IS 3978 : 1993

( Reaffirmed 1998 )

Indian Standard
MANUFACTURE OF BURNTCLAY
MANGALORE PATTERN ROOFING TILES-
CODE OF PRACTICE
( First Revision )

UDC 691.421 - 431 : 626

@ BIS 1993

BUREAU OF INDIAN aSTANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

February 1993 Price Group 3

Clay Products for Buildings Sectional Committee, CED 30

FOREWORD
This Indian Standard ( First Revision ) w-as adopted by the Bureau of Indian Standards, after the
draft finalized by the Clay Products for Buildings Sectional Committee had been approved by the
Civil Engineering Division Council.
This standard was first published in 1967. This revision has been prepared to unify the practice
followed and to guide the producer of burnt clay mangalore pattern roofing tiles. This is also
to improve the manufacturing operation and utilizing the existirg knowledge and experience
gained in the manufacture of better quality of tile.
Tile-maker in the country usually utilizes whatever soil is locally available and makes only the
minimum modifications, which are absolutely essential for moulding in its composition. How-
ever, investigations made at the Concrete and Soil Research Laboratory, Madras have indicated
certain broad limits within which the mechanical grading of the soil should lie in order to obtain
the required strength, low water absorption and other requirements for burnt clay tiles. Com-
position of the soil suitable for the tile manufacture has therefore been specified, based on the
test results conducted by the Concrete and Soil Research Laboratory, Madras.
In the formulation of this standard due weightage has been given to international co-ordination
among the standards and practices prevailing in different countries in addition to relating it to the
practices in the field in this country.
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 cff numerical values ( revised )‘.
The number of significant places retained in the rounded cff value should be the same as that of
the specified value in this standard.
 IS 3978 : 1993

Indian Standard
MANUFACTURE OF BURNTCLAY
MANGALORE PATTERN ROOFING TILES-
CODE OF PRACTICE
( Fimt Revision )
1 SCOPE 4 SELECTION OF SlTE FOR MANUFAC-
TIJRE OF THE BURNT CLAY ROOFING
This standard covers the selection of raw TILES
material, moulding and burning of burnt clay
roofing tiles with specific reference to machine
pressed inter-locking clay roofing tiles of the 4.1 The site shall be selected after giving due
mangalore pattern. consideration to the suitability of soil and the
location of water-table.
2 REFERENCES NOTE - It is a good practice to select a site such
that the water table during burning season is at least
The Indian Standards listed in Annex A are about one metre below the kiln floor.
necessary adjuncts to the standard.

3 TERMINOLOGY 4.2 The site should be located in conformity

with the prevailing town planning regulations,
For the purpose of this standard, the definitions or other bye-laws of similar nature, particularly
given in IS 1498 : 1970 and the following shall as the smoke from the kiln may prove a
apply. nuisance otherwise.

3.1 Drying Shrinkage 4.3 The availability of suitable clay conforming

to the requirements laid down in 5, within an
The percentage reduction in length or volume economical distance shall be an important
of tiles on drying, due to the removal of the factor influencing the location of the factory;
film of water which surrounds the individual greater consideration shall, however, be given
grains in the plastic form. to the distance of the distribution centre of the
Drying shrinkage V_ Vd x loo finished tiles rather than only to be guided by
( Shv ), percent =---- the lead of the source of raw materials, as it
V may prove more costly to arrange the distri-
bution and despatch of finished tiles rather
where than procurement of raw materials at factory
V = the plastic ( wet and green ) volume of rate.
tile, and
4.4 Though the availability of suitable clay, the
Vd = dry volume of the tile. nearness to a rail head or transport facilities
through road or water shall be important consi-
3.2 Fired Shrinkage derations in the selection of a factory for the
The percentage reduction in length or volume manufacture of burnt clay roofing tiles, the
of dry tiles when subjected to heating to a most important factor for selection of a suitable
temperature at which they are ultimately fired. place shall be congenial and suitable weather
and atmospheric conditions. Raw materials
Fired shrinkage for the manufacture of tiles being very suscepti-
( Stv ), percent vd-vf
= vd x 100 ble and vulnerable to the rigours of the
changing climatic and weather conditions in
where the process of drying, the economic operation
of the factory, may get crippled irrevocably,
Vd = dry ( unburnt ) volume of the tile, and if proper consideration is not given to such
Vf = dry ( fired ) volume of the tile. conditions.

