IS9140:1996 ( Reaffirmed 2002 ) Indian Standard METHODS FOR SAMPLING OF VITREOUS AND FIRE CLAY SANITARY APPLIANCES (Second Revision) ICS 91.140.70 0 BIS 1996 BUREAU OF INDIAN MANAKBHAVAN, 9 BAHADti STANDARDS SHAH ZAFAR MARG NEW DELHI 110002 October 1996 Price Group 3 Sanitary Appliances and Water Fittings Sectional Committee, CED 3 FOREWORD Thislndian Standard ( Second Revision ) was adopted by the Bureau of Indian Standards, after the draft finalized by the Sanitary Appliances and Water Fittings Sectional Committee had been approved by the Civil Engineering Division Council. The increasing production of sanitary appliances has made it imperative to formulate rational and economic sampling procedures for the proper and objective evaluation of the various characteristics of these appliances. Such sampling procedures will also help in development and expansion of the sanitary appliances industry and also provide adequate protection to the consumer. Proper quality control during the process of manufacture would substantially reduce the quality fluctuations of the ultimate products. Further, the purchasing organizations may need guidance for economic and effective sampling inspection of the lots being received by them to evaluate their quality before their actual use. The~sampling procedures recommended in this standard, therefore, include the provisions for both process control and lot inspection. This standard was originally issued in 1979 and was first revised in 1985. In this revision, modifications recommended by the expert panel (constituted earlier under the erstwhile Statistics Department of EIS) have been incorporated. Besides, it was felt that the frequency of testing and inspection during process control needs to be reviewed in the light of current trade practices in this field. This opportunity has also been utilised to include or delete requirements according to the various product standards under IS 2556 as revised in 1994 and in 1995 since the first revision of this standard. The scale~of sampling has been based on IS 2500 ( Part 1 ) : 1992 `Sampling inspection procedures: Part 1 Attribute sampling plans indexed by acceptance quality level ( AQL ) for lot-by-lot inspection ( second revision )`. The frequency of testing and inspection for process control as given in 4.3 serves mainly as a guide to the manufacturer and IS not mandatory. In the evaluation of modulus of rupture, water absorption and crazing, recourse has to be taken to the test bars/plates which are prepared by the manufacturer by casting from the same body slip and glaze, dried and fired along with the appliances. To a very large extent, it is true that the test bars/plates possess characteristics similar to the appliances when prepared from the same body slip and glaze and fired side by side in a kiln. This correlation has been assumed in this standard to be reasonably high. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 `Rules for rounding off numerical values (revised)`. The number of significant places retained in the rounded off value should be the same as that of the specified value inthis standard. The composition of the committee responsible for the preparation of this standard is given in Annex B. IS 9140 : 1996 Indian Standard METHODS FOR SAMPLING OF VITREOUS FIRE CLAY SANITARY APPLIANCES (Second 1 SCOPE AND Revision ) processes and firings shall constitute a lot. 3.4 Lot Size Number of items in the lot. 3.5 Sample Group of items drawn from a lot for inspection. 3.6 Sample Size Number of items in the sample 3.7 Acceptance Number This standard prescribes methods for sampling and criteria for conformity of vitreous and fire clay sanitary appliances manufactured in accordance with various parts of IS 2556 and IS 771 respectively. Broad outlines with regard to controls to be exercised during the process of manufacture have also been included in this standard. 