THERMAL INSULATION-R MATTRESSES

(DFA INDONESIA)

TECHNICAL SPECIFICATION
FOR
BONDED MINERAL (ROCK) WOOL MATTRESSES
(LIGHT RESIGN BONDED MATTRESS)

SPECIFICATION NO. VVF-TIM-22-23-01 Rev.

No.: 00
 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

CONTENTS

SECTION – I

 SPECIFIC TECHNICAL REQUIREMENT

SECTION – II

 DATA SHET- A

 QUALITY PLAN

 COMPLIANCE SHEET
 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

1.00.00 GENERAL
This specification covers the requirements of manufacture, physical & chemical
properties, inspection & testing and packing for supply of bonded mineral (rock) wool
mattresses having metallic hexagonal wire netting as facing on one or both side,
suitable for service temperatures up to 750 deg C.

2.00.00 CODES AND STANDARDS

2.01.00 INDIAN STANDARD
2.01.01 The manufacture, physical & chemical properties, inspection and testing of the
bonded mineral rock wool mattresses shall conform to the latest editions of the
following appropriate standards.
2.01.02 IS: 8183 Specification for bonded mineral wool.
2.01.03 IS: 3144 Methods of test for mineral wool thermal insulation materials.
2.01.04 IS: 3346 Methods for the determination of thermal conductivity of thermal insulation
materials (two slab, guarded hot plate method).
2.02.00 In case of any conflict between the above standards and this specification, the latter
shall be final.

3.00.00 MANUFACTURE
3.01. 00 The mattresses shall be made from rock processed from a molten state into fibrous form
with minimum organic thermosetting binder, and shall be machine felted, bakedand
metallic stitched / faced with metallic hexagonal wire netting on one or both sides.
3.02.00 The metallic hexagonal wire netting shall be of Galvanized steel (made from wire
conforming to IS: 280 medium coated to IS: 4826) / Stainless steel (made from wire
to IS: 6528) having wire size and aperture conforming to IS: 3150.
3.03.00 The mattress shall be continuously stitched / tied on to the wire netting with minimum
0.4 mm dia. galvanized steel / stainless steel wire,. The spacing between the stitching
/ ties shall not be more than 250 mm along the width and 150 mm along the length.

4.00.00 DIMENSIONS AND DIMENSIONAL TOLERANCES

4.01.00 The length and width of the mattresses shall be 1520 mm x 1220 mm or 1640 mm x 1220
mm. Nominal thickness shall be 30, 40, 50, 60, 70, 75 mm.
4.02.00 The method of measuring the dimensions i.e. length, width and thickness shall be as
prescribed in IS: 3144. Tolerance on length and width shall be as per IS:8183.
Tolerance on thickness shall be +6mm/-2mm.

5.00.00 BULK DENSITY AND TOLERANCES ON DENSITY

5.01.00 The bulk density of the bonded mineral (rock) wool mattresses without the facings, shall
be 120 kg/m3 unless otherwise specified. Tolerances on bulk density shallbe +15 %
and - 5% when tested as per method prescribed in IS: 3144.
 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

6.00.00 MATERIAL PROPERTIES

6.01.00 SHOT CONTENT:
The method for determination of shot content shall be as prescribed in IS: 3144. The
maximum shot content shall be 5% by weight. Any shot present in the materials shall
not be greater than 5 mm in any dimension.

6.02.00 THERMAL CONDUCTIVITY

The thermal conductivity (k-value) of the bonded mineral wool mattresses shall not
exceed the values given in IS: 8183 Latest when determined in accordance with the
method prescribed in IS: 3346.

K’ Value test (for minimum four mean temperatures i.e.100oC, 200oC,300oC & 350oC
) results to be provided to VVF for acceptance in accordance with conditions given
below: -
Mean temperature (oC) Thermal Conductivity in W/m.K for 120 Kg/M3
density
100 0.045
200 0.060
300 0.083
350 0.091

The test will be carried out on samples identified and sealed by customer / VVF
authorized representative and related test results to be provided. The test will be
carried out at govt. approved labs or test houses (at CBRI – Roorkee, IIT – Chennai,
PIBCO R & D Centre - N. Delhi, NIRMA University, Ahmedabad) recognized by
reputed customers.

6.03.00 HEAT RESISTANCE

When a sample of mattress is heated to the maximum recommended temperature of
use (750 oC for 120 kg/m3 density) as per method prescribed in IS:3144 (test for
maximum recommended temp), the material shall not suffer visible deterioration of
the fibrous structure, any fusion of fibers and shall not show any evidence of internal
self-heating. Any colour change shall not be considered as visible deterioration in
fibrous structure.

