RAKSHA MANTRALAYA

MINISTRY OF DEFENCE
JOINT SERVICES SPECIFICATION
ON
HOSE ASSEMBLY, RUBBER SUCTION,
ARMOURED, HEAVY DUTY
(DS CAT NO. 4210-000 546)

JSS 4210-20 : 2001

MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, DHQ PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, DHQ PO
NEW DELHI - 110 011

JSS 4210 -20: 2001

RAKSHA MANTRALAYA
MINISTRY OF DEFENCE

JOINT SERVICES SPECIFICATION

ON

HOSE ASSEMBLY, RUBBER SUCTION,

ARMOURED, HEAVY DUTY
(DS CAT NO. 4210-000 546)

MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, DHQ PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, DHQ PO
NEW DELHI - 110 011
i

JSS 4210 -20: 2001

LIST OF MEMBERS ASSOCIATED WITH FORMULATION OF THIS
STANDARD
This Joint Service Specification has been approved by Brig Ashok Coomar,
Director, DQA(E), Chairman, Engineering Equipment Standardisation Sub Committee in
the 23rd Sub Committee Meeting held on 22 Sept 98 / by circulation.
2.
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

The following members were present/ consulted in approving the document:Name and Designation

Organisation

Shri NK Maahavar, DY. Dir.

Col Rakesh Puri
Col Gp Krishnamurthy
Lt Col M S Katti, Dy, Dir
Cdr S Chakravoty
Sqn Ldr Abharti, Bharti, Admit(T)
Sqn Ldr Naik, ADME (ASV) T
Lt Cdr A Rana, ADME
Shri JP Sing, Dy. Dir
Cdr Suresh Malhotra
Wg Cdr Satya Parkash
Shri SS Kundi
Shri CV Ramachandran, JASG
Cdr Brahm Swaroop
Shri JR Goyal, CSO
Wg Cdr NB Singh
Shri Iqbal Singh, To'B'
Maj Pawan Wahi, DDOS(5D)

JD(GE)- DGAQA, `H' Block,

CQA(E),Aundh Camp, Pune-411027
CQA(FE), Aundh Camp, Pune-411027
DQAE (e), Kashmir House, New Delhi
DQA (N), RK Puram, New Delhi
DMT, Air HQ, RK Puram, New Delhi
DMT, Air HQ, RK Puram, New Delhi
DOS 'E' NHQ, Sena Bhavan, New Delhi
DQA (WA),'H' Block, New Delhi
DFM, NHQ, Sena Bhavan, New Delhi
DES, Air HQ, RK Puram, New Delhi
HQ TGAME, Delhi Cantts
CQA(v), Ahmendnager-414001
DLS (Std Cell Navy), New Delhi
EM(Std Cell Navy), New Delhi
JDQAS (Air, RK Puram, New Delhi
Dte of Engg, R&D HQ, New Delhi
DGOS (OS-14), MGO BR, New Delhi
DIFR, Def R&D Org., Delhi-110054
Dte of Standardistion, New Delhi

Lt Col PK Mishra, Secy

ii

JSS 4210 -20: 2001

RECORD OF AMENDMENTS
Amendment
No.

Date

Amendment
pertains to :
Sl. No./Para No./
Column No.

Authority

Amended by
Name & Appointment
(IN BLOCK LETTERS)

iii

Signature
&
Date

JSS 4210 -20: 2001

CONTENTS
Page No.
0.

FOREWORD

1.

SCOPE

2.

RELATED SPECIFICATIONS

3.

STANDARD PATTERN

4.

MATERIAL

5.

MANUFACTURE/ CONSTRUCTION

6.

WORKMANSHIP AND FINISH

7.

MARKING

8.

PRE-INSPECTION OF STORES/ CONSIGNMENT

9.

QUALITY ASSURANCE

10.

WARRANTY

11.

PACKAGING

12.

DEFENCE STORES CATALOGUE NUMBER

13.

SUGGESTIONS FOR IMPROVEMENT

14.

APPENDIX 'A'

10

iv

JSS 4210 -20: 2001

0.

