DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/PRBO

DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS
Our Ref.: NRO/PRBO
13 Jan 2014
Please find enclosed the following draft certification manual:
Product manual on Portland Pozzolana Cement Part 2 Calcined Clay Based
as per IS 1489 (Pt 2) : 1991
Kindly examine the draft product certification manual and forward your comments on the
draft manuals.
Last date for comments: 28 Jan 2014.
Comments, if any, may please be made in the format as given below and mailed to PRBO at
the following email id: nlbo@bis.org.in.
Sl.
No.
Name
of RO /
BO
Clause/
Sub-clause
Paragraph /
Figure /
Table
Type of
comment
(General /
Technical /
Editorial)
Comments
Proposed Change
Note: Separate sheets may be attached in case comments are lengthy and cannot be
incorporated in the table.
For BIS Use Only
Doc No.: SM/IS 1489 Pt 2/01
Date of Issue: January 2014
PRODUCT MANUAL
FOR
PORTLAND POZZOLANA CEMENT
PART 2 CALCINED CLAY BASED
(First Issue)
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9, BAHADUR SHAH ZAFAR MARG,
NEW DELHI – 110002
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
PRODUCT MANUAL
DATE: NOV 2013
APPROVED BY:
PAGE: 1 OF 4
AMENDMENT SHEET
To ensure that each copy of the Manual contains a complete record of Amendments, this
Amendment Sheet should be updated for each revised/new pages of the Manual. While
issuing any amendment, an acknowledgment slip will be included for signatures and return
by all Controlled Copy holders.
DISCARD
AMENDMENT
No.
Section
Page
Issue
No.
INSERT
Date
Section
Page
Issue
No.
SUMMARY
OF
CHANGE
Date
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
DATE: NOV 2013
APPROVED BY:
PRODUCT MANUAL
PAGE: 2 OF 4
FOREWORD
This Indian Standard ( Part 2 ) ( Third Revision ) was adopted by the Bureau of Indian
Standards after the draft finalized by the Cement and Concrete Sectional Committee had been
approved by the Civil Engineering Division Council. Portland-pozzolana
pozzolana cement can be
produced either by grinding together Portland cement clinker and pozzolana with addition of
gypsum or calcium sulphate, or by intimately
intimat
and uniformly blending Portland cement and
fine pozzolana. While grinding of the two materials together presents no difficulty, the
mixing of dry powders uniformly is extremely difficult. The blending method should,
therefore, be resorted to only when the grinding method is impossible or proves
uneconomical in a particular case. Where blending method is adopted, every care should be
taken to see that the blending is as intimate as possible. Generally, if the blending is not
uniform, it is reflected in the
he performance tests. The Sectional Committee responsible for the
preparation of this specification is of the opinion that the blending method should be confined
to factories and such other works where intimate and uniform blending is feasible with the
employment
loyment of requisite machinery so as to ensure uniformity of production and guaranteed
performance. Portland-pozzolana
pozzolana cement produces less heat of hydration and offers greater
resistance to the attack of aggressive waters than normal Portland cement. More
Moreover, it
reduces the leaching of calcium hydroxide liberated during the setting and hydration of
cement. It is particularly useful in marine and hydraulic construction and other mass concrete
structures. Portland-pozzolana
pozzolana cement can generally be used wherever
ever 33 grade ordinary
Portland cement is usable under normal conditions. However, it should be appreciated that all
pozzolanas need not necessarily contribute to strength at early ages. In view of this fact, this
present specification has been prepared to enable manufacturers to produce Portland
Portlandpozzolana cement equivalent to 33 grade ordinary Portland cement on the basis of 3, 7 and
28-days compressive strength. For construction of structures using rapid
pid construction
methods like slip form construction, Portland pozzolana cement shall be used with caution
since 4 to 6 h strength of concrete is significant in such construction. This standard was first
published in 1962 and subsequently revised in 1967 and 1976. In this revision the standard
has been split into two parts based on the pozzolana used in the manufacture of such cements
in view of the special needs of some hydraulic structures which require pozzolana cement
manufactured only with fly ash pozzolana and for easy identification of pozzolana used in the
manufacture of Portland-pozzolana
pozzolana cement in the interest of consumers. Part 1 of this
standard covers pozzolana cement manufactured by using only fly ash pozzolana and Part 2
covers pozzolana cement manufactured by using either calcined clay or a mixture
mixture of calcined
clay and fly ash as pozzolana. In this revision both chemical and physical requirements have
been kept the same as was given in 1976 version of this standard as amended from time to
time. Various requirements of Portland
Portland-pozzolana cement given
ven in 1976 version of this
standard had been modified from time to time by issuing amendments based on the
experience gained with the use of the standard and the requirements of the users and also
keeping in view the raw materials and fuel available in the
the country for manufacture of cement
The important amendments include lowering the value of compressive strength in lime
reactivity test from 5 MPa to 4 MPa, incorporating a value of 3 day compressive strength as
16 MPa, modifying the requirement of sulphur
sulphuric
ic anhydride ( SOs ) and insoluble residue,
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
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deleting the requirement of pozzolanicity test, increasing the
the value of 28 days compressive
strength
th from 31 MPa to 33 MPa, making autoclave soundness test compulsory irrespcctivc
of the magnesia content in cement,
ment, incorporating a provision for retest in respect of autoclave
soundness test after aeration of the cement, incorporating a clause on false set of cement and
permitting packaging of cement in 25 kg bag\.
