BUREAU OF INDIAN STANDARDS. (Southern Regional Office) Our Ref: 60/CM

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1 (Southern Regional Office) Our Ref: 60/CM Subject: Preparation & Review of Product Manuals for Product Certification This has reference to CMD-I s circular CMD-1/31 dated 11 Nov 2013 on the above subject. In this connection, the draft Product Manual in respect of IS 12269: 2013 allotted to SRO has been prepared. The same is attached herewith for hosting on the BIS Intranet for inviting suggestions and comments for a period of 15 days. The comments may be sent to SRO/BNBO. HITSD (E. Devendar) Sc.G & DDGS

2 PRODUCT FOR CERTIFICATION OF ORDINARY PORTLAND CEMENT 53 GRADE AS PER IS 12269:2013

3 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 2 of 12 AMENDMENT SHEET Sl No Amendment No Date Page No(s)

4 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 3 of 12 FORWARD This manual covers the guidelines for certification of Ordinary Portland Cement 53 grade as per IS 12269:2013. It is intended that this manual ensures following of uniform procedure by all the BOs of BIS for certification of the product, and would also facilitate the prospective applicants to get the BIS certification. This manual has to be read in conjunction with the specification IS 12269:2013 and in case of any conflict, the specification holds supreme.

5 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 4 of 12 TABLE OF CONTENTS Sl NO Title Page No 1 Amendment Sheet 2 2 Forward 3 3 Table of contents 4 4 Section I : Product Description 5 5 Section II :Raw materials/ Components 7 6 Section III : Manufacturing Process and In-process Quality Controls 8 7 Section IV : Certification Criteria 10 8 Section V : Inspection and Testing 12

6 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 5 of 12 SECTION I : PRODUCT DESCRIPTION 1. Product: Ordinary Portland Cement, 53 grade is manufactured by grinding Portland Clinker along with gypsum. A small amount of performance improvers may be added as specified in the standard. The number 53 corresponds to the minimum requirement of the 28 days compressive strength. The standard also covers 53 S grade, for use in manufacture of railway sleepers. The Clinker, consisting mostly of calcium silicates, is obtained by heating a predetermined and homogeneous mixture of materials principally containing lime and silica, with a smaller proportion of alumina and iron oxide. The clinker can be internally produced or brought in. 2. Standard: The latest applicable standard for this product is IS 12269: Cross referred standards: The cross referred standards are: 456 : 2000 Code of practice plain and reinforced concrete (fourth revision) 650 : 1991 Specification for standard sand for testing of cement (second revision) 1727 : 1967 Methods of test for pozzolanic materials (first revision) 1760 (Part 3) : Methods of chemical analysis of limestone, dolomite and allied materials: Part 3 Determination of iron oxide, alumina, calcium oxide and magnesia (first revision) 2580 : 1995 Textiles Jute sacking bags for packing cement (third revision) 3535 : 1986 Methods of sampling hydraulic cements (first revision) 3812 (Part 1) : Specification for pulverized fuel ash: Part 1 For use as pozzolana in cement, cement mortar and concrete (third revision) 4031 Methods of physical tests for hydraulic cement (Part 2) : 1999 Determination of fineness by specific surface by Blaine air permeability method (second revision) (Part 3) : 1988 Determination of soundness (first revision) (Part 5) : 1988 Determination of initial and final setting times (first revision) (Part 6) : 1988 Determination of compressive strength of hydraulic cement (other than masonry cement) (first revision) (Part 8) : 1988 Determination of transverse and compressive strength of plastic mortar using prism (first revision)

7 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 6 of : 1985 Methods of chemical analysis of hydraulic cement (first revision) 4082 : 1996 Recommendations on stacking and storage of construction materials and components at site (second revision) 4845 : 1968 Definitions and terminology relating to hydraulic cement 4905 : 1968 Methods for random sampling : 1986 Specification for high density polyethylene (HDPE)/polypropylene (PP) woven sacks for packing cement (second revision) : 1986 Specification for multi-wall paper sacks for cement (first revision) : 1987 Specification for granulated slag for manufacture of Portland slag cement : 1987 Light weight jute bags for packing cement : 1987 Jute synthetic union bags for packing cement : 2003 Specification for silica fume 4. Check-list for submission of an application for grant of licence: 4.1 The standard checklist given in the BIS website may be used. The application can be made by an integrated cement plant, grinding unit or a repacking unit of a parent cement manufacturing unit. The applicant has to specify this detail in the application. Details of performance improvers, if added, also has to be given in the application. 4.2 When the application is recorded, a letter shall be sent to the cement desk recommending giving permission to the firm to manufacture cement. Further process of carrying out the inspection shall be done after receipt of the permission from cement desk and firm manufacture a lot. Time norms for grant of licence would apply from the date of receipt of permission from cement desk. 4.3 Simplified procedure is not applicable for this product.

