proposal for “upvc windows” indian standard oct 2011 / ver 1.0 / rev 0 p a g e | 1 of 28...

Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 1 Of 28

Proposal For “uPVC Windows” Indian Standard

Windows & Doors Manufactured from

Multi-chambered un-plasticized Poly Vinyl Chloride Profiles

Released : 14th October 2011

Version : 1.0

Revision : 0


CONTENTS

Page no.

1. Foreword 3

2. Scope 3

3. Normative reference 3

4. Terminology 5

4.1 Profiles 5

4.2 6

5. Raw Materials 9

7.1 Profiles 9

6. Annexure: A- N 23-


1. FOREWORD

This is the first standard prepared to provide key parameters required for manufacturing and

testing of uPVC windows & doors.

This standard covers aspects relating to input material to uPVC windows, testing of

windows and its components, relevant process and standards.

The methods of tests are primarily based on ISO, BIS and ASTM standards.

2. Scope

This standard covers the requirements for unplasticized polyvinyl chloride (uPVC) profiles

used for fabrication of windows and doors.

The standard covers multi chambered extruded and co-extruded profiles.

3. NORMATIVE REFERENCE

This Indian Standard incorporates, by dated or undated reference, provisions from other

publications. These normative references are cited at the appropriate places in the text, and

the publications are listed hereafter. For dated references, subsequent amendments to or

revisions of any of these publications apply to this Indian standard only when incorporated

in it by amendment or revision. For undated references the latest edition of the publication

referred to applies (including amendments).

ISO 305:1990 Plastics Determination of thermal stability of poly (vinyl chloride), related chlorine-containing homopolymers and copolymers and their compounds -- Discoloration method

ISO 527 Method of testing plastics-Mechanical Properties Tensile strength, Elongation & elastic modulus ISO 178 Plastics -Determination of flexural properties (ISO 178:1993)

ISO 179-2 Plastics- Determination of Charpy impact properties- Part 2: Instrumented impact test (ISO 179-2:1997)

ISO 306 Plastics-Thermoplastic materials- Determination of Vicat softening temperature (VST) (ISO 306:1994)

ISO 8256 Plastics-Determination of tensile impact strength (ISO 8256:1990, including technical corrigendum 1:1991)


ISO 1163-2:1999 Plastics-Unplasticized polyvinyl chloride (uPVC) molding and extrusion materials Part 12: Preparation of test specimens and determination of properties (ISO 1163-2:1995) ISO 4892-1:1999 Plastics- Methods of exposure to laboratory light sources -- Part 1: General guidance ISO 4892-2:2006 Plastics-Method of exposure to laboratory light source- Part 2: Xenon arc source

ISO 291:2005 Plastics -- Standard atmospheres for conditioning and testing

4. Terminology

For the purpose of this Indian Standard, the following terms and definitions apply.

4.1 Profile

4.1.1 Main profile : Multi chambered continuous section of uPVC

Profile which has a load bearing function in the door and window. Main profiles are

broadly classified as Frame, Sash & Transom / Mullion

4.1.2 Auxiliary profile Profile, which has a reduced load bearing function within the door and window and are of supportive function. Auxiliary profiles are broadly classified as Beads, packer etc.

4.1.3 Co-extruded profile

Profile, which consist of two or more feedstock in different areas of its cross section

4.1.4 Sight Surface

Face surface of a profile that is seen from either side when the window is closed. 4.1.5 Nominal profile shape

Standard Shape and dimensions of the profile, as specified by the manufacturer

4.1.6 Deviation from straightness

This is also known as bow and is a deviation of the profile’s longitudinal axis from the straight line

4.1.7 Depth of a profile (D)


Distance between the two faces of profile which is measured at right angles to the glazing plane, (see figure 1)

4.1.8 Overall width of a profile (W)

Greatest distance, measured in the direction of the glazing plane and perpendicular to the longitudinal axis of the profile (see figure 1)

5. Profiles Raw Materials

UPVC profile is one of the major and critical input materials for windows. Detailed of the

profile requirement is elaborated in forthcoming sections.

Auxiliary profiles

Auxiliary profiles shall be similarly marked either on the profile itself or its packaging.