bag All thc\c an~enclments have been taken care
of in this revision. Mass of cement packed in bags and the tolerance
tolerance requirements for the
mass of cement packed in bags shall be in accordance with the relevant provisions of the
standard of weight and measures (packaged commodities) Rules 1977 and B
B- 1.2 (See
Annexure B). Any modification in these rules in respect
respe of tolerance on mass of cement
would apply automatically to this standard.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
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PRODUCT MANUAL
PAGE: 4 OF 4
TABLE OF CONTENTS
C
Sections
Title
Section 1
Product Description
1.1
Description of product(s)
1.2
Latest Indian Standard Number with product title and number
of amendments
1.3
List of referred standards
1.4
Checklist for submission of an application for grant of licence
Section 2
Raw materials/ Components
2.1
List of important raw materials/components
Section 3
Manufacturing process and In-process
In
Quality controls
3.1
Description of manufacturing process(es)
3.2
Infrastructure for production
Section 4
Certification criteria
4.1
Identification of critical requirements
4.2
Scheme of testing and inspection
4.3
Marking fee rates
4.4
Grouping guidelines
4.5
Guidelines for scope of licence
4.6
Guidelines for inclusion of new varieties
4.7
Sample size and Guidelines for drawl of separate samples
4.8
Manner of sealing of sample(s)
4.9
Dealing with sample remnants
4.10
Procedure for destruction of non conforming product
Section 5
Inspection and testing
5.1
Packaging material requirement
5.2
List of test equipment/ facilities
5.3
Test facilities in BIS Labs/ OSLs with testing charges and
approximate
mate time
5.4
Basis of grant of licence
5.5
Details of tests to be carried out in the factory
Annexes
Annexure – 1
Page No.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
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PRODUCT MANUAL
PAGE: 1 OF 2
SECTION 1: PRODUCT DESCRIPTION
1.1. Description of product: The Portland Pozzolana Cement is a kind of Blended Cement
which is produced by either inter grinding of clinker along with gypsum and pozzolanic
materials in certain proportions or grinding the OPC clinker, gypsum and Pozzolanic
materials separately and thoroughly blending them in certain proportions.
Portland Clinker
Clinker, consisting mostly of calcium silicates, obtained by heating to incipient fusion, a
predetermined and homogeneous mixture of materials principally containing lime ( CaO )
and silica ( SiO2 ) with a smaller proportion of alumina ( Al 2O3 ) and iron oxide ( Fe 203 ).
Pozzolana
An essentially silicious material which while in itself possessing little or no cementitious
properties will, in finely divided form and in the presence of water, react with calcium
hydroxide at ambient temperature to form compounds possessing cementitious
ous properties.
The term includes natural volcanic material having pozzolanic properties as also other natural
and artificial materials, such as diatomaceous earth, calcined clay and fly ash.
1.2. Latest Indian Standard Number with product title and number of amendments
Indian Standard Number: IS 1489: Pt 2: 1991
Product title: Portland Pozzolana Cement Part 2 Calcined clay based
No. of amendments: 4
1.2. List of referred standards
IS No.
269:1989
650:1991
1344:1981
Title
IS No.
