uPVC Windows Indian Standard

Proposal For “uPVC Windows” Indian Standard

Windows & Doors Manufactured from
Multi-chambered un-plasticized Poly Vinyl Chloride Profiles

Released Version Revision

: 14th October 2011 : 1.0 : 1.0 Feb 1, 2012

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CONTENTS Page no. 1. 2. 3. 4. Foreword Scope Normative reference Terminology 4.1 Profiles 4.2 Windows 5. Abbreviation of types of window and doors 5.1 Abbreviations for design and style 5.2 Opening representation on drawing 6. Function requirement of uPVC Window 7. Raw Materials 7.1 Profiles 7.2 Reinforcement 7.3 Gasket 7.4 Hardware 7.5 Glass 8. Welds & Mechanical Joints 9. Window Construction 9.1 Drainage & Pressure equalization 9.2 Glass Glazing 9.3 Glazing Bead 9.4 Installation packers 9.5 Location of Fixing points 9.6 Fixing / Filling material 10. Testing of Windows 10.1 Air permeability test 10.2 Water tightness under static pressure 10.3 Wind resistance test 11. Marking of windows 12. Annexure: A- N 3 3 3 5 5 6 7 7 9 9 9 9 15 16 16 16 16 17 17 18 19 19 20 20 20 20 21 21 22 23-55

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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 The standard mentioned in this proposal specifies the requirements for the windows and doors made out of multi chamber uPVC profile and its accessories. The proposal includes the window requirements and test methods for windows.

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)

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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 IS 4020 (PART-2) – 1994 Determination of squareness at welded joints of the profile. IS 4020 (PART-7) – 1994 Determination deflection due to load applied on the edges. IS 4020 (PART-8) – 1994 Determination of shock resistance of fixings, fastenings and hangings in the window. IS 4020 (PART 11) – 1994 Determination of any deformation of parts, hindering the normal working of the shutter. IS 277:2003 Determination of the standard of galvanized steel sections used as reinforcement in UPVC profiles. ISO 9227:2006 Determination of salt spray test on reinforcement steel ISO 7619 -1: 2000 Determination of Shore hardness of EPDM gasket. ISO 527-2:1993 Determination of tensile strength of EPDM gasket. ISO 815-2:2008 Determination of compression of EPDM gasket ISO 9227:2006 Determination of window fittings when subjected to salt spray test. ISO 6613:1980 Testing of air permeability of windows. ISO 15821: 2007 Testing of water tightness under dynamic pressure for doors and windows. ISO 6612 - 1980 Determination of wind resistance in windows. Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 4 Of 56

ISO 15099: 2003 Method of calculating U-value of the window. ISO 10077-1:2007 Method of calculating U-value of the Window ISO 12567 – 1 Thermal Performance of Windows & Doors – Determination of Thermal Transmittance by hot box method – Part 1: Complete Windows & Doors

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) Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 5 Of 56

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

FIGURE 1

W

Sight Surface

4.2

Windows 4.2.1 Casement Framed opening window that is hinged or pivoted.

D

4.2.2 Window Fastening Component that is used to secure a completed window assembly into the structure of a building. 4.2.3 Glazing gasket EPDM (or TPE) used between the glass and the frame and/or the glass and glazing bead. 4.2.4 Window Hardware Any fitting attached to the window, which is used to operate and/ or secure it. 4.2.5 Multi – Window (bay / coupled) Window incorporating more than one opening and/or fixed within one perimeter frame coupled with members to form single entity in straight or angled. 4.2.6 Frame It is the non-movable or fixed portion of the window attached to the wall and the sash is assembled to it. 4.2.7 Sash Opening part in the window / door. 4.2.8 Glazing Bead Profile which holds the glass or other partition material (e.g. board) in door and window profile section 4.2.9 Transom / Mullion Is a profile used within the frame, vertically or horizontally in and / or frame / sash. 4.2.10 Switch barrier Device that prevents a tilt and turn window from engaging in the tilt mode and the turn mode at the same time Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 6 Of 56

4.2.11 Friction stays or Hinges Device which assembled in the windows / doors frame and sash, enables the movement of sash in the window / door frame. 4.2.12 Weather pile strip Strip designed to reduce air infiltration and water penetration. 4.2.13 Reinforcement The GI steel section or other material placed inside or coextruded to provide strength to the uPVC profile section. In case of steel section, the same should be placed in a separate chamber in the profile. 4.2.14 Wind load Peak wind pressure that can be expected on a surface of a building window or component. Relevant Standards applicable for the same should be referred. 4.2.15 Ventilation Device Ventilator other than opening light incorporated in a window or door 4.2.16 Water Penetration Continuous or repeated wetting of the internal surface of the test specimen or parts which are not designed to be wetted when water drains back to external surface. 4.2.17 Weather tightness Performance in respect of air permeability, water tightness and wind resistance 4.2.18 Design Height Max height of wall in which the window or door occurs

5.

