SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF 53 GRADE ORDINARY PORTLAND CEMENT ACCORDING TO IS:

Transcription

1 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF 53 GRADE ORDINARY PORTLAND CEMENT ACCORDING TO IS: A laboratory shall be maintained, which shall be suitably equipped and staffed, where the chemical analysis and the different tests given in the specification will be carried out. 2. All records of tests and analysis shall be kept in suitable forms approved by the Bureau. (See Form 1 to 8). 2.1 Copies of any records or charts that may be required by the Bureau shall be made available at any time on request. 2.2 It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for testing and analysis as envisaged in this Scheme [See IS:397 (Part I)-1972, IS:397 (Part II)-1985 and IS:397 (Part III)-1980]. 3. The Standard Mark as given in column 1 of the First Schedule of the Portland licence shall be printed or stenciled on each bag of 53 Grade Ordinary cement, provided always that the material in each bag or package to which the mark is thus applied conforms to every requirement of the specification. 4. In addition, the following information should be given in each bag or package or on the label applied to it: a) Name of the manufacturer and/or registered trade mark, if any; b) Type of cement (53 Grade Ordinary Portland Cement); c) Net mass; and d) Identification in code or otherwise to enable a week s lot of manufacture to be traced back to factory records. For this purpose on each bag shall be marked the week and year of packing. NOTE: i) For each calendar year the first week shall be counted as 7 days from 1 st of January and subsequent weeks numbered serially accordingly. The bags shall be marked as W.. W(01).. (51).. etc. ii) In addition to above, for marking month and year of packing of cement on bags the statutory requirements of the Standards of weights & measures (Package Commodities)Rules 1977 shall apply.

2 5. The tests, as indicated in Table 1 and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this Scheme and appropriate records and charts maintained in accordance with paragraph 2 above. All the production which conforms to the Indian Standard and covered by this license shall be marked with Standard Mark. 5.1 The tests, as indicated in Table 1 and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this Scheme and appropriate records and charts maintained in accordance with paragraph 2 above. All the production which conforms to the Indian Standard and covered by this license shall be marked with Standard Mark. 5.1 Each of the s of cement taken for test shall satisfy the requirements of the specification. 5.2 Five filled bags shall be taken at random every hour in each shift of operation and weighed and appropriate records maintained (See Form 1 for record). The weighing and packing machines shall be adjusted as and when necessary as indicated by the mass of these bags in such a way that not mess of each bag shall be 50 kg subject to the tolerances as given in clause 0.3 of IS: The date of such adjustments for each nozzle shall be recorded in Form Routine analysis of various raw materials going into the manufacture of 53 Grade Ordinary Portland cement shall be made at intervals of a month or whenever there is a change in the source/mine area stratification whichever is earlier and appropriate records shall be maintained of the physical composition of the mixtures (See Form 2). 7. In respect of all other clauses of the specification, the factory will maintain appropriate controls and checks to ensure that their product conforms to the various requirements of the specification. 8. A separate record shall be maintained giving information relating to the rejection of lots of 53 Grade ordinary Portland cement, if any, which do not conform to the specification, and the method of their disposal. Such lots shall, in no case, be stored together with those conforming to the specification (See Form 3). 9. PACKING: In case cement is packed in jute sacking bags (See Clause 8.1 of the standard) the bags shall conform to IS:2580 and duly carry ISI Mark with regard to their conformity to IS: Specification for Jute Packing Bags for packing cement (Second Revision). 10. The licensee shall supply, free of charge, the s required in accordance with Regulation 5 of Bureau of Indian Standards Act, 1986, from his factory or godowns. The Bureau shall pay for the s taken by it from the open market.

3 11. Whenever a complaint is received soon after the goods with Standard Mark have been purchased and used and if there is adequate evidence that the goods have not been misused, defective goods or their components are replaced or repaired free of cost by the licensee in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge conformity of the product to the Indian Standard shall be with the Bureau. 12. The marking of the product shall be suspended under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of the product to the specification, or the testing equipment goes out of order, or if directed to do so by the Bureau for any reason. The marking may be resumed as soon as the defects are removed or when the Bureau gives the permission to do so. The information regarding resumption of marking shall also be sent to the Bureau. 13. The licensee shall send to the Bureau, as per the enclosed proforma a statement of quantity produced, marked and exported by him and the trade value thereof during the half year ending 30 June and 31 December. This statement is required to be forwarded to the Bureau on or before the 31 st day of July and January for the preceding half year. TABLE 1.

