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IS 1528-7 (2010): METHODS OF SAMPLING AND PHYSICAL TESTS

FOR REFRACTORY MATERIALS, Part 7: METHODS OF SAMPLING AND
CRITERIA FOR CONFORMITY [MTD 15: Refractories]

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IS 1528 (Part 7) : 2010

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Indian Standard
METHODS OF SAMPLING AND PHYSICAL TESTS
FOR REFRACTORY MATERIALS
PART 7 METHODS OF SAMPLING AND CRITERIA FOR CONFORMITY

( Second Revision )

ICS 81.080

BIS 2010

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
May 2011

Price Group 3

Refractories Sectional Committee, MTD 15

FOREWORD
This Indian Standard (Part 7) (Second Revision) was adopted by the Bureau of Indian Standards, after the
draft finalized by the Refractories Sectional Committee had been approved by the Metallurgical Engineering
Division Council.
This standard was first published in 1962 and subsequently revised in 1974. This standard deals with the
methods of sampling and criteria for conformity. Other parts in this series are:
IS No.
Part
Part
Part
Part
Part

1
2
3
4
5

Part 6
Part
Part
Part
Part
Part

8
9
10
11
12

Part 13
Part 14
Part 15
Part
Part
Part
Part
Part
Part
Part

16
17
18
19
20
21
22

Title
Determination of pyrometric cone equivalent (PCE) or softening point
Determination of refractoriness under load
Determination of spalling resistance
Determination of cold crushing strength
Method for determination of modulus of rupture at ambient temperature of dense and
insulaitng shaped refractory products
Determination of permanent linear change after reheating for shaped insulating and dense
refractories
Determination of apparent porosity
Determination of true density
Determination of size of refractory bricks
Determination of warpage
Method for determination of bulk density and true porosity of shaped insulating refractory
products
Determination of resistance to carbon monoxide
Determination of sieve analysis
Method for determination of bulk density, apparent porosity and true porosity of dense shaped
refractory products
Determination of thermal conductivity according to hot-wire method (parallel)
Determination of cold crushing strength of shaped insulating refractory products
Determination of creep in compression
Determination of thermal expansion
Determination of modulus of rupture at elevated temperature
Determination of thermal conductivity according to hot-wire method (cross-array)
Methods for determination of permeability to gases of dense shaped refractory products

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 off numerical values (revised). The number of significant places
retained in the rounded off value should be the same as that of the specified value in this standard.

IS 1528 (Part 7) : 2010

Indian Standard
METHODS OF SAMPLING AND PHYSICAL TESTS
FOR REFRACTORY MATERIALS
PART 7 METHODS OF SAMPLING AND CRITERIA FOR CONFORMITY

( Second Revision )
1 SCOPE

IS No.
Title
(Part 3) : 1992 Determination of iron oxide,
alumina, calcium oxide and
magnesia (first revision)
(Part 4) : 1991 Determination of carbon dioxide
(first revision)
(Part 5) : 1991 Determination of chlorides (first
revision)
(Part 6) : 2001 Determination of free silica (first
revision)
4041 : 2006
Terminology for refractories (first
revision)
4905 : 1968
Methods for random sampling
12107 (Part 1) : Methods of chemical analysis of
1987
almino-silicate refractory materials:
Part 1 Determination of loss on
ignition
12667 (Part 1) : Methods of chemical analysis of
1989
chromite
sand:
Part
1
Determination of silica

This standard (Part 7) prescribes the methods of

sampling and criteria for conformity for refractory
raw materials, finished shaped refractories, mortars
and monolithics (excluding refractory castables).
2 REFERENCES
The following standards contain provisions, which
through reference in this text, constitute provisions
of this standard. At the time of publication, the
editions indicated were valid. All standards are
subject to revision and parties to agreements based
on this standard are encouraged to investigate the
possibility of applying the most recent editions of
the standards indicated below:
IS No.
2 : 1960
397 (Part 0) :
2003