Abbreviations for types of windows and doors Code F CW SW CD SD 5.1 Description Fixed Casement window Sliding Window Casement Door Sliding Door

Abbreviations for design/ style options Description Top hung Bottom hung Vertical pivot Horizontal pivot Vertical sliding

Code TH BH VP HP VS

HS TT TS LS SF

Horizontal sliding Tilt and turn Tilt and Slide Lift and Slide Slide and Fold

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F

Casement Window/ Door (Outward open)

Fixed Window

Sliding Window/ Door

Horizontal Pivot

Top Hung

Lift Slide Door

Tilt & Turn

Bottom Hung

Slide Fold Window/ Door

Tilt Slide Door

Note: All windows are viewed from inside

Figure 2 (Symbolic representation of windows)
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5.2

Opening (inside / outside) symbolic representation on drawing

Outward Opening

Inward Opening

Figure 3 6. Functional Need of uPVC WINDOW 1. UPVC Windows should be fabricated with “Fusion welded corners”. The Mullion / Transom can be either Fusion welded or mechanically joined with desired sealing. 2. Windows / doors must conform to the strength requirements based on wind load as per IS 875-3. For Calculation of strength requirements refer Annexure N 3. Appropriate thickness of steel reinforcement should be selected to meet the desired strength. The reinforcement must be installed within 6 to 50mm distance from the face of the weld. Strength of the member / window to be determined as per Annexure N. 4. For window size ≤ 1500mm tolerance is ± 3.0mm and sizes above ≥1500 mm tolerance is ± 5.0mm on both height and width. 5. The window diagonal should be less than equal to 5mm for window upto 1500mm, above 1500mm, the diagonal difference should not be more than 10mm 6. The minimum overlap of sashes on Frame/ mullion should be 5mm, higher overlap is desirable. 7. Water drainage / ventilation slot should be provided in sash / frames as described in section 9 8. Min Gap of 3mm should be maintained per face between aperture and window to allow expansion / contraction of uPVC windows 9. The gap between window and its aperture should be filled with weatherable & elastic material to allow expansion / contraction of PVC and performance over period of years. 7. Raw Materials 7.1 Profiles 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. Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 9 Of 56

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 reprocessable or recyclable material has been added. c. Recyclable material Own recyclable / re-processable material 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
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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.
i) ii) iii) iv) v) vi)

Properties
Vicat Softening point Apparent modulus of elasticity Color Fastness Heat Stability Charpy Impact strength (milled sheet) Retention of Charpy impact strength after artificial aging

Test Method
ISO 306 ISO 178 ISO 4892-2 ISO 182 ISO 179 ISO 179

Permissible Value
≥75 ° C ≥ 2200MPa DE ≤ 5 ≥30 min ≥10 kJ/m² ≥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
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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 External dimension Depth (D) ≤ 80 > 80 Tolerance ± 0.3 ± 0.5
All Dimensions in mm

Diagram for Example

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 0.3 mm max
The difference between the maximum & minimum readings across the face

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

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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.

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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.

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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
i) ii) iii) iv) v) vi) vii) viii)

Characteristics
Appearance Dimensions & straightness Mass of profile Heat Reversion Heat aging Resistance to impact Color Fastness Weld ability

Method of test
Annexure A Annexure A Annexure A Annexure I Annexure F Annexure E ISO 4892-2 Annexure G

Requirement as per section
7.B 7.C 7.D 7.E 7.G 7.F 7.H 7.I

7.2 Reinforcements The steel reinforcement of profiles shall be of galvanized steel sections which are typically housed in closed chamber of uPVC profile or if on external face should be sealed with auxiliary profiles / caps / silicones The steel sections should conform to IS 1079 / IS 513 and should be galvanized with min Zn coating of 120 gram per square meter (gsm) with no visible rust at 144 hours. For
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external usage of reinforcement (ex – couplers), it is recommended to have 275gsm Zn coating. The steel section should be used in the frame and / or sash to meet the desired specifications of window performance. The steel section thickness should be based on the strength required as per the wind load specification of the window. For steel thickness & strength calculation of section refer to Annexure-N 7.3 Glazing Gaskets & Weather strip The gaskets / weather strip shall be of EPDM/ TPE or any equivalent material which meets the following properties a) b) c) d) Shore A Hardness of the material should be 60±10° A; (ref ISO 7619) Ozone resistance: No visible cracks; (ref ISO 1431) Compression set: should not exceed 50% ; (ref ISO 815) Aging test: The properties after aging should be (ISO 188) i. Hardness +10 / -5 ii. Tensile Strength not to exceed drop beyond 25% iii. Elongation not to exceed drop beyond 25%

7.4 Window Hardware’s The window hardware including the fastenings shall be tested in accordance with ISO 9227: 2006 for corrosion resistance when subjected to neutral salt spray test. The performance parameters like load bearing, MOC, endurance should be specified by the supplier or mutually agreed between the two parties.
Note1: It should be noted that there is no direct correlation between a given no. of hours salt spray testing and real time natural environment exposure. Note2: In coastal or industrial environment, the hardware performance should be specified.