The marking of auxiliary profile shall contain the following minimum information • the name or trade mark of the manufacturer • reference to this Indian standard • production code sufficient to enable traceability

7.1.1 Material

Compound of uPVC in the form of granules or powder for the production of profiles for

the fabrication of windows and doors

a. Defined formulation

Stated formulation which is a controlled composition of polymer and its additives

b. Virgin Material

Material of defined formulation in granular or powder form, which has not been

processed, earlier other than required for its manufacture is virgin material. No re-

processable or recyclable material has been added.

c. Recyclable material

Own recyclable / re-processable material

D

W FIGURE 1 Sight Surface


Material of defined formulation free of contamination and degradation, made from UPVC profiles

including off cuts from own fabricator, which is re-processable in the same factory in which it was

extruded. This can be used in the extrusion process with or without additional compounding to

adjust the specified properties of material, as stated in annexure A.

External recyclable /re-processable material

Material free of contamination and degradation, made from unused uPVC window

profiles, including off cuts from other fabricators, which has been originally processed by

a manufacturer other than that carrying out reprocessing. This material shall be used in

core of a profile. Any surface or parts of surfaces which may be visible after installation of

window, fabricated from the profiles, shall be completely covered by co extrusion by

virgin material. The thickness of co extruded outer surface layer shall not be less than 0.5

mm.

This standard does not allow using external re-processable uPVC material, not made for

uPVC window & door application.

d. Composition

Profile shall be made from material/additives constituting of un-plasticized polyvinyl

chloride (uPVC).

e. Physical Properties

Un-weathered uPVC material from which profiles are made shall conform to the

requirements in Table 1 when tested in accordance with the test method specified.

Tests shall be carried out on sample cut from the visible surfaces of extruded profiles

except for the apparent modulus of elasticity test for which samples shall be tested on

pressed plaques prepared from milled sheet under the conditions specified in ISO 1163-2

Table 1 – Physical Properties of uPVC Compound

S. No.

Properties

Test Method Permissible Value

i) Vicat Softening point

ISO 306 ≥75 ° C

ii) Apparent modulus of elasticity ISO 178

≥ 2200MPa

iii) Color Fastness

ISO 4892-2 DE ≤ 5

iv) Heat Stability

ISO 182

≥30 min

v) Charpy Impact strength (milled sheet)

ISO 179

≥10 kJ/m²

vi) Retention of Charpy impact strength after artificial aging

ISO 179

≥60 % of original value


7.1.2 Requirements of profile

A. Color

This standard applies to profiles in the color range of white to cream. Annexure C defines

the applicable color range and permissible tolerance.

B. Appearance The appearance of the profile shall be the same and uniform on any surfaces and/or parts of surfaces which may be visible after installation of the window fabricated from the profile, when viewed in accordance with Annexure A The surface of the profiles shall be flat, smooth and free from pitting, impurities, cavities and other surface defects when viewed in accordance with Annexure A. The edges of the profile shall be clean and free of burr. Note1: Further arrangements with respect to appearance such as color range and tolerance on the standard color should be made between the customer and the manufacturer and are not part of this standard (see Annexure C). Note 2: Extrusion lines, pitting, impurities, cavities & other surface defects caused by the process are admissible so long as they are not visually intrusive from 1m.

C. Dimensions and tolerances

C.1 Shape The cross section, perpendicular to longitudinal axis, shall conform to the nominal shape of profile.

The tolerances of the external dimensions of the profile (see figure 1) with respect to the nominal profile shape shall be in accordance with table 2.

Table 2 - Tolérances on external dimensions

All Dimensions in mm

External dimension Tolerance Diagram for Example Depth (D) ≤ 80 > 80

± 0.3

± 0.5

Overall width (W) All overall profile dimensions shall be subject to a tolerance of ± 0.5 mm

±0.5


Wall Thickness Sight & non-sight surface wall thickness ≥ 2.0mm

± 10 %

.

Sight surface flatness The difference between the maximum & minimum readings across the face

0.3 mm max

Squareness The sight surface of outer frame profile & its base shall be perpendicular to each other

0.3 mm max

Parallelism The sight surfaces of sash profile shall be parallel to each other

0.4 mm max

The determinations of external dimensions is in accordance with Annexure A

C.2 Thickness of profile

Wall thickness of sight surfaces shall be uniform and determined in accordance with Annexure A. The min wall thickness of sight surface should be 2.0 ± 10%

C.3 Other dimensions

The dimensions of profile other than the thickness of external walls as well as their tolerances shall be specified by the manufacturer.