2 REFERENCES The Indian Standards given in Annex A are necessary adjuncts to this standard. 3 TERMINOLOGY 3.0 For the purpose of this standard, the following definitions shall apply. 3.1 Item Ultimate unit of product on which inspection will be performed. 3.2 Defective An item, the quality of which does not meet the specific requirements. 3.3 Lot A collection of items of single pattern (including all sizes) such as sinks, wash basins, cisterns, closets, etc, manufactured under relatively uniform conditions of manufacture, such as uniform materials, similar Stage The maximum permissible number of defectives in the sample for acceptance of the lot 4 PROCESS CONTROL 4.1 The inspection done by the manufacturer during production is to ensure uniformity and reduce quali:) fluctuations to the minimum whereas the object of inspection of sanitary appliances by the ~purchaser is to ensure their compliance to the specified requirements. 4.2 The manufacturer should USCall raw materials after appropriate tests to ensure that no substandard raw materials go into production. The raw materials may be tested to ensure their conformity to relevant Indian Standards/manufacturer's standard. 4.3 The manufacturer should carry out the Inspection at various stages in the process of manufacture. It is recommended to institute system&c inspection on the following stages at the frequency level indicated. Recommended Frequency of lnspertion and Testrng 1. Mould: a) For chippage/breakage b) For shape, dimensions, ovality, etc Each mould: i) 10 percent of moulds manufactured selected randomly. everyday, ii) 5 percent of the moulds in use selected randomly once every fortnight. 2. Mix (casting slip) before moulding One test per day for requirements like fineness, density, viscosity, casting rate, etc. 1 IS 9140 : 1996 Stage Recommended Frequency of Inspection and Testing 3. Greenwares before glazing: a) For construction, war-page and visual requirements b) For minimum thickness Each individual ware. 1 in 100 of each type and pattern ( total not exceeding 5 in number) manufactured in a day. Preferably thickness measurement may be done on wares broken during normal handling/rejections. 4. Wares after firing: a) Construction b) Finish c) Warpage d) Visual requirements ( blemishes and defects ) e) Minimum thickness Each appliance do do do Two appliances of each type and pattern from a day's production in case of a continuous kiln and from each firing in case of intermittent kiln. NOTE - For this test, appliances which are broken/rejected during normal process of manufacturing/handling, chosen at random, can also be used. f) Dimensions Five appliances of each type and pattern from a day%production in case of a continuous kiln and from each tiring in case of an intermittent kiln. All the five should pass, otherwise 100 percent inspection. Five appliances of each type and pattern from a day's production in case of a continuous kiln and from each firing in case of an intermittent kiln. All the five should pass, otherwise 100 percent inspection. Three sample pieces from every day's production in case of a continuous kiln and from each firingincaseofan intermittent kiln. Alternatively, this test may be done on test pieces separately made as specified in 10.3 of IS 2556 (Part 1) : 1994. Three sample pieces twice a-week in case of a continuous kiln and from every firing in case of an intermittent kiln. Alternatively, this test may be done on test pieces separately made as specified in 10.2 of IS 2556 (Part 1) : 1994. Eight sample test pieces once a week in case of a continuous kiln and from every firing in case of an intermittent kiln. Two sample pieces once a week in case of a continuous kiln and from every firing in case of an intermittent kiln. This test shall be done on