7.5 Glass Glass thickness should meet the wind load requirements as per IS 875-3. The glass should be of at least the 4mm thickness. Hermetically sealed flat double glazing units can be provided by the manufacturers of windows with requisite glass beading. 8. Welds & Mechanical Joints The uPVC window welds should meet the norms as specified in section 7.1.2 (I).
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Mechanical joints can be made with adequate sealing to prevent any water / air ingress in the reinforcement chambers. Water should not penetrate through the joints into the reinforcement chambers other than those designed to allow water ingress

9.

Window Construction & Installation

9.1 Drainage & pressure equalization holes: Ventilation / Drainage holes / slots is to created on Frames / Sash / Transom / Mullions to drain entrapped water / moisture / hot air from the system. The no. of holes / slots should be in line with profile manufacturer’s recommendation. Typical drainage is recommended to be slots of min 5 x 20mm The holes / slots should not puncture the reinforcement chamber The holes / slots are offset between the inner & outer wall to prevent back flow Holes / slots to be created for ventilation / pressure equalization in sash(s) / frame(s) for prevention of deformation of profiles due to heat entrapment.

Typical drainage schematic

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9.2 Glass Glazing: Glazing Support – are supports which installed on the frame / sash to take / distribute the load of the glass. These are installed first to place the glass in the frame / sash. Glazing Spacers – are packers which support the glass in the frame / sash and installed after the glazing support are installed. The Glazing spacers / support must not block the drainage slots. The glass packer position should be adopted basis type of window illustrated below. Typical Glazing Spacer:

The glazing support position for different styles of windows:

F

Tilt & Turn

Bottom Hung

Fixed Window

Side Hung

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Load Bearing Wedge Spacer Wedge

Sliding Window/ Door

Top Hung

Horizontal Pivot

9.3 Glazing beads In general glazing beads must be inside (inside glazing), exceptions - Roof glazing and facades. Glazing Bead Cutting - The glazing beads are cut a 45 degree mitre .The foot of the glazing beads must be cut free at angle 45 degree (exceptions ventilators or louvers) 9.4 Installation packers (Supporting Blocks / Load Distribution) (Supporting blocks below the window frame ) Loads are distributed to the building structure through installation packers / supporting blocks or wedges. For cavity wall situation , where the window unit is positioned at the cavity zone , appropriate metal supporting brackets ( consoles ) must be take up the window weight . Plugs, anchors, fixing lugs, installation foams are not sufficient to take up loads which occur to the plane of the window. The supporting blocks should be positioned near the frame corner, at mullions or transoms and dependence to the type of window opening. However, the positioning of the supporting blocks must be such, that: - The frame is not clamped in – between supporting blocks - The vertical or horizontal frame members (profile) mullions or transoms can expand or contact due to the coefficient of expansion of the frame material The dimensioning of the supporting blocks must be in relation to the frame thickness, allowing for perfect sealing of the installation joints. The material of the supporting blocks must be durable and should have a low thermal transmittance.

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9.5 Location of fixing points

“A” is the distance between two neighboring fixing points and shall not exceed 700mm “E” is the distance between the fixing points to the end of the profile joint and recommended between 100 150mm

9.6 Fixing Material The fixing material should be selected in a way which does not hinder expansion or contraction of the window at the building joint at the same time secures the window with the aperture to sustain the max wind load. Fixing material can be anchor bolts, installation screws, fixing clips, sub- frames etc. 10. TESTING OF WINDOWS The window subjected to the testing should adopt the following Sequence of Test. a) Air Permeability b) Water tightness c) Resistance to wind – deflection measurement at Pressure P1 (=P3/1.5) d) Resistance to wind – pulsating test to P2 pressure (=0.5P1) e) Resistance to wind – Safety test to pressure P3 (the max wind load as per IS 875) 10.1 Air Permeability Test It is to let air pass when it is subjected to differential pressures under closed condition of the window. The method to be used for the air permeability testing of windows to be fitted in exterior walls and supplied in the form of completely assembled and finished units as per the test procedure given in the Annexure M Classification for air permeability Class 0 1 2 3 4 Max. test No 150 300 600 600 pressure Pa test Reference air NA 50 27 9 3 permeability at 100 Pa (m3/ h.m2)
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10.2

Water tightness under static pressure (water flow rate 3L/sq.m/min ± 10%) Water tightness is the ability of the window to resist water leakage into the building. ISO 15821: 2007 defines the test method for determining the water tightness under dynamic pressure of doors and windows assembled for normal use and installed as in practice. The test procedure is given in the Annexure – K. The classifications of the windows tested as per ISO 15821 can be classified as per table below. The window is said to of the class when water is seen at during the testing at the test value Classification for Water Tightness Class 0 1 2 A B A B Test - 0 50 100 150 Pressure Pa

