SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ORDINARY PORTLAND CEMENT, 33 GRADE ACCORDING TO

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3 1 Doc: STI/269/6 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ORDINARY PORTLAND CEMENT, 33 GRADE ACCORDING TO IS 269:2013 (Fifth Revision) 1.0 LABORATORY: A laboratory shall be maintained, which shall be suitably equipped and staffed, where the chemical analysis and physical tests given in the specification shall be carried out. Environmental conditions to be maintained as required. 2.0 TEST RECORDS: All records of tests and analysis shall be kept in suitable forms as per Form 1 to Copies of any records or charts that may be required by BIS shall be made available at any time on request. 2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the various requirements of the specification. 3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part 1), IS 397(Part 2), IS 397(Part 3) and IS 397(Part 4)]. 3.1 In addition, effort should be made to gradually introduce Quality Management system in accordance with IS/ISO CALIBRATION: Periodic calibration of various testing equipments shall be carried out and records of such calibrations kept. The following equipments shall be calibrated at a frequency shown against each and records kept: TEST EQUIPMENT FREQUENCY OF CALIBRATION (i) Blaine s apparatus Daily with licensee s own Standard cement and weekly with standard cement s supplied by NCCBM. (ii) Compressive strength testing machine. Once in a month with Licensee s own Proving Ring and the Proving Ring shall be Calibrated once in two years from the Accredited independent agency or NPL or Proving Ring manufacturer. (iii) Autoclave Pressure Gauge Once in a month by licensee s own dead weight pressure gauge tester OR once in six months from accredited independent agency or by manufacturer of such gauges. (iv) Vibration Machine Once in a month by licensee s own Tachometer. The tachometer shall be calibrated once in a year from accredited independent agency. (v) Dead wt pressure gauge Tester Once in four years from NABL accredited Lab or (if available) OEM (original Equipment manufacturer) having NPL certified calibrator.

4 Doc: STI/269/6 5.0 STANDARD MARK: The standard mark as given in column 1 of the First Schedule of the license shall be printed or stenciled on each bag or package of Portland 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. 5.1 Marking: In addition, the following information shall be given on each bag or package. The information and ISI Mark shall be applied on each bag in BLACK COLOUR. (a) Name of the manufacturer and his registered trade mark, if any. (b) The words 'Ordinary Portland Cement, 33 Grade'. (c) Net Quantity in kg. (d) The words 'Use no Hooks'. (e) Address of Manufacturer. (f) Type and percentage of performance improver(s) added, in case of addition of performance improvers. (g) Batch /Control unit number in terms of the week, month 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. In such an event, the bags shall be marked as W01. W51.. etc. (ii) In addition to the 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 also apply. (h) The words FOR EXPORT, if required. (j) License Number(CM/L...). 6.0 LEVELS OF CONTROL: 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 the Standard Mark. 6.1 Each of the of cement taken for test shall satisfy the requirements of the specification. 6.2 Weighment: 12 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 bags shall be so chosen for weighment that bags from each nozzle are taken for weighment. Records of such weighment shall be as per Form No.1. 2

5 3 Doc: STI/269/6 7.0 RAW MATERIALS: Routine analysis of various raw materials going into the manufacture of Ordinary Portland cement, 33 Grade 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 of the analysis shall be maintained as per Form Clinker analysis shall be maintained as per Form No.4. In addition, in case clinker is procured from outside, it is to be ensured that each consignment is accompanied with test certificate of clinker manufacturer. The licensee in such cases shall also test and keep records as per Form No REJECTION: A separate record shall be maintained giving information relating to the rejection of lots of 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). 9.0 PACKING: Packing and Net quantity of cement shall conform to clause 9 of the standard. Each consignment of bags/sacks shall be accompanied with a test certificate conforming to relevant Indian Standards either from the manufacturer or from any recognized testing laboratory. Alternately, the s of bags/sacks from each consignment shall be tested by the cement manufacturer either in his own laboratory or any other recognized laboratory before they are used for packing cement. No testing would be necessary if the bags/sacks carry Standard Mark. 9.1 Colour of Bags: Any colour except red can be used. However, the colour of bags shall be in contrast to the colour of marking so that marking on the bags is clear and legible STORAGE: Storage shall conform to clause 7 of the Standard SAMPLES: The licensee shall supply free of charge, the or s required in accordance with Bureau of Indian Standards (Certification Marks) Regulation, from his factory or godowns. BIS shall pay for the s taken by it from the open market REPLACEMENT: Whenever a complaint is received soon after the material with ISI Mark has been purchased and used and if there is adequate evidence that the material has not been misused, defective material shall be replaced by the licensee free of cost 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 BIS STOP MARKING: The marking of the product shall be stopped under intimation to BIS 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 BIS for any reason. The marking may be

