JSS 9330-05:2002

RAKSHA MANTRALAYA
MINISTRY OF DEFENCE

JOINT SERVICES SPECIFICATION

ON

MOULDING POWDERS, MOULDED PLASTICS (PHENOLIC)

JSS 9330-05:2002

MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN AUR POORTI VIBHAG
RAKSHA MANTRALAYA, H-BLOCK, DHQ DAK GHAR
NEW DELHI - 110 011

DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, H-BLOCK, DHQ PO
NEW DELHI - 110 011

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 JSS 9330-05:2002

LIST OF MEMBERS ASSOCIATED WITH FORMULATION OF THIS STANDARD

This Joint Services Standard has been approved by Maj Gen C.S. Barar, AVSM, Addl. DG
(WE), Chairman, Armament Standardisation Sub Committee by circulation.

2. The following members have been present/consulted in approving the document :-

Sl. Name & Designation Organisation

No.
1. - DGWE/GS(WE-2/3), Sena Bhavan
2. - Dte of Arty (GS/Arty-7), Sena Bhavan
3. - DGAS(Naval HQ)
4. - DGQA/Arm – 13, ‘H’ Block
5. - Dte of Armament and Safety Equipment
(Air HQ)
6. - DGEME (Army HQ), Sena Bhavan
.
7. Shri BP Kardam, Chief Draft man DGNAI, Naval HQ
8. Shri Jitender Kumar, SSO. 1 DGAQA, H-Block

9. Shri VD Mardikar, Dy Controller CQA(ME), Pune

10. Lt Col Balbir Singh, Offg. Dy Controller CQA(Amn), Pune
11. Lt Col HK Tiwari, Dy Controller CQA(SA), Ichapur

12. - CQA(W), Jabalpur

13. GC Adhikari, Scientist ‘E’ ARDE, Pune

14. - HEMRL, Pune

15 Shri V K Bhalekar, Works Manager AFK , Pune

16. Lt Col Narender Kumar DSC, Pune

17. Lt Col TS Virdi DSC, Ichapur
18. Shri L. Mishra, JT GM O Equpt Fy, Kanpur

19. Sh. RL Wadhwa, Secy ASSC Dte of Standardisation,

New Delhi – 110 011

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 JSS 9330-05:2002

RECORD OF AMENDMENTS

Amendment Amendment Amended by Signature

pertains to :
Authority Name & Appointment &
No. Date Sl. No./Para No./
(IN BLOCK LETTERS) Date
Column No.

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 JSS 9330-05:2002

CONTENTS

Page No.

0. FOREWORD 1

1. SCOPE 2

2. RELATED SPECIFICATIONS/DOCUMENT 2

3. DESCRIPTION 3

4. TENDER SAMPLE 3

5. PRE-INSPECTION OF STORES/CONSIGNMENT 4

6. QUALITY ASSURANCE 4

7. WARRANTY 7

8. PACKAGING 7

9. MARKING 7

10. SAFETY OF OPERATIONS 8

11. SUGGESTIONS FOR IMPROVEMENT 8

APPENDICES ‘A’ ‘B’ ‘C’ ‘D’ 9 to 12

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 JSS 9330-05:2002

0. FOREWORD

0.1 This Joint Services specification has been prepared by Armament Standardisation Sub
Committee on the authority of the Standardisation Committee, Ministry of Defence.

0.2 This specification has been approved by the Ministry of Defence and is mandatory for use by
the Defence Services.

0.3 This specification supersedes JSS 1097: Apr 1968 and new number allotted to this
specification is JSS 9330- 05.

0.4 This specification would be used for supply and quality assurance of Moulding Powders,
Moulded Plastics, (Phenolic).

0.5 Quality Assurance Authority for the item covered by this specification is the Controller,
Controllerate of Quality Assurance (Military Explosives) Aundh Road, Kirkee, Pune - 411 003.
Enquiries regarding this specification, relating to any contractual conditions shall be addressed to the
Quality Assurance Authority named in the tender or contract. Other enquiries shall be referred
to :-

The Director,
Directorate of Standardisation,
Ministry of Defence, `H' Block,
DHQ PO, New Delhi - 110 011

0.6 Copies of this specification can be obtained on payment from:-

The Director,
Directorate of Standardisation,
Standardisation Documents Centre,
Room No. J-13 ‘J’ Block,
DHQ PO, New Delhi - 110 011

0.7 This specification holds good only for the supply order for which it is issued.

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JSS 9330-05:2002

1. SCOPE

1.1 This specification is meant to govern, supply and quality assurance of Moulding Powders,
Moulding Plastics (Phenolic) suitable for preparation of moulded plastic stores for use in Armament
stores to replace parts, even metallic.