8 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 7 of 12 SECTION II : RAW MATERIALS/COMPONENTS 5. Important Raw Materials / components of the product are : a) Clinker b) Gypsum c) Performance improvers (if any) 5.1 Important raw material for Clinker are: a) Lime b) Silica c) Alumina d) Iron Oxide

9 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 8 of 12 SECTION III : MANUFACTURING PROCESS AND INPROCESS CONTROLS 6. Manufacturing Process: The process consists of grinding clinker with gypsum. A typical manufacturing flow chart is given below. It may be noted that this only for reference and is not intended to restrict the process or machinery for production. Raw materials Grinding Kiln Gypsum Clinker Performance improvers Grinding Storage silos 7. Infrastructure for production A typical manufacturing machinery list will include the following facilities:

10 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 9 of 12 Crushers Raw material Grinding mill Kiln Cement grinding mill Storage cilos Packing machine Conveyors The list is only representative. The firm may need to have many ancillary machinery for processing of cement.

11 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 10 of 12 SECTION IV : CERTIFICATION CRITERA 8. Critical Requirements : All the requirements given in the standard are considered as critical requirements. 9. Scheme of Testing and Inspection Different schemes of testing and inspection are available for small scale unit, large scale unit and re-packing unit. The latest STIs are: Doc:STI/12269//2:Aug 2013 Doc:STI/12269/LS/2:Aug 2013 and Doc:STI/12269/Pack/2:Feb (Document needs revision on implementation of IS 12269:2013). 10. Marking Fee Rates The current applicable marking fee for the product is : Rs 2 for all units (1 unit = 1 Tonne) with a minimum of Rs for Large Scale and Rs for Small Scale units in an operative period of one year. 11. Grouping Guidelines, if any The standard covers 53 grade and 53S grade. These are to be separately tested to be covered in the scope of the licence. Addition of performance improvers is not considered as a separate variety. 12. Guidelines for writing Scope of Licence Scope is to be written as " Ordinary Portland Cement 53 grade or Ordinary Portland Cement 53S grade. Repacking to be added in the scope for repacking unit. 13. Guidelines for Inclusion of new Varieties Guideline as given in clause 11 to be followed. 14. Sample size, including guidelines for drawal of separate samples when samples are required to be sent to different labs for testing: 8kg for mechanical tests and 500g for chemical tests. Clinker sample shall not be drawn for testing.

12 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 11 of Manner of Sealing of Sample(s) 15.1 The cement may be packed in suitable bag without any identification of the manufacturer, attached a tag with code number and signature on it, and sealed with BIS sealing wax and seal Whether remnants of sample(s) are returnable / non-returnable, to be scrapped / used, to be deshaped before disposal In case of safety items), any other precaution required for dealing with remnants : As destructive tests are involved, sample need not be returned Procedure to be followed for destroying / deshaping / recycling the product that does not meet the quality parameters during regular production: The non conforming product has to be disposed off as waste.

13 DOC: PM/12269/1 ISSUE: 01 DATE: FEB 2014 PAGE: Page 12 of 12 SECTION V : INSPECTION AND TESTING 16. Packing Material requirement (to be available in factory at all times) for Packing / Dispatch of Samples Availability of suitable bags for packing cement may be ensured. 17. List of required Test Equipment / Facilities with requirement and frequency of Calibration (to be provided by CL) 18. Status of Test Facilities in BIS Labs and OSLs with Testing Charges, and approximate time required for testing by BIS labs / OSLs CL, NROL, PBOL, SROL and BNBOL has got complete test facilities for this product. The testing charges are Rs for chemical requirements and Rs 1500 for physical reqirements. There are many recognised OSLs for testing this product. BIS website may be referred for the latest list. The actual testing time will be about a month. 19. Whether Grant of Licence will be based on: Grant of licence may generally be based on independent testing as many recognised labs are available. 20. Details of Tests to be carried out in the Factory Fineness Setting time (initial) Loss on ignition Chloride content -End of document-

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