chemical resistant mortars, Part III: Sulphur type
1968 Edition

IS 4832 Part 3 (1968) - Overview & Principal Requirements

1. Objective

• Defines the use of sulphur-based chemical resistant mortars for acid-proof brickwork, flooring, and linings.
• These mortars resist most acids except concentrated oxidizing acids and are not suitable against alkalies.
• For application guidelines, refer to IS:4442-1967.

2. Physical Criteria (Table 1)

3. Particle Size Distribution for Silica Filler (Clause 3.2)

4. Additional Remarks

• Avoid overheating sulphur mortar during preparation.
• Chemical resistance details: IS:4442-1980 Table 1.
• Testing procedures as per IS:4456 (Part II)-1967.

Sieve Analysis Summary Diagram:

graph LR
A[Silica Filler] --> B[425 micron sieve: ≤5% retention]
A --> C[150 micron sieve: ≥10% retention]
A --> D[75 micron sieve: ≥35% retention]

This section highlights the primary physical and chemical requirements alongside sieve analysis as per IS 4832 Part 3.

Scope & Principal Specifications of IS 4832 Part 3 (Sulphur-Based Chemical Resistant Mortars)

1. Scope (Clauses 2.0 & 3.3)

• Defines the sulphur-type chemical resistant mortars.
• A batch is accepted only when all tests meet the specified criteria.

2. Physical Performance Standards (Table 1, Clause 3.2)

3. Silica Filler Sieve Analysis (Clause 3.2, Table A-4)

4. Additional Information

• Chemical resistance reference: IS 4442-1980 Table 1.
• Test sieves conform to IS 460 (Part I) - 1978.
• Minimum batch quantity updated to 5000 kg.

flowchart TD
    A[Raw Materials] --> B[Silica Filler Sieve Analysis]
    B -->|Meets Criteria| C[Mixing with Sulphur]
    C --> D[Physical Testing (Strength, Absorption)]
    D --> E{All Tests Passed?}
    E -->|Yes| F[Batch Accepted]
    E -->|No| G[Retest or Reject]

This segment covers the scope, physical and sieve requirements, and testing criteria vital for adherence to IS 4832 Part 3.

Terminology and Definitions in IS 4832 Part 3

Key Terminology (Clause 2.0)

• Clarifies terms related specifically to sulphur-based chemical resistant mortars.
• Establishes a standardized understanding for testing and quality control.

Physical Criteria (Clause 3.2, Table 1)

Sieve Analysis for Silica Filler (Clause 3.2, Table A-4)

Additional Notes

• Chemical resistance guidelines are in IS 4442-1980 Table 1.
• Testing sieves are as per IS 460 (Part I) wire cloth standards.
• Acceptance of each batch depends on passing all specified tests.

flowchart TD
    A[Raw Material] --> B[Sieve Analysis]
    B --> C[Physical Tests]
    C --> D{Conformity?}
    D -- Yes --> E[Batch Approved]
    D -- No --> F[Retest or Reject]

This section summarizes definitions, crucial physical and chemical requirements, and sieve analysis according to IS 4832 Part 3.

Chemical Composition and Specifications for Sulphur-Based Chemical Resistant Mortars (IS 4832 Part 3)

1. Chemical Constituents (Clause 3.1)

*Inert fillers typically include silica or other chemically resistant substances.

2. Particle Size Distribution of Fillers (Clause 3.2)

3. Physical Performance Criteria (Clause 3.2, Table 1)

4. Additional Information

• Sulphur mortar is an inorganic mixture of sulphur and inert fillers.
• Small quantities of chemically resistant inert additives may be included.
• Testing procedures are referenced in IS:4456 Part II (1967).

flowchart TD
    A[Sulphur (55-70%)] --> C[Blending Process]
    B[Inert Fillers (30-45%)] --> C
    C --> D[Final Sulphur-Based Chemical Resistant Mortar]
    D --> E[Physical Testing]
    E --> F[Compressive Strength ≥ 280 kg/cm²]
    E --> G[Tensile Strength ≥ 30 kg/cm²]
    E --> H[Flexural Strength ≥ 70 kg/cm²]

Physical Performance Criteria for Sulphur Type Chemical Resistant Mortars (IS 4832 Part 3)

Essential Physical Properties (Table 1, Clause 3.2)

Grading of Silica Filler (Clause 3.2)

Additional Details:

• Manufacturers must certify filler grading if requested (Clause 3.2.1).
• For chemical resistance, refer to IS 4442-1980 Table 1.
• Testing is performed according to IS: 4456 Part II (1967).

These requirements guarantee mortar strength, durability, and chemical resistance for industrial applications.

Chemical Resistance Criteria for Sulphur-Based Mortars (IS 4832 Part 3)

Primary Physical Properties (Clause 3.2, Table 1)

Sieve Analysis for Silica Filler (Clause 3.2, Table A-4)

Chemical Resistance Testing

• Limits for chemical resistance are established mutually between buyer and supplier.
• Testing follows Clause 10 of IS 4456 (Part II)-1967.
• Consult Table 1 of IS 4442-1980 for general chemical resistance guidance.

Summary Diagram of Essential Properties

graph LR
A[Physical Properties] --> B[Compressive Strength ≥ 280 kg/cm²]
A --> C[Tensile Strength ≥ 30 kg/cm²]
A --> D[Flexural Strength ≥ 70 kg/cm²]
A --> E[Bond Strength ≥ 10 kg/cm²]
A --> F[Retained Strength After Thermal Shock ≥ 20%]
A --> G[Moisture Absorption ≤ 1%]
A --> H[Aggregate Settling Variation ≤ 0.6]

Note: Always confirm chemical resistance through tests adhering to IS 4456 Part II methods.