6.04.00 OTHER TESTS

The following tests are to be conducted as per IS:3144/IS:8183 and the acceptance
norms shall be as per IS:8183.

a. Moisture content

b. Moisture Absorption

c. Incombustibility

d. Sulphur content

e. Recovery after Compression

f. Alkalinity
 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
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g. Chloride Content

h. Fibre Diameter

i. Resistance to vibration

j. Resistance to jolting

7.00.00 PACKING AND MARKING

7.01.00 Stack of mattresses shall be packed in unfolded condition and sealed in polythene bags
of at least 0.2mm thickness. Then the sealed bags shall be put inside the polythene
lined HDPE or HDPP Woven netting bags and sealed by machinestitching.

To account for looseness in packing (if any) due to machine stitching, the bags shall
be properly stacked and tightly fastened during transportation to avoid any possible
damage due to relative movements. Sharp edges of wire netting shall be bent
inwards to avoid damage to packing.

7.02.00 Each bag of mattresses shall be serial numbered. Also, printed sheets indicating the
nominal thickness, density and wire netting details (i.e. material and size) shall be
placed below the wire netting.
7.03.00 For easy identification of mattresses as per density & wire netting material, following
colour codes for the HDPE bags is to be followed:
a) Yellow bags with marking as shown in Fig 1 (Page 5 of 5) for 150 kg/m3 with
Galvanized steel wire netting
b) White bags with marking as shown in Fig 1 (Page 5 of 5) for 100 kg/m3 with
Galvanized steel wire netting
c) Yellow bags with marking as shown in Fig 1 (Page 5 of 5) for 150 kg/m3 with SS
wire netting
d) In case of both side SS/ GS wire meshing, additional marking “BOTH SIDE MESH”
is to be provided.
7.04.00 Following details shall be legibly and indelibly marked on the packages.
a) Project Name
b) Vendor name:
c) Purchase Order No. and Date
d) Sl. No. of package/Batch No:
e) Size of mattresses (Thickness x Length x Width)
f) Density of mattresses
f) Wire netting material and size
g) Weight of the package
h) No. of mattresses in the package
i) A caution note “Always store under covered shed and on raised
platforms"
 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

8.00.00 INSPECTION AND TESTING

8.01.00 Bonded mineral wool mattresses to be supplied under this specification shall be of tested
quality and workmanship. Inspection and testing of thermal insulation materials shall be
as per this specification / quality plan enclosed. Manufacturer shall conduct all tests and
stage inspections as per the approved quality plan to ensure that the material conforms
to the requirements of this specification and of applicable standards. All shop tests shall
be conducted in the presence of VVF’s / VVF’s customer’s representative, on the samples
identified by him / them.
8.02.00 The Quality Plan enclosed with this specification specifies minimum quality control
requirement. During contract stage vendor shall furnish this Quality Plan duly signed &
stamped for VVF approval. Quality plan shall be approved by VVF and customer.
Inspection and testing shall be carried out as per Quality Plan by VVF/ VVF representative
and customer (as applicable). In case inspection is by both VVF and theircustomer, then
the inspection can be carried out jointly or separately, which will be informed later. In case
of the foreign bidder, inspection shall be carried out by reputed third party.

8.03.00 The charges for third party inspection (Lloyds, TUV or equivalent) for foreign bidders shallbe
included in the base price of the item by the bidder. This third party agency shall be
approved by VVF. Bidder to inform the same in the offer and mention the same in Quality
Plan.

Note: There may be minor changes in quality plan depending on customer/consultant comments
which will HAVE TO BE ACCOMMODATED BY VENDOR AT NO EXTRA COST.

9.00.00 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT:

1. Quality plan duly signed and stamped.
2. Datasheet for Approval by VVF/Customer.

Approval of Quality plan/ Data sheet shall be required for manufacturing clearance and the
same shall be considered for delay analysis by VVF.
TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

Fig 1: Sketch for marking on bags

 TECHNICAL SPECIFICATION SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) REV. NO.: 00 DATE: 13-05-2022
WOOL MATTRESSES
SHEET 1 OF 1

STANDARD TECHNICAL DATA SHEET FOR LIGHT RESIN BONDED MINERAL (ROCK) WOOL
MATTRESSES
PROJECT: DFA INDONESIA
QP NO: VVF-QP-22-23-01
SPECIFICATION NO: VVF-TIM-22-23-01
SL. No. CHARACTERISITCS ACCEPTANCE/PERMISSIBLE LIMIT
1 MATERIAL LRB Rock wool mattresses confirming to IS:8183/Latest.
2 Bulk Density 120 Kg/m3 with (+)15% & (-)5% tolerance.
3 Mattresses Size 1640mm x 1220mm/1520mm x 1220mm