3 A 200 B 250 A 300

4 B 450 A 600

5 X >600

10.3

Wind Resistance Test This test is to determine the resistance to wind load for completely assembled windows and doors when subjected to positive and negative test pressures. The test pressures used for the testing are defined as, i. P1 applied to measure deflections of parts of the test specimen ii. P2 pulsating pressure applied for 50 cycles to assess performance under repeated wind load iii. P3 applied to assess the safety of the test specimen under extreme conditions. The values of P1, P2 P3 are related as follows: P3 = max wind load as per IS 875 P3 = 1.5P1 P2 = 0.5P1 Following 3 sets of test pressures are to carried out in the sequence defined a) Deflection measurement under wind load Pressure P1 is conducted till deflection achieved is 15mm or (i) L/125 for single glass (ii) L/175 for double glass, whichever lower is achieved. b) Pulsating test to P2 pressure. After completion of test, test piece is opened and closed and any deformation / damage / malfunctions observed are recorded c) Safety test to pressure P3. All deformation, damage and malfunctions that have occurred are to be recorded in the report. Classification for Window Load Class 0 1 Test Pressure P1 No 500 (Pa) test

2 1000

3 1500

4 2000

5 2500

WR >2500

For simulating above tests, test procedure as per ISO 6612-1980 to be adopted.

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11.

Window Testing Report The window tested as per this standard shall have following
Reference to this Indian standard Name of the test laboratory The name or trade mark of the manufacturer to identify the manufacturer Date of manufacture Date of the test the apparatus and its calibration All relevant details concerning the dimensions of the specimen, its material, design, construction and manufacturer & manufacturing location and its surface finish and fittings; 11.8 Drawings of details of the specimen including cross section to a scale of 1:2 or larger 11.9 number of samples 11.10 purpose of the test 11.11 characteristics to be determined and clear identification of which samples to be used 11.1 11.2 11.3 11.4 11.5 11.6 11.7

for the required characteristic(s), wherever necessary 11.12 signature of the sampler and the manufacturer if necessary 11.13 Test procedures, including storage and conditioning prior to test, and mounting the test specimen ready for test 11.14 results of the test including analysis if relevant 11.15 place, date and authorized signature

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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). Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 23 Of 56

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 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. Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 24 Of 56 processing and to

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

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

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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 hours 1 year’s equivalent 5 year’s equivalent 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.

6.6 x100000/I 3.3x 1000000/I

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.

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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. 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. Web A membrane connecting two walls of a profile.

E.2

E.4.3 E.4

Apparatus An impact testing machine incorporating the following basic components (see figure 1) shall be used: E.4.1 E.4.2 E.4.3 E.4.4 main frames, rigidly fixed in the vertical position guide rails, fixed to main frame to accommodate the falling mass and allowing it to fall freely in the vertical plane 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 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;

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E.4.5 E.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.

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

E.6

E.7

Figure 1 – Impact Test Apparatus

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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. 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 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. 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.2

F.3

F.4

F.5

Test Piece The test piece shall be as follows: F.5.1 F.5.2 for testing in oven, a minimum length of 200 mm profile 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. Issue: Oct 2011 / Ver 1.0 / Rev 0 P a g e | 30 Of 56

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. b. c. d. e. f. g. reference to this Indian Standard; the test laboratory; full identification of profile; the date of testing the apparatus used and for the liquid bath method, the type of liquid the result of the examination of the test piece; 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

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

G.5.2 Test arrangement a. b. c. d. Corner weld sample for tensile bending test (see figure 1) T joint weld samples for tensile bending test (see figure 2) Corner weld sample for compression bending test (see figure 3) T joint weld samples for compression bending test (see figure 4)

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3 1

3 1

F1

F1 4

4

1 Clamping device 2 Rigid support over a minimum clamping length of 400mm 3 Frame 4 Optional support block (5 +/- 0.5) mm

1 Clamping device 2 Rigid support over a minimum clamping length of 400mm 3 Frame 4 Optional support block (5 +/- 0.5) mm

Figure 1- Weld Test Apparatus

Figure 2 : T Arragement

Fc

Figure 3
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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)

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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 √2
= 283

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

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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

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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;

Where:

σt= (L-Ft) / W

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:

Where:

σc= Fc [(a/2 – e / √2) / 2W]

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
A

A

Z

Z' Direction of loading

Figure H1: Position of point of maximum bending stress

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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. Talc dusted or non stick coated stainless steel plate ,not exceeding 2 mm thickness Fine felt tip pen Measuring device, capable of reading to an accuracy of at least 0.1 mm

I.3.2 I.3.3 I.3.4

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 I.6.2 Measure the distance between the mid points of the lines on each face within ± 0.1 mm 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 I.6.4

Heat for 60 +5 / - 0 min. at 100 ± 2 ° C. The test time shall commence when the 100±2 °C temperature is regained. 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. P a g e | 38 Of 56