FOREWORD

0.1
This Joint Services Specification has been prepared by Engineering Equipment
Standardisation Sub Committee on the authority of the Standardisation Committee,
Ministry of Defence.
0.2
This specification has been approved by the Ministry of Defence and is
mandatory for use by the Defence Services.
0.3
This specification has been prepared based on Defence Specification
IND/CQAFE/PROV/0059(b) and supersedes the same.
0.4
This specification shall be used to guide design, manufacture, quality assurance
and procurement of Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete
with Screw Couplings used in Trailer/ Truck Fire Fighting & Crash Fire Tender.
0.5
Quality Assurance Authority for the item covered by this specification is
CQA(FE), Pune for Army, Navy and Air Force being inter service AHSP. Enquiries
regarding this specification relating to any contractual conditions should be addressed to
the Quality Assurance Authority named in the tender or contract. Other enquiries should
be referred to :The Director,
Directorate of Standardisation,
Ministry of Defence,
`H' Block, DHQ PO,
New Delhi - 110 011.
0.6

Copies of this specification can be obtained on payment from:The Controller,

Controllerate of Quality Assurance
(Fire Fighting Equipment),
Aundh Camp,
Pune - 411 027.

0.7

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

JSS 4210 -20: 2001

1.

SCOPE

1.1
This specification relates to manufacture, construction and quality assurance of
Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete with Screw
Couplings.

2.

RELATED SPECIFICATIONS

2.1

Reference is made in this specification to :(a)

IS 280:1978

Mild steel wire for general engineering purposes

(third revision)
(Amendment 1)
Reaffirmed 1992

(b)

IS 318:1981

Leaded tin bronze ingots and castings

(second revision)
Reaffirmed 1991

(c)

IS 443:1975

Methods of sampling and test for rubber hoses

(second revision)
(Amendments 2)
Reaffirmed 1991

(d)

IS 902:1992

Suction hose couplings for fire fighting purposes

(third revision)

(e)

IS 937:1981

Washers for water fittings for fire fighting

purposes
(second revision)
(Amendment 1)
Reaffirmed 1992

(f)

IS 3400(Part 1):1987

Methods of test for vulcanized rubbers: Part 1

Tensile stress-strain properties
(second revision)

(g)

IS 3400(Part 4):1987

Methods of test for vulcanized rubbers: Part 4

Accelerated Ageing
(second revision)

JSS 4210 -20: 2001

(h)

2.2

IS 3549:1983

Water suction and discharge

Hose or rubber, heavy duty
(second revision)
Reaffirmed 1991

Copies of the Indian Standards are obtainable on payment from :Bureau of Indian Standards,
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110 002.
or
their regional/branch offices

3.

STANDARD PATTERN

3.1
The Standard Pattern, if held with purchasing or Quality Assurance Authority,
may be referred and shall constitute a general guide only. The stores shall conform to this
specification otherwise.
3.2

4.

Hose assembly consists of the following components :

a)

Hose rubber suction armoured

b)

Coupling screw male with end connection.

c)

Coupling screw, female with washer and end connection.

MATERIAL

4.1
Material used for the manufacture of Hose Assembly, Rubber Suction, Armoured,
Heavy Duty shall be of the highest grade and shall conform to the latest relevant
specification.
4.2
Hose Assembly, Rubber Suction, Armoured, Heavy Duty shall be manufactured
from the following materials:
4.2.1

Hose Rubber

4.2.1.1 Lining and Cover: The lining and cover shall be made from a suitable rubber
compound conforming to the requirements of Clause 4.6 and 4.7 of IS 3549 and shall be
free from air blisters, porosity or any other visible defects.
3

JSS 4210 -20: 2001

4.2.1.2 Reinforcement: The re-inforcement shall be of woven fabric applied on bias at
approximately 45 angle. The woven fabric shall be well rubberized with a suitable
rubber compound.
4.2.1.3 Spiral Wire: The wire used for the helical reinforcement shall be galvanised steel
wire conforming to IS 280.
4.2.2 Coupling Screw and Washer: The coupling screw male and female shall be
made from copper alloy, sand casting conforming to IS 318 Gd-LTB.2. Washer for
female coupling shall be conforming to IS 937 (Type B).
4.2.3 Binding Wire: The wire used for binding the coupling with hose shall be
galvanised mild steel wire of 2 mm diameter conforming to IS 280.
5.

