Requirements (IS 4832 Part 2)

Additional Details:

• Sampling and testing must be conducted as per Table 1.
• If the initial test fails, a second sample is tested; failure again results in rejection of the batch.
• Chemical resistance guidelines are provided in IS:4443-1980 Table 1.
• Amendment reduces minimum batch size to 500 kg.

flowchart TD
    Sample[Take Sample from Lot] --> Testing[Test per Table 1]
    Testing -- Pass --> Accept[Lot Accepted]
    Testing -- Fail --> SecondSample[Take Second Sample]
    SecondSample --> Retest[Test Second Sample]
    Retest -- Pass --> Accept
    Retest -- Fail --> Reject[Lot Rejected]

Core Specifications (Table 1, Clause 3.1)

• Bond strength testing requires no joint failure at or below the specified strength.

Sampling and Testing Requirements (Clauses 3.1 to 3.3)

• Samples must be drawn from each batch and tested as per Table 1.
• Batch acceptance is contingent on all parameters meeting the standard.
• Failing batches are retested with a second sample; failure again leads to rejection.

Additional Information

• 1981 amendment reduced minimum batch size to 500 kg.
• Chemical resistance guidelines are available in IS 4443-1980 Table 1.
• Testing methods align with IS 4456 Part 1 (1967).

flowchart TD
    Sample[Batch Sample] --> Test[Conduct Tests]
    Test --> Result{Pass or Fail}
    Result -- Pass --> Accept[Batch Accepted]
    Result -- Fail --> Retest[Retest with New Sample]
    Retest --> RetestResult{Pass or Fail}
    RetestResult -- Pass --> Accept
    RetestResult -- Fail --> Reject[Batch Rejected]

Physical Property Requirements (Summary from Table 1)

• Bond strength tests must confirm no failure at or below specified thresholds.

Retesting Protocol (Clause 3.3)

• If the initial sample is non-compliant, a second sample is tested.
• Failure of the retest results in lot rejection.

Additional Requirements

• Minimum joint thickness must be 1.5 mm.
• Resin viscosity should permit manual mixing with powder components.
• Chemical resistance limits are to be mutually determined by purchaser and supplier (Clause 6.1).
• Refer to IS:4443-1980 for chemical resistance guidance.

flowchart TD
    Sample[Lot Sample] --> Testing{Meets Table 1 Criteria?}
    Testing -- Yes --> Accept[Lot Accepted]
    Testing -- No --> Retest[Retest Second Sample]
    Retest -- Yes --> Accept
    Retest -- No --> Reject[Lot Rejected]

Shelf-life Specifications (Clauses 7.1 & 7.2)

• Phenolic and Polyester resins have an approximate shelf-life of 3 months at 27°C ± 2°C.
• Furane and Epoxy resins maintain shelf-life up to approximately 12 months under similar conditions.
• Manufacturers must clearly declare maximum shelf-life for both resin and dry-mix components.

Storage Requirements (Clause 9.1)

• Resins should be stored in airtight, sealed containers to prevent degradation.
• Fillers must be packaged to avoid moisture ingress and deterioration.
• Packaging must clearly display:
  • Manufacturer's name
  • Product designation
  • Manufacturing date or batch number
  • Storage instructions
  • Shelf-life duration
  • Expiry date

Reference Physical Properties (Clause 3.1, Table 1)

flowchart TD
    Manufacture[Manufacture Resin and Dry Mix] --> Packaging[Package in Airtight Containers]
    Packaging --> Label[Apply Labels with Details]
    Label --> Storage[Store at 27°C ± 2°C]
    Storage --> ShelfLife{Shelf-life Duration}
    ShelfLife -->|Phenolic/Polyester| ThreeMonths[3 Months]
    ShelfLife -->|Furane/Epoxy| TwelveMonths[12 Months]
    ShelfLife -->|Dry Mix| ManufacturerSpecified[As Specified]

Sampling Procedure (Clause 8.1 & Appendix A)

• A lot is defined as a batch produced under uniform conditions.
• Samples must be collected representatively from each lot individually.
• The sample size depends on the lot volume, as detailed in Appendix A and standards like IS 2500 or IS 4905.
• Each sample undergoes testing for all critical parameters.

Acceptance Criteria (Clauses 3.2 & 8.1)

• A lot is accepted only if all samples comply with the specified requirements.
• Failure in any test results in rejection or retesting of the lot.

flowchart TD
    Lot[Batch of Material] --> Sampling[Draw Representative Samples]
    Sampling --> Testing[Perform Tests on Samples]
    Testing --> Decision{All Tests Passed?}
    Decision -- Yes --> Accept[Accept Lot]
    Decision -- No --> Reject[Reject Lot]

Packaging Requirements (Clause 9.1)

• Resin components are to be sealed in airtight containers.
• Fillers should be packed adequately to prevent moisture and contamination.

Labelling Details (Clause 9.1)

• Manufacturer's name
• Product identification
• Manufacture date and batch number
• Storage instructions
• Shelf-life information
• Expiry date

Optional Markings (Clause 9.1.1)

• ISI certification mark, subject to applicable regulations.

Physical Properties Summary (Clause 3.1, Table 1)

• Bond strength testing must confirm that failure does not occur at or below the stated values.

flowchart TD
    Start[Resin and Filler Ready] --> PackagingDecision{Packaging}
    PackagingDecision -->|Resin| ResinPack[Seal in Airtight Containers]
    PackagingDecision -->|Filler| FillerPack[Properly Pack to Avoid Deterioration]
    ResinPack & FillerPack --> Labelling[Apply Package Labels]
    Labelling --> ManufacturerName[Manufacturer Name]
    Labelling --> ProductName[Product Name]
    Labelling --> BatchInfo[Manufacture Date / Batch Number]
    Labelling --> StorageInfo[Storage Requirements]
    Labelling --> ShelfLifeInfo[Shelf Life]
    Labelling --> ExpiryDate[Expiry Date]
    Labelling --> OptionalISI[Optional: ISI Mark]

Sampling Guidelines (Appendix A)

• Each lot must be sampled separately to confirm conformance (Clause A-1.2).
• Acceptance requires all test results to satisfy specifications (Clause A-3.2).
• Test specimens are prepared from mortar samples for all parameters listed in Table 1 (Clause A-3.1).

flowchart TD
    Start[Identify Lot] --> SelectSamples[Randomly Choose Samples]
    SelectSamples --> PerformTests[Test Specimens per Table 1]
    PerformTests --> PassCheck{All Tests Passed?}
    PassCheck -- Yes --> Accept[Accept Lot]
    PassCheck -- No --> Reject[Reject Lot]