6 Doc: STI/269/6 resumed as soon as the deficiencies are removed or when BIS gives the permission to do so. The information regarding resumption of marking shall also be sent to BIS PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma1 to be authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported by them and the trade value thereof at the end of each operative year of the license. Table1. 4

7 Magnesia IS 269:2013 Ordinary Portland Cement, 33 Grade TABLE 1 LEVELS OF CONTROL (Para 6 of do Daily composite do Doc: STI/269/6 Test the Scheme of testing & Inspection) Levels of Control Clause Requirement Clause Test Reference Clinker (FORM 4&5) Cement Grinding (FORM 6&7) Cement Packing(FORM 8) (1) (2) (3 (4) (5) (6) (7) (8) 5. 0 Chemical composition Full analysis IS 4032 Daily composite Weekly composite Weekly composite 5.0 Chloride content IS 4032 do This test shall also be carried out whenever there is any change in source of any raw material. Sulphuric anhydride IS 4032 Insoluble Residue. do do Loss on ignition. Alkali content IS Fineness IS 4031 (Part 2) 6.0 do Soundness Lechatlier method IS:4031 (Part 3) Soundness Autoclave Method IS 4031:(Part 5 Daily clinker ground with Gypsum (Clinker taken hourly. A composite of the day is mixed with gypsum at the laboratory ballmill and tested). do 1) Every alternate hour from each mill separately. 2) Daily composite do Daily composite Daily composite Daily composite do do Daily Composite See Note 1

8 Doc: STI/269/6 (1) (2) (3) (4) (5) (6) (7) (8) 6.0 Setting time. IS 4031 (Part 5) do a) Hourly b) Daily Daily composite composite 6.0 Compressive strength. IS 4031 do Daily composite do 6.0 Transverse strength (Optional) (Part 6) IS 4031 (Part 8) do Weekly composite Weekly composite Note 1: If desired by the purchaser, the manufacturer shall carry out test for alkali content. The manufacturer shall furnish a certificate indicating the alkali content, if requested. Note 2: Limit of addition of performance improver shall be as given in Table 1 of the standard and shall be as per clause Note 3: Composite shall be made out of hourly s for the required period (See clause 4 of IS 3535:1986 Methods of sampling hydraulic cements). Note 4: Where there is no packing silo and cement is packed directly from cement grinding mill, the frequency of tests specified for cement grinding stage would apply for the various tests to be carried out on s taken from cement mill spouts. Note 5: When asked for by agreement between purchaser and manufacturer, transverse strength value to be agreed between purchaser and manufacturer at the time of placing an order. FORM NO.. 6

9 Doc: STI/269/6 DATE SHIFT Form No.1 FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE (Clause 6.2 of STI) TIME (HOURLY) HOURLY CHECK OF MASS OF BAGS NO. OF NET MASS OF BAGS BAGS FROM NOZZLES No.1, RECORDS OF CALIBRATION/DATE OF CALIBRATION OF NOZZLE(S) No.2. No.12 (1) (2) (3) (4) (5) (6) 1 st Hour 12 2 nd Hour 12 3 rd Hour 12 Form No.2 RAW MATERIAL TESTING (Clause 7 of STI) Date of receipt Date of Name of the Source of supply and Details of analysis for of material Testing Material consignment No. specified requirements. (1) (2) (3) (4) (5) Note : A separate register may be opened for each raw material. Form No.3 PRODUCTION DATA (POST GRINDING DETAILS OF PRODUCTION ACCEPTED & REJECTED FOR ISI MARK) (Clause 8 OF STI) Date/Shift Quantity Passed for ISI Marking Rejected Reasons for not marking 7