MANUFACTURE/CONSTRUCTION

5.1
The bore size of hose (nominal size 75 mm & 100 mm) when measured according
to the method prescribed in Clause 4.2.1.2 of IS 443 shall not vary more than 2.0 mm.
5.2
Thickness of lining filler and cover: The thickness of lining filler and cover
when measured according to the method prescribed in Clause 4.2.2 of IS 443 shall not be
less than that specified in Table 2 of IS 3549.
5.3
The dimensions/tolerances of coupling screw male and female (nominal size 75
mm & 100 mm) shall be conforming to IS 902.
5.4

Length

5.4.1 Hose Assembly, Rubber Suction, Armoured, Heavy Duty, Complete with Screw
Couplings shall be supplied in lengths of 2.5 m, 3 m and 4.5 m which includes the length
of soft end portions of the hose.
5.4.2 The length of the soft ends (ends free of wire) for hoses having nominal bore 75
mm and 100 mm shall be 100 5 mm and 125 5 mm respectively.
5.4.3 Tolerance on length of hose assembly, complete with couplings shall be + 2%, 1% and for this purpose the length shall be measured before the hose is subjected to
hydraulic pressure test.
5.5

Construction

5.5.1 Hose Rubber: Hose Rubber shall be constructed conforming to Clause 4.5.2 and
Clause 4.5.3 of IS 3549.
4

JSS 4210 -20: 2001

5.5.2

Coupling Screw: Coupling Screw shall be constructed conforming to IS 902.

5.5.3 Couplings shall be securely tied into enlarged ends of hose by means of
galvanised mild steel wire of 2 mm dia in close spacing. The shanks of the couplings
shall fit into the end of the hose to their full length. The binding wires shall then be
wound tightly over the ends of the hose covering the shanks making the joints water tight.
After binding the loose ends shall be turned in and the entire binding shall be soldered
along the place where the ends are turned in.
6.

WORKMANSHIP AND FINISH

6.1
Hose rubber shall be free from air blisters, porosity and other surface defects.
Couplings shall not have sharp edges. The water way shall have smooth finish. Wire
binding shall be done properly so that both the coupling screw do not come out from the
hose during use. Also, there should be no leakage while in use.
7.

MARKING

7.1

The Hose and Coupling shall be marked as per details given below:a)

Nomenclature:
i)

On Hoses

Complete nomenclature
indicating size

ii)

On Couplings

Screw Coupling Male/Female

indicating size

b)

DS Cat No.

c)

Month and year of manufacture

d)

Manufacturers Name/ Trade

Mark, if any

To be marked on Hoses as
well as on Couplings

JSS 4210 -20: 2001

8.

PRE-INSPECTION OF STORES/CONSIGNMENT

8.1
Manufacturers/suppliers shall satisfy themselves that the stores are in accordance
with the terms of the contract and fully conform to this specification by carrying out a
thorough pre- inspection of each lot before actually tendering the same for inspection to
the Quality Assurance Officer nominated under the terms of the contract. A declaration
by the contractor that necessary pre-inspection has been carried out on the stores
tendered, will be submitted alongwith the challan. The declaration will also indicate the
method followed in carrying out pre-inspection showing the feature checked/tested and
will have the test certificate attached to the challan/declaration.
8.2 If the Quality Assurance Officer finds that pre- inspection of the consignment as
required above has not been carried out, the consignment is liable for rejection.
9.

QUALITY ASSURANCE

9.1
The contractor shall extend to the Quality Assurance Authority or his authorised
representative, free of cost, all reasonable facilities for inspection and testing of stores
including inspection gauges for satisfying themselves that the stores are manufactured in
accordance with this specification and subcontractors premises at all times during run of
contract. The contractor shall notify to the Quality Assurance Authority, of all subcontract placed by him and provide inspection facilities for all stores so sub-contracted.
9.2
No deviation shall be accepted from the governing design and specification
without concurrence in writing of the Quality Assurance Authority. The contractor shall
remain responsible for quality/ quantity in any fabrication done by the subcontractors.
9.3
Detailed test schedule shall be followed as per the procedure given in Appendix
`A' attached with this specification.
9.4
The store shall be inspected at the supplier's premises for satisfactory performance
and proper packaging before despatch to the consignee.
9.5

Advance Sample

9.5.1 One advance sample of Hose Assembly, Rubber Suction, Armoured, Heavy Duty,
Complete with Screw Couplings of the required size duly wire bound together with
rubber compound, test slabs of sizes 300 x 300 x 2.5 mm and 150 x 150 x 6.5 mm,
used for Washer and 3 m each of Reinforcement Wire and Binding Wire shall be
submitted to the Controller, CQA(FE), Pune-27 for test and approval before
commencement of bulk production.