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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 dark external glazing bead or ancillary profiles necessitates lower reversion. surfaces. The use of

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Annexure – K METHOD OF TESTING WATER TIGHTNESS 1. Scope This annexure defines the conventional method to be used to determine the water tightness of completely assembled windows and doors of any materials. 2. Field of Application This test method is designed to take account of conditions in use, when the window or door is installed in accordance with the manufacturer’s specification and the requirements Indian Standards and codes of practice. This annexure does not apply to the joints between the window or door frame and the building construction. 3. Definition 3.1. test pressure difference between the static air pressures on the external face and the internal face of the test specimen. Test pressure is positive if the static air pressure on the external face is higher than that on the internal face. 3.2. watertightness the ability of the closed and fastened test specimen to resist water penetration under the test conditions up to a pressure. (Pmax =limit of the watertightness). 3.3. water penetration continuous or repeated wetting of the internal surface of the test specimen or parts which are not designed to be wetted when water drains back to external face. 3.4. limit of watertightness maximum test pressure Pmax up to which the test specimen remains watertight under the test conditions for the specified time. 4. Principle Constant spraying of a specified quantity of water onto the external surface of the test specimen while increments of positive test pressure are applied at regular intervals during which details are recorded of test pressure and location of water penetration. 5. Apparatus 5.1. A chamber with an open side to which the test specimen can be fitted. It shall be constructed so as to be able to withstand the test pressures without deflecting to an extent likely to influence the test results. 5.2. Means for applying controlled test pressure to test specimen.
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5.3. Means of producing rapid changes in test pressure, controlled within defined limits. 5.4. Instrument suitable for measuring the quantity of water supplied within an accuracy of ± 10 %. If several rows of nozzles with different flows are included, at least two such instruments are needed. 5.5. Means of measuring the test pressure applied across the specimen, within an accuracy of± 5%. 5.6. A spraying system capable of applying a continuous regularly dispersed film of water, all over the surface likely to be wetted in real exposure conditions, by means of full circular cone nozzles with the following features: a) angle of spay: ( )° b) pressure working range : 2 bar to 3 bar according to manufacturer's specifications c) nozzle rate : top row 2 1/min ± 0.2 l/min per nozzle additional rows 1 1/min ± 0,1 1/min per nozzle and 2 1/min ± 0,2 1/min per nozzle (see 6.2.4). 6. Preparation of test specimen 6.1. Set-up of the test specimen The test specimen shall be fixed as intended for use in the works without any twists or bends which may influence the test results. The test specimen shall be fully operable. The surround shall be prepared and installed so that any water penetration, including that through the frame joints, shall be readily detectable. The test specimen shall be cleaned and surfaces dry. Ventilation devices, if any, shall be taped over. 6.2. Set-up spraying system (see figure 1 to figure 3) The location and the size of the specimen in the intended works shall be taken into account when selecting the method of spraying. A test shall be carried out using only one set up. A template is recommended to set up the spraying system. 6.2.1. Positioning of the line connecting the nozzle tips (the nozzle line) The nozzle line shall be located not more than 150 mm above the topmost horizontal joint line of any moving frame or the glazing line of any fixed glazing, in order to provide complete wetting of the adjacent horizontal frame member(s).The nozzle line shall be located at a distance of ( ) mm from the external face of the specimen as defined by the outermost external joint plane of moving parts or the glazing plane of fixed parts.

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6.2.2.

Positioning relative to specimen width

Nozzles shall be spaced at 400 mm ± 10 mm along the axis of the spray bar and the nozzles shall be arranged in order that the lateral distance "c" between the outer edge of the surround and the outermost nozzles shall be greater than 50 mm but not exceeding 250 mm, see figure 3. 6.2.3. Direction of nozzle spray The nozzle axis shall lie on a line ( 6.2.4. Number of nozzle rows )° below the horizontal line see figure 1.