4 IS: GRADE ORDINARY PORTLAND CEMENT TABLE 1 LEVELS OF CONTROL (Para 5 of the Scheme of testing and Inspection) Doc:STI/12269/1 Clause Requirement Test Details Clause Test Method Reference Clinker Levels of Control Cement Grinding Packed Cement (1) (2) (3) (4) (5) (6) (7) (8) FORM 4 & 5 FORM 6 & 7 FORM Chemical composition Full analysis. - IS: Weekly composite Weekly composite Sulphuric anhydride - -do- - - Magnesia - -do- - - Insoluble residue - -do- - - Loss on ignition. - -do Fineness - IS:4031 (Pt-II) & Soundness i) Le-chetlier method - IS:4031 (Part-III) 1988 Daily clinker ground with gypsum (Clinker taken hourly. A composite of the day is mixed with gypsum at the laboratory ball-mill and tested) -do- i) Every alternate hour from each mill separately. ii) Remarks ii) Autoclave method - -do- -do-

5 (1) (2) (3) (4) (5) (6) (7) (8) 5.3 Setting time. - IS:4031 (Part V) 1988 Daily clinker ground with gypsum (Clinker taken hourly. A composite of the day is mixed with gypsum at the laboratory ballmill and tested) i)hourly daily composite ii) Daily composite 5.4 Compressive Strength. - IS:4031 (Part VII) do-. NOTE: Composite shall be made out of hourly s for the required period (See clause 4 of IS: Methods of sampling hydraulic cements).

6 FORM NO.1 FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE (Clause 5.2 of STI) HOURLY CHECK OF MASS OF BAGS Doc:STI/12269/ Date Shift Time No. of Bags Net Mass of Bags from nozzle Record of Calibration (Hourly) No.1 No No.14 Date of Calibration of Nozzle(s) (1) (2) (3) (4) (5) (6) st hour nd hour rd hour

7 Form NO.2 RAW MATERIAL TESTING (CL.6 OF STI) Doc:STI/12269/1 Date of receipt of Date of Testing Name of the Material Source of Supply and Details of analysis for Material consignment No. specified requirements. (1) (2) (3) (4) (6) Note: A separate register be opened for different raw materials. FORM NO.3 PRODUCTION DATA (POST GRINDING DETAILS OF PRODUCTION ACCEPTED AND REJECTED FOR ISI MARK) (Clause 8 of STI) Date/Shift Quantity Passed for ISI Marking Rejected Reasons for not marking (1) (2) (3) (4) (5) Date of Manufacture Total Loss on ignition Insoluble Residue FORM NO.4 CLINKER (DAILY COMPOSITE SAMPLE) [See Column 5 of Table] SiO2 Ca O Al2 O 3 Fe2 O 3 SO3 Mg O LSF Lime Saturation Factor Alumina factor Sample pass/fails Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

8 FORM NO.5 CLINKER GROUND WITH GYPSUM (Daily Composite Sample) [Column 5 of Table 1] Doc:STI/12269/1 Date of Grinding Disposal/Action taken if fails FORM NO.6 CEMENT GRINDING (DAILY/WEEKLY COMPOSITE SAMPLES( (Column 6 of Table 1) f ing IOI IR SO3 Mg O Ca O Al2 O 3 Fe2 O 3 Si O 2 LSF Alumina factor Fineness Soundness Setting Compressive strength Sample pass/fail Fineness Soundness Setting Time Compressive Strength Sample Lechatelier Autoclave Initial Final 3 days 7 days 28 days pass/fail method (IST) (FST) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Lechatelier method Auto clave method Time IST FST 3 days 7 days 28 days (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Date of Grinding Time at FORM NO.7 CEMENT GRINDING (FOR HOURLY SAMPLES (Column 6 of Table 1) Fineness Initial setting time (IST) Setting time Final setting time (FST) Sample pass/fail Mode of Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7)

9 Date of packing LO 1 FORM NO.8 PACKING STAGE (CEMENT) DAILY/WEEKLY AVERAGE SAMPLE (Column 7 of Table 1) IR SO3 Mg O Ca O Al2 O 3 Fe2 O 3 SiO2 LSF Alumina factor Fineness Soundness Setting time Compressive strength Auto IST FST 3 7 clave day day method s s (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) Le Chate -lier metho d 28 day s Sample pass/ fail Mode of disposa l Action taken if fails