test pieces separately made as specified in 10.5 of IS 2556 ( Part 1 ) : 1994. Two sample pieces once a week in case of a continuous kiln and from every firing in case of an intermittent kiln. 2 g) Flushing test, and cleanability test (wherever applicable) h) Water absorption j) Crazing k) Test for chemical resistance m) Test for resistance to staining and burning n) Test for modulus of rupture p) Test for thermal shock ( for flreclay wares only ) IS 9140 : 1996 4.4 For effectiveprocess control, the use of statistical quality control technique is recommended and guidance may be obtained in this respect from IS 397 ( Part 1 ) : 1972, IS 397 ( Part 2 ) : 1985 and IS 397 ( Part 3 ) 1980. 4.5 The inspection data or the results of tests done at the place of manufacturer may be made available along with the items supplied to enable the purchaser to judge the acceptability of the lot. 4.5.1 When such information cannot be made available to the purchaser or when the purchaser so desires, the procedure laid down in 5 shall be followed for judging the conformity of the lot. 5 LOT INSPECTHIN 5.1 Non-destructive Tests Table 1 Scale of Sampling and Acceptance Number ( Clause 5.1.1 ) Number of Appliances in the Lot (1) up 26 51 91 151 281 501 to to " " " " *' I 25 50 90 150 280 500 200 Sample Size (2) 8 13 20 32 50 80 125 Acceptance (3) 0 0 1 2 3 5 7 No. 5.1.2 Scale of Sampling and Criteria for Conformity for Warpage, DimensionalP Construction, Flushing and Cleanability Test ( Wherever Applicable ) The number of appliances to be selected at random for these tests from a lot having been found satisfactory according to 5.1.1 shall be in accordance with Table 2. Table 2 Scale of Sampling and Acceptance Number ( Clauses 5.1.2 and 5.1.2.2 ) Number of Appliances in the Lot (1) Upto 91 to 151 " 90 I50 500 Sample (2) 5 8 13 20 Size Acceptance No. (3) 0 0 0 1 The following tests can be done without causing any damage to the items: a) Visual ( permissible blemishes and defects, finish and marking ), warpage, dimensions and construction; and b) Flushing and cleanability test, wherever applicable. 5.1.1 Scale of Sampling and Criteria for Conformity for Visual Requirements The number of appliances to be selected from a lot shall be in accordance with co1 1 and 2 of Table 1. While taking samples from the lot, approximately, equal number of appliances shall be taken for each size so as to constitute the requisite sample size. Each appliance in the sample shall be subjected to visual inspection. An appliance failing in one or more of these requirements shall be considered as defective. NOTE - In case the number of different sizes in a lot exceeds the sample size, at least one appliance from each size shall be taken and appliances so selected shall constitute the requisite sample size. In such cases, the sample size may consist of more number of appliances than given in co12 of Table 1. However, the corresponding acceptance numbers given in co13 of Table 1 shall be used for the purpose of deciding the conformity of the lot. 501 " 1 200 5.1.2.1 These appliances shall be selected at random ( see IS 4905 : 1968 ) from the appliances already inspected and found satisfactory according to 5.1.1.2. 5.1.2.2 The lot shall be considered as conforming to these requirements if the number of defectives do not exceed the acceptance number given at co1 3 of Table 2. 5.2 Destructive Tests 5.2.1 These include the tests for minimum thickness, crazing, water absorption, chemical resistance, resistance to staining and burning, modulus of rupture and thermal shock. 5.2.2 For lots, if found satisfactory according to 5.1.2.2, one test for lots containing up to 280 items, two tests for lots containing 281 to 500 items and three tests for lot containing more than 500 items shall be conducted for each of these requirements. 