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in order to promote transparency and accountability in the working of every public authority,
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education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

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Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 8119 (1976): Copper brazed steel tubing [MTD 19: Steel

Tubes, Pipes abd Fittings]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”

है”
ह
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
 IS : 8119- 1976
(Reaffirmed 2002)
Indian Standard
SPECIFICATION FOR
COPPER BRAZED STEEL TUBING

( First Reprint OCTOBER 1990 )

UDC 621.643.2:669.146.9-462.2:669.387:621.791.36

0 Copyright 1976
BUREAU OF INDIAN STANDARDS
MAKAK BtlAVAN. 9 BAHADUR SHAH ZAFAR MARG
NtiW DELHI 1loo02

Gt3 Odober 1976

J

IS I 8119- 1976

Indian Standard ’

SPECIFICATION FOR
COPPER BRAZED STEEL TUBING
Steel Tubes, Pipes and Fittings Sectional Committee, SMDC 22

Chairman Representing
SHRI J. G. KESWANI Indian Tube Co Ltd, Calcutta

Members
SHRI S. C. ANAND Bharat Steel Tubes Ltd, New Delhi
SHIU K. C. SRIV~ST~VA ( Alternnte )
SHRI E. ANANDA RAO Tube Products of India, Madras
SHRI T. SIV~SHANKAR ( Alternate )
ASSISTANT DIRECTOR STANDARDS Ministry of Railways
s;R$“,;Hz;xNow
Hindustan Steel Ltd, Rourkela
S&I C. Das GVPTA ( Alternate )
SHRI B. B. CHAKRAVERTI Superintendence Co of India ( Private ) Ltd,
Calcutta
SHRI A. K. SHOME ( Alternate )
DR R. K. DUBEY National Metallurgical Laboratory ( CSIR ),
Jamshedpur
EXECUTIVE ENOINEER, CENTRAL Central Public Works Department, New Delhi
STORES DIVISION No. 1
SHRI S. K. GUPTA Indian Tube Co Ltd, Jamshedpur
SHRI D. DUTTA ( Alternate )
SHRI T. N. JH~ Central Boilers Board. New Dellti
SHRI JACOB JOHN Kalinga Tubes Ltd, Calcutta
SHRI AJIT MOHaPATRA ( &&?I& )
SHRI M. T. KANSE Directorate General of Supplies & Disposals
( Inspection Wing ), New Delhi
SKRI S. C. KAPUR ( Alternate )
SHRI B. Kul1.4~ Stewarts & Lloyds of India Ltd, Calcutta
SHRI P. N. CHOWRANCHI (_Alternale )
CDR V. N. ~IADHAV RAO Defence Metallurgical Research Laboratory,
Hyderabad
S+rnr S. MITT.~L Indian Oil Corporation Ltd, Bombay
SHRI R. K. AIRY ( Alternnte)
SHRI S. NEELAKANTAN Zenith Steel Pipes Ltd, Khopoli
SHRI B. A. D~s.41 ( Alternate )
SIIKI GOP~L J. PATEI. Gu,jarat Steel Tubes Ltd, Ahmadabad
SHIII SHAILESH V. SHAH ( Alternate )
SHJ~I N. B. ROY CHOWDH~:TRY Burmah-Shell Refineries Ltd, Bombay
SHW S. L. ARANJIA ( Alternate )
( Continued on pn ge 2 )

@ Copyright 1976
BUREAU OF INDIAN STANDARDS
This publication is protected under the Indian Copyright Act ( XIV of 1957 ) and.
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
 IS : 8119- 1976

( Continued from page 1 )

Members Represeriting
&RI J. L. SET-I Public Works Department ( Public Health Branch ),
Government of Haryana, Chandigarh
SHP.I A. N. MEHESDALE ( Alternote )
SHRI s. SRIXIVASAN Hindustan
Shipyard Ltd, Visakhapatnam
&Rx M. C. KEW~VA RAO ( Altern& )
SHRI .A. SRINIVASULU Bharat Heavy Electric& Ltd, Tiruchirapalli
SIIJLI C. R. R_~NA RAO, Director General, IS1 ( Ex-oBcio Member )
Director ( Strut & Met )
( SecretmY )

