1S : 1528 ( Part 3) - 1983 Indian Standard METHOD OF SAMPLING AND PHYSICAL TESTS FOR REFRACTORY MATERIALS PART 3 DETERMINATION OF SPALLING RESISTANCE (Second Revision ) First Reprint NOVEMBER 1988 UDC 666.76:620,193,19 © Copyright 1983 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 Gr2 July 1983IS : 1528 ( Part 3 ) - 1983 Indian Standard METHOD OF SAMPLING AND PHYSICAL TESTS FOR REFRACTORY MATERIALS PART 3 DETERMINATION OF SPALLING RESISTANCE (Second Revision ) Refractories Sectional Committee, SMDC 18 Chairman Representing Dr D. N. Naxpr Kumardhubi Fireclay & Silica Works Ltd, Calcutta Members Dr G, D. Sivan ( Alternate to Dr D. N. Nandi ) Samt P.S, V. ANwwruanana- Engineering & Mineral Industrial Research Labora= Yana tory, Bangalore Sunt D. N; Basprsice Indian Iron & Steel Co Ltd, Burnpur Snar A. K. Muxutnsen ( Alternate ) Sarr BaaRAt BHASK AR Ishwar Industries Led, New Delhi Suri Ragrey Buaskar ( Alemate ) Dr A. K. Bose Associated Cement Companies Ltd, Bombay Suri M. R. Vixavaxa ( Alternate 1) Dr A. K. Caarrensex (Alternate 11) Sarr S. K, Cuarrersee Steel Authority of India Ltd (Durgapur Steel Plant ), Durgapur Sarr P. K. Roycuowpnury ( Alternate ) Sura B. K.P. Cxarppax Steel Authority of India Ltd ( Bokaro Steel Plant ), Bokaro Steel City Surt A, S. Kuarxuo ( Alternate) ‘Suez M. H, Davai, Orissa Cement Ltd, Rajgangpur Sunt K. K. Prasap ( Alternate ) Sunr8. K. Das Directorate General of Supplies and Disposals (Inspection Wing ), New Delhi Sur R. N. Sawa ( Alternate ) Derory Drmercror (Mer )-I Ministry of Railways RDSO, Lucawow Curis? & Meranuureisr (SF) CLW, Currraraysan ( Alternate ) Sunr D. M. Guera Belpahar Refractories Ltd, Belpahar Sunt T. K. Guosn ( Alternate ) Suar A. V, Hixcorant Steel Authority of India Ltd ( Alloy Steels Plant ), Durgapur Sunt $. K, Jauxsnunwata Orissa Industries Ltd, Rourkela Sunr M. M. Sanu ( Alternate ) ( Continued on page 2 ) © Copprigns 1983 BUREAU OF INDIAN STANDARDS This puvheation 1s protected under the Indian Copyright dct (XIV of 1957) and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said AciIS : 1528 ( Part 3) - 1983 ( Continued from page 1 ) Members Representing SuprS, R. Keanna Directorate General of Technical Development, ‘New Delhi Sarr R. Sacupev ( Alternate ) Suex I. C. Mopt Steel Authority of India Ltd (Rourkela Steel Plant), Rourkela Sut R, K. Sanaa ( Alternate ) Sunt $8. K. Mogaxry ‘Ministry of Defence ( DGOF ) Sarr N. C. Mugxenser India Firebricks & Insulation Co Ltd, Marar Sunt V.S. Baura ( Alternate) San S. K. Muxsersee Bharat Refractories Ltd, Bokaro Steel City ‘Suex H. N. Teraras ( Alternate ) Suet J.R. K. Murray Harry Refractory & Ceramic Works Pvt Ltd, Calcutta; and Indian Refractory Makers Associa” tion, Calcutta . Sun N.C. Sana ( Alternate) Harry Refractory & Ceramic Works Pvt Ltd, Calcutta Sarr R. C. Nanny M.N. Dastur & Co (P) Ltd, Caleutta SunrA. K, Guosa ( Alternate ) Dr J. D. Paxpa Dalmia Institute of Scientific and Industrial Research, Rajgangpur Dr N. Sastoo ( Alternate ) Dr T. V. Prasap Engineers India Ltd, New Delhi Sunr B. RAMACHANDRAN Metallurgical & Engineering Consultants ( India) Ltd, Ranchi Sur T. B. Srxaxt ( Alternate ) Sarr Ramesi Cxaxp All India Glass Manufacturers’ Federation, New Delhi Dz M.R.K. Rao National Metallurgical Laboratory (CSIR ), Jamshedpur Sux P. C, Sen ( Alternate ) Sun A. K. Sana National Test House, Calcutta Sarr D. Kaxonco ( Alternate ) Sarr O. P. Saxpnme Steel Authority of India Ltd, Research & Develop- ment Wing, New Delhi Sunt K. C, Caarrensmn ( Aliernate) Sunr R, Sankaran Bharat Heavy Electricals Ltd, Tiruchchirappalli Sunt C, S. R. Apurrayan ( Alternate) i Suer K. C. Sivma Ministry of Defence (DGI ) Directorate of Produc- tion and Inspection (Navy ) Surz Rasenpra Prasap ( Alternate ) De N. R. Srnoar Central Glass & Ceramic Research Institute (CSIR ), Calcutta Snur K. Ramesam ( Alienate ) Dr B.V, Suppa Rao Ministry of Defence ( R&D ), Hyderabad Surxk. 