1
IS 3978 : 1993
5 SOIL
5.1 The soil used for making burnt clay Manga-
lore pattern roofing tiles shou!d be processed
so ai to be free from gravel, coarse sand, lime
and KANKAR particles, roots, vegetable
matter etc.
5.2 Regarding the mechanical composition, the
soil or mixture of soils should preferably con-
form to the following requirements:
a) The total fines shall not b: less than 75
percent and the miilimum ckcy content
shall be 40 percent [see IS 1498 : 1970
and IS 2720 ( Part 4 ) : 1985 1.
b) The total lime ( CaO ) and magnesia
( MgO ) ( see IS 1727 : 1967 ) shall be
not more than I.5 percent by.weight and
the lime shall be in finely divided form.
The total water soluble material shall be
not more than one percent by weight
[ see IS 2720 ( Part 21 ) : 1977 1.
Cl Iron content in the clay shall be not
more than 5 percent by weight [ see IS
2720 ) ( Part 25 ) : 1982 1.
5.2.1 The chemical analysis of the soil shall
be made in accordance with IS 1727 : 1967, IS
2720 ( Part 21 ) : 1977 and IS 2720 ( Part 25 ) :
1982.
NOTES
1 Simple test for fire shrinkage may also be made on
rectangular clay tile slabs of 20 x 10 cm keeping the
thickness same-as that of the tile made unaer the
same conditio.1 as the actual manufacture of the
tile. Shrinkage shall be measured along both
longitudinal and lateral axes and expressed as an
average.
2 Generally the drying and fired shrinkage of the
tile can be taken on the average as 9 percent for
the purpose of designing the dimensions of the
mou Id.
6 PREPARATION OF CLAY
6.1 Weathering
The soil shall be lzft in heaps and exposed to
weather as long as possible and for at least
three months. This is done to develop a
homogeneity in the mass of clay, particularly if
they are from different sources, and also to
eliminate the impurities in the clay which get
oxidized, rendering the clay harmless to effect
a uniform and burnt clay colour at the time of
burning. Also if there be any insoluble salts
in the clay this would be washed off by rain to
a great extent which otherwise will cause
scumming at the time of burning the tiles in
the kiln.
2
6.2 Tempering
Addition of water to the clay at the dumps
shall be necessary for the easy mixing and
workability, but the addition of water shall be
controlled in such a way, that it may not create
problems in the process of drying as, it shall
ultimately be driven out in the process of
drying. Excessive moisture content may effect
the size and shape of the finished product. The
tempering of the clay shall be carried out by
storing the clav in a cool place in layers of
about 20 cm thick for not less than 36 hours.
This \r;iil produce homogeneii,y in the mass of
clay for subsequent satisfactory processing.
6.3 Mixing
Two or more soils may have to be mixed so as
to conform to the requirements of clay as laid
down in 5. The mixing may be done in a vat or
the clay may be passed through a proportioning
box clay feeder and double shaft mixer after
assessing the composition of the mixture.
6.4 Grinding
The clay mixed in the proper proportion shall
then be passed through high speed grinding
rollers and then extruded through a pugmill.
NOTE - It may sometimes be necessary ( especially
in case of harder clay ) to grind the weathered clay
before tempering and this is genarally done in pan
roller mills before being fed into the high speed
rollers.
6.5 Pugging
6.5.1 Consolidation of the clay shall be done
by extrusion through a suitable mouth piece
attached to the discharge end of the pugmill
and different sizes and shapes of slabs shall be
obtained by suitable design of the die.
6.5.2 The design of the die for the extrusion of
the flat slabs for roofing tiles shall be carefully
made out to avoid the slab cracking, occurrence
of dog ears, variation in the size of the sIabs,
variation in the density of the slab, etc. The
condition and the design of the screw or the
auger may influence the efficiency of operation,
power consumption and the elimination of
lamination of the slabs and it shall be suitably
controlled.
6.5.3 To achieve better quality production and
better finish with regard to appearance, the
extrusion of the slab shall be carried through a
deairing pugmill.
 IS 3978 : 1993