C.4 Straightness of profiles

For main profiles like outer frame, transom and sash, the deviation from straightness measured in accordance with Annexure A shall not be > 1 mm for a length of 1m (table 2) For auxiliary profiles like, glazing beads, decorative profiles, parkers etc., the deviation from straightness measured in accordance with Annexure A shall be specified by the manufacturer.


D. Mass of profiles

When measured in accordance with Annexure A the mass per m length of profile shall not be < 95 % of the nominal mass per m length specified by supplier.

E. Heat reversion

E.1 Main profile

When tested in accordance with Annexure I for each test specimen, the heat reversion of the two largest opposing sight surfaces shall not be > 2.0 % The difference in heat reversion for each test specimen between these sight surfaces shall not be >0.4 %

E.2 Auxiliary profiles

When tested in accordance with Annexure I, the heat reversion for each test specimen shall not be > 3.0 %

F. Resistance to impact of main profiles by falling mass

When tested in accordance with Annex E, there shall be no crack of the surface of test specimen when subjected to free wall of mass from height of 1m. No more than one test specimen shall show rupture in the wall. For co extruded profiles the de-lamination of the co extruded layer is also considered as failure.

G. Heat Aging Behavior at 150°C

When tested in accordance with Annex F, the profiles shall show no defects as blisters, cracks, surface peel off. For co extruded profiles the de-lamination of the co extruded layer is also considered as failure.

H. Resistance to weathering

H.1 Exposure procedure

Test specimen (refer ISO 4892-1) taken from sight surfaces of main profiles shall be exposed accordance with ISO 4892-2, Method A, for a time period of 6000 hr. Calculation of exposure hours representing five years outdoor weathering is given in Annexure D. Note: For quality control purpose the time period can be decreased to representing two years out door exposure.

H.2 Impact strength after artificial weathering


After exposure in accordance with H.1 the reduction in impact strength expressed as a percentage of the impact strength of the unexposed test specimen and the exposed test specimen shall not be > 40% The determination of the impact strength is in accordance with ISO 179. Note: The value of 40 % is tentative and subjected to the results of current research.

H.3 Color fastness

After exposure in accordance with H.1, the change in color between the unexposed and exposed test specimens expressed in Δ E* shall not be > 5 and Δ b* not > 3. Note: The visual change in color can be determined using the methods specified in ISO 7724-1, ISO 7724-2, and ISO 7724-3

I. Weld ability

For the determination of the Weldability of profiles, welded corners are tested in accordance with Annex G. The calculated mean stress at maximum load of each corner, σ t or σ c, shall not be < 25 N/mm² for the tensile bending test and not be < 30 N/mm² for the compression bending strength. σ t = the failure stress by tensile bending (N/mm²) σ c = the failure stress by compression bending (N/mm²) The sample subjected to weld test shall not be finished by grooving, knifing etc, except for the outside edge of 90° angle, which shall be cleaned to permit the sample to sit fully onto the support.

J. Marking

Main profiles

Main profiles shall be legibly and visibly marked in an unobtrusive position not visible when the window is closed at least once in every 1 m along the length of the profile.

The marking of the main profiles shall contain the following minimum information

• the name or trade mark of the manufacturer • reference to this Indian standard • Production code sufficient to enable traceability (e.g. Date, machine, and/or shift

no.) • Example ABC LTD –IS xxxx- Date-M/C-Shift

Optional additional information contained within the mark may include:

• Profile type/code


Table -3 provides guidelines on the test requirements of profiles

Table-3

Sr no

Characteristics Method of test Requirement as per section

i) Appearance

Annexure A 7.B

ii) Dimensions & straightness

Annexure A 7.C

iii) Mass of profile

Annexure A 7.D

iv) Heat Reversion

Annexure I 7.E

v) Heat aging

Annexure F 7.G

vi) Resistance to impact

Annexure E 7.F

vii) Color Fastness

ISO 4892-2 7.H

viii) Weld ability

Annexure G 7.I

Annexure - A Test Methods for uPVC Profiles

A.1 Determination of the appearance

The appearance is determined by viewing by normal or corrected vision at a range of 1m, at 45° north sky light.

A.2 Determination of dimensions

Measuring devices The measuring devices for the determination of the external dimensions and the wall thickness shall have an accuracy of 0.05 mm and for the deviation from the straightness shall have an accuracy of 0.1 mm

Test specimen For the determination of the deviation from straightness the length of the profile to be tested shall be 1000 ±5mm & for dimension measurement sample size shall be 300 ± 5 mm. In case of dimension measurement on optical instruments, suitable sample size shall be taken for measurement of dimension.