8, SwaniwaTHAN The Tata Iron & Steel Go Ltd, Jamshedpur Sunx B. N. Gosn ( Alternate ) ae Sunt B.S. Ven avaRamran Steel Authority of India Ltd (Bhilai Steel Plant ), Bhilai Suer V. K, Nirvawawpan ( Alternate ) : Sunt K, RagHavenpran, Director General, BIS ( Ex-oficio Member ) Director ( Struc & Met ) Secretary Sunt B, MuxHenst Senior Deputy Director ( Metals ), BIS ( Continued on page 8 ) 2IS : 1528 ( Part 3) - 1983 Indian Standard METHOD OF SAMPLING AND PHYSICAL TESTS FOR REFRACTORY MATERIALS PART 3. DETERMINATION OF SPALLING RESISTANCE (Second Revision ) 0 FOREWORD 0.1 This Indian Standard ( Second Revision ) ( Part 3 ) was adopted by the Indian Standards Institution on 21 April 1983, after the draft finalized by the Refractories Sectional Committee had been approyed by the Structural and Metals Division Council. 0.2 ‘This standard was first published in 1962 and subsequently revised in 1974 when it was issued in separate parts. This part ( Part 3) deals with the determination of spalling resistance and the other parts are as follows: IS: 1528 (Part 1)-1980 Determination of pyrometric cone equivalent (PCE) or softening point (second revision ) IS ; 1528 ( Part 2)-1974 Determination of refractoriness under load (first revision ) IS : 1528 ( Part 4)-1974 Determination of cold crushing strength ( fast revision) IS : 1528 ( Part 5)-1974 Determination of modulus of rupture ( first revision ) IS ; 1528 ( Part 6 )-1974 Determination of permanent change after reheating (first revision ) IS ; 1528 ( Part 7 )-1974 Methods of sampling and criteria for conformity ( first revision ) IS : 1528 ( Part 8 )-1974 Determination of apparent porosity ( first revision ) ciIS : 1528 ( Part 3) - 1983 S: 1528 ( Part 9 )-1980 Determination of true specific gravity and true density ( second revision ) S : 1528 ( Part 10 )-1974 Determination of size of refractory bricks ( first revision ) IS : 1528 ( Part 11 )-1974 Determination of warpage ( first revision ) IS : 1528 ( Part 12 )-1974 Determination of bulk density (first revision ) IS : 1528 ( Part 13 )-1974 Determination of resistance to the disinte- grating effect of carbon monoxide ( first revision ) IS: 1528 ( Part 14 )-1974 Determination of sieve analysis (_jirst revision) 0.3 In the present revision of the method for determination of spalling resistance, the panel spalling test has been deleted and the water quench- ing test has been included. 0.4 Spalling is a fracture of refractory bricks resulting from strugtural and thermal shocks. The method of testing refractories for spalling implies the determination of the number of heating and cooling cycles which can be resisted by the refractory product until it reaches a specified degree of fracture. 1, SCOPE 1.1 This standard ( Part 3) prescribes the method of test for determin- ing the spalling resistance of refractory materials by the following two methods: a) Water quenching test, and b) Small prism test. 2, TERMINOLOGY 2.0 For the purpose of this standard, the definitions given in IS : 4041- 1967* and the following shall apply: 2.1 Spalling — The cracking or fracture of refractory product caused by differential expansion due to thermal shock, a steep temperature gradient, a crystalline conversion or a change in composition near the hot face. *Glossary of terms relating to refractory materials. 4IS : 1528 ( Part 3 ) - 1983 3. WATER QUENCHING TEST 3.1 Apparatus BLA Test Furnace — An electric furnace with carbon heating element shall be used for heating the specimens. The furnace shall be designed for simultaneous testing of three standard bricks. The furnace shall be provided with a suitable controlling device so that the tempera- ture can be maintained within an accuracy of 10°C. 3.1.2 Water Tank — A suitable water tank shall be used for cooling the heated specimen with running water. 