Panel for Copwr Brazed Steel Tubes, SMDC-22 : P22

Conoener
SHRI D. DUTTA Indian Tube Co Ltd, Jamshedpur

Member
DR A. P. I\/IAIiADEVIN Bundy Tubing of India Ltd, Vadodara
SHRI S. SWAIINATRAN ( Alternate )

2
 IS r 8119 - 1976

Indian Standard
SPECIFICATION FOR
COPPER BRAZED STEEL TUBING

0. FOREWORD
0.1 This Indian Standard was adopted by the Indian Standards
Institution on 15 July 1976, after the draft finalized by the Steel Tubes,
Pipes and Fittings Sectional Committee had been approved by the
Structural and Metals Division Council.
0.2 There has been a long felt need for copper brazed steel tubes used
specially in automotive, refrigeration and stove industries for fuel lines,
brake lines, oil lines and in heating and cooling units. It is hoped that
this standard will give necessary guidance to the industry and users.
0.3 In the preparation of this standard assistance has been derived from
ASTM : A 254-1970 ‘ Specification for copper brazed steel tubing ’ issued
by the American Society for Testing and Materials.
0.4 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, express-
ing the result of a test or anaLyysis, shall be rounded off in accordance
with IS : 2-1960*. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this
standard.

1. SCOPE
1.1 This standard covers two classes of copper brazed steel tubes suitable
for general engineering uses, particularly inthe automotive, refrigeration,
and stove industries for fuel lines, brake lines, oil lines, heating and cool-
ing units, etc.

2. SUPPLY OF MATERIAL
2.1 General requirements relating to the supply of copper brazed steel
tubes shall conform to IS : 1387-19671_.

*Rules for rounding off numerical values ( revised ).

jGenera1 requirements for the supply of metallurgical materials (first revision ).
lS:8119-1976

3. MANUFACTURE

3.1 The steel shall be aluminium-killed, rimming or capped Steel and

shall be made by the open hearth, electric furnace, basic oxygen or a
combination of these processes.

3.2 The tubing shall be made by rolling electrolytically copper plated

steel strip in the form of tubes and subsequently brazing in a reducing
atmosphere.

3.3 Class 1 brazed tubes shall be constructed as shown in Fig. 1.

3.4 Class 2 brazed tubes shall be constructed as shown in Fig. 2.

0 0
SINGLE STRIP TYPE DOUBLE STRIP TYPE

FIG. 1 CLASS 1 BRAZEDTUBES DOUBLE WALL 360” BRAZED

CONSTRUCTION

BUTT @RAZED tYPE BEVEL.BRAZED TVPE

t(w .

Fro. 2 CLASS2 BRAZED TUBES SINGLE WALL CONSTRUCTION

4
 IS t 8119 - 1976

4. CHEMICAL REQUIREMENTS
4.1 The steel when analyzed in accordance with relevant parts of IS: 228;
shall conform to the following requirements:
Element Percent, Max
Carbon 0.10
Manganese 0’50
Phosphorus 0’035
Sulphur 0.035
4.2 Each heat shall be analyzed by the steel manufacturer to determine
the percentages of the elements specified in4.1. The chemical composition
thus determined shall be reported to the steel purchaser, or his represcn-
tative, and shall conform to the requirements specified.