7 MOULDING OR PRESSING 7.3 Moulding or Pressing Procedure

7.1 Design and Construction of a Tile Press 7.3.1 A Rat slab of clay, depending upon the
size of the mould, as extruded from the pug-
7.1.1 The tile press may be manually operated mill explained in 6.5.2, shall be placed on the
or power operated, the latter may be of the working surface of the bottom mould. The
rotary or revolver press type. The construction mould face shall be smeared with smearing oil,
of the press shall be such that five bottom which may be a mixture of kerosine oil and
moulds can be assembled on the five faces of vegetable oil to facilitate easy release of pressed
the revolving pentagon drum in a horizontal tile from the metal mould. The setting and
plane and operated upon by a common top adjustment cf the top mould on to the bottom
mould havirg reciprocatirg motion vertically. mould shall be done carefully to avoid any
variation in the section of finished tile, which
NOTE - Such a press with good workmanship is otherwise may effect the flexural strength of
capable of producing up to 7 000 tiles. per day of the finished product. After the slab has been
feh;?. The hp requrred to operate this Press ~111
. . pressed and when the rotating drum in the
revolver press comes to the next halting position,
the pressed tile shall be received on a wooden
7.1.2 For lesser output capacity, to the extent frame called pallet. No force shall be applied
of 4 500 tiles per day of 8 hcurs, crank power by the receiver to extricate the pressed tile from
press may be used. Here two moulds on either the mould, if there be any sticking, which may
side of a solid frame shall slide backward and cause drying damages.
forward on a horizontal bar and receive the top
mould moving up and down through the 7.3.2 The surplus clay adhering to the sides of
medium of a crank shaft in such a way that the pressed tile after pressing shall be scrapped
one bottom mould shall be discharging the ofi or trimmed with a sharp knife. This surplus
tile already pressed, while the second bottom clay usually called spew shall be collected and
mould shall be subjected to the process of returned to the pugmill.
pressing. When this one is withdrawn, the
first bottom mould shall come into the position -8 DRYING
to receive the top mould.
8.1 The tile pressed and trimmed as described
NOTES in 7.3.1 shall then be passed on to the drying
racks, where they shall be allowed to dry at a
1 The hp that will be required to operate this press slow and steady rate so that warping of the
will be 3.5.
tile is avoided to a great extent. This will be
2 The crank press may also be operated manually greatly influenced by the weather and climate
and the outout in such a case is about 3 000 tiles per conditions apart from the ambient temperature
day of 8 hours.
in the building where these drying racks would
be situated. Rapid drying of the green tile shall
7.2 Design and Construction of the Tile Mould not be permitted as it may show distress by
checking, cracking and crazing. The pressed
The mould shall be constructed of cast iron. tiles after being dried shall present a light grey
The size of the mould shall be decided by taking appearance before these are fed into the kiln. A
into consideration the shrinkage factor of the tile with a residual moisture content not exceed-
clay used.. The shrinkage factor of the clay ing 4-O percent by weight shall be considered
proposed to be pressed can be assessed by sufficiently drv to go into the kiln. Artificial
preliminary tests of drying and burning. The fire may be raised to heat and dry the tiles,
working surface of the moulds shall be well particularly in the monsoon times to advance
polished and smooth and when the top and the drying cycle. Indiscriminate artificial fire
bottom mould are kept in the closed position, may, however, cause heavy breakage.
the gap in between shall be suchas to produce
a uniform section tile with predetermined NOTE - Humidity dryers may also be employed for
quicker and efficient dryiug of tiles, but the schedule
configuration. of drying should be carefully selected to suit the type
of clay used for manufacture.
The mould shall be maintained in a perfect 9 KILN
condition to avoid any possible variation in the
finished size of a tile due to wear and tear of 9.1 Though there are many types of kilns, such
the metal and the dimensions of the mould as bulls, kilns, clamps, intermittent kilns, zig-
shall be checked at frequent intervals to ensure zag kilns, continuous kilns, etc, the most
that the wear of the metal is within the per- commonly adopted for substantial output,
missible limits. with comparatively economic operation and