JSS 4210 -20: 2001

9.6

Performance Test

9.6.1 Couplings: Before wire binding both male and female couplings shall be
subjected to hydraulic pressure of 21 kgf/cm2 for a period of 2 minutes as per Clause 8 of
IS 902 and shall not show any sign of leakage or failure at the end of test.
9.6.2 Tensile Strength and Elongation at Break: This shall be tested on rubber
compound used on lining/ filler/ cover conforming to Clause 4.6 of IS 3549 i.e. Tensile
Strength and % Elongation at Break shall not be less than 7.0 MN/m2 and 300%
respectively when tested according to method prescribed in Clause 5 of IS 443.
9.6.3 Accelerated Ageing Test: This shall be carried out on rubber compound on
lining/ filler/ cover conforming to Clause 4.7 of IS 3549 and shall not vary by more than
+10%, -15% for tensile strength and percentage Elongation at break of corresponding
value obtained before ageing.
9.6.4

Hydrostatic Tests for Hose

9.6.4.1 When tested at designed working pressure of 0.7 MPa for 5 minutes, in
accordance with clause 8.3 of IS 443, it shall not show any leakage or failure at the end of
test.
9.6.4.2 Elongation of nose at its designed working pressure shall be tested conforming to
Clause 4.8.1 of IS 3549. It shall not exceed 7.5 % of its original length measured at 0.07
MPa hydraulic pressure.
9.6.4.3 Proof Pressure Test: This shall be tested to 1 times (one and half times) the
design working pressure i.e. 1.05 MPa as per Clause 4.8.2 of IS 3549 for a period of
1 minute without any failure/ damage to the hose.
9.6.4.4 Burst Pressure Test: This shall be tested conforming to Clause 4.8.3 of IS 3549.
Hose shall not burst till the pressure is 3 times, the design working i.e. at 2.1 MPa.
9.6.4.5 Resistance to Vacuum: This shall be tested as per Clause 4.9 of IS 3549, when
tested under vacuum of 83 kPa (approximately 625 mm of mercury) hose should not
collapse. In case of smooth bore Hose, there shall not be any separation of the ply and the
lining.

JSS 4210 -20: 2001

10.

WARRANTY

10.1 The stores supplied shall bear a warranty as per contract. In absence of such
mention, the following warranty shall apply.
" The stores supplied against this specification shall be deemed to bear a warranty of the
contractor against defective design, material, workmanship and performance for a period
of 12 months from the date of receipt of stores by the consignee. During this period, if
any of stores is found to be defective by the consignee, the same shall be replaced by the
supplier, free of any charges at the consignee`s end but not later than 3 months from
receipt of such intimation."
11.

PACKAGING

11.1 The store shall be delivered in new, clear, dry and sound condition duly preserved
with french chalk and only the accepted stores duly stamped with Acceptance Mark shall
be packed as per details given below:"Each length of Hose connected with Screw Couplings duly preserved shall be
completely wrapped spirally with double layer of 15 cm strip of cloth Hessian Medium
with sufficient over lapping after providing cushioning material at both the coupling
ends, so as to prevent any damage during transit. The overlapped portion of the Hessian
Cloth shall be securely stitched with double 3 Ply Jute Twine with not less than
12 stitches per decimeter, taking care not to pierce the Hose during stitching."
NOTE: The packing material to be used for packing shall be got approved by the
Quality Assurance Officer.
11.2 Before despatch, each package shall be legibly marked with indelible ink or paint
showing the following details:i)
ii)
iii)
iv)
v)
vi)
Vii)
viii)

DS Cat No. and Nomenclature

Sl. No. of package
Month and year of packing
Suppliers Name or Trade Mark
Name and Address of Consignee
AT/SO No. and date
Inspection Note No. and date
Gross Mass of the package in kg.

JSS 4210 -20: 2001

12.

DEFENCE STORES CATALOGUE NUMBER

12.1

The Defence Store Catalogue Numbers allotted to the store are as follows:-

i)
ii)
iii)
iv)
v)
vi)

Nomenclature
Hose Assembly Rubber
Suction Armoured
-do-do-do-do-do-

Size (Dia x Length)

75 mm x 2.5 m

DS Cat/Part No.
4210-002 580

75 mm x 3 m
75 mm x 4.5 m
100 mm x 2.5 m
100 mm x 3 m
100 mm x 4.5 m

4210-002 637
4210-002 581
4210-002 582
4210-002 636
4210-002 583

13.