5. MECHANICAL REQUIREMENTS
5.1 Tensile Test -Test pieces shall be taken from the ends of tubes
(prior to cold-work) and tested in accordance with IS : 1894-19727 and
shall comply with the following requirements:
Tensile strength 290 N/mma, Min
Yield strength 180 N/mm”, Min
Elongation on a gauge 25 percent, Min
length of 5 65 4A
5.2 Flattening Test-The test shall be conducted in accordance with
1s : 2328-1963:. A ring not less than 65 mm in length, cut from one end
of each selected tube shall, when cold, be flattened between two parallel
flat surfaces without showing any crack or flaw, until the inside walls are
in contact. In case of Class 2 tubes, the seam shall be located so as to
receive the maximum deformation upon flattening.
5.3 Expansion Test - It shall be carried out in accordance with
IS : 2335-19635. A section of tube approximately 50 mm in length shall
withstand being expanded over a tapered mandrel or cone having an
included angle of 30” until the outside diameter at the eipanded end is
increased 20 percent without cracking or otherwise showing flaws. Prior
to expansion test, tubes shall be cut off, square edge crowned and
deburred. The tube and cone shall remain concentric during expgdsion
tests.
-_-___
*Methods of chemical analysis of pig iron, cast iron, and plain carbon low alloy steels
( rcviscd).
+Methods for tensile testing of steel tubes (Jirst r~$~n ).
fMethod for flattening test on steel tubes.
OMethodfor drift expanding test on steel tubes.

5
 IS:8119-1976

5.4 Bend Test -The test sludl be carried out in accordance with
IS : 2Y29-1Wi3*. The tube selected ~for test. shah withstand bending
arolmd a cylindrical former through 360”, with the joint line at 90’- to
the plane of bending. The diameter of the former shall be six times the
outside diameter. The test piece shall withstand this test without
kinking, cracking or developing other flaws.
5.5 Bending Shear Test - If a cut piece of tube bent by hand in the
form of a hair pin (seam on inner side) shears-by reverse bending at
bending radius in a direction perpendicular to the axis of the bend,
neither should the walls of the tube separate nor should the seam get
cracked.
5.6 Non-destructive Testing - The tubes shall be checked 100 per-
cent for brazing and surface defects by non-destructive testing during
production ( see IS : 4853-19687 and Is : 7343-1974:).

6. HYDRAULIC TEST

6.1 Each tube shall be capable of withstanding hydraulic test for a

period of 5 seconds with no evidence of failure, at a pressure calculated
by the follo\ving equation:

p22!
D
where
P = hydraulic pressure in N/mm?;
S = allowable stress of material, that is;
1 IO N/mm? for Class I
45 N/mm2 for Class II;
t = wall thickness of tube in mm; and
D = outside diameter of tube in mm.

7. INSIDBURFACE CLEANLINESS
7.1 \Vhen specified by the purchaser, tubes for certain uses, such
as refrigeration condensers, shall conform to the following requirements
for internal cleanliness.
7.1.1 When a length of tube is washed, internally with redistilled
chloroform or redistilled trichloroethylene, the residue remaining upon
evaporation of the solvent shall not exceed 0.194 g/m*of internalsurface.

*Method for bend test on steel tubes.

tRecommended practice for radiographic examination of fusion welded circumferen-
tial joints in steel pipes.
$Code of practice for ultrasonic testing of welded pipes and tubular products.

6
 Es t 8119- 1976

To perform the test, pour 100 ml of solvent through the tube and collect.
The total length of tube tested shall be not less than 12.2 m, although
this total length may be obtained by washing several separate lengths
.and pouring the same solvent through each in succession. Evaporate
the solvent on a steam-bath or hot water-bath and dry at 110°C until
the vapours are completely removed.
7.2 To maintain this level of cleanliness in shipping, handling, and
storage, the purchaser may request the manufacturer to seal tube ends
with caps or closures.
8. DIMENSlONAL TOLERANCES
8.1 Tubes shall conform to permissible variations indimensions as speci-
fied below:
Outside Diameter

Below 4.8 mm f 0.05 mm

4.8 mm up to and including 95 mm f 0’08 mm
Over 9.5 mm up to and including 15.9 mm f 0’10 mm
Wall Thickness