Conditioning Condition the test specimen at 27± 2°C for at least 1 hour prior to testing

Procedure Dimensions and wall thicknesses Dimensions and wall thicknesses shall be measured with precision equipments (e.g. Vernier Caliper, Projector, Scanner) having minimum accuracy of 0.05 mm as per standard operating procedure of the equipment.


Deviation from straightness Put the test specimen on flat surface (e.g. Surface table). Measure the gap(s) between the profile and the flat base with an appropriate measuring device (e.g. Distance gauges, filler gauge).Rotate the sample in 90 ° and again check the gap(s). Report the maximum gap observed between profile and flat surface.

A.3 Determination of the profile mass

Apparatus Balance with accuracy of 1 gm Use Measuring device with an accuracy of 0.5 mm for the determination of the profile length. Test specimen The length of the profile to be tested shall be 200 mm to 300 mm Conditioning Condition the profiles before measuring at 27 ± 2 °C for at least 1 hour. Procedure Measure the length of the test specimen to 1mm, weigh the test specimen to 1 gm. Determine the mass per length expressed in Kilogram per meter (Kg/m).

Annexure B

Material characteristics- Sample preparation and requirements 1) Scope It covers sample preparation from uPVC profiles or from granules or powder for the determination of the characteristics and the requirements for those characteristics.

2) Terminology Material: Compound mix with PVC and suitable additive to facilitate processing and to give the desired properties to end product.

3) Material properties

B.3.1 Vicat softening temperature

When tested in accordance with ISO 306 using method B with temperature rate of 50 ± 5 °C /h the Vicat Softening Temperature (VST) shall not be< 75 °C

For non co extruded profiles the test specimens shall be taken directly from the profiles or from pressed plaques

For Co extruded profiles the test specimens shall be taken directly from pressed plaques made from materials separately

In case of dispute the test on pressed plaques is the reference method.


B.3.2 Charpy Impact strength

When tested in accordance with ISO 179-2 at 27± 2°C with method designation 1eA the Charpy impact strength shall not be <10 KJ/m²

For non co extruded profiles the test specimens shall be taken from pressed plaques.

For co extruded profiles the test specimens shall be taken from pressed plaques made from both materials separately. In case of dispute the test on pressed plaques is the reference method.

B.3.3 Flexural modulus of elasticity

When tested at 27 ± 2 °C in accordance with ISO 178 the flexural modulus of elasticity (Eb) shall not be <2200 N/mm²

For non co extruded profiles the test specimens shall be taken directly from the profiles or from the pressed plaques.

For co extruded profiles the test specimens shall be taken from pressed plaques made from both materials separately. In case of dispute the test on pressed plaques is the reference method.

B.3.4 Test specimen

The test specimens for the determination of the material characteristics according A.3 shall be taken either from profiles or from pressed plaques.

B.3.5 Preparation of pressed plaques The preparation of the pressed plaques shall be in accordance with the procedure given in clause 3 of ISO 1163-2:1999 and with the following

• the material used shall be shredded extruded uPVC profiles, granules or powder materials

• the differential speed between the two rolls of mixing mill shall be within the range 1:1.4 to 1:1.1

• the pressed plaque shall have a thickness of 4± 0.2 mm • the cooling of the plaque given in accordance 3.3.3 of ISO 1163-2:1999 shall be at

nominal rate 15 K/min

B.3.6 Test report The test report shall include the following information;

• reference to this annex • details of the test specimen • Standard for the Charpy impact strength • values obtained


Annexure C Color range & Permissible tolerance

C.1 Scope This gives an advice on applicable color range and permissible tolerance. C.2 Applicable color range and Permissible tolerances on standard color

The standard is applicable to uPVC profiles of following colour

L* ≥ 82 (chromaticity co-ordinate Y>=60)

-2.5 ≤ a* ≤5

-5 ≤ b*≤15

When determined according to ISO 7724-3 with the apparatus according to ISO 7724-1 and ISO 7724-2 with the following specifications:

• employing CIE standard illuminant D65 including specular reflectance; • measuring condition 8/d or d/8 (without gloss trap for both)

It is advisable that no profile should have a difference in colour to the standard colour more than the following

Δ L* <= 1.0 Δ a* <= 0.5 Δ b* <= 0.8 Δ E* <= 1.0

The colour of profiles used in an assembled window shall be uniform and consistent when viewed by normal or corrected vision at a range of 1 m in 45° north sky light. Note: the perception of colour on installed window is affected by orientation, ambient light, length of time after installation and other factors.