2. RELATED SPECIFICATIONS/DOCUMENT

2.1 Reference is made in this specification to: -

IS 138:1992 Ready Mixed Paint, Marking for Packages

and Petrol Containers Specification
(Third Revision)
Reaffirmed 1999 Amds 1

IS 867:1963 Methods of test for phenolic moulding materials

Reaffirmed 1991

JSG 0112:1997 General method of testing and assessment of

(Revision No. 1) impurities in chemicals/materials used in the
manufacturing of explosives and ammunition.

2.2 Copies of the Indian Standards, are obtainable on payment from: -

Bureau of Indian Standards,

Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110 002

or

their regional/branch offices.

2.3 Copies of the Joint Services Guide are obtainable on payment from: -

The Director,
Directorate of Standardisation,
Ministry of Defence
`H 'Block, DHQ PO
New Delhi-110 011.

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 JSS 9330-05:2002

3. DESCRIPTION

3.1 The Moulding materials shall consist of a synthetic resinoid derived from the reaction of
Phenol or its homologous with Formaldehyde. The uncured material suitable for feeding the mould,
shall be in powder, flake or granular form or compressed pellets or tablets and comprising a mixture
of thermosetting resin with various fillers which become hard, infusable and insoluble after being
cured by heat and pressure. The articles moulded from it shall have the required Tensile strength,
Impact strength and other desired mechanical properties.

3.2 The mouldings shall conform to the drawings quoted in the contract and shall comply in all
respects with this specification.

3.3 The powder may be supplied in appropriate type as ordered according to the end use which
shall be stated in the contract.

3.4 No other form or type of moulding composition may be used without the prior sanction of
Quality Assurance Authority.

3.5 The moulder shall not add to or mix with the moulding powder any other moulding powder,
whether it be of the same type or not, any filler or any other material whatsoever without the prior
sanction of the Quality Assurance Authority.

3.6 Types

3.6.1 The moulding material shall be classified into three types viz Type I, Type II and Type III
based on mechanical strength as given in clause 6.7.

3.6.2 The specific type (I, II or III) shall be mentioned by the purchaser in the supply order/Tender
enquiry.

4. TENDER SAMPLE

4.1 The contractor shall submit the material in its premoulding state and its moulded pieces of
stores, free of charge, when called for in the tender. Both shall be in accordance with the
requirements of this specification.

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5. PRE-INSPECTION OF STORES/CONSIGNMENT

5.1 Manufacturer/Contractor must satisfy themselves that the stores are in accordance with the
terms of the contract and fully conform to the required specification, by carrying out a thorough pre-
inspection of each lot before actually tendering the same for inspection to the Quality Assurance
Officer nominated under the terms of the contract. A declaration by the contractor that necessary pre-
inspection has been carried out on the stores tendered will be submitted along with the challan. The
declaration will also indicate the method followed in carrying out pre-inspection showing the features
checked/tested and will have the test certificate attached to the Challan/declaration.

5.2 If the Quality Assurance Officer finds that the pre-inspection of the consignment as required
above has not been carried out, the consignment is liable for rejection.

6. QUALITY ASSURANCE

6.1 Inspection

6.1.1 The Moulding material and in the case of moulded stores, the material in the pre moulding
stage and its finished stores, both shall be subject to inspection by and to the approval of the Quality
Assurance Officer/Quality Assurance Authority.

6.1.2 Samples of the required material and of the packages may be taken from any portion of the
batch/lot/consignment.

6.2 Sampling

6.2.1 Representative samples of the material in the premoulding stage and moulded stores shall be
drawn as per instruction of the Quality Assurance Authority.