3.2 Test Specimen — Test specimens used shall be standard bricks of 230 x 113 x 65 mm or 230 x 115 x 75 mm size with a tolerance of +5 mm in all dimensions. Side skew or end skew bricks may be used and shall be treated as standard bricks. Products of other shapes may be used provided a test specimen of standard brick size may be obtained from them. In such cases only products up to 80 mm thick are allowed to be tested. 3.2.1 Product which are not suitable for preparing specimens of standard brick sizes like stopper heads and bottom pouring sets can not be tested by this method. 3.3 Procedure 3.3.1 Preparation of Specimen — The test specimen shall be dried at 110 + 5°C until a constant weight is obtained, and shall be weighed to an accuracy of + 5g. One end of the test specimens shall be marked with the batch number and the specimen number. 3.3.2. Heating and Cooling of Specimens ~The test specimens shail be inserted in’ the furnace chamber up to a depth of 50mm. The furnace should be pre-heated to 1 300°C and the temperature of 1 300°C: shall be maintained for 15 minutes before insertion of the test specimens. The space between the individual specimens as well as the space between the specimens and the walls of the charging hole of the furnace should be filled with light fireclay inserts and asbestos. After insertion of the test specimens in the furnace, the temperature should again be raised to 1300°C within 10 to 20 minutes and the specimens should be maintained in the furnace at that temperature for 10 minutes. The temperature of the furnace should be controlled to remain at 1 300°C. +- 10°C. A thermo- couple should be placed in the furnace between the test specimen and the heating elements at mid-distance of the specimen and at a distance of 10 mm from the end of the brick which is put into the furnace. After heating, the specimen should be withdrawn from the furnace and the heated ends dipped into the water tank to a depth of 50 mm. The water tank should have running water at ambient temperature and the rate of 5IS : 1528 ( Part 3 ) - 1983 water flow shall be maintained at 7 + 1 litre per minute. The specimen should be held in the water tank for 5 minutes, taken out and kept in air for 5 to 10 minutes. These should be reinserted in the furnace. The cycle of heating and cooling of the specimen shall be repeated until 20 percent of the mass of the specimen have been lost by flaking off. 3.4 Test Results 3.4.1 The loss of mass is measured after each cycle of heating and cooling. The test is stopped when either the minimum specified cycles of spalling resistance are reached or at a stage when apparently 20 percen# loss in mass is observed. Final reporting of the percentage of loss o¥ mass and the number of cycles are related to initial and final weights of the specimen both taken after drying at 110 + 5°C. 3.4.2 The test results should be expressed as the number of full cycles which has been withstood by the specimen before 20 percent loss in mass. The cycle in which the loss in mass exceeds 20 percent should not be taken into consideration. The individual results obtained on $ test specimens shall be reported. 4, SMALL PRISM TEST 4.1 Apparatus — A furnace of the muffle or semi-mufile type is needed. It shall be of such a size as to allow sufficient heat release to the test pieces. The furnace size should be such as to accommodate at least 3 test specimens, if a large number of specimens are to be tested, the furnace shall be of such asize that the fall in temperature when the test pieces are inserted after the first cooling shall not exceed 20°C. A thermocouple shall be used for the measurement of temperature. 