SUGGESTIONS FOR IMPROVEMENT

13.1

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

The Director
Directorate of Standardisation
Ministry of Defence
'H' Block, DHQ PO,
NEW DELHI - 110 011

JSS 4210 -20: 2001

APPENDIX `A'
(Refer para 9.3)
TEST SCHEDULE
FOR
HOSE ASSEMBLY, RUBBER SUCTION, ARMOURED, HEAVY DUTY,
COMPLETE WITH SCREW COUPLINGS
Sl. No.
1.

Test
VISUAL EXAMINATION: 100%
a) Each length of hose connected with coupling
screw, one end male and other end female, duly
wire bound of required size against the order shall
be checked visually for any material defects, like
porosity blow hole, scales, cracks on the outer/
inner surfaces of the couplings and hose. Any
other deformities/ damages to the parts and
fitment shall also be checked.

Remarks
It shall be free from all defects.
The water way shall have
smooth

It shall cover all the details

b) Marking : 100%
The store shall be marked/ stamped with all the
details as per clause 7 of this specification.
2.

MATERIAL
Material should conform to
clause 4 of the specification
requirement.

a) Lining and cover

b) Reinforcement
c) Spiral wire
d) Coupling screw and washer
e) Binding wire

10

JSS 4210 -20: 2001

Sl. No.
3.

Test

Remarks

DIMENSIONAL TEST
The hose rubber selected at random from the lot
shall be tested for dimensions of the following
components: a) Hose: The bore size and thickness shall be The dimensions shall be
strictly as per the specification
measured in accordance with the method.
requirement
Inter
change
Described in Clause 4.2 of IS 443
ability shall be checked with
gauges sampling as per Table 1
of IS 443
b) Coupling screw (with enlarged end & shanks) Same sampling plan i.e. Table
shall be checked as per IS 902
1 of IS 443 adopted for Hose
be also adopted for Male
Coupling, Female Nut and
Washer.

4.

c) Washer Type 'B' shall be checked as per

IS 937.
TESTS

-do-

a) Coupling Screw Hydraulic Test

During and after the test there
All the coupling shall be tested for hydraulic test shall not be any sign of
as per Clause 9.6.1 of this specification (Test leakage or failure.
pressure 21 kgf/cm for 2 minutes)

11

JSS 4210 -20: 2001

Sl. No.

Test

Remarks

Tensile strength shall not be

less than 7 MN/m2 and
Minimum one sample of rubber compound used elongation at break shall not be
in the lining filler and cover of the hose from less than300%.
each lot shall be tested as per Clause 9.6.2 of this
Specification.
b) Tensile Strength and Elongation at Break :

c) Accelerated Ageing Test

Minimum one number of rubber compound from
each lot used for lining, filler and cover shall be
tested as per Clause 9.6.3 of this specification.
The tensile strength and elongation at break shall.
be checked/measured after ageing.

Variation in tensile strength

and percentage elongation at
break after ageing shall not be
more than +10%, -15% of the
corresponding values obtained
before ageing

d) Hydrostatic Test
i) All the hoses on order shall be tested at No sign of leakage from hose
designed working pressure (0.7 MPa) as per coupling or wire binding shall
be observed.
Clause 9.6.4.1 of this specification.
ii) While testing hose as per (i) above elongation Change in length shall not
at designed working pressure shall be checked as exceed 7.5% of its original
length measured at 0.07 MPa
per Clause 9.6.4.2 of this specification.
hydraulic pressures.
iii) Proof Pressure Test
Hose assembly shall be checked as per Clause It should withstand the proof
test pressure for one minute
9.6.4.3 of this Specification.
without any failure or damage
to the hose. Sampling as per
Table I of IS 443.

12

JSS 4210 -20: 2001

Sl. No.

Test

Remarks

iv) Burst Pressure Test

This shall be carried out as per Clause 9.6.4.4 of
this specification.

One No. per order or at the

discretion
of
Quality
Assurance Officer shall be
selected from the lot. During
the test it should not burst.

e) Resistance to Vacuum
Qty one number of hose fitted with couplings
from each lot should be tested in accordance with
the method prescribed in Clause 14 of IS 443
under vacuum of 83 KPa (625 mm of mercury
approximately)
5.

During the test the lining and

cover of the Hose shall not
show any sign of collapse or
blistering or there shall not be
any sign of separation of Ply
and the lining.

PACKING AND MARKING

Marking on stores, packing and marking on It should be strictly as per
packages shall be checked as per Clause 7 and 11 specification requirements.
of this specification.

13