Free Standard provided by BIS via BSB Edge Private Limited to Bodhraj Solanki - Kota,
rajasthan(bodhrajsinghsolanki@gmail.com) 115.178.99.202 [for non-commercial use only].
(Reaffirmed 2013) 

(Reaffirmed 2012) 
(Reaffirmed 2017)
 

(Reaffirmed 2011) 

(Reaffirmed 2010) 

PATTERNMAKINGBYUSING (Reaffirmed 2009) 

EXPANDEDPOLYSTYRENEMATERIAL-  

CODEOFPRACTICE (Reaffirmed 2008) 

(First Revision )  

(Reaffirmed 2007) 

 
TCS 25.120.30 : 8X080.20
(Reaffirmed 2006) 

(Reaffirmed 2005) 

0 BIS 1998

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

September 1998 Price Croup 1

 Free Standard provided by BIS via BSB Edge Private Limited to Bodhraj Solanki - Kota,
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Foundry Sectional Committee, MTD 14

FOREWORD

This Indian Standard (First Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Foundry Sectional Committee had been approved by the Metallurgical Engineering Division Council.

This standard was first published in 198 I. While reviewing the standard, the committee decided to revise it to
align with the present practices being followed by the industry.

The use of expanded polystyrene material has progressively increased in the recent years inthe Indian foundries
for jobbing work and small batch production. The material is particularly useful for complex shapes of patterns.
This standard prescribes Code of practice for using expanded polystyrene material for pattern making and
moulding.
 Free Standard provided by BIS via BSB Edge Private Limited to Bodhraj Solanki - Kota,
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Zndian Standard
PATTERNMAKINGBYUSING
EXPANDEDPOLYSTYRENEMATERIAL-
CODEOFPRACTICE
(First Revision )
1 SCOPE
This standard describes the code of practice for pattern
making and moulding by using expanded polystyrene
material.
2 MATERIAL
2.1 Expanded polystyrene used for pattern work shall
have a density in the range of 20 kg/m3 to 30 kg/m3.
The material having density less than 20 kg/m’, being
very soft and porous, is not suitable for casting work.
In case where the pattern made in expanded
polystyrene is to be used as a gasifiable material
namely for full mould casting, its residual content
(obtained after burning at 600°C for 15 min) shall not
be more than 0.20 percent.
2.2 Expanded polystyrene is obtained in the form of
slabs in varying lengths, widths and thicknesses and
also in the form of preformed beads.
3 CODE OF PRACTICE FOR PATTERN
MAKING
3.1 Expanded polystyrene pattern may be made in
any pattern shop which can make wooden patterns. It
is easily machined with hand tools or on
wood-working machine tools. It may be sawn, sharp
knived, planed, miled or sanded using high spindle
speeds. Polystyrene sawn with an ordinary band saw
has a poor finish. Better results are obtained by cutting
with a band saw from which the teeth have been
broken off and remaining edge sharpened. It may also
be easily machined with a hot tool, more particularly
with a nichrome wire (about 0.5 to 0.8 mm diameter)
heated electrically by passing a dc current at 24 volts.
3.2 While preparing patterns, necessary allowances
are given for the metal shrinkage and machining.
When the pattern is to be used for full mould casting,
no draft is required, otherwise suitable taper shall be
given if it is required to be withdrawn from the mould
for re-use. The accuracy of the castings, as for castings
made from wooden patterns, is conditioned by the
accuracy of the patterns themselves.
3.3 The pattern may be composed of separate parts
glued together with a formaldehyde glue or any special
IS loo94 : 1998
glue which does not dissolve the plastic. The glue is
to be applied in a thin layer on the surfaces of the parts,
with a wooden spatula. Excessive adhesive may cause
defects in castings as any unburnt residue will form a
slag. Small parts of the pattern can be bonded together
immediately after the adhesive is applied but the larger
sections should be left to stand for lo-15 min after
application and then clamped together. A smooth
overall surface may be obtained further by finishing
with sand paper and by sealing the pattern joints and
odd flaws with gummed paper strip. Small fillets may
also be formed from this strip. Large fillets should be
made in polystyrene. Massive patterns may be made
hollow, to reduce gas formation.
3.4 When batch type full mould castings are to be
made, patterns may be moulded using polystyrene raw
material or prefoamed heads, by heating with steam or
hot air and water cooling in specially made metallic
moulds (see Fig. 1). Close control is required in the
process to ensure proper moulding operation. At times,
combination of all the above processes could be
adopted to get full mould patterns.
4 CODE OF PRACTICE FOR MOULDING
4.1 The moulding sand mixes used with expanded
polystyrene patterns shall be such that the need for
ramminng is minimum. Thus, no-bake or
air-hardening sand mixes based on sodium silicate or
organic compounds, like phenolics, amino plastics or
furan may be quite suitable. Fluid sand mixes may be
further advantageously used.
4.1.1 Sufficient mould permeability shall be
maintained for the gases to come out.
4.1.2 Clean dry sand may also be used with the full
mould -process because the expandable pattern
supports the sand, until it is replaced by metal.
Unbonded sand is compacted around the pattern by
gravity, by vibration, by jolting and by confining the
sand to form a rigid structure. As the pattern is replaced
by molten metals, the resulting gas pressure, the
condensed product of vaporization, and the metal
itself, all combine to support the sand and maintain the
rigid structure of the mould. Running and feeding
system may also be made of the same material.
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KS 10094 : 1998

1. Raw materia! 5. Storage bin

2. Prefoamer 6. Pattern forming machine
3. Slever 7. Pattern
4. Pneumatic conveyor 8. Getting complicated pattern by gluing

Flc.1 SCHEMATICDIAGRAM- MOULDINGOFPOLYSTYRENEPATTERNS

4.2 The dressed polystyrene pattern is set on a pattern The pouring basin is then set and the metal poured. The
plate or level floor in moulding box and fitted wifh a polystyrene gasifies as soon as the molten metal comes
polystyrene gating system, preferably having a in contact with it and escapes from the mould.
ceramic sprue. The pattern is then covered with air
hardening moulding sand and all cavities, pockets and
4.3 In full mould casting, cores are dispensed with in
the whole surface are carefully packed by hand with a
a majority of cases. If necessary, these are passed
layer of sand at least 50-75 mm thick. The rest of the
through the polystyrene pattern, the print portion
box is filled with ordinary moulding sand and rammed.
hanging out which goes into the moulding sand.
The box is then inverted and other side of the box
moulded in a similar way. Vents are pierced from top.
4.4 For small castings, top gating or parting gating
If the pattern is to be removed the boxes may be
can be used but for heavy ones, bottom gating is
opened, pattern withdrawn if possible, or chiseled out
recommended.
or burnt with a gas torch and the boxes closed again.

2
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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 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. MTD 14 ( 3974 ).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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