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इंटरनेट मानक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. “जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ” Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru “The Right to Information, The Right to Live” “Step Out From the Old to the New” IS 15541 (2005): Low cement and ultra low cement castables for general purposes [MTD 15: Refractories] “!ान $ एक न’ भारत का +नम-ण” Satyanarayan Gangaram Pitroda ““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee”” “!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै” Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen” : n IS 15541:2005 w?i+kTwmF wFT1-wmiEFit . w22JGmri{dPm-@T4Nz m-TwlaaTFm%k-mlrw Indian Standard LOW CEMENT AND ULTRA LOW CEMENT CASTABLES FOR GENERAL PURPOSES — SPECIFICATION ICS 81.080 0 BIS2005 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 February 2005 Price Group 2 ,. .. ... Refractories Sectional Committee, MTD 15 FOREWORD This Indian Standard wasadopted bytheBureau ofIndian Standards, afterthe draft finalized bythe Refractories Sectional Committee, had been approved by the Metallurgical Engineering Division Council. This standard has been prepared for specifying the requirements of lowcement and ultra low cement castables for general purpose. Six grades of low cement castables and two types of ultra low cement castables and their methods of sampling have been specified inthis standard. For the purpose of deciding whether aparticular requirement ofthis standard iscomplied with the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS2:1960 ‘Rules for rounding offnumerical values (revised)’. Thenumber ofsignificant places retained inthe rounded off value should be the same asthat ofthe specified value inthis standard. IS 15541:2005 Indian Standard LOW CEMENT AND ULTRA LOW CEMENT CASTABLES FOR GENERAL PURPOSES — SPECIFICATION 1 SCOPE graded refractory agreegates with high aluminina cement in order to have total CaO content between This standard covers the requirements of low cement 0.31 to 0.5 per cent, the plasticisers may also be castables and ultra low cement castables for general incorporated inthe ultra lowcement castables. purpose. The specific usesmay bedecided bymutual understandingbetweenthemanufacturerandpurchaser. 3.4 Lot — In any consignment, all the containers The scope alsodescribes themethod of sampling. containing lowcement andultra lowcement castables ofthesametype andgrade, manufactured bythesame 2 REFERENCES firm under similar conditions of production shall be grouped together to constitute a lot. The maximum The following standards contain provisions, which massofany lothowever shallbe limited to25tonnes. through reference inthistext, constitute provisions of this standard. Atthe time of publication, the editions 4SAMPLING AND TEST PIECE PREPARATIONS were valid. All standards are subject to revision, and parties to agreement based on this standard are 4.1 Forthecomplete series oftest aminimum quality encouraged to investigate the possibility of applying of about 50 kg is required as sample. As those are the most recent editions of the standard indicated normally supplied in 50kg containers, the number of below: containers mentioned below shall be released at random onthe following basis: IS No. Title 1527:1972 Methodsofchemicalanalysisofhigh Lot Size No. of 50 kg Containers/ silica refractory materials ~irst Bags to be Selected revision) as Sample’) 1528 Method of sampling and physical (1) (2) tests forrefractory materials: (Part 1): 1980 Determination of pyrometric cone Upto and including 1tonne 1 equivalent (PCE ) or softening point Over 1tonnes and upto and 2 (second revision) including 4tonnes (Part 14):1974 Sieve analysis @rst revision) Over 4tonnes and upto and 5 (Part 16):1991 Determinationofthermalconductivity including 25tonnes upto 1250°Cofdenseandinsulating o Eachcontainerhag sampleshall bemadeavailable fromat refractory products according tothe least 10locationsrandomly. hot wire parallel method 4041:1987 Glossaryoftermsrelatingtorefractory 4.2 The selected containerdbags shall beemptied on materials a suitable dry surface and the material be thoroughly 10570:1983 Methodforesting refractorycastables mixed andreduced to50kgbyconing and quartering. This final sample shall be divided equally into eight 3TERMINOLOGY test samples by successive coning and quartering 3.1 For the purpose of this standard, the following method. These test samples shall be used for various definitions inaddition to those giveninIS4041 shall physical tests, sieveanalysis, bulk density, permanent apply. linear change, pyrometric cone equivalent, modulus of rupture, cold crushing strength and thermal 3.2 Low Cement Castabies — Mixture of graded conductivity. refractory agreegates with high alumina cement in order tohave total CaOcontent between 1-2percent. 