Storage and Physical Requirements for Sulphur-Based Chemical Resistant Mortars (IS 4832 Part 3)

Key Physical Properties (Clause 3.2, Table 1)

Silica Filler Particle Size Distribution (Clause 3.2, Table A-4)

Storage Instructions (Clause 8.2)

• Each package should be labeled with:
  • Manufacturer’s name or trademark
  • Manufacture date or batch number
  • Net weight
  • Storage directions (keep dry, avoid sunlight, store in cool place)

Additional Remarks:

• Testing methods per IS:4456 (Part II).
• Chemical resistance references in IS:4442-1980.
• Appropriate storage preserves mortar quality and performance.

flowchart TD
    A[Manufacturing] --> B[Packaging]
    B --> C[Labeling: Manufacturer, Date, Weight, Storage]
    C --> D[Storage: Dry, Cool, Covered]
    D --> E[Utilization in Construction]

This section ensures the maintenance of mortar quality and longevity during storage and usage.

Sampling Procedures for Acceptance Testing (IS 4832 Part 3)

Highlights from Appendix A (Clause 7.1)

• Sampling Approach: Samples must be drawn independently from each batch for conformity verification (A-1.2).

• Testing Requirements: Samples must undergo all tests specified in Table 1 of the standard (A-3.2).

• Sieve Analysis Limits for Silica Filler (Clause 3.2, Table A-4):

• For other fillers, refer to item (vii) in Table 1.

• Batch Size: Updated to 5,000 kg from the previous 2,500 kg.

• Test Sieves: Use wire cloth sieves complying with IS:460 (Part I) - 1978.

Sampling and Testing Process Flowchart

flowchart TD
    A[Received Batch] --> B[Select Samples from Batch]
    B --> C[Conduct All Required Tests (Table 1)]
    C --> D{Sieve Analysis for Silica Filler}
    D -->|425 micron| E[Max 5% Retention]
    D -->|150 micron| F[Min 10% Retention]
    D -->|75 micron| G[Min 35% Retention]
    E & F & G --> H[Assess Compliance]
    H --> I{Pass?}
    I -->|Yes| J[Accept Batch]
    I -->|No| K[Reject or Retest]

Note: For chemical resistance evaluation, consult IS:4442-1980 Table 1.

Packaging and Marking Instructions under IS 4832 Part 3

Packaging and Marking Details (Clause 8)

• Each package must be clearly marked with:

  • Manufacturer’s name or trademark
  • Date of manufacture or batch identification number
  • Net weight of the contents
  • Storage instructions

• Optional Marking:

  • The Standard Mark (BIS certification) may be applied as per BIS Act 1986 to indicate compliance with IS standards and ongoing quality surveillance.

Sampling (Appendix A, Clause 7.1)

• Samples for acceptance testing must be:
  • Collected following procedures in Appendix A
  • Stored in moisture-proof, airtight containers
  • Clearly labeled with supplier details, lot number, and sampling date

Marking Information Summary Table

flowchart TD
    A[Package] --> B[Marking]
    B --> C[Manufacturer Name/Trademark]
    B --> D[Date/Batch Number]
    B --> E[Net Weight]
    B --> F[Storage Instructions]
    B --> G[Standard Mark (Optional)]

This ensures traceability, quality assurance, and proper handling in accordance with IS 4832 Part 3.

Detailed Sampling Methodology as per IS 4832 Part 3

Key Provisions

• Acceptance Sampling (Appendix A, Clause 7.1):

  • Samples are drawn separately for each batch to verify conformance.
  • All tests listed in Table 1 must be conducted on these samples (Clause A-3.2).
  • Sampling method and acceptance criteria are fully described in Appendix A.

• Marking (Clause 8.2.1):

  • Packages may bear the Standard Mark, indicating BIS certification and compliance.
  • The use of the Standard Mark is governed by the Bureau of Indian Standards Act, 1986.

Sampling Process Summary

Notes

• Sampling plays a critical role in quality control and ensuring product compliance.
• The Standard Mark confirms ongoing BIS surveillance.

flowchart TD
    A[Batch of Material] --> B[Draw Representative Samples]
    B --> C[Test Samples per Table 1]
    C --> D{Do Samples Meet All Criteria?}
    D -- Yes --> E[Accept Batch]
    D -- No --> F[Reject Batch]

Refer to Table 1 and Appendix A of IS 4832 Part 3 for detailed sampling sizes and testing requirements.

Summary of Updates to IS 4832 Part 3 (1968 Edition)

Major Revised Specifications:

1. Silica Filler Particle Size Analysis (Clause 3.2)

Note: For other fillers, consult Table 1, item (vii).

2. Physical Property Requirements (Table 1, Clause 3.2)

3. Retesting Protocol (Clause 4.1)

• In case initial sample testing fails Table 1 requirements, a second random sample must be tested.
• Failure in the second test results in rejection of the entire batch.

4. Chemical Resistance Reference

• Consult IS:4442-1980 Table 1 for chemical resistance details of sulphur mortars.

5. Other Amendments

• Test sieve standards updated to IS:460 (Part I)-1978 (wire cloth sieves).
• Batch size increased from 2,500 kg to 5,000 kg.

Important Reference Standards:

• IS:4442-1980: Chemical resistance guide.
• IS:4456 (Part II)-1967: Testing methods.
• IS:460 (Part I)-1978: Test sieve specifications.

Retesting Procedure Flowchart:

flowchart TD