6.2.4.1. For specimens with a height up to 2.5 m measured from the topmost horizontal joint line of any moving frame or glazing line of any fixed glazing to the next joint, see figure 1, a single row of nozzles shall be used, with each nozzle spraying on average 2l/min/m2. 6.2.4.2. For specimens exceeding 2.5 m height, see figure 2, an upper row of nozzles shall be fixed as described in 6.2.4.1. Additional rows of nozzles shall be fixed at vertical intervals at 1.5 m (within a tolerance of± 150 mm) below the top nozzle line. Where any horizontal projection occurs, these additional rows shall be installed at a level such that no water is sprayed upwards under the projection. 6.2.4.3. For specimens containing one or more horizontal waterbars which project more than 50 mm. See figure 5, an additional row of nozzles, as described in 6.2.4.2 shall be arranged for each waterbar as shown in figure 2. 6.3. Water characteristics Water temperature shall be between 4°C and 30°C and the water shall be clean enough to ensure that all nozzles spray correctly. 7. Test procedure 7.1. Preliminaries The test specimen shall be conditioned for at least 4 h within the range 10°C to 30°C and 25 % to 75 % RH immediately before testing. Temperature shall be measured to within ± 3°C and humidity to within ±5 %. Atmospheric pressure shall be measured to within ± 1 kPa. All the opening parts of the test specimen shall be opened and closed at least once before finally being secured in the closed position. If an air permeability test has not been performed during the previous 24 h, three test pressure pulses shall be applied, the duration of increase in test pressure shall not be less than 1 s. Each pulse shall be maintained for at least 3 s. These pulses shall produce a test pressure 10 % greater than the maximum test pressure required for the test, without, however being less than 500 Pa. 7.2. Spraying phase Spraying is applied first with the test pressure of 0 Pa for 15 min then with the test pressure increasing every 5 min, see figure 4. Overall duration is dependent on the watertightness of the test specimen. The duration of each pressure steps shall be within a tolerance of ( min.
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The test pressure shall be applied in steps of 50 Pa up to 300 Pa and from 300 Pa in steps of 150 Pa. Immediately prior to testing the flow of each row of nozzles shall be adjusted according to 5.6. 7.3. Test results Report the location and pressure at which any water penetrated the specimen and the time for which the maximum pressure was maintained before water penetrated. Mark this data on a drawing of the face view of the test specimen. 8. Test report This shall state the devices used for the test and record on a drawing or a photograph of the test specimen the location of any significant water penetration observed. The report shall contain as a minimum the following information: reference to this test ; the name of the test institution ; date of the test ; all necessary references to identify the- specimen and the method of selection-of .the test ; all relevant details concerning the dimensions of the specimen, its materials, design, construction and manufacture and its surface finish and fittings ; drawings of details of the specimen including cross section to a scale of 1:2 or larger ; presence of ventilation, type and condition {i.e. closed, taped over etc.); test procedures, including storage and conditioning prior to test, and mounting the test specimen ready for test; test climates used.

-

-

-

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Dimensions in mm

1

2500

1. (2 ± 0.2) 1/min per nozzle 2. Nozzle lip shall be above this level and spray the head member thoroughly 3. Outermost external joint plane or glazing plane Figure 1 - Specimen not more than 2500 mm

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Dimensions in mm

1. limit of spray 2. 1500 or less Figure 2 - Specimen more than 2 500 mm or with horizontal waterbar projecting more than 50 mm (see figure 5)

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Dimensions in mm W

C shall be between 50 and 250 mm Figure 3 - Set-up of nozzles seen from above

Figure 4 - principle of test pressure steps

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If S > 50mm, an additional spraying line of nozzles is required below the waterbar If S ≤ 50mm, no additional spraying line of nozzles is needed Figure 5 – Definition of horizontal projection

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Annexure – L METHOD OF TESTING WIND RESISTANCE 1 Scope

The ISO 6612 – 1980 defines the method of testing to be used for assessing the structural performance, under positive or negative static air pressure of windows to be fitted in exterior walls and supplied in the form of completely assembled and finished units.

2 Test Apparatus Testing chamber LOCK TEST SPECIMEN GAUGE DIFFERENTIAL AIR PR. CONTROLLER AIR INLET

MANUAL OUTLET FIGURE -5

GAUGE

-

Closed chamber with a opening to place the window as shown in fig – 5 Differential air pressure controller across the window Device for measuring the difference in pressure between the two faces of the window Devices for measuring displacement

3 Test Method Subject the window to static air pressure Increase the pressure in stages for a minimum of 10 seconds upto maximum pressure required ( P1 ) The P1 pressure stages are 100,200,300 upto 500 Pa Measure the deflection at each stage of the pressure along the longitudinal axis of either the frame or shutter of the window When the pressure reduced to zero note the residual permanent deflection along the longitudinal axis
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4 Repeated Pressure test The window shall be subjected to n – pressure impulses between 0 and P2 The period of transition from one pressure value to another shall not be less then 1 seconds The pressure shall be held at their maximum or minimum values for at least 3 seconds at each impulse After completion of the test open and close the moving parts of the window 5 times and note the damages or functioning defect detected after this test

5 Safety Test The maximum required pressure P3 shall be reached as quick as possible but not less then 1second and held for 3 second Note any deformations, damages or functioning defects detected after the test