0.50 mm up to and including 0.76 mm f 0.08 mm

Over~0.76 mm up to and including 1.25 mm f 0.09 mm
Length

Up to and including 0.5 m f 0’75 mm

Over 0.5 m up to and including 1.0 m f 1’5 mm
Over 1.0 m up to and including 20 m f 3’0 mm
Over 2.0 m up to and including 3.0 m h 6.0 mm
+ 25’0 mm
Over 3-O m
- 0’0 mm
9. WORKMANSHIP l

9.1 Finished tubes shall be clean, smooth and round, both inside and
outside and shall be free from rust, scale and defects which impair pro-
cessing and serviceability. Finished tubes shall be reasonably straight.

10. SUPPLEMENTARY RIQUiREMENTS

10.1 FlareTest -Class 1 tubes shall stand being double flared to the
dimensions shown in Tables 1 and 2. The double flaring shall be done
on square, deburred tube ends, using a hand tool or powered press, in
two stages. Jn the first stage a tool forms the upset (see Fig. 3A ), while
in the second stage another tool gives the final shape ( see Fig. 35).

7
IS t 8119- 1976

The tubes shall not split through the wall at the major diameter of
the flare. A separation of the outer lap joint is permissible on the flared
end of the tube only in area A (see Fig. 3 ). This separation shall not
exceed 3’0 mm in length and shall be confined to outer thickness only.
Seam separation is not permitted in the following areas:
a) Area B (the flare seat, defined as the surface within the 90”’
included angle): conical surface shall be smooth and free from
cracks or other irregularities that could cause leaks after
assembly.
b) Area C ( the surface beyond the length of the double thickness
cracked by the flare ).

3A First Stage in Double Flare Formation

38 Second Stage in Double Flare Formation

FIG. 3 DOUBLE FLARE TEST

8
 IS: 8119- 1976

TABLE 1 DIMENSIONS OF 45” FLARES

( Clause 10.1 and Fig. 4 )
All dimensions in millimetres.
NOMINAL DOUBLE FLAIW DIA, B, Corsw LENGTH,
OUTSIDE _-h--- C,,Min
DIAMETER A4a.v .Min
(‘1 (2) (3) (4)
3~18 5.4 5.0 1
476 7.1 6.7
6.35 9.1 8.7 :
7.94 10.8 10.4 1.6
9.52 12;7 12-3 1%
11.11 14.5 14.1
12.70 16.3 15.9 ::;
14.29 18.1 17.7 1.6
15.88 19.6 19.2 1.6

2 ‘I IMES ACTUAL WALL THICKNESS 2 o t>,,,m

WALLS TO’BE IN INTIMATE CONTACl
OVER ENTIRE SEAT LENGTH

ACTUAL TUBE ID+oaa

All dimensions in millimetres.

FIG. 4 DOUBLE 45” FLARES FOR TUBES
TABLE 2 DIMENSIONS OF 37” FLARES
( C’lause 10.1 and Fig. 5 )
All dimensions in millimetres.
NOXINAL DOUBLE FLARE DIA, B, RADIUS, WALL
OUTSIDE c__-__~ RI THICKNESS,
DIAMETER Max Min D,, Max
(1) (2) (3) (4) (5)
3’18 5.1 4.6 0.8 f 0.5 0.63
4.76 7’1 6.6 0.8 & 0’5 0.71
6’35 8.6 0.8 f 0.5 0.88
7.94
9.52
12
12.4
10.2
11.7
0.8
1.0
& 0.5
+ 0.5
0’88
1.24
12.70 16’7 16.0 1.5 ? 0.5 1.24
15.88 20.0 193 1’5 f 0.5 1.24
IS:8119-1976

WALLS TO BE
CONTACT OVE
SE AT LENGTH

ACTUAL TUBE IO +0.25

All climcnsions in millimetres.