5.2.3 The lot shall be considered as conforming to the requirements of the relevant specification if in respect of each ~ofthese requirements the relevant test(s) is found satisfactory. 3 5.1.1.1 These appliances shall be selected at random fromthe lot, in accordance with IS 4905 : 1968. 5.1.1.2 The lot shall be considered as conforming to the visual requirements if the number of defectives found in the sample does not exceed the corresponding acceptance number given in co1 3 of Table 1. IS 9140 : 1996 ANNEX A ( Clause `2 ) LIST OF REFERRED IS No. INDIAN STANDARDS IS No. Title Title 397 Methods for statistical quality control during production Control charts for variables ( first revision ) Control charts for attributes and count of defects ( second revision) 2556 for vitreous Specification sanitary appliances ( Vitreous China ) General requirements revision ) ( Part 1 ) : 1972 ( Part 1 ) : 1994 (Part2): 1994 ( third ( Part 2 ) : 1985 Specilic requirements of wash down water closets (jmrth revision) ( Part 3 ) : 1980 771 Special control charts Specification glazed for lireclay sanitary appliances: General requirements (second revision ) (Part3): 1994 Specific requirements of squatting pans (fourth revision) Specific requirements of wash basins ( third revision ) Specific requirementsof laboratory sinks ( third revisron ) Specific requirements of urinals and partition plates ( fourth revision ) requirements of Specific accessories sanitary for appliances ( third revision ) Specific requirements of pedestal close coupled wash down and syphonic water closets ( fourth rewsion ) requirements of Specific pedestal type bidets ( fourth revision) ( Part 4 ) : 1994 ( Part 5 ) : 1994 ( Part 6 ) : 1995 ( Part 1 ) : 1979 ( Part 2 ) : 1985 Specific requirements of kitchen and laboratory sinks ( third revision ) Part 3 Specific requirements of urinals, Section 1 Slab urinals ( second revision j Part 3 Specific requirements of urinals, Section 2 Stall urinals ( third revision ) Specific requirements of post( second slabs mortem revision ) ( Part 3/Set 1 ) : ( Part 7 ) : 1995 1979 ( Part 8 ) : 1995 ( Part 3/Set 2 ) : 1985 ( Part 4 ) : 1979 (Part9): 1995 (Part 5 ) : 1979 Specific requirements of shower trays ( second revision ) Specific requirements of bedpan sinks ( second revision ) Specific requirements of slop sinks ( second revision ) (Part 14 ) : 1995 Specific integrated (first requirements of squatting pans ) revision ( Part 6 ) : 1979 requirements of (Part 15 ) : 1995 Specific univeral water closets (first revision ) (Part7): 1991 4905 : 1968 Methods for random sampling 4 IS 9140 : 1996 ANNEX B ( Foreword ) COMMITTEE COMPOSITION Sanitary Appliances and Water Fittings Sectional Committee, CED 3 Chairman SHRIS. PRAKASH Member.7 SHRIP K. JAIN(Alternate to Shri S. Prakash ) THE ADVISER (PHE) DEPUTY ADVISER (PHE) ( Alternate ) SHRII. R. ACCARWAI. SHRISANJA~ AG(;ARWAL ( Alternate ) SHRIK. AUDISE~HIAH SHRIK. JAYAKAN.TH ( Alrernofe SHRIVIDURBHASKAR SHRIARUNKANTIBISWAS SHRIK. B. CHOPRA LT-COL G. T. KAUSHIK ( Alternate LT-COL S. K. SHARMA(Alternate DR T. K. DAN HYDRAULIC ENGINEER DEPUTY HYDRAULIC ENGINEER ( Alfernare SHRID. K. KANUNGO SHRIR. KA~~OR(Alternate ) Kerala Water Department, Shipyard Authority, Trivandrum Public Health Engineering ) Bhaskar Stoneware Pipes Private Engineering Limited, Faridabad Institute (CSIR). Delhi Water Supply Delhi Representing and Sewage Disposal Undertaking (MCD), Central Public Health and Environmental Engineering, New Delhi Messrs Goverdhan Das P. A. ( Calcutta ) E. I. D. Parry ( India ) Ltd. Madras National Environmental Nagpur I ) II ) Engineer-in-Chiefs Headquarters, Research Branch, New~Delhi Ministry of Defence. Army Central Glass and Ceramic Corporation Research Institute(CSIR).Calcutta Mumbai. Mumbai Municipal of Greater ) National Test House, Calcutta MANAGING DIRECTOR CHIEF ENGINEER ( PS&G ) ( Alternare ) SHRI K. LAKSHMI NARAYANA SHRIA. SHARIFF ( Alternate ) SHRIS. K. NECGI SHRIA. K. SENGLIPTA ( Alternare ) SHRI0. F? RATRA SHRIR. S. R~ITHOR SHRIS. D. JOSHI ( Alternate ) SHRID. K. SEHGAL SHRIB. B. SIKKA( Alrernnre ) SENIOR CIVIL ENGINEER ( WATERSUPPLY ) SHRIR. C. SHARMA SHRISUDESH KUMARSHARMA SHRISURE~H KUMARSHARMA(Alternate SUPERINTENDING ENGINEER ( TAC) EXECUTIVE ENGINEER ( TAC) ) Hindustan Ltd. Visakhapatanam Institution of Public Health Engineers India, Calcutta Building Messrs Material and Technology Kirloskar Brothers Promotion Pune Council, New Delhi Limited, Leader Engineering Works, Jallandhar Ministry Directorate Central of Railways General ( Railway of Supplies Board ), New Delhi New Delhi and Disposals, Roorkee Building Research Institute, U. P. Jal Nigam, Lucknow ( Alternate . ) Hindustan Sanitaryware Industries Limited, Bahadurgarh SHRIR. K. SOMANY SHRISANDIP SOMANK ( Alternate > SUPERINTENDING SURVEYOR OF WORKS ( NDZl ) SURVEYOR OF WORKS ( NDZl) ( Alrernate ) SHRIS. SUNDARAM Central Public Works Department, New Delhi Glass Fibre Division, Ceat Limited, Hyderabad ( Continued on page 6 ) 5 IS 9140 : 1996 ( Continued from page 5 ) Members REPRESE~ATIVE REPRESENTATIVE SECRETARYGENERAL SHRI D. K. THOMBRE SHRI VINOD KUMAR, Representing Central Institute of mastic Engineering Institution of Engineers and Technology, Madras ( India ), New Delhi Mumbai Board, New Mumbai Indian Water Works Association, Maharashtra Director ) Water Supply and Sewage General, BIS ( Ex-officio Member ) Director ( Civ Engg Member Secretary SHRI R. S. JUNWA Joint Director ( Civ Engg ), BIS Domestic Sanitary Appliances and Accessories Subcommittee. CED 3 : 1 Convener SHRI R. K. SOMANY Hindustan Sanitaryware and Industries Ltd. Bahadurgarh Members SHRI V. ANANTHANARAYANAN CHIEF ENGINEER CHIEF ENGINEER( SEWERAGE ) DEPIITY CHIEF ENGINEER ( DR T. K. DAN DEPIITY DIRECTOR SHRI G. DHAMODARAhl SHRI V. GOPAI. ( East India Ceramics, Tamilnadu Municipal Vellore, Tamil Nadu Board, Madras Water Supply Corporation and Drainage of Greater Mumbai. Mumbai Alternate ) Central Glass and Ceramic Directorate General (India) Research Institute (CSIR), Calcutta New Delhi of Supplies Limited, and Disposals, Madras E. I. D. Parry AIternute ) Kerala Water Department. Designs Authority, Trivandrum Public Health Engineering MANMING DIRECTOR DEPUTY CHIEFENGINEER ( WORKS ) EXECIITIVE ENGINEER ( WORKS ) ( SHRI A. A. GANPIILE SHRI RAJBNC)RA KUMAR ( SHRI B. D. KOTHARI SHRI S. RAMKUMAR ( Research, and Standards Organization, Lucknow Alternate ) Parshuram Pottery Works Co, Thangadh Alternate ) Madhusudan Ceramics, New Delhi Alternate ) Phenoweld Polymer Private Limited, Mumbai SHRI B. S. MIR~HANDANI SHRIP R. GLI~TA ( SHRI S. PRAKASH SHRIS. S. RAMRAKHYANI( SHRI Y. N. OR. RAO Alternafe ) Alternate ) Delhi Water Supply and Sewage Disposal New Delhi Engineer in Chiefs Branch, Undertaking (MCD), Army Headquarters, New Delhi MAJ K. B. SINGH ( Alternate ) SHRI 0. P RATRA Building Materials Delhi Hindustan and Technology Promotion Council, New SHRI U. SARKAR SHRI V. K. JAIN ( Sanitaryware and Industries Ltd. Bnhadurgarh Alternate ) Central Building Research Institute, Roorkee SHRI SUDESH KUMAR SHARMA SHRI SURESH KUMAR SHARMA (Alternate SUPERINTENDING SURVEYOR OF WORKS (NDZl) SURVEYOR OF WORKS (NDZl) ) Central Public Works Department, New Delhi (Alternate ) 6 Bureau of Indian Standards BIS is a-statutory institution established under the Bureau oflndian StandardsAct. 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing~the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession~of the latest amendments or edition by referring to the latest issue of `BIS Handbook' and `Standards : Monthly Additions'. This Indian Standard has been developed from Dot : No. CED 3 ( 5336 ). 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