Specification for 33 grade 4032:1985
ordinary Portland cement
(fourth
revision )
Specification for standard sand 4845:1968
for testing of cement ( second
revision )
Specification for calcined clay 4905:1968
pozzolana ( second revision )
Title
Method of chemical analysis of
hydraulic cement (Jirst revision
)
Definitions and terminology
relating
to hydraulic cement
Methods for random sampling
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
1727:1967
Methods of test for pozzolanic
materials ( first revision )
2580:1982
Specification for jute sacking
bags
for packing cement ( second
revision )
Methods of sampling
hydraulic
cements (first revision )
3535:1986
3812:1981
Specification for fly ash for
use as
pbzzolana and admixture
(first
revision )
DATE: NOV 2013
APPROVED BY:
PRODUCT MANUAL
PAGE: 2 OF 2
11652:1986 Specification for high density
polyethylene ( HDPE ) woven
sacks for packing cement
11653:1986 Specification for polypropylene
(PP ) woven sacks for packing
Cement
11761:1986 Specification for multi
multi-wall
paper
sacks for cement valved-sewn
valved
gusseted
12154:1987 Specification for light weight
jute
bags for packing cement
4041 (Part Methods of physical tests for
12174:1987 Specification for jute synthetic
1 to 14)
hydraulic cement
union bag for packing cement
12423:1988 Method
for
calorimetric
analysis
of hydraulic cement
1.4. Check-list
list for submission of an application for grant of licence: As per Annexure 1
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
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DATE: NOV 2013
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SECTION 2: RAW MATERIALS/ COMPONENTS
2.1. List of important raw materials/components
a)
b)
c)
d)
Pozzolana
Portland Cement Clinker
Portland cement
Other Admixture – Gypsum (Natural or Chemical)
PRODUCT MANUAL
PAGE: 1 OF 1
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
PRODUCT MANUAL
DATE: NOV 2013
APPROVED BY:
PAGE: 1 OF 2
SECTION 3: MANUFACTURING PROCESS AND IN-PROCESS
IN PROCESS QUALITY
CONTROLS
3.1. Description of manufacturing process
A TYPICAL PROCESS FLOW CHART
Raw material receiving
↓
Laboratory Testing
↓
PASS
NO
Yes
Grinding
↓
Blending of components
↓
Fine Grinding
↓
Burning (in kiln)
↓
Finish grinding
↓
Laboratory testing
↓
PACKING AND DESPATCH
Return to supplier
BUREAU OF INDIAN STANDARDS
ST
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TITLE: GENERAL
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3.2. Infrastructure for production
Following basic manufacturing facilities shall be available at applicant unit for the production
of Rubber hose:
Sl No.
1
2
3
4
5
6
7
8
9
10
Name Of Machinery
jaw crusher (For Lime stone, Clay,
Iron dust, coke, Clinker)
Hammer mill
Raw mill
Kiln
Blower
Cement mill
Packing machine
Elevator
Belt conveyor
Reverse pulse jet
The capacity and number of manufacturing machines or testing machines may vary as per
production needs and applicability. The process quality controls shall be followed as per STI
for the product.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
DATE: NOV 2013
APPROVED BY:
PRODUCT MANUAL
PAGE: 1 OF 2
SECTION 4: CERTIFICATION CRITERIA
4.1. Identification of critical requirements
All requirements documented in standard shall be considered critical unless mentioned
otherwise.
4.2. Scheme of testing and inspection
The STI for IS 1489 part-2 as in force shall be applicable i.e. Doc: STI /1489 (Part
(Part-2)/Pack/4,
October 2004. The implementation
ion of STI shall be verified during surveillance inspection.
4.3. Marking fee rates
The details of rate of marking fee are available on BIS intranet/website.
4.4. Grouping guidelines
No grouping guidelines are available for IS 1489 Pt-2
Pt : 1991
4.5. Guidelines for scope of licence
Licence shall be granted with scope specifying the type(s) of the product. Licence shall not be
granted with “open scope”. The grant of licence letter and the Licence Document shall clearly
indicate the following:
‘Portland Pozzolana Cement Part 2 Calcined Clay based’
4.6. Guidelines for inclusion of new varieties
No other varieties are available for PPC cement Part 2 Calcined Clay based.
4.7. Sample size and Guidelines for drawl of separate samples
Sample sizes - 8 kg for mechanical testing
500 g for chemical testing
In cases where only partial testing is to be done in any of the approved laboratories, the
samples shall be draw in duplicate and send them directly to the concerned laboratory for the
appropriate tests, indicating in the test request, the tests which are to be carried out. The
information about the laboratory where the test could be carried out, may be obtained from
CL, if required.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
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4.8. Manner of sealing of sample(s)
sample(s
Effort shall be made, as far as possible, to send samples without the manufacturer’s
identification and/or markings. Any label and/or manufacturer's identification shall be
removed or defaced.