1527 : 1972

1528

(Part 1) : 2010

(Part 10) : 1974

(Part 14) : 1974
1760

(Part 1) : 1991
(Part 2) : 1991

Title
Rules for rounding off numerical
values (revised)
Methods for statistical quality
control during production: Part 0
Guidelines for selection of
control charts (first revision)
Methods for chemical analysis of
high silica refractory materials
(first revision)
Methods of sampling and
physical tests for refractory
materials:
Determination of pyrometric cone
equivalent (PCE) or softening
point (third revision)
Determination
of
size
of
refractory bricks (first revision)
Determination of sieve analysis
(first revision)
Methods of chemical analysis of
limestone, dolomite and allied
materials:
Determination of loss on ignition
(first revision)
Determination of silica (first
revision)

3 TERMINOLOGY
For the purpose of this standard, the definitions
given in IS 4041 shall apply.
4 SAMPLING
4.1 The object of inspecting refractories by the
consumer is to ensure conformity to the
specification, whereas inspection done by the
manufacturer during production is to reduce quality
fluctuations to the minimum. For production control,
the manufacturer should take representative samples
of the raw material (see 4.4.1) at regular intervals to
control quality fluctuations, samples of refractories
should be tested to control quality fluctuations,
samples of refractories should be tested kiln wise or
periodically to check uniformity in firing. The
following tests are recommended for routine control
over the manufacturing process:
a) Pyrometric Cone Equivalent Test one for
each lot of individual clays as well as
mixtures;
1

IS 1528 (Part 7) : 2010

b) Screen Analysis of the Ground Mortar
once a day;
c) Moisture Content and Drying Shrinkage
once a day;

4.4.1.2 Sampling from extruders

The sample weighing about 15 kg shall be collected
by taking equal quantities of material at 5 equally
spaced intervals over the time required for
exhausting the batch of mixture being sampled from
the extruder.

d) Porosity, bulk density, CCS, true specific

gravity, warpage on finished refractories
from each kiln or periodically; and
e) Other Tests once in a month.

4.4.1.3 Sampling from mixtures

In the case of dry process, a sample of about 15 kg
shall be collected from the mixtures by taking
increments of suitable weight regularly as the
mixture is delivered to the hopper on the dry press.

4.2 For production control, use of control chart

technique is recommended to the manufacturer for
which a reference may be made to IS 397 (Part 0).
The variation in the final product can be reduced to
a large extent if suitable controls are exercised at
strategic stages of production, such as, raw material
selection, mixing (with particular emphasis on
homogenization), pressing (with proper control on
density) and firing (with uniform temperature
distribution) and so on. The results of the tests carried
out at the manufacturers end shall be made available
to the purchaser when so asked by them to judge the
deviation in the properties. However, this shall in no
way influence the acceptance otherwise of the
inspected lot when the lot conforms to the criteria
for conformity.

4.5 Sampling
Monolithics

of

Refractory

Mortar

and

4.5.1 Lot
In any consignment, all the containers/bags containing
refractory mortar or monolithics of the same type and
grade, manufactured by the same firm under similar
conditions of production shall be grouped together to
constitute a lot. The maximum weight of any lot,
however, shall be limited to 50 tonnes.
4.5.2 Number and Weight of Samples
From each lot, three containers/bags shall be so
selected at random over the whole of the lot. From
each of the containers/bags so selected, material
weighing about 1 kg shall be collected after
thorough mixing and coning and quartering for the
tests for pyrometric cone equivalent, moisture
content, sieve analysis and chemical analysis.

4.3 When such information cannot be made

available to the purchaser, or when the supply
consists of material from different kilns or the
supplier is unknown or is new; the procedure laid
down in 4.5 may be followed in the case of sampling
refractory mortars and the procedure laid down in 4.6
may be followed in the case of sampling refractory
bricks or shapes.

NOTE If the lot consists of less than three containers,

a sample of 1 kg material shall be collected from each
of the containers.

4.4 Sampling of Dry or Wet Mixture (Raw

Material)

4.6 Sampling of Finished Refractories

4.4.1 Number and Weight of Samples
4.6.1 Lot

From each batch of mixture, a sample shall be

collected as specified in 4.4.1.1, 4.4.1.2 or 4.4.1.3,
which shall be subjected to the tests of pyrometric
cone equivalent IS 1528 (Part 1), sieve analysis
IS 1528 (Part 14) and chemical analysis.

