wooden flush door shutters (solid core type): Part 2 Particle board and hardboard face panels
1983 Edition

The standard permits using particle boards or veneered particle boards along with hardboards as face panel materials. Particle boards should have a minimum thickness of 4 mm, while hardboards must be at least 3 mm thick. Phenol formaldehyde adhesives are specified for bonding both core and face panels, ensuring dimensional stability with swelling limits not exceeding 5% in thickness and length. Relevant IS standards for particle boards include IS 3087-1965 (types FPSI and FPTH) and IS 3097-1980 for veneered variants. These materials must conform to workmanship and finish requirements as per the cited IS codes to guarantee durability and quality.

IS 2202 Part 2 specifies that flush door shutters typically come in nominal thicknesses of 25 mm, 30 mm, or 35 mm depending on the door designation. For example, 8 DS 20 and 8 DS 21 are usually 25 mm thick, while 9 DS 20 and 9 DS 21 may be 30 or 35 mm thick. The 10 DS and 12 DT series shutters generally have a thickness of 35 mm. Size tolerances allow +3 mm variation in width and height, ±1.2 mm in thickness, with a maximum uniformity variation of 0.8 mm. Additionally, allowances for frame, floor finish, clearance, and rebates are considered to ensure proper installation and fitting.

Construction involves a core made from particle boards (types FPSI or FPTH per IS 3087:1965) or veneered particle boards (types EXSOD or EXSOGP per IS 3097:1980). Solid timber beading, matching specified species, is applied around the full thickness of the door, with a beading depth of at least 25 mm excluding the tongue. The tongue must be at least 12 mm deep and one-third the shutter thickness in width, secured by tongue-and-groove joints with BWP adhesive (IS 848:1974) and screws. Face panels are bonded on both sides using hot pressing, with minimum thicknesses of 4 mm for particle board facings and 3 mm for hardboard facings, employing phenol formaldehyde adhesives that limit swelling to 5% as per IS 2380 Part 17.

The ECO Mark certification, managed by BIS under the Ministry of Environment and Forests, is awarded to flush door shutters that meet both BIS Standard Mark requirements and additional environmental criteria. To qualify, products must comply with sampling and conformity tests outlined in IS 2202 (Part 1)-1983 and meet thickness specifications (generally ≥30 mm). Timber species used must be eco-friendly, preferably plantation-grown or sustainably sourced. The product's environmental credentials, such as use of low-emission adhesives and sustainable materials, must be clearly documented. This ensures the door shutters are manufactured with consideration for ecological sustainability.

Each door shutter must be clearly and permanently marked on any edge with the manufacturer’s name or trademark, an abbreviation indicating the shutter’s construction type per Clause 2.1, and a designation of size type—either 'Modular' or 'Non-modular.' Modular size shutters should carry the designation code as per Table 2 of the standard, while non-modular shutters require actual width and height dimensions along with appropriate shutter symbols. Additionally, thickness, timber species (if applicable for ECO Mark), and ECO Mark criteria should be indicated. This labeling ensures traceability, quality assurance, and adherence to the standard.