4 Thickness 25,30,40,50,60,70,75mm (Thickness values as per BOM) Tolerance on thickness

shall be +6mm/-2mm.
5 Service Temperature Upto 4000 C - 120 Kg/m3

6 Thermal Conductivity as per IS 8183/93 Mean Temp. 120 Kg/m 3 (Group 4)

(Group 3/Group 4) K value in mW/cm.°C (Max)

100° C 0.045
200° C 0.060
300° C 0.083
7 Chloride content 0.01 % max.
8 Shot content Shot shall not exceed 5% maximum by weight.
Shot shall not be greater than 5mm in any dimension.

9 Sulphur content 0.6% max

10 Moisture Content (Weight gain by 2 % max
moisture absorption)

11 Incombustibility Test (loss of weight after 5% max

test)

12 Resistance to vibration 1 % max

13 Resistance to jolting 3 % max

14 Alkalinity 7-10 pH
15 Recovery After Compression 90% minimum after compression to 75% of the original Thickness.
16 Fibre Diameter 7.0 Micron max.
17 SS wire netting (above 400 deg.C) As per IS:6528 & 3150, Aperture 19 mm & Wire Dia 0.71mm.( Wire Dia and
single side wire netting as per BOM).
18 SS Tieing/Stitching wire (above 400 Wire Dia 0.40mm As per IS:6528.
deg.C)

19 GI wire netting (upto 400 deg.C) As per IS:280 & 3150, Aperture 19 mm & Dia 0.71mm.( Wire Dia and single side/
Both sides wire netting as per BOM).

20 GI Tieing/Stitching wire (upto 400 deg.C) Wire dia 0.40mm As per IS:280.

21 Packing, Marking &other requirement Stack of mattresses shall be packed in unfolded condition and sealed in polythene
bags of at least 0.2mm thickness. Then the sealed bags shall be put inside the
polythene lined HDPE or HDPP Woven netting bags and sealed by machine stitching.
Packing to be duly marked with a caution note “Always store under covered shed
and on raised platforms". For marking and other details Technical specification is to
be referred.

BIDDER/SUPPLIER VVF
 MANUFACTURER/BIDDER/VENDOR
NAME & ADDRESS
STANDARD QUALITY PLAN SPEC. NO : VVF-TIM-22-23-01 DATE: 13-05-2022
CUSTOMER : QP NO.: VVF-QP-22-23-01 DATE: 13-05-2022
VVF/Customer Approved Suppliers
PROJECT: DFA INDONESIA PO NO.: DATE:
ITEM: THERMAL INSULATION – RESIN BONDED MINERAL (ROCK) WOOL
SECTION: SHEET 1 OF 3
MATTRESSES
SL NO. COMPONENT & CHARACTERIST- CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
OPERATIONS ICS CHECK OF CHECK DOCUMENT NORMS RECORD
1 2 3 4 5 6 7 8 9 * ** 10
M C/N D M C N
1.0 MATERIAL
1.1 CHEMICAL CHEMICAL MA CHEMICAL ONE ONE MANUFACTURER MANUFACTURER TC √ P V V
COMPOSITION PROPERTIES SAMPLE SAMPLE STANDARD STANDARD
(RAW MATERIAL) PER LOT PER LOT
1.2 GS WIRE 1.DIMENSIONS þ MA MEASUREMENT IS 3150 IS 3150 IS 3150 IS 3150/ IR √ P W V #Witness shall be
Appendix A Appendix A VVF/CUSTOMER # carried out at the stage
APPROVED DATA SHEET of Clause 3.1.
2.GAUGE DIAMETER MA MEASUREMENT IS 280 IS 280/ IR √ P W V
VVF/CUSTOMER #
APPROVED DATA SHEET
3. CHEMICAL MA LAB. TEST IS 280 IS 7887 TC √ P V V
4. COATING TEST MA LAB. TEST IS 280 IS 4826 TC √ P V V
5. TENSILE TEST MA LAB. TEST IS 280 IS 280 TC √ P V V
6. WRAPPING TEST MA LAB. TEST IS 280 IS 280 TC √ P V V
7. BEND TEST MA LAB. TEST IS 280 IS 280 TC √ P V V
1.3 SS WIRE 1.DIMENSIONS þ MA MEASUREMENT IS 6528 IS6528 IS 3150 IS 3150/ IR √ P W V #Witness shall be
VVF/CUSTOMER # carried out at the stage
APPROVED DATA SHEET of Clause 3.1.
2.GAUGE DIAMETER MA MEASUREMENT IS 3150 IS 3150 IS 6528 IS 6528/ IR √ P W V
VVF/CUSTOMER #
APPROVED DATA SHEET
3.CHEMICAL MA LAB. TEST 16 6528 IS 6258 IS 6528 IS 6528 TC √ P V V
ANALYSIS
4.TENSILE TEST MA LAB. TEST IS 6528 IS6528 IS 6528 IS 6528 TC √ P V V
5. REVERSE BEND MA LAB. TEST IS 6528 IS6528 IS 6528 IS 6528 TC √ P V V
TEST
6. WRAPPING TEST MA LAB. TEST IS 6528 IS6528 IS 6528 IS 6528 TC √ P V V
7. TORSION TEST MA LAB. TEST IS 6528 IS6528 IS 6528 IS 6528 TC √ P V V
2.0 IN-PROCESS INSPECTION