3
IS 3978 : 1993

fuel efficiency, is a transverse or barrel arch or tiIes in the forward chambers get the benefit of
top fired straight Hoffman kiln. These kilns smoking, pre-heating and then gradually
shall be connected to a masonry chimney stack subjected to the advancing heat.
or may be operated by induced draft fans.
With the latter, control and performance of the 11.2 The fire place for starting the fire shall
kiln operation would be better as this is preferably be separate from the space kept for
independent of the influence of the atmospheric the tiles set in the kiln and there shall be
conditions. temporary arrangements to ensure that the hot
gases and fire issuing from the fire place travels
10 SETTING OR LOADING OF THE TILES through the set tiles and sole flue with an even
IN THE KILN spread.
10.1 Before setting the tiles, the floor of the kiln
shall be completely paved with burnt bricks. 11.3 It shall be ensured by a suitable operation
Construction of sole flues for the passage of dampers that the necessary draft is obtained
of the hot gases from chamber to chamber is for supplying air for burning the fuel and
an important factor to be looked into before maintaining the flow of hot gases through all
setting the tiles and this shall be maintained in the first set of chambers before exit into the
good state of repair. The arrangement of the chimney or drawn by the fan draught.
sole flue shall be such that there shall be about
10 to 12 openings, covering the entire width of 11.4 As the heat progresses more chambers with
the chamber. The green tiles shall be stacked tiles set in them shall be brought into operation
over the sole flue platform with their long axis by suitable operation of the dampers. It shall be
parallel to the ground floor. Depending upon ensured that paper baffler is also destroyed
the design, the tile shall be set face to back, before a fresh chamber is brought into the
face to face or back to back ( see Fig. 1 ). firing circuit. The process of firing and the
control of the fire travel shall be carefully
NOTE - The Hoffman continuous kilns having the regulated.
firewood feeding holes at the top of the kiln,
depending upon-the internal measurements of the
chamber, may contain 15 000 tiles between two fire 12 CONTROL OF BURNING
lines.
12.1 Fuel Feed
11 STARlING KILN FIRE
12.1.1 Fuel used for burning of tiles may be
11.1 Tiles that are fully dry shall be set in the either firewood, coal or furnace oil. The fuel
kiln for the initial firing. Once the fire shall conform to the specification of the design
advances depending upon the firing cycle, the of the kiln.

lSOLE FLUE
1 GREEN TILES LOADED OVER
FLUE PLATFORM
THE SOLE FLUE PLATFORM
WITH THEIR LONG AXIS
PARALLEL TO THE GROUND
FLOOR

ENLARGED DETAlt AT r(

FIQ. 1 TYPICALCIWS-SIGTI~N
OFCONTINUOUS
KEN SHOWYNO SE-Q op •rt~~s

4
 IS 3978 : 1993

12.1.2 The fuel shall be fed directly to the quantity of free air admitted at the back lines
chambers through the feed holes at the top, behind the firing zone, the number of feed
only when the tiles have been slowly and holes kept open behind the fire lines and the
progressively heated to about 450°C. The number of chambers under fire.
fuel shall bz fed in small quantities at regular
intervals. The feed holes shall be covered 12.3.5 Paper bathes, covering the entire width
tightly after every feed. of the chamber in front of the chamber con-
nected to the first damper opening, to arrest
,12.2 Control of Temperature and Rate of Fire the counter flow of air rushing into the area
Travel under smokirg, cvhich otherwise may affect the
fire travel and the draft shall be provided with
12.2.1 The temperature at which the tiles are care. It is preferable to use two paper baffles
to be fired may range from 800 to 900°C to ensure against any possible leakage of cold
depending upon the quality of clay. The air, should one paper baffle get torn or damaged.
temperature shall preferably be observed fre- When the fire advances, this paper will get
quently by means of suitable high temperature automatically burnt and connect the next
measuring devices and the fuel-feed and chamber to the main flue.
draft adjusted for control.
12.3.6 The wicket openings to the chambers
i2.2.2 The rate cf fire travel shall not be less shall be carefully regulated. The tiles reaching
than 40 cm/h. Operation of the dampers, a temperature of about 850°C shall not be the
setting of the tiles and empting cf the tiles shall only factor, the duration of the soaking period
keep pace with the advancing fire cycle.
shall also be considered. The tiles shall be
12.3 Draft Control subjected to longer hours of operation with
slower heat rather than to have it at a shorter
12.3.1 The draft of the kiln shall be observed time with more intense heat, though the ulti-
by suitable draft gauges at various points of the mate temperature reached may be the same in
kiln and shall be adjusted by operating, the both cases.
dampers as specified by the designer of the kiln.
12.3.7 Where there are no facilities for scienti-
12.3.2 There are five distinct and separate fic control of the kiln performance through
stages in the firing cycle, such as smoking, pre- instruments, it shall be achieved by careful
heating, firing, soaking, and cooling, to which examination of the colour of the fire and the
the tiles in the kiln shall be subjected to. The tiles in the chamber under fire and also by the
proper and efficient control of these stages will intensity of the blowing out of hot gases
greatly depend upon the technique and through the feed holes. The flexural strength
experience of the burner. and porosity of the tiles will be influenced by
the efficiency of burning of the tiles in the kiln.
NOTE - If the temperature gradient covering all the
above distir.ct stages are studied ar.d a graph drawn, 13 UNLOADING AND SORTING
it will approximately follow the familiar pattern of
a parabolic curve. 13.1 Cooling of the tiles in the kiln shall be
12.3.3 The temperature of the gases at the pre- gradual. Depending upon the designing of the
heating area shall be controlled by proper kiln, the number of chambers under fire, the fire
opening of the dampers to avoid the tiles being travel, the quality of output required, the fuel
subjected to thermal shock and the consequent used, etc, the loaded tiles, from the beginning
high breakage. it starts absorbing the heat until it is sufficiently
cooled for removal, shall be inside the kiln for
12.3.4 During the smoking and pre-heating about 74 hours.
periods, any residual moisture left in the tile
shall be slowly and steadily driven out through 13.2 Tiles shall be unloaded from the kiln
the first damper. The practice of keeping carefully and conveyed to the sorting shed
two or three dampers with varying degrees with minimum breakage.
of opening shall be adopted depending upon
the design of the kiln, the efficiency of the fan 13.3 Tiles shall then be sorted out into
or the chimney, the method of setting the tiles different classes of quality as laid down in
in the chambers the type of fuel used, the IS 654 : 1992.
 ANNEX A
( Chse 2 )