4.3 Preparation of Test Pieces The plasticisers may also be incorporated in the low The method of preparing test pieces of the material cement castables. has a marked effect on their properties and it is 3.3 Ultra Low Cement Castables — Mixture of necessary touse astandard procedure. ,. ‘“..+ IS 15541:2005 4.3.1 Apparatus 6.2 The requirement of physical tests for ultra low cement castables isgiven inTable 2. The apparatus used for the specimen preparation for bulk density, firing,shrinkage, modulus ofrupture and 6.3 Maximum Grain Size cold crushing strength are: Wetsieveanlaysis forcastables, shallbecarried outin a) h40ula!s— asper7.1.1ofIS 10570. accordance with IS 1528 (Part 14). Grading shall be b) Planetary bowl mixer — as per 7.1.3 of as per agreement between the manufacturer and the Is 10570. purchaser. c) Vibrating table — asper 7.1.4 of IS 10570. 6.4 Flowpropertiesshallbetestedasgiven inAnnex A d) Drying oven.. of Is 10570. 4.3.2 Test Pieces 6.5 Bulk density shall be determined as per method Thetestpieces used forthetestsprescribed in4.2shall specified in 8 of IS 10570. be in the form of bar 40 mm x 40 mm x 160 mm. 6.6 Coldcrushing strength shallbedetermined asper These test pieces shall be cast using gang mould of specified in 10of IS 10570. three bars as per IS 10570. The consistency of the material, forthetestpieces, shallbeasper instructions 6.7 Permanent linear change shall be determined as given by manufacturer. per method specified in 11of IS 10570. Whenshapingiscompleted themouldswithcompacted 6.8 Thermal conductivity test shall be carried out test specimens are kept for 24 h in mould. After in accordance with IS 1528 (Part 16) of any other 24h, the test pieces are removed from the mould and suitable method can be used as agreed between the placed for drying at 11O°Cin an oven to constant manufacturer and thepurchaser. weight. After drying, thetestpiecesarecooledtoroom temperature and dimensions aremeasured. 7 DETERMINATION OF PYROMETRIC CONE EQUIVALENT (PCE) Inspecial cases, thecuring schedule asrecommended by the manufacturers maybe adopted. 7.1 The test shall be carried out in accordance with 1S 1528 (Part 1). 5 CHEMICAL ANALYSIS 5.1 Chemical analysis, for low cement castable when 8 PACKING carriedoutinaccordance with IS 1527 shallbeasgiven 8.1 These castables shall bepacked inpolythene lined inTable 1. HDPE bags/containers of suitable weights. 5.2 Chemical anlaysis for ultra low cement castable when carried out inaccordance w ith IS 1527shall be 9 MARKING asgiven inTable 2. 9.1 All the bags shall bemarked with: 6 PHYSICAL PROPERTIES a) Manufacturers name, product name, net weight and 6.1 The requirement ofphysical tests for low cement castable isgiven inTable 1. b) Month andyear of manufacture. 2 * .. .. ... IS15541:2005 Table 1 Requirement forLow Cement Castable (Clauses 5.1 and 6.1) Grade 45 60 70 80 90 95 (1) (2) (3) (4) (5) (6) (7) . ChemicalAnalysis(weightpercent) AIzOJ,Min 45 60 70 80 90 94 SiOz,Max 48 35 25 13 06 4.2 FezOj,Max 1.5 1.5 1.5 1.8 1.0 0.3 TIo*,Max 2.4 2.6 2.8 3.3 1.2 Traces CaO,Max 2.0 2.0 2.0 2.0 1.7 1.2 PhysicalProperties MORat1400”Ckgf/cm2 50 50 50 50 60 60 MaximumGrainSize,mm 6 6 6 6 6 6 WaterforCasting,percent 4.8-5.5 4.7-5.4 4.0-4.6 3.8-4.5 4.2-5.0 4.0-4.8 B.D.(gin/cc)at110°C/24h,A4in 2.3 2.6 2.65 2.9 3.0 3.1 C.C.S. kg/cm2,Min 110°C/24h 700 750 750 800 950 1000 1100”C/3h 900 900 950 1050 1100 1100 1500°C/3h 1000 1000 — — 15 50°C/3h — 1000 1150 1200 1250 RefractoriesOrtorr/°C,&fin 3211717 36/1804 36/1804 37/1820 37/1820 38/1835 PLC(percent) I100°C/3h,Max +(3.30 +0,30 +0.30 +0.20 *0.30 +0.30 I500”C/3h,Max +1.0 +1.0 — — — I550°C/3h,Max — — +1.0 +1.5 +0.80 &O.80 Thermal Conductivity (kcal/m/hP’C) 400”C 0.85 0.95 1.15 1.70 2.20 2.25 600”C 1.05 1.10 1.25 1.75 2.30 2.30 800”C 1.20 1.25 1.30 1.80 2.35 2.35 Storage Life(months) 6 6 6 6 6 6 Table 2 Requirement for Ultra Low Cement Castables (Clauses 5.2 and 6.2) Type 90Percent 95Percent (1) (2) (3) MORat 1400”C 60 60 Chemical Analysis (weightpercent) AllOj,Min 90 95 FelOJ,Max 1.5 0.5 CaO,Max 0.5 0.5 Water,percent 4-4.5 4-4.5 CCS kg/cm2,MirI II0°C/24h 400 200 I100°C/3h 900 800 I550°C/3h 1100 I200 MOR 11O°C/24h 50 50 I1OO°C/3h I50 150 I550°C/3h 200 220 PLC,percent 1i00°C/3h *0.3 +0.3 1550°C/3h +] *I Storagelife(months) 6 6 3 Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters inthe 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 tothe Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards asthe need arises onthe basis of comments. Standards are also reviewed periodically; a standard along with amendments isreaffkmed 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 areinpossession ofthe latestamendments oredition byreferring tothe latest issue of ‘BIS Catalogue’ and’ Standards: Monthly Additions’. This Indian Standard has been developed from Doc :No. MTD 15(4346). 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