1.1 FINISHED DIMENSION & MA MEASUREME IS 8183 IS 8183 IS 3144 IS 8183/ TC √ P V V

MATTRESS TOLERANCE NT VVF/CUSTOMER
APPROVED DATA SHEET

3.0 FINAL INSPECTION

VVF BIDDER/ SUPPLIER FOR CUSTOMER REVIEW & APPROVAL

ENGINEERING QUALITY Sign & Date Doc No:
Sign & Date Name Sign & Date Name Seal Sign & Date Name Seal
Prepared by: Sandip Kundu Checked by: A. Sangle Reviewed by:
Reviewed by: Vinayak Bamne Reviewed Aniruddha
by: Bansod Approved by:
 MANUFACTURER/BIDDER/VENDOR
NAME & ADDRESS
STANDARD QUALITY PLAN SPEC. NO : VVF-TIM-22-23-01 DATE: 13-05-2022
CUSTOMER : QP NO.: VVF-QP-22-23-01 DATE: 13-05-2022
VVF/Customer Approved Suppliers
PROJECT: DFA INDONESIA PO NO.: DATE:
ITEM: THERMAL INSULATION – RESIN BONDED MINERAL (ROCK) WOOL
SECTION: SHEET 2 OF 3
MATTRESSES
SL NO. COMPONENT & CHARACTERIST- CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
OPERATIONS ICS CHECK OF CHECK DOCUMENT NORMS RECORD
1 2 3 4 5 6 7 8 9 * ** 10
M C/N D M C N
3.1 BONDED MINERAL 1. DIMENSIONS MA MEASUREMENT IS 8183 IS 8183 IS 3144 IS 8183/ IR √ P W V
(ROCK) WOOL VVF/CUSTOMER
MATTRESSES APPROVED DATA SHEET
(FINISHED 2. APPEARENCE MA VISUAL IS 8183 IS 8183 IS 3144 SHALL BE FREE FROM IR
VOIDS, CRACKS
PRODUCT)
3. BULK DENSITY MA LAB. TEST IS 8183 IS 8183 IS 3144 IS 8183/ TC √ P W V
VVF/CUSTOMER
4.SHOT CONTENT MA LAB. TEST IS 8183 IS 8183 IS 3144 APPROVED DATA SHEET TC √ P W V
5. SULPHUR CONTENT MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V .
6. ALKALINITY MA LAB. TEST IS 8183 IS 8183 IS 8183 TC √ P W V Routine tests
7. CHLORIDE MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
CONTENT
8. MOISTURE MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
CONTENT
9.THERMAL CR LAB. TEST IS 8183 IS 8183 IS 3346 IS 8183/ TC √ P W V Type test
CONDUCTIVITY VVF/CUSTOMER REFER NOTES 4 & 5
(K VALUE) APPROVED DATA SHEET
10. HEAT RESISTANCE MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
11.MOISTURE MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
ABSORPTION
12. RECOVERY AFTER MA LAB. TEST IS 8183 IS 8183 IS 8183
IS 8183/
TC √ P W V
COMPRESSION
VVF/CUSTOMER
13. MA LAB. TEST IS 8183 IS 8183 IS 3144 APPROVED DATA SHEET TC √ P W V
Type tests
INCOMBUSTIBILITY
REFER NOTE 6
14.RESISTANCE TO MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
VIBRATION
15. RESISTANCE TO MA LAB. TEST IS 8183 IS 8183 IS 3144 TC √ P W V
JOLTING
16. FIBRE DIAMETER MA LAB. TEST One for each One for each IS 3144 TC √ P W V
density density
3.2 PACKING & PACKING TYPE AND MA VISUAL RANDOM RANDOM VVF/CUSTOMER VVF/CUSTOMER SOFT √ P W - REFER NOTE 2
MARKING IDENTIFICATION APPROVED DATA APPROVED DATA SHEET/ COPY OF
MARKING SHEET/PACKING PACKING PROCEDURE PHOTO
PROCEDURE
GRAPH