6 Report the test value

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Annexure – M METHOD OF TESTING AIR PERMEABILITY OF WINDOWS 1. Scope This annexure defines the conventional method to be used to determine the air permeability of completely assembled uPVC windows and doors to be fitted in exterior walls, when submitted to positive or negative test pressures. 2. Field of application This test method applies to all windows including door height windows in their normal operating condition for which they are designed and installed according to the manufacturer’s recommendations as in a finished building, bearing in mind the conditions of test as defined below. This test method does not apply to the joints between the windows and surrounding components and material 3. Definition 3.1.pressure differential: Difference between the static air pressure on the external surface of a window and the static air pressure on the internal surface of the same window The difference is positive when the external pressure is higher than the internal pressure. In the opposite case, it is negative. This pressure is expressed in Pascals 3.2.air permeability: The property of a closed window to let air pass when it is subjected to a differential pressure The air permeability is characterized by a flow of air, in standard conditions, expressed in cubic meters per hour as a function of the pressure. 3.3.opening joint: line of discontinuity between:  either a frame and its matched component which can be opened by means of its hardware, see figure 1;  or two components which can be opened by means of their hardware, see figure 2. Conventionally, this discontinuity is as seen from the inside face of the test specimen. 3.4.length of opening joint: length of the line of frame, sash, casement, leaf or infilling, as seen from the inside face, separating the two contiguous components, determined as shown in figure 1 and figure 2. Actual length of gaskets or seals fitted into the underlying profiles of the components or joints of components built into opening parts are not relevant. The length of joint shall be expressed in meters (m).
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3.5.overall area: area of the test specimen measured parallel to the glazing or the leaf, see figure 1 and figure 2 The overall area shall be expressed in square meters (m2). 3.6.standard conditions: For the purpose of the test, the following are considered the standard conditions for determining air flow temperature: 20ºC pressure: 101.3 kPa air density: 1.202 kg/m3 4. Principle of test Application of a defined series of test pressures (positive and negative) and at each test pressure measurement of the air permeability with a suitable test device. 5. Test apparatus 5.1. A chamber with an open side to which the test specimen can be fitted. It shall be constructed so as to be able to withstand the test pressures without deflecting to an extent likely to influence the test results. 5.2. Means for applying controlled test pressure to test specimen. 5.3. Means of producing rapid changes in test pressure, controlled within defined limits. 5.4. Instrument suitable for measuring the quantity of air flow into or out of the chamber within an accuracy of ± 5% (calibrated at + 20ºC, 101 kPa). 5.5. Means of measuring the test pressure applied across the specimen, within an accuracy of ± 5%. 5.6. Means of sealing all joints of the specimen when required. 6. Preparation of test specimen A surround for the specimen to be tested shall be prepared. This shall be stiff enough to withstand the test pressures without deflecting to an extent likely to impair jointing or to impose bending stresses on the test specimen. When the installation conditions are known, the specimen shall be installed to simulate these, wherever practical. The test specimen shall be fixed as intended for use in the works without any twists or bends which may influence the test results. The specimen shall be fully operable. The test specimen shall be cleaned and surfaces dry. Ventilation devices, if any, shall be taped over, except when it is required to determine the amount of air flow through such devices.
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The thickness, type of glass and method of glazing shall comply with the requirements of the manufacturer. When there is no specification or when there is a possibility that the window will be used with different glasses, test shall be carried out with a glass of minimum thickness with respect to the surface area. 7. Test procedure 7.1. Preliminaries The ambient temperature and humidity close to the specimen shall be within the range 10ºC to 30ºC and 25% to 75% RH and the specimen shall be conditioned thus for at least 4 h immediately before testing. Temperature shall be measured to within ± 3 ºC and relative humidity to within ± 5%. Atmospheric pressure shall be measured to within ± 1 kPa. The test pressure shall be applied in steps of 50 Pa upto 300 Pa and from 300 Pa in steps of 150 Pa. the air permeability result shall be given to an accuracy of 10%. 7.2. Air permeability of test chamber Determine the procedure to follow in accordance with what is known about the air permeability of the test chamber. 7.2.1.Test chamber with known air permeability Assume the air permeability of the test chamber is zero if it is less than 5% of the maximum air permeability permitted throughout the range of the classification that is attributed to the test specimen. When this is not so, measure the air permeability of the test chamber as described in 7.2.2 unlessit is known and shown to be approximately constant within the limit of accuracy of the measurement recorded by the test laboratory. In no case shall the air permeability of the test chamber exceed 30% of the overall air permeability of the test specimen and the test chamber. 7.2.2.Test chamber with unknown air permeability Seal all joints in the test specimen with adhesive tape or an airtight sheet covering the whole test specimen. Measure the air permeability of the test chamber with positive test-pressures as described in 7.3.1. When it is intended to carry out an air permeability test with negative test pressures, measure the air permeability of the test chamber with negative test pressures as described in 7.3.1. Remove the adhesive tape or airtight sheet covering the test specimen.
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7.3. Overall air permeability of test specimen and the test chamber-Positive pressures Open and close all opening parts of the test specimen at least once before securing them in the closed position. Measure the air permeability of the test specimen with positive test pressures as described in 7.3.1 see figure A 7.3.1.Measurement of air permeability Apply three pressure pulses each 10% greater than the maximum test pressure to be used in the test or 500 Pa, whichever is greater. The time to reach the maximum test pressure shall be not less than 1 s and the pressure shall be sustained for at least 3s. Apply positive test pressure steps as specified in 7.1. Measure and record the air permeability at each step. The duration of each step shall be sufficient to allow the test pressure to stabilize before the air permeability is measured. 7.4. Overall air permeability of test specimen and the test chamber – Negative pressures Perform this test only when specifically required. Open and close all opening parts of the test specimen at least once before securing them in the closed position. Measure the air permeability of the test specimen and test chamber with negative pressures as described in 7.3.1, see Figure A. 8. Test result 8.1.Adjust the result of the air flow measurements (Vx) at each step, to calculate the air flow (Vo) at normal conditions (To = 293 k, Po = 101.3 kPa), considering the actual Tx expressing in ºC and atmospheric pressure Px, expressed in kPa, during the test. Vo = Vx. 293 . Px 273 + Tx 101.3
.