Annexure D The radiation dose and exposure time to be used for artificial weathering

D.1 Scope This describes duration of the exposure needed to assess resistance to artificial weathering. D.2 Calculation D.2.1 For the purpose of calculation the following assumption is made on the solar energy

for sever climate like India has, the amount of annual solar energy is estimated to be between 5 – 8 GJ/m²/year.

D.2.2 For usual practice in artificial weathering, it is necessary to consider solar radiation

energy falling in the ultraviolet and visible regions between 300nm to 800 nm. This is about 60% of the total solar radiation energy. A further correction factor of 67% is applied to allow for the fact, that not all this radiation is acting at higher summer temperature and so will be less damaging to the effected surfaces.

For testing purpose, it is recommended to use 6 GJ/m²/year radiation doses for the wavelength range between 300 nm to 800 nm given in table 1

Table 1 GJ/m²

1 year’s equivalent 2.4 5 year’s equivalent 12.0

D.2.3 For an artificial weathering device having a time average irradiance (I) of w/m² in

the range 300nm to 800 nm the exposure time are given in table 2

Table 2 Recommended exposure times for the wavelength range 300nm to 800 nm

Where I = 550 W/m². This means for 5 year’s equivalent radiation, minimum 6000 hours exposure time is needed for Indian climatic Condition.

Note: This calculation method represents only approximate means of estimation. However it does put the requirements on some sort of logical basis bearing in mind that natural weathering itself is a variable phenomenon depending on location, aspect, shading etc.

D.3 Assessments of colour difference: The change during exposure of the test piece from their initial color or the difference between the test pieces and an unexposed reference piece shall be measured periodically after weathering for approximately 24 h, 250h, 1000 h, 3000 h and 6000 hr. The samples are measured after 24 hr removal from exposure and inspected visually and surface erosion noted.

hours

1 year’s equivalent 6.6 x100000/I

5 year’s equivalent 3.3x 1000000/I


Annexure E Resistance to impact of main profiles by falling mass

E.1 Scope

This standard specifies a method for the determination of the resistance to impact by a falling mass at -10 °C (minus ten degree Celsius) of Unplasticized poly vinyl chloride (uPVC) main profiles for the fabrication of windows and doors for the assessment of the extrusion.

E.2 Principle Test pieces cut from length of main profiles are subject to blow from a mass falling from a known height on the sight surface at a mid way between two supporting webs at a fixed temperature. After testing the profiles are examined visually for failures.

E.3 Definitions For the purpose of this Indian Standards following definitions apply:

E.4.1 main profiles

Profile having load bearing function in the door and window. Main profiles are broadly classified as follows;

Outer Frame: Profile used to make door and window and which is fixed to the wall / structure. Sash: profile used to make openable panel Transom: profile used within the frame vertically or horizontally

E.4.2 sight surface

A face surface of a profile that is exposed to view from either side , when the window or door is closed.

E.4.3 Web

A membrane connecting two walls of a profile.

E.4 Apparatus An impact testing machine incorporating the following basic components (see figure 1) shall be used: E.4.1 main frames, rigidly fixed in the vertical position E.4.2 guide rails, fixed to main frame to accommodate the falling mass and allowing

it to fall freely in the vertical plane E.4.3 Test piece support, consisting of a rounded off support With a distance

between (200 ± 1) mm. The support shall be made from Steel rigidly fixed in a solid foundation or on a table with a mass of more than 50 kg

E.4.4 release mechanism, such that the falling mass can fall through a height which can he adjusted up to (1500 +100 / -0) mm, measured from the top surface of the test piece to be tested;


E.4.5 Falling mass, of (1000±5) gm, this has a hemispherical striking surface of (25 ±0.5) mm radius. The striking surface shall be free from all imperfections.

E.5 Test pieces

Ten test pieces, each of length of 300 mm shall be taken from a main profile.

E.6 Conditioning

The test pieces shall be conditioned at a temperature of -10 + 0/-2 °C for at least 1 hr before testing. Each test piece shall be tested within 10 Seconds of removal from the conditioning chamber.

E.7 Procedure The test shall be executed on sight surface of the main profile (preferably on the sight surface which is designed to be exposed to the weather). Drop the falling mass from a given height as required in the product standard at a point mid way between two supporting webs. Note 1: wherever it is impracticable for the mass to hit the profile in accordance with 7.2 due to its geometry other impact position for the falling mass should be agreed upon between the profile manufacturer and testing laboratory.