VVF BIDDER/ SUPPLIER FOR CUSTOMER REVIEW & APPROVAL

ENGINEERING QUALITY Sign & Date Doc No:
Sign & Date Name Sign & Date Name Seal Sign & Date Name Seal
Prepared by: Sandip Kundu Checked by: A. Sangle Reviewed by:
Reviewed by: Vinayak Bamne Reviewed Aniruddha
by: Bansod Approved by:
 MANUFACTURER/BIDDER/VENDOR
NAME & ADDRESS
STANDARD QUALITY PLAN SPEC. NO : VVF-TIM-22-23-01 DATE: 13-05-2022
CUSTOMER : QP NO.: VVF-QP-22-23-01 DATE: 13-05-2022
VVF/Customer Approved Suppliers
PROJECT: DFA INDONESIA PO NO.: DATE:
ITEM: THERMAL INSULATION – RESIN BONDED MINERAL (ROCK) WOOL
SECTION: SHEET 3 OF 3
MATTRESSES
SL NO. COMPONENT & CHARACTERIST- CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
OPERATIONS ICS CHECK OF CHECK DOCUMENT NORMS RECORD
1 2 3 4 5 6 7 8 9 * ** 10
M C/N D M C N
NOTES:

1. In case of foreign supplier, all test certificates shall be furnished by the supplier, duly witnessed/verified by supplier’s TPI.
2. Following to be noted for packing:
a. Material shall be packed suitably in order to avoid damage during transit and also during storage at site in tropical climate conditions.
b. Photographs of items duly placed inside the box just before the final packing and Photographs of the box just before dispatch to be sent to VVF purchase group for review before issuing MDCC.
3. VVF reserves the right for conducting repeat test, if required.
4. ‘K’ Value test will be carried out on samples identified and sealed by VVF Inspector once in twelve (12) months irrespective of ongoing projects. The tests will be carried out at govt. approved labs (at CBRI -
Roorkee, IIT - Chennai or PIBCO R & D Centre, N. Delhi, NIRMA University, Ahmedabad). ‘K’ Value test will be carried out for at least three mean temperatures i.e.100 0C, 200 0C & 300 0C for each density.
5. Thermal conductivity type test reports shall be submitted to VVF Engineering for review and approval.
6. Type tests (except thermal conductivity) shall be done once in 3 months in the presence of VVF/VVF TPIA.
7. The latest revisions/year of issue of all the IS indicated in the QP shall be referred.

LEGENDS:

*D: Records, identified with "Tick"(√) shall be essentially included by supplier in QA Documentation.
** M: Supplier/ Manufacturer/ Sub-Supplier C: Main Supplier/VVF/ Third Party Inspection agency N: Customer
P: Perform W: Witness V: Verification
MA: Major Characteristic MI: Minor Characteristic CR: Critical Characteristic
IR: Inspection Report TC: Test Certificate `

VVF BIDDER/ SUPPLIER FOR CUSTOMER REVIEW & APPROVAL

ENGINEERING QUALITY Sign & Date Doc No:
Sign & Date Name Sign & Date Name Seal Sign & Date Name Seal
Prepared by: Sandip Kundu Checked by: A. Sangle Reviewed by:
Reviewed by: Vinayak Bamne Reviewed Aniruddha
by: Bansod Approved by:
 COMPLIANCE SHEET SPECIFICATION NO. VVF-TIM-22-23-01
BONDED MINERAL (ROCK) WOOL SECTION : II
MATTRESSES REV. NO.: 00 DATE: 13-05-2022
Sheet 1 of 1

I hereby comply/not comply (*) to all the requirements of this technical

specification in totality.

* In case the bidder does not comply to the technical specification, the
deviations shall be explicitly listed in the technical deviation sheet of GCC.
Deviations listed in technical deviation sheet shall only be considered.

Name of Bidder / Authorized Representative :- _______________

Designation :- _______________

Signature :- _______________

Company Seal :- _______________

Date :- _______________

PARTICULARS OF BIDDER / AUTHORISED REPRESENTATIVE

NAME DESIGNATION SIGNATURE DATE COMPANY SEAL