Test request shall clearly indicate the following:
a) Date of manufacture;
b) Quantity,
c) Week No.
d) Pozzolana content
The sample
le shall be sealed in a manner that moisture doesn’t come in contact with the
sample. For this sample may be sealed in air tight plastic jar or plastic bag.
4.9. Dealing with sample remnants
The remnants of samples may be disposed off after testing.
4.10. Procedure for destruction of non conforming product
The non conforming cement shall be disposed off .
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
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DATE: NOV 2013
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SECTION 5: INSPECTION AND TESTING
5.1. Packaging material requirement
The PPC cement shall be pack in bags. The cement shall be packed in bags [ jute sacking bag
conforming to IS 2580 : 1982, double hessian bituminized ( CR1 type), multiwall paper
conforming to IS 11761 : 1986, polyethylene lined ( CR1 type ) jute, lightweight jute
conforming to IS I2154 : 1987, woven HDPE conforming to IS 11652 : 1986, woven
polypropylene conforming to IS 11653 : 1986, jute synthetic union conforming to IS 12174 :
1987 or any other approved composite bags ] bearing the manufacturer’s name or his
registered trade-mark,
mark, if any. The words ‘Portland-pozzolana cement - calcined clay based’
or a bright colour band to distinguish Portland calcined clay based pozzolana cements from
other cements and the number of bags ( net mass ) to the tonne or the nominal average net
mass of the cement shall be legibly and indelibly marked on .each bag. Bags shall be in good
condition at the time of inspection.
5.2.
.2. List of test equipment/ facilities
The list of test equipment is to be prepared / provided by CL.
5.3. Test facilities in BIS Labs/ OSLs with testing charges and approximate time
The list of BIS laboratories and laboratories recognized by BIS, where sample of PPC cement
part-2 can be sent for independent testing, are available on BIS intranet/website. The
inspecting officer/agent shall collect latest status in respect of any labora
laboratory before
proceeding for inspection.
5.4. Basis of grant of licence
The basis of grant of licence shall be based on satisfactory preliminary inspection and passing
of drawn sample in independent testing. The preliminary inspection shall be done after
permission granted by Cement Desk for manufacturing of non ISI mark cement.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
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PREPARED BY:
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5.5. Details of tests to be carried out in the factory
Following tests may be carried out in factory:
Sr No.
TEST DETAILS
Cl No. Test Methods
Requirements
REMARKS
PHYSICAL REQUIREMENTS
1.
2.
3.
4.
Fineness
Soundness
Setting time
Compressive
Strength
5.
Drying Shrinkage
7.1
7.2
7.3
7.4
IS 4031 Pt-2 1988
IS 4031 Pt-3 1988
IS 4031 Pt-5 1988
IS 4031 Pt-6 1988
7.5
IS 4031 Pt-10 1988
One day
One day
One day
After 3 days
After 7 days
After 28 days
One day
CHEMICAL REQUIREMENTS
6.
7.
8.
9.
Loss on Ignition
(% by mass)
Magnesia
(% by mass)
Sulphuric anhydride
(% by mass)
Insoluble mataerial
(% by mass)
6
IS 4032:1985
One day
6
IS 4032:1985
One day
6
IS 4032:1985
One day
6
IS 4032:1985
One day
BUREAU OF INDIAN STANDARDS
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TITLE: GENERAL
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Annexure - 1
CHECK-LIST
LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS
WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS
The following check-list
list is required to be submitted with all the applications for grant of BIS licence under
the Product Certification Scheme of BIS. Please tick ((√) in the relevant box.
Whether applied under: Simplified Procedure
□
Normal Procedure
□
Note: Refer BIS website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence.
No.
Check-point
General
1.
Name &
Address
2.
Status of
Applicant
(Manufacturi
ng
Unit)
3
IS No. &
Varieties
4.
History
5.
Signature
6.
Machinery
Requirement
Is the application form completely filled?
Is the name and address of applicant (manufacturing
unit applying for licence) same in the application as
given in the attached document of Central/State
Government
a. Has it been indicated whether the applicant is a
large scale or small scale unit?
b. In case the applicant is a small scale unit, does the
applicant hold valid Registration Certificate from
the Local / State authority or from a Chartered
Accountant, and is the certificate attached.
c. Has it been indicated whether the applicant is a
Public Sector or a Private Sector company?
a. Has applicant recorded the applicable Indian
Standard with correct title of the Standard?
b. Where applicable, has applicant
a
mentioned
designation, grade, type, variety, size, etc., of the
product for which the BIS licence is sought?
a. Where applicable, has the applicant provided
information regarding earlier BIS licence(s) held by
them and / or cancelled in the past?
b. Where applicable, has the applicant provided
information regarding BIS licences currently held
by them?
a. Is the application signed by the CEO of the
applicant?
b. In case the application is signed
si
by a person other
than the CEO, is the application signed by the
authorized signatory of the applicant and his
authorization
uthorization is attached by the authorized
signatory?
a. Does applicant possess requisite
requisi manufacturing
infrastructure to manufacture the product as per the
Indian Standard?