Figure 1 – Impact Test Apparatus


Annexure F Heat Aging Behavior at 150°C

F.1 Scope

This standard specifies two methods for the determination of the effect of heat on unplasticized poly vinyl chloride (uPVC) profiles for the fabrication of windows and doors. The oven method is considered as the reference method.

F.2 Principle A test piece of a specified length of profile is maintained in an oven or liquid bath at 150 °C for 30 min. and is inspected visually on the inside, outside and the cross section of the wall for defects after heating.

F.3 F.3 Definition For the purpose of this Indian standard the following definition applies Defect: The visual appearance of blisters, cavities, or crack on any of the surfaces (inner or outer) of the profile and of any delamination in the cross section.

F.4 Apparatus

F.4.1 Ventilated oven, thermostatically controlled, with air circulation, in which the test pieces can e exposed to a temp. of 150 °C. The oven shall be equipped with a thermo stat capable of maintaining the temperature at 150 ± 2 °C. The capacity of the oven shall be such that, after insertion of the test piece, the test temp. is regained with in 15 min.

F.4.2 Liquid bath, thermostatically controlled, in which the test pieces can be exposed to a

temp. of 150 °C. The capacity of the bath shall be such that after insertion of the test piece, the test temp. is regained with in 5 min. The liquid to be used shall be glycerin or an aromatic free hydro-carbon. This liquid shall be free of substances which may affect the properties of uPVC

F.4.3 Thermometer, graduated in 0.5 °C

F.5 Test Piece The test piece shall be as follows: F.5.1 for testing in oven, a minimum length of 200 mm profile F.5.2 for testing in liquid bath, a minimum length of 300 mm of profile

F.6 Test Procedure F.6.1 Oven method

a. Set the oven temp. to 150 °C

b. When the oven has reached 150 °C, place the test piece horizontally in oven.


c. Maintain the test piece in the oven for 30 + 3 / -0 min, measuring

from the time when the oven temp has returned to 150 °C

d. Remove the test piece from the oven, taking care not to distort or otherwise damage it

e. Allow the test piece to cool in air. When the test piece is cool

enough for handling, examine it for defects. F.6.2 Liquid bath method

a. Set the liquid bath temperature to 150 °C

b. When the liquid bath has reached 150 °C, hang the test piece vertically in the test liquid, so that the upper part does not protrude more than 100 mm out of the fluid. The means of suspending a test piece shall be such that it does not touch either the floor or wall of the bath.

c. Keep the test pieces in the liquid bath for 30 +3/-0 min. measuring

from the time when the liquid bath temp. has returned to 150 °C

d. Remove the test piece from the bath, taking care not to distort or otherwise damage it.

e. Allow the test piece to cool in air. When the test piece is cool enough for

handling examine it for defects.

F.7 Expression of results The nature and the location of any defects shall be noted

F.8 Test report

The test report shall include the following information:

a. reference to this Indian Standard; b. the test laboratory; c. full identification of profile; d. the date of testing e. the apparatus used and for the liquid bath method, the type of liquid f. the result of the examination of the test piece; g. all operating details not specified in this Indian standard, as well as any

incidents likely to have influence the results When tested with surface covered profiles shall show no bubbles between the acrylic layer and the foil of more than 1 mm, cracks, surface irregularities or delamitation. Note: There is no requirement for the flexible element of rigid and flexible co-extrusion. An increase

in gloss does not constitute failure


Annexure G Determination of the strength of welded corners and T joints

G.1 Scope This annexure specifies two test methods for the measurement of the failure load of welded corners and T joints made from unplasticized poly vinyl chloride (uPVC) profile for the fabrication of windows and doors.

G.2 Definitions Failure load: That load at which yield occurs or if yield does not occur, the load at which the test piece breaks.

G.3 Principle Welded corners and T joints made from unplasticized poly vinyl chloride (uPVC) profiles are subjected to a tensile bending or compression bending test at specified temperature and test speed. The failure load is recorded and the failure stress is calculated.