6.3 Criteria for conformity

6.3.1 If, on examination, any sample be found not to conform to this specification, the whole
batch/lot/consignment may be rejected.

6.3.2 The foregoing provisions shall equally apply to the prime contractors and sub contractors, if
any.

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6.4 Testing

6.4.1 In the case of moulding materials, the finished material and its moulded test specimen made as
per Appendix ‘A’ or finished store and in the case of mouldings, the mouldings and its respings shall
be tested as given below :-

6.4.2 Testing of moulding powders (pre-moulding stage) as received.

Srl. Characteristics Requirement Test Method

No.

1. Nature of filler __ Appendix ‘B’

(organic)
Qualitative examination

6.5 Visual fillet examination of specks prepared test specimen or mouldings :

6.5.1 The mouldings shall be free from porosity, blisters, gas pockets, or any other defects and
complying in all respects with dimensions shown on the drawing. The mouldings shall be normally
black in colour, free from fillet specks, of even and smooth finish and without surface defects. The
cut section shall have a homogenous texture. Undesirable fins or flash marks shall be removed by a
method approved by the Quality Assurance Officer. Metal or other inserts shall be incorporated in the
mouldings only when shown in the drawing. Such inserts shall be incorporated thoroughly and there
shall be no pockets between insert and moulding. Screw threads shall be well and truly formed.
Where split moulds have been used in the formation of screw threads the finish shall be such that the
action of the thread is easy and free from jerkiness or undesirable looseness.

6.6 Chemical tests on moulded stores/test specimen:-

6.6.1 The rasping of the moulded stores/test specimen, passing through a 250 micrometre IS sieve
shall comply with the requirements shown below :-

6.6.2 The iron particles from the raspings shall be removed by a magnet.

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Srl. Characteristics Requirements Test Method

No.
1. Water soluble matter, per cent Max 2.0 Appendix ‘C’

2. Aqueous extract tested for

(i) Formaldehyde, per cent Max 0.05 Appendix ‘D’

(ii) Phenol, per cent Max 0.5 IS : 867 Method 15

(iii) Ammonia, per cent Max 0.02 IS : 867 Method 16

(iv) Chlorides as Sodium JSG 0112

chloride, per cent Max 0.1 Method 7 (b)

(v) Sulphates as Sodium Max 0.2 JSG 0112

sulphate, per cent Method 8

(vi) pH 5 to 8 JSG 0112

Method 5 (b)

3. Acetone soluble matter

per cent Max 6.0 IS : 867 Method 14

6.7 The moulded stores/specimen in addition shall comply with the requirements shown below :-

Srl. Characteristics Requirements Refer to

No. IS 867
Type Type Type
I II III
1 2 3 4 5 6

1. Tensile strength,
kg/cm ² , Min 400 350 350 Method No. 9

2. Izod Impact
Strength (notched), kg.m,
Min 0.03 0.05 0.07 Method No. 10

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 JSS 9330-05:2002

1 2 3 4 5 6
3. Water absorption,
mg , Max 100 100 150 Method No. 12

4. Swelling after
immersion in
water, mm , Max 0.152 0.152 0.254 -do-

7. WARRANTY

7.1 The stores supplied against the contract shall be deemed to be warranted against defective
material and performance by the contractor for a period of 12 months from the date of
receipt of the store at the consignee's end and if during this period any of the stores supplied is found
defective, the same shall be replaced by the contractor/manufacturer, supplier or contractor free of all
charges, at the consignee's premises.

8. PACKAGING

8.1 The moulding material shall be supplied in sound, clean and dry approved packages,
containing an approved quantity.

8.2 The moulded stores shall be packed and delivered as required by the store specification,
drawing or contract.

8.3 The inclusion of any foreign matter or impurities in any of the packages shall render the whole
consignment liable to rejection.

9. MARKING

9.1 All packages containing the material shall be indelibly legibly marked with the following
details as applicable :-

i) Nomenclature and specification number of the material with type.

ii) Name and address of the consignee.

iii) A/T or S.O number and date.