IS No. Title IS No. Title

654 : 1992 Specification for clay roofing and plastic limit ( second
tiles, mangalore pattern xetision )
( third revision )

1498 : 1970 Classification and identifica- 2720 Methods of test for soils .
tion of soils for general ( Part 21 ) : 197’7 Part 21 Determination of
engineeri’ng purposes ( first total soluble solids (jrst
revision ) revision ),

1727 : 1967 Methods uf test for poizolanic

materials ( $rst revision ) 2720 Methods of test for soik :
( Part 25 ) : 1982 Part 25 Determination of silica
2720 Methods of test for soils : sesquioxide ratio ( first
( Part 4) : 1985 Part 4 Determination of liquid revision )

; :

c
_
4

t 7
Standard Mark
The use of the Standard Mark IS governed by the provisions of the Bureau of Inah
Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark
on products covered by an Indian Standard conveys the assurance that they have been
produced to comply with the requirements of that standard under a well defined system
of inspection, testing and quality control which is devised and supervised by BIS and
operated by the producer. Standard marked products are also continuously checked by
BIS for conformity to that standard as a further safeguard. Details of conditions under
which a licence for the use of the Standard Mark may be granted to manufacturers or
producers may be obtained from the Bureau of Indian Standards.
Bureau of Indian Standards
BIS is a statutory institution established under the Bureau of Indian Standards Acr, I986 to
promote harmqnious 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 designat ions. Enquiries relating to copyright be addressed to the Director
( Publications ). RIS.

Revision 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’. Comments on this Indian Standard may be sent to BIS giving the following
reference:

Dot : No CED 30 ( 5182 )

Amendments Issued Since Publication

Amend N‘t. Date of Issue Text Affected

BUREAU OF 1NDIAN STANDARDS

Headquarters:
Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002
Telephones : 331 01 31, 331 13 75 Telegrams : Manaksanstha
( Common to all Offices )

Regional Offices : Telephone

Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg 331 01 31
NEW DELHI 110002 I 331 13 75
Eastern : I/ 14 C. 1. T. Scheme VlI M, V. 1. P. Road, Maniktola 378499, 378561
CALCUTTA 700054 I 37 86 26, 37 86 62
53 38 43, 53 16 40
Northern : SC0 445-446, Sector 35-C, CHANDIGARH 160036
I 53 23 84
235 02 16, 235 04 42
Southern : C. I. T. Campus, IV Cross Road, MADRAS 600113
E235 15 19, 235 23 15
Western : Manakalaya,
E9 MiDC, Marol, Andheri ( East ) 632 92 95, 632 78 58
BOMBAY 400093 632 78 91, 632 78 92
Branches : AHMADABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE.
FARIDABAD. GHAZIABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR.
LUCKNOW. PATNA. THIRUVANANTHAPURAM.

Printed at Printwell Printers, Aligarh. India