8.2.For a specimen the air permeability at each step is equal to the overall air permeability adjusted in accordance with 8.1 less the air permeability of the chamber, when at zero, adjusted in accordance with 8.1 8.3. Using the length of the opening joint as defined in 3.4 and the overall area as defined in 3.5 calculate the air permeability in terms of m3 and m3 , expressing the results to two significant figures h.m h.m2 9. Test report This shall state the airflow measurement devices used for the test and record on a drawing or a photograph of the test specimen, the location of any significant points or air leakage observed. Where appropriate the report shall contain as a minimum the following information:  Reference to this test;
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        

The name of test institution; Date of the test; All necessary references to identify the specimen and the method of selection of the test; All relevant details concerning the dimensions of the specimen, its material, design, construction and manufacturer and its surface finish and fittings; Drawings of details of the specimen including cross section to a scale of 1:2 or larger; Presence of ventilation, type and ventilation (i.e. closed, taped over, etc.); Test method; Test procedures, including storage and conditioning prior to test, and mounting the test specimen ready for test; Test climates used.

Definition of reference parameters

Length of opening joints: 2 HO + 2 BO
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Overall area: HT x BT Figure 1: Single leaf operation

Length of opening joints: 3 HO + 2 BO Overall area: HT x BT

Figure 1: Double leaf operation

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Air Permeability Test pressure sequence for air tight chambers

Test pressure sequence for non air tightness chambers

Figure A

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Annexure – N METHOD OF CALCULATING STRENGTH OF WINDOWS & DOORS 1. Scope This annexure describes the method to be used to determine the window strength required to meet specific wind load of the region / building laid down as per IS 875. 2. Method of Calculation The strength of window can be calculated as per procedure laid down in the subsequent section 2.1. Wind Load as per IS 875-III The customer may specify the wind load or may be calculated as per the IS875-III. Below is guideline for wind load calculation (Note: The parameters should be validated with customer)
a. Basic wind speed b. Risk factor c. Terrain category d. Topography factor e. Building Height f. Pressure Coefficient g. H/L Ratio h. L/W Ratio i. Max wind load, P = Vb in m/sec = K1 = K2 = K3 = H in m = Cp = HL = LW Cp.(0.6).(Vb.K1.K2.K3)2 Pascal

=

The wind load, P, calculated above is the max load which the window is subjected to. 2.2. Desired Structural Strength of uPVC Window A typical slider window is illustrated in Fig 1 and the trapezoidal load distribution on the window is shown in the adjoining illustration Fig 2.

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Fig 2 Fig 1

The total wind load is divided in two part which can be unequal part. As per the trapezoidal load distribution in Fig 2, the load on the frame (fixed to the wall with fastener all around) is considered negligible. The EI value required for section can be calculated as per the below formulae. (Refer Fig B-1-3)

Eq (1) where,

Example: Now considering the values, a or b = 450 W = 1000 Pa (as specified by customer or calculated as per 2.1) L/Def. = 1/175 L = 2450 mm The required EI value for Sash as per Eqn (1) will be, EI (required) = 14.28 x 109 N-mm2 2.3. Calculating Actual Structural Strength of uPVC Window

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For the sake of simplicity, it is proposed to use only the data of steel for strength calculation. Strength of PVC and other accessories are quite low and are factored as safety factor. The second moment of inertia for steel reinforcement section is obtained from the CAD data, Iyy = 90196.19 mm4 (Refer Fig. 3)

Fig 3

Young’s modulus for steel is, E = 210GPa, Therefore, EIyy(reinf) = 18.94 x 109 N-mm2

2.4. Comparing and result interpretation The said window can considered to be passing the strength requirement, if following corelation holds true. Actual EIyy(reinf) ≥ EI (required)

2.5. Reporting the result Following parameters should be reported in the report 2.5.1. Wind load as stated by the customer or wind load calculations as described in section 2.1 with all parameters used for the calculations 2.5.2. Desired Strength as stated in section 2.2 2.5.3. Actual strength as stated in section 2.3. The steel cross section should be added with moment of inertia value. E value of the steel used 2.5.4. Result of acceptance or failure.

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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 256599 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 EN 479 EN 514 EN 513 Determination of appearance after exposure at 150 °C Determination of heat reversion Determination of the strength of welded corners & T joints Determination of the resistance to artificial weathering

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