In any consignment, all the refractories of the same

type and manufactured by the same firm under
similar conditions of production shall be grouped
together to constitute a lot.
4.6.2 Size of Sample

4.4.1.1 Sampling from stacks after souring

4.6.2.1 From each lot of standard shapes or bricks, a

sample of size specified in Table 1 shall be collected
at random over the whole of the lot. For enabling the
selection of a random sample, any of the applicable
methods given in IS 4905 may be made use of. In
situations where samples are to be selected while
unloading bricks from kiln cars, systematic method
of sampling may be most appropriate. In such cases,
if N and n denote the number of bricks in the lot and
the number of bricks to be selected, respectively, the
integral part of N/n (say r) shall be computed.

The stack of mixture shall be divided into three

approximately equal parts, by suitably marking the
lines of demarcation on the surface. In each of the
parts, five points evenly distributed over the whole
surface of tile part, shall be located. From each of
the points material weighing about 1 kg shall be
collected from the surface, with the help of a
suitable scoop. The material collected at all these
points (weighing about 15 kg) shall constitute the
sample.
2

IS 1528 (Part 7) : 2010

5 CRITERIA FOR CONFORMITY

Starting from any brick, the bricks shall be counted

in one order as 1, 2,..r and so on and every rth brick
so counted shall be withdrawn till the requisite
number of bricks are obtained. Each of the bricks in
the sample so selected shall be inspected for general
requirements and tolerance on sizes.

5.1 For ascertaining the conformity of a lot of

finished refractories to the requirements of any
Indian Standard specification, the test results of the
samples drawn in accordance with 4.6 shall be made
use of in the manner described in 5.2.

In case of the palletized/cardboard packed bricks or

shapes, 5 percent pallets/cardboard packed boxes are
to be selected from a lot (see 4.6.1). The bricks or
shapes from the selected pack shall be inspected for
general requirements and tolerance on sizes. In case
of lots of special shapes and insulating bricks, the
size of such a sample shall be as agreed to between
the purchaser and the supplier. The sample sizes
given in Table 1 relate to non-destructive testing
only, that is, for finding the permissible number of
defectives and not for physical and chemical tests.
The details of the number of samples for physical and
chemical tests are given in 4.6.2.2 and these samples
shall be drawn from the samples already collected
from the lot in accordance with Table 1.

5.2 The lot of refractories sampled shall be

considered as conforming to the general
requirements and the tolerance on size laid down in
the relevant specification if the number of each type
of defective refractories (namely, those not satisfying
all the general requirements and those not satisfying
the tolerance on all the sizes) in the sample
(see 4.6.2.1) is less than or equal to the
corresponding permissible number given in Table 1.
NOTE While measuring the thickness of refractories
whose thickness is 75 mm or under, if the average
thickness of a refractory obtained in accordance with
the procedure given in IS 1528 (Part 10) is beyond the
limits laid down in the specification, the refractories in
the stack (made for measuring the thickness) shall be
individually measured for thickness in accordance with
the procedure recommended for refractories of
thickness over 75 mm, to assess the number of defective
bricks in the stack.

4.6.2.2 The number of samples to be tested for each

of the physical and chemical test requirements, and
the number of finished refractories required to prepare
the necessary test specimens shall be as follows:
Characteristic

Number of Samples
to be Tested

Refractories Required

Pyrometric cone equivalent

1 kg material from portions of bricks

left over from other tests (see Note 2)
2 (one for retest)

Refractoriness under load

Spalling resistance

3 or portions of bricks left over from

other tests (see Note 2)

Cold crushing strength

Modulus of rupture

Permanent linear change after reheating

Apparent porosity

5 or portions of bricks left over from

other tests (see Note 2)

True specific gravity and true density

3 or portions of bricks left over from

other tests (see Note 2)

Bulk density

Resistance to carbon monoxide

Chemical analysis

A composite sample from portions of

bricks left over from other tests
(see Note 2)

NOTES
1 Whenever possible portions of refractories left after certain tests may be used for preparing test specimens or samples
for other tests.
2 This should apply only when other tests are called for and not when only these tests are stipulated. The test specimens
required to be subjected to various tests shall be prepared from different refractories in accordance with the details of
test specimens given under each of the tests. The specimens meant for each test shall be tested individually.