G.4 Apparatus G.5.1 Tensile or compression testing machine with the following specifications;

a. measuring range of load :2kN to 20 kN; b. load indication with zero point setting and peak recording c. measurement accuracy:±3% d. test speed: 50 ± 5 mm/min

G.5.2 Test arrangement

a. Corner weld sample for tensile bending test (see figure 1) b. T joint weld samples for tensile bending test (see figure 2) c. Corner weld sample for compression bending test (see figure 3) d. T joint weld samples for compression bending test (see figure 4)


1

3

4

1 Clamping device2 Rigid support over a minimum clamping length of 400mm3 Frame4 Optional support block (5 +/- 0.5) mm

F1

1

3

4

1 Clamping device2 Rigid support over a minimum clamping length of 400mm3 Frame4 Optional support block (5 +/- 0.5) mm

F1

Figure 1- Weld Test Apparatus Figure 2 : T Arragement

Fc

Figure 3


Fc

Figure 4

G.5 Test piece G.5.1 Welding of corner test piece The test piece is a welded corner with as angle of 90 ± 1°C.Two lengths of profile cut at 45 ° are heat welded G.5.2 Welding of T joint test pieces The test piece is welded T joint with an angle of 90±1°.The joint is fabricated by heat welding one piece of ,for instance, sash or outer frame profile at least 500 mm long and one piece of ,for instance, transom profile at least 400 mm long. Before welding the sash or outer frame profile is notched at 2 x 45 °C to depth in Accordance with the formula: 0.5 x (w-s) ,

Where, w= width of transom profile s= welded head stroke The transom profile end is sawn into a symmetrical 90° point. The position of the 90° notch in the sash or frame is such as to leave a minimum 400 mm leg measured from the top of the transom profile(see figure 2)


G.5.3 Tensile bending test piece

a. The inside leg length of the test piece for the corner testing shall be at least 400 mm (see figure 1)

b. The T joint test piece is fabricated with the sash or frame arms of inside length at

least 400 mm and 100 mm, and the transom or mullion stem length at least 400 mm (see figure 2)

G.5.4 Compression bending test piece The legs of the corner test piece are cut at an angle of 45± 1 ° in such a way that the neutral axes of the end sections are located vertically over the axes of rotation of the carriage (approximately the middle of the main chamber of the profile (see figure3).The inside length of the leg Li in millimeters is obtained from the following formula Li = Ln -2e Ln = 400 = 283

√2 Li = 283 -2e Where Ln, the length of the neutral axis of the profile in millimeters E, the distance between the inside of the section and the neutral axis in millimeter The short arm of the T joint test piece is cut off level with the outer face of the stem to produce a 90° corner. Further preparation of the corner is accordance with 5.4.1 G.5.5 Tensile bending test piece A minimum of three samples per profile type, all made on the same welder head, shall be tested to obtain a mean value

G.6 Conditioning The test pieces shall be conditioned at 27±5 °c for at least two hours immediately prior to testing

G.7 Procedure Test temperature The test is carried out at a temperature of 27±5 °C G.7.1 Tensile bending test


Clamp the test piece in the apparatus as shown in figures 1 or 2.Contoured support block may be used, if necessary, to limit twisting. Apply the load to the test piece in such a way that the speed of application is 50 mm / min. Continue until the test piece fails. G.7.2 Compression bending test Place the test piece on the trolley as shown in figures 3 or 4.In order to avoid excessive deflection, the open frame end of the T joint can be supported in the corner area by inserting a cavity filling block(e.g. a piece of metal reinforcement or wooden block). Apply the load to the test piece in such a way that the speed of application is 50 mm/min. Continue until the test piece fails

G.8 Test Report The test report shall include the following information: a. reference to this standard; b. the name of the test laboratory; c. full identification of the joint 1. the type of joint (corner or T joint) 2. the presence or absence of welding sprue (bead) 3. if more than one welding head is in use, the nominated head; e. the date of testing; f. the welding conditions; g. the test method(tensile bending or compression bending) h. for compression bending testing the inside length of the leg of the test piece; i. the test temperature; j. the failure load of every test piece; k. the calculated failure stress for every test piece and the average failure stress l. all operating details not specified in this standard, as well as any incidents likely to have influence the result


Annexure H Method for calculation of failure stress

H.1 Tensile Bending test

The failure stress of welded corner or T joint depends on the failure load, he profile geometry and the test arrangement (see fig.1 or 2).It is calculated by the formula; σt= (L-Ft) / W