Observations
Page No.
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
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b. Is installed capacity of production indicated in the
application?
7.
Test
Equipment
&
Calibration
8.
QC personnel
9.
Raw
Materials
and
Components
10.
Plant Layout
c. Does applicant have all machineries installed as
per manufacturing process at the applicant’s
applicant’
manufacturing premises?
d. If answer to ‘c’ above is no, does the applicant
outsource any of its manufacturing processes and
possesses
valid
agreement(s)
with
other
manufacturing units for the outsourced processes
and traceability of material, thus produced, etc.?
e. If answer to ‘d’ above is yes, does the applicant
has any control over such outsourced activity? Are
these outsourced process will ensure testing the
quality
uality of final product for all requirements at the
applicant's manufacturing premises?
a. Does applicant possesses requisite
requis test facilities
in-house
house as per the relevant Indian Standard at its
factory address?
b. Are valid calibration certificates
certifica for relevant test
equipment attached are complete and valid
va at least 3
months after the date of recording?
c. If reply to ‘a’ above is no, does applicant have
arrangement with a BIS recognized outside lab for
testing of the requirements for which it does not
possess
ossess test facilities inhouse? Is the consent letter
ass attached by applicant in this regard in order?
Note: Relaxation in in-house
in
test facilities may be
allowed on submission of proper justification for
requirements which are obligatory to get tested and
for which frequency of testing, as prescribed in the
relevant scheme of testing and inspection (STI),
is, normally, one month or more.
more
Does the applicant employ qualified & experienced
Quality Control (QC) personnel on permanent basis
and possess documentary evidence to establish the
same?? Are the copies of the qualification certificates
andd appointment letters of the QC personnel are in
order.
Where ever requirements for raw
ra
materials/
components used in the manufacturing of the
product aree specified in the standard, do test
reports/suppliers’ test ce
certificates, as submitted by
the applicant show that these requirements are met
as per the standard?
Does copy of the plant (applicant manufacturing
premises) layout clearly indicates locations of
manufacturing machinery, laboratory, office,
workshop, amenities, storage area, etc.?
PRODUCT MANUAL
PAGE: 2 OF 3
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
11.
Test
Report(s)
12.
Undertaking
ISSUE: 01
DATE: NOV 2013
APPROVED BY:
a. Is the attached test report of in-house or from
independent laboratory cover all requirements of the
Indian Standard and ispassing in such requirements?
b. In case the application is filed under “simplified
Procedure” is the test report(s), in original, as
submitted a) from BIS or its recognized
laboratories? b) the test report is not older than
one month from the date of submission of
application, c) covers all the requirements of the
standard, and d) passes in all such requirements
In case application is under simplified
simpl
procedure, an
undertaking shall be obtained from the applicant on
his letter-head
head that the licence if granted against his
application
ication shall be put under Stop Marking by BIS
if the verification sample(s) (any sample including
the long duration test samples)
samples drawn during visit of
the BIS officer prior to grant of licence fail to
conform to the requirements of relevant Indian
Standards.
rds. The
Th licensee shall take necessary
corrective actions and inform the same to BIS along
a
with fresh samples (of rating/size/variety which
facilitates verification of corrective actions on the
reported
ed failures) manufactured after taking the
corrective actions.
ac
The resumption of marking in
such cases shall be allowed only
o
on the basis of
independent satisfactory Test Reports of the fresh
samples offered (including long duration tests where
failures were
ere in long duration tests). In case the
fresh sample drawn
dra
by BIS for independent testing
fails, or the licensee does not inform corrective
co
actions taken and does not offer improved samples
within
hin 1 month of the date of Stop Marking, the
licence shall be processed for cancellation and no
further chance would be given to the licensee
PRODUCT MANUAL
PAGE: 3 OF 3
BUREAU OF INDIAN STANDARDS
PRODUCT CERTIFICATION
TITLE: GENERAL
DOC: PC-1489 Pt 2
PREPARED BY:
ISSUE: 01
DATE: NOV 2013
APPROVED BY:
PRODUCT MANUAL
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