4.2 Test Specimen — Three test pieces shall be cut or ground to the shape of prisms 75 mm high with a square base of 50 mm in the case of standard shapes, and bricks; or rings 50 mm high from sleeves, nozzles or any other type of pouring refractories. ‘The test pieces shall ba thoroughly dried before use. 4.3 Procedure — Place the test pieces in the cold furnace. Heat the furnace at a uniform rate so that in 3 hours it attains a temperature of 450°C, if silica bricks are being tested, or 1 000°C. if firebricks, siliceous bricks or basic bricks are being tested. Maintain the testing temperature for 30 minutes and remove the test pieces from the furnace with a pair of light tongs, which shall have been warmed in the furnace for a short time before use, Place the test pieces on end on a brick floor in a position free from draughts. After they have been cooled in this way for 10 minutes, replace the test pieces in the furnace ( which shall have been maintained at the temperature of the test ) for a further 10 minutes and the cycles is repeated. The furnace shall be maintained at the required 6IS : 1528 ( Part 3) - 1983 constant temperature during testing. Examine the test pieces towards the end of each 10 minutes cooling period. The test shall be concluded when the specimens can be pulled apart ( to be specified for each type of refractory in the material specification depending upon the service condition ). 4.4 Report — Report the number of complete cycles of heating and cooling required to promote fracture together with a note of the cycle during which cracks first appeared. Three individual results shall be included in the report. 5. SAMPLING AND CRITERIA FOR CONFORMITY 5.1 The procedure for sampling and the criteria for conformity shall be as laid down in IS : 1528 ( Part 7 )-1974*. *Mothod for sampling and physical tests for refactory materials: Part 7 Methods of sampling and criteria for conformity ( first revision ), 718 : 1528 ( Part 3) - 1983 { Continued from page 2) Refractories Investigations Subcommittee, SMDC 18: 3 Convener Representing Da NR. Smcax, Central Glass & Ceramic Research Institute, (CSIR ), Calcutta Members Suez K, Rawesam ( Alternate to DrN. R. Sircar ) Sunz D. N. Banerser Indian Iron & Steel Co Ltd, Burnpur Sant A. K, Moxwersnn ( Alternate) Sunt Vivex N. Buaskan Ishwar Industries Ltd, New Delhi Surr H, V. Buasrar Rao ( Alternate ) Dr A. K. Cxarrerses The Associated Cement Co Ltd, Thane Sunt S. K. Biswas ( Alternate ) Surx M. H, Darana Orissa Cement Ltd, Rajgangpur Sumi K, K. Prasan ( Alternate ) Suez D. M. Guera Belpahar Refractories Ltd, Belpahar Sunt T. K. Guoss ( Alternate ) Sanr A. V. Huxconant Steel Authority of India Ltd ( Alloy Steels Plant ), Durgapur Suns 8. K. Juunsnunwata Orissa Industries Ltd, Rourkela Suet M. M. Sanu ( Alternate ) ‘Suni A. S. KuaKno Steel Authority of India Ltd ( Bokaro Steel Plant ), Bokaro Steel City Surr A. G. Gare ( Aliernate ) Suni P. MuxuorapHyaya Steel Authority of India Ltd (Rourkela Steel Plant ), Rourkela Sart J. R. K. Mortny Harry Refractory & Ceramic Works Pvt Ltd, Calcutta Smnr N. G. Sasta ( Alternate ) Dr D.N, Naor Kumardhubi Fireclay & Silica Works Ltd Kumar- dhubi and Indian Refractory Makers’ Association, Calcutta Dx G.D. Sivan ( Alternate) Kumardhubi Fireclay & Silica Works Ltd, Kumardhubi Dr J.D. Paxpa Dalmia Institute of Scientific & Industrial Research, Rajgangpur Dr B. Rao ‘The Tata Iron and Steel Co Ltd, Jamshedpur Suri B, N. Guosn ( Alternate ) Dr M.R. K. Rao National Metallurgical Laboratory (CSIR ), Jamshedpur Sunt M, V, Ranoa Rao Cement Research Institute of India, New Delhi Suez S. Soxuaran ( Alternate ) Suar O. P, Saxpete Steel Authority of India Ltd (Durgapur Stcel Plant ), Durgapur Surat P. K. Roy Guowpuany ( Alternate ) Dr B.S. R. 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