Acceptable Physicochemical Properties Thin-Walled Large & Special Hand-Made

APPLICABLE TOLERANCES FOR Page: 1
No.: 19
FINISHED PRODUCTS No. of pages: 4
PHYSICOCHEMICAL PROPERTIES
DIMENSIONAL DEVIATIONS Version No.: 9
ACCEPTABLE SURFACE DEFECTS Date of issue: 2020-09-08
FIRECLAY BRICKS OF INCREASED ABRASION RESISTANCE
EXTRATON: A25s; A28Hs; A30s; A33Hs; A35S10; A35s; A40s; A30Zr; Al40s; Al42s, Al45s
1. Acceptable physicochemical properties 1) thin-walled 2) large & special 3) hand-made
Bulk density [g/cm3] - 0,05 - 0,1 - 0,15

Open porosity [%] +1 +2 +4
Cold crushing strength [MPa] - 4) - 15 - 20
Al2O3 content [pp] - 2 5)
1)
defined as the difference between the average values of the production batch and the declared values of standard shapes
2)
mechanically-formed thin-walled shapes: plates of thickness <50mm and weight <12kg, tubes, channels, funnels, rosettes, grates
3)
other mechanically-formed large and special shapes: plates and rectangular bricks of weight ≥12kg (blocks), wedges, complex shapes
(tongues&grooves, bricks with holes or cavities etc.)
4)
not applicable
5)
refers to all shapes (including standards) and results from the uncertainty of the chemical composition determination methodology
2. Acceptable dimensional tolerances <12 kg ≥12 kg hand-made

< 200 mm +/- 2 mm +/- 2 mm +/- 3 mm
201 mm ÷300 mm +/- 3 mm +/- 3 mm +/-5 mm
> 300 mm +/- 1 % +/- 1,5 % +/- 2 %
2.1 Measuring points
✓ Length L: about mid-height of the

brick.
✓ Width W: about mid-height of the
brick.
✓ Height H: halfway along the length
of the brick between the two plane
surfaces.
3. Permissible surface defects:
3.1. Corner defects
<12 kg ≥12 kg hand-made

A or B or C <15mm < 20mm < 30mm
Sum A+B+C < 45mm < 60mm < 90mm
The total permissible
length of defects: A+B+C
< 80 mm <100 mm <150 mm
Damages of less than 5 mm ( A or B or C < 5 mm) are not considered as a defects and are
allowed without restrictions.
The applicable tolerances for finished products and the acceptance criteria were developed based on international ISO standards,
industrial standards BN and Polish standard PN. In case of the absence of applicable regulatory records tolerances were based on
many years of manufacturing experience of PCO Żarów S.A.
Polska Ceramika Ogniotrwała „ŻARÓW” S.A.

ul. Hutnicza 1, 58-130 ŻARÓW (POLAND) tel. +48 74 856 26 00 fax. (+48 74) 858 04 65 e-mail: pco@pco.pl
All rights reserved. The data included on the present sheet constitute trade secrets of PCO Żarów S.A.
Copying, disclosure or transfer of data to third parties without prior written consent of PCO Żarów S.A.is strictly forbidden
P-8.2.4
No.: 19
3.2. Edge defects

A or B < 10 mm < 15 mm < 20 mm
< 1/5 < 1/4 < 1/3
Damage length C of the of the of the longest
longest size longest size size
Damages of less than 5 mm ( A or B or C < 5 mm) are not considered as a defects
and are allowed without restrictions.
3.3. Permissible surface cracks:
L ≤ 30 mm ≤ 50 mm ≤ 75 mm
L1 + L2 ≤ 30 mm ≤ 50 mm ≤ 75 mm
The width of crack: ≤ 0,2 mm ≤ 0,5 mm ≤ 0,5 mm
The depth of crack ≤ 5 mm ≤ 5 mm ≤ 7 mm
Cracks of depth ≤ 2 mm are allowed without restrictions. Hairline cracks, forming a
single grid or cracks on the surface, of a width less than 0,25 mm are allowed without
restrictions.
3.4. Melts, craters:
D = D1 + D2 ≤10 mm ≤15 mm ≤20 mm