IS 1528 (Part 7) : 2010

Table 1 Size of Sample and Permissible Number of Defective Pieces
(Clauses 4.6.2.1 and 5.2)
Sl No.

Lot Size

Sample Size

Permissible Number of Defective

Pieces
General
Requirement

(1)

(2)

(3)

(4)

Tolerance on
Size or Shaped
Bricks
(5)

i)

300 500

30

ii)

501 800

40

801 1 300

55

iii)
iv)

1 301 3 200

75

10

v)

3 201 8 000

115

14

vi)

8 001 2 2 0 0 0

150

18

NOTES
1

Above 22 000 numbers not exceeding another 22 000 will form a separate lot.

2 General requirement, iron spots, warpage, cracks, chipping, lamination, etc. For lots of size less than 300, the size
of the sample and the corresponding criteria for conformity shall be as agreed to between the purchaser and the supplier.

lot. However, if one of the test results is not

more than 10 percent of the specified
maximum, the lot shall be declared as
conforming to if the average of all the test
results is found to be equal to or less than
the maximum specification limit.

5.2.1 The criteria for conformity in the case of

apparent porosity and cold crushing strength shall
be as agreed to between the purchaser and the
manufacturer.
5.2.2 The lot sampled shall be considered as
conforming to the requirements of true specific
gravity, true density and bulk density if the test
results satisfy the following conditions:
a) Number of samples to be tested Three (5
in the case of bulk density); and
b) Criteria for conformity If all the
individual results are satisfactory, accept the
lot. However, if one of the results is,

5.2.4 The lot sampled shall be considered as

conforming to the requirements of pyrometric cone
equivalent test if the two test results satisfy the
relevant requirements of the specification.
5.2.5 The lot sampled shall be considered as
conforming to chemical requirements of the relevant
material specification if the results obtained for each
of the chemical characteristics when tested according
to IS 12107, IS 1527, IS 1760 (Parts 1 to 6)
and IS 12667. Chemical composition of material not
covered by these standards shall be done as agreed
to between the purchaser and the manufacturer.

1) When maximum limit is specified not

more than 0.01 in excess of the specified
maximum, the lot shall be accepted if the
average of all the results is equal to or
less than the maximum specification
limit; and

NOTE Alternatively XRF can be used if agreed to

between the purchaser and the manufacturer.

2) When minimum limit is specified less

than the specified minimum by not more
than 0.01, the lot shall be accepted if the
average of all the results is equal to or
more than the minimum specification
limit.

5.2.6 The lot sampled shall be considered as

conforming to the requirements of refractoriness
under load and spalling resistance if the specimens
subjected to these tests satisfy the relevant
requirements of the specification.

5.2.3 The lot sampled shall be considered as

conforming to the requirements of permanent linear
change if the test results satisfy the following
conditions:

5.2.7 In the case of spalling resistance test and the

resistance to carbon monoxide, the results of
individual test pieces shall conform to the relevant
requirements of the specification.

a) Number of samples to be tested Five; and

5.2.8 The lot sampled shall be considered as

conforming to the requirements of sieve analysis, if
the sample subjected to sieving satisfies the relevant
requirement of the specification.

b) Criteria for conformity If all the

individual results are satisfactory, accept the
4

IS 1528 (Part 7) : 2010

5.2.9 The lot shall be considered as conforming to
the expression of test result or analysis when the
results are rounded off in accordance with IS 2.

for that property, if mutually agreed between the

purchaser and the manufacturer. If all the results of
retest conform to the specifications, the lot shall be
accepted.

5.2.10 If any one of the properties does not conform

to the stipulated value, re-testing will be done only

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