Where: Ft = the failure load determined by tensile bending testing (N) L = the distance between the corner in the highest flange and the point of application of the Load (mm) W = the moment of resistance in the loading direction = l/e (mm³) l= the moment of inertia about the neutral axis ZZ’ (see figure A.1) of the cross section of the profile given by the manufacturer, for T joints with different profiles, the lower moment of inertia shall be used. e = the distance between the critical point A and the neutral axis ZZ’ (see figure A.1 (mm)

σt = the failure stress by tensile bending

H.2 Compression bending test The failure stress of a welded corner or T joint depends on the failure load, the profile geometry and the test arrangement (see figure 3 or 4).It is calculated by the formula:

σc= Fc [(a/2 – e / √2) / 2W]

Where: Fc = the compression bending failure load (N) W = the moment of resistance in the loading direction = l/e (mm³) l= the moment of inertia about the neutral axis ZZ’ (see figure A.1) of the cross section of the profile given by the manufacturer mm4, for T joints with different profiles, the lower moment of inertia shall be used. e = the distance between the critical point A and the neutral axis ZZ’ (see figure A.1 (mm) a = the distance between the axes of rotation of the carriages = (400 ± 2) mm

σc = the failure stress by compression bending (N/mm²) Z-Z’ = neutral axis A = points of maximum stress

AA

Z Z'

Direction of loading

Figure H1: Position of point of maximum bending stress


Annexure I Heat Reversion Test

I.1 Scope

This describes the method of conducting heat reversion test on uPVC profile. I.2 Principle Lengths of profile are heated in an oven and reduction in length is measured. I.3 Apparatus I.3.1 Thermostatically controlled electrically heated air oven, with circulating fan, the

whole interior of which is controlled at a temperature of 100 ± 2 °C. The heating capacity shall be such that after insertion of the test pieces the test temperature is regained in within 15 minutes.

I.3.2 Talc dusted or non stick coated stainless steel plate ,not exceeding 2 mm

thickness

I.3.3 Fine felt tip pen

I.3.4 Measuring device, capable of reading to an accuracy of at least 0.1 mm

I.4 Test Pieces Three test pieces, 220 mm approx long, shall be taken for each profile. On each Visible surface of the profile samples, lines shall be drawn across the face 20 mm from each ends of the sample.

I.5 Conditioning The test shall be conditioned at 27 ± 1°C for at lest 30 min. prior to testing. I.6 Procedure I.6.1 Measure the distance between the mid points of the lines on each face within ±

0.1 mm I.6.2 Place the sample horizontally in the oven in apposition that will ensure the

minimum contact with the talc dusted / non stick coated plate.

Note 1: This part of the process is very important to ensure accuracy & consistency. It is recommended that drawing or the sketches are produced which shows the point contacts so that the

test is carried out in the same way every time. I.6.3 Heat for 60 +5 / - 0 min. at 100 ± 2 ° C. The test time shall commence when the

100±2 °C temperature is regained. I.6.4 Remove the plate with the sample and allow it to cool at room temp. until the

profile surface temperature has reached 27 ± 1 °C, exercising care in handling.


I.6.5 Measure the distance between the mid points of the lines on each face and calculate the reversion as follows:

% reversion = measured distance x 100

Original measurement length I.6.6 Record the individual values of each face of each of the three samples and

calculate the mean reversion for each of the three samples in accordance with the requirement in 5.4

Note 2: The measurement should be made along the chord of the curved sample and not along the

centerline of the sample.

The main profiles tested shall have a mean reversion up to 2% and there shall not be more than a 0.4% difference between two faces. Note: for ancillary profiles there is no requirement for difference of individual surfaces. The use of dark external glazing bead or ancillary profiles necessitates lower reversion.


Bibliography

EN 12608 Unplasticized Poly Vinyl Chloride (uPVC) profiles for the fabrication of windows and doors – Classification, requirements and test methods BS 7413 Unplasticized Poly Vinyl Chloride (uPVC) profiles for windows and doors - Specifications ASTM D Standard specification for Rigid Poly Vinyl Chloride (PVC) exterior 4726 profile extrusions used for assembled windows and doors ASTM D Standard practice for Xenon Arc exposure of plastics intended for 2565-99 out door applications AAMA 303 Voluntary Specification for rigid Poly Vinyl Chloride (PVC) exterior profiles (American Architectural Manufacturers Association) EN 477 Determination of the resistance to impact of main profiles by falling mass EN 478 Determination of appearance after exposure at 150 °C EN 479 Determination of heat reversion EN 514 Determination of the strength of welded corners & T joints EN 513 Determination of the resistance to artificial weathering

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