H ≤ 5 mm ≤ 5 mm ≤ 8 mm
Superficial stains, not damaging the structure of the product, are not considered as a
defects and are allowed without restrictions.
3.5. Deformation:
Dimension H=(H1+H2)/ 2
< 200 mm ≤ 1,5 mm ≤ 2 mm ≤ 3mm

≥ 200 mm ≤ 0,75 %* ≤ 1%* ≤ 1,5 %*
*% of a diagonal length

P-8.2.4
No.: 19
3.6 Rectangularity tolerance

Dimension L ΔL
< 200 mm ≤ 1,5 mm ≤ 2 mm ≤ 3mm
≥ 200 mm ≤ 0,75 %* ≤ 1%* ≤ 1,5 %*
*% of dimension L
3.7 Tongue or Groove Defects
L - Permitted up to 20 % of the
Cracks:
length of the tongue or groove,
max 50 mm
B - Permitted up to 20 % of the
Damage:
length of the tongue or groove,
max 50 mm;
A - to a depth of 6 mm
4. Surface of the product

The surfaces of the product must be undamaged, without cracks and slag contamination. Allowed defects
are listed in point 3. Deposits from the fuel ash should not be regarded as the slag, if the texture of the
product is not destroyed.
Products with different colors are permitted if the material meets the physical and chemical properties.
5. Breakthrough, texture
Surface of the breakthrough should expose the uniform texture without layers and voids. Cracks should
not exceed the size limit for the surface of the product.
Texture defects are internal cracks, lamination and voids with lengths exceeding 20 mm or several defects
greater than 5 mm separated by a distance of less than 20 mm. Texture defects are revealed by:
1. Hammer test
2. On cut faces on bricks for sampling.
If texture defects are revealed the batch concerned shall be assessed by a sequential sampling plan as
per PN-ISO 5022 based on an AQL-6,5.

P-8.2.4
No.: 19
Isolated broken out grains shall not be regarded as texture defects

6. Sampling plan and acceptance criteria.
Single sampling plans of physical properties

in case of guaranteed value for the mean 1)
(due to p. 5.5 of PN-ISO 5022)
Sample size Total mass of batch 2)
[n] [t]
6 1
8 10
12 100
16 200
20 300
24 400
28 500
1) The table is suitable for unit masses limited to 35kg. In case of unit masses
greater than 35kg, the sample size is to be agreed upon by contracting parties.
2) This column is given only as a guide.
The sampling plan for non-destructive testing

(acc. to PN-ISO 5022 in accordance with AQL = 6,5%)
L.p. The batch size Number of samples Permitted number of
[N] [n] defective
[c]
1 2 ÷15 2 0
2 16 ÷ 50 8 1
3 51 ÷ 90 13 2
4 91 ÷ 150 20 3
5 151 ÷ 280 32 5
6 281 ÷ 500 50 7
7 501 ÷ 1 200 80 10
8 1 201 ÷ 3 200 125 14
9 > 3 200 200 21

P-8.2.4

Acceptable Physicochemical Properties Thin-Walled Large & Special Hand-Made

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APPLICABLE TOLERANCES FOR Page: 1

1. Acceptable physicochemical properties 1) thin-walled 2) large & special 3) hand-made

Bulk density [g/cm3] - 0,05 - 0,1 - 0,15

2. Acceptable dimensional tolerances <12 kg ≥12 kg hand-made

✓ Length L: about mid-height of the

3. Permissible surface defects:

3.1. Corner defects

<12 kg ≥12 kg hand-made

Polska Ceramika Ogniotrwała „ŻARÓW” S.A.

3.2. Edge defects

<12 kg ≥12 kg hand-made

3.3. Permissible surface cracks:

3.4. Melts, craters:

D = D1 + D2 ≤10 mm ≤15 mm ≤20 mm

< 200 mm ≤ 1,5 mm ≤ 2 mm ≤ 3mm

Polska Ceramika Ogniotrwała „ŻARÓW” S.A.

3.6 Rectangularity tolerance

<12 kg ≥12 kg hand-made

4. Surface of the product

Polska Ceramika Ogniotrwała „ŻARÓW” S.A.

Isolated broken out grains shall not be regarded as texture defects

Single sampling plans of physical properties

The sampling plan for non-destructive testing

Polska Ceramika Ogniotrwała „ŻARÓW” S.A.

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