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JSS 9330-05:2002

iv) Consignment number

v) Lot/batch number and date of manufacture

vi) Gross and net mass.

vii) Consecutive number of package and total number of packages in the consignment.

viii) Date of supply.

ix) Contractor's initials or recognised trade mark.

9.2 In addition to the above the Quality Assurance Officer/Quality Assurance Authority may
suggest some more marking/identification considered suitable at the time of Inspection.

9.3 The paint used for marking the outer packages shall conform to IS: 138 and to the
satisfaction of the Quality Assurance Officer/Quality Assurance Authority.

10. SAFETY OF OPERATIONS

10.1 Nothing in this specification shall relieve the manufacturer / supplier / contractor / user of his
responsibility for the safety of operations in manufacture, storage, transit or use of this store.

11. SUGGESTIONS FOR IMPROVEMENT

11.1 Any suggestion for improvement in this document may be forwarded to: -

The Director,
Directorate of Standardisation,
Ministry of Defence, H Block,
DHQ PO, New Delhi -110 011.

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 JSS 9330-05:2002

APPENDIX ‘A’

A. PREPARATION OF TEST SPECIMEN

A.1 Test specimen from moulding powders shall be prepared in positive moulds with a moulding
pressure of 150kg to 480 kg per square cm and temperature between 150ºC to 170 ºC.

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JSS 9330-05:2002

APPENDIX ‘B’

B. QUALITATIVE IDENTIFICATION OF NATURE OF THE FILLERS

(Tests are to be done on the original, uncured moulding powder only).

B.1 Take a little of the Acetone extracted powder and disperse it in a little water. Take few drops
of the dispersion on microscopic slide. Dry it on a water bath. Add Standard staining solution (two
drops of Phloroglucinol in Hydrochloric acid) and observe it under microscope (100 magnification)
for colour and shape of fibre.

For wood pulp. (mechanical filler) Magenta colour; thick, short fibres having
irregular cross section like cut wood pieces.

For chemical pulp No change in colour,

(paper, rag, cotton, etc.) (i) for Cotton and rag twisted fibrous structure
(ii) for paper partly structure of wood pulp
having magenta colour and partly of cotton
fibrous structure without any colouration.

B.2 Take few drops of dispersion on another microscopic slide, dry it on a water bath and add two
drops of standard staining solution i.e. Herzberge solution (I2 and ZnC12). Note the colour change :-

For wood pulp(mechanical filler) No change in colour.

For chemical pulp. Wine red colour.

(i) Rags, cotton etc. Partly wine red and partly colourless
(ii) Paper pulp

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APPENDIX `C'

C. DETERMINATION OF WATER SOLUBLE MATTER

C.1 A weighed amount of raspings passing through a 250 micrometre IS sieve are covered with
10 times their own mass of boiling distilled water and the suspension allowed to cool naturally for
one hour with occasional shaking. The extract is then filtered by suction through a sintered glass
filter, 10 ml. of the filtered extract is evaporated and the residue dried to constant mass in a suitable
oven at a controlled temperature not exceeding 105 ºC.

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JSS 9330-05:2002

APPENDIX `D'

D. DETERMINATION OF FORMALDEHYDE

D.1 To 100 ml of the aqueous extract prepared as in Appendix 'C' above are added 5 ml of a 5 per
cent solution of Dimedone in grade 1 alcohol. A few drops of Bromophenol blue indicator are
added and sufficient dilute Hydrochloric acid is added to produce a yellow colour. Dilute Sodium
hydroxide is then added until the mixed solution is just purple and then added 50 ml of a mixture of 2
volumes of IN Sodium acetate and 1 volume of IN Hydrochloric acid.

D.2 The whole solution is allowed to stand 12 hours and is filtered on a tared sintered glass Gooch
funnel (porosity G.8), washed free from chloride with a little cold water and dried to constant mass at
60°C (Approx. 3 hours) or at 100°C. (Approx. ½ hour).

Calculation: -

Formaldehyde, per cent (CH2O)= 1.03 X M

Where M = mass of the Formaldehyde dimedone precipitate.

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