FIG. 5 DOUBLE 37” FLARES FOR TUBES

10.2 External Coating -The outside surface of the tubes shall have
a coating of hot-dipped lead-tin alloy-coating or electroplated zinc
as specified by the purchaser. Weight and other requirements of coating
shall be agreed upon between the manufacturer and the purchaser.
10.3 End Finish -When so specified by the purchaser, finished tubes
shall have smooth ends free of burrs.

11. MARKING
11.1 The following information shall be marked on a tag or label securely
attached to the bundles or boxes in which the tubes are dispatched:
a) Manufacturer’s name or trade-mark,
b) Size, and
c) Class of tubes.
11.1.1 The tubes may also be marked with the ISI Certification Mark.
NOTE - The use of the ISI Certification Mark is governed by the provisions of the
Indian Standards Institution ( Certification Marks) Act and the Rules and Regulations
made thereunder. The ISI mark on products covered by an Indian Standard conveys
the assurance that they have been produced to comply with the requirements of that
standard under a well-defined system of inspection, testing and quality control which
is devised and supervised by ISI and operated by the producer. IS1 marked products
are also continuously checked by IS1 for conformity to that standard as a further safe-
guard. Details of conditions under which a licence for the use of the IS1 Certification
Mark may be granted to manufacturers or processors, may be obtained from the
Indian Standards Institution.

10
 IS t 8119 - 1976

12. INFORMATION TO BE SUPPLIED BY THE PURCHASER

12.1 The purchaser shall state in his enquiry or order:
a) the size ( outside diameter, wall thickness and length of tubes);
b) the class of tube required;
c) the inside surface cleanliness where requir&d;
d) the external coating where required; and
e) special requirements, if any.
 BUREAU OF INDIAN STANDARDS
Headquarters:
Manak Bhavan, 9 Bahadur Shah Zafar Marg. NEW DELHI 110002
Telephor;es: 331 01 31, 331 13 75 Telegrams: Manaksanstha
( Common to all Offices 1
Regional Offices: Telephone
Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg, 331 01 31
NEW DELHI 110002 331 1375
I
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Maniktola. CALCUTTA 700054
Northern : SC0 445-446, Sector 35-C, 21843
CHANDIGARH 160036 I 3 16 41
41 24 42
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{ t: f f ::
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BOMBAY 400093
Branch Offices:
‘Pushpak’. Nurmohamed Shaikh Marg, Khanpur, 2 63 46
AHMADABAD 380001 I 2 63 49
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inspection Offices ( With Sale Point ):
Pushpanjali. First Floor, 205-A West High Court Road, 2 51 71
Shankar Nagar Square, NAGPUR 440010
Institution of Engineers ( India ) Building, 1332 Shivaji Nagar, 5 24 35
PUNE 411005

*Sales Office in Calcutta is at 5 Chowringhse Approach, P. 0. Princep 27 68 00

Street. Calcutta 700072
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Bombay 400007
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Bangalore 560002

Reprography Ud.t, BIS, New Delhi, In tia

 AMENDMENT NO. 1 FEBRUARY1984
TO
IS:8119-1976 SPECIFICATION FOR COPPER BRAZED
STEEL TUBING

Alterations
------

(Page 5, dause 4.1) - Substitute the following

for the existing clause:

'4.1 The steel when analyzed shall.conform to the

following requirements:

Element Percent, Max

Carbon 0.10
Manganese 0.50
Phosphorus 0.035
Sulphur 0 0035

4.1.1 !Pheanalysis of steel shall be carried out

either by the method specified in IS:228* and its
relevant parts or any other established instrumental/
chemical method. In case of dispute the procedure
given in 18:228* and its relevant parts shall be
referee method. However, where the method is not
given in 1s:228* and its relevant parts, the referee
method shall be agreed to between the purchaser and
the manufacturer.'

(Page 5_,foot-note with I+' mark) - Substitute

the following for the existing foot-note:

'*Methods for chemical analysis of steels

(issued in several parts).'

(SMDC 22)

Reprography Unit, BIS, New Delhi, India