10 Doc: STI/269/6 Date of manufacture Total loss on Ignition Insoluble Residue Form No.4 CLINKER (DAILY COMPOSITE SAMPLE) (SEE COLUMN 5 OF TABLE 1) SiO 2 CaO Al 2 O 3 Fe 2 O 3 SO 3 MgO LSF (Lime Alumina Saturation Factor Factor) Sample Pass/Fails Disposal/Action taken if Sample fails (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Date of Grinding Fineness Form No.5 CLINKER GROUND WITH GYPSUM (DAILY COMPOSITE SAMPLE) LABORATORY BALL MILL(COLUMN 5 OF TABLE 1) Setting Time Compressive Transverse Initial(IST) Final (FST) Strength Strength (Optional) days Soundness (Lechatelier/Auto clave method) Sample/pass/fail Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7) (8) Date of Grinding Form No.6 CEMENT GRINDING (DAILY/WEEKLY COMPOSITE SAMPLES)(COLUMN 6 of Table 1) LOI IR SO 3 MgO CaO Al 2 O 3 Fe 2 O 3 SiO 2 LSF Alumina factor Fineness Soundness Le/Aut o Setting time IST/FST Compressive strength days Transverse Strength (Optional) Sample pass/fail Mode of disposal/action taken if fails (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) 8

11 Doc: STI/269/6 Form No.7 CEMENT GRINDING (FOR HOURLY SAMPLES) (Column 6 of Table 1) Date of Grinding Time Fineness Setting time Sample Mode of Initial Setting Time (IST) Final Setting Time (FST) Pass/Fail Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7) Date of Packing Form No.8 CEMENT PACKING (DAILY/WEEKLY AVERAGE SAMPLE) COLUMN 7 OF TABLE 1) LOI IR S0 3 MgO CaO A Fe 20 3 SiO 2 LSF Chloride content (1) (2) (3 ) Alkali Content (refer Note 1) Alumina factor Fineness Soundness Le/Auto Setting time IST/FST Compressive strength days... Transverse Strength (Optional) Sample pass/fail Mode of disposal/action taken if fails (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Form No.9 S.No. Date of Calibration CALIBRATION RECORD NAME OF EQUIPMENT Identification. NO. (if any Result of Calibration (Test records indicating details of Action taken if equipment Remarks standard values and found observed values for each defective equipment to be kept in proforma for which various columns be devised, as required) Note: The above records are to be kept separately for each equipment. 9

12 Doc: STI/269/6 PERFORMA 1 PROFORMA FOR OBTAINING QUARTERLY PRODUCTION DETAILS Period covered * Name of Licensee CM/L No. Name of Articles (s) IS No. Grade/Type/Size 1.1 Brand/Trade/Name(s) of BIS Certification Marked Products 2. Total production of the articles(s) licensed for certification marking 2.1 Total production of the article(s) conforming to Indian Standard 3. Production covered with BIS Certification Mark and its value a) Quantity (tonne) b) Invoice sale price 3.1 Brand Name used on production covered under BIS Certification Mark 3.2 Calculation of marking fee as per agreed Rate of Marking Fee a) Unit b) Quantity covered with BIS Certification Mark *Information to be filled up by BO before forwarding to the licensee. Note : Incase a clause is not applicable, suitable remarks may be given against it. c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b) 4. Quantity not covered with BIS Certification Mark. If any, and the reasons for such noncoverage 4.1 Brand Name under with non certified goods were sold 5.0 Quantity Exported with BIS Standard Mark and its value 5.1 Brand Name under which BIS Certified goods are exported 6.0 Authentication by Chartered Accountant Name Date Signature of Authorized Signatory 10

13 11 Doc: STI/269/6

14 1 Doc: STI/269/LS/2 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ORDINARY PORTLAND CEMENT, 33 GRADE ACCORDING TO IS 269:2013(Fifth revision) (For Large scale Cement plant having capacity above 600tpd) 1.0 LABORATORY: A laboratory shall be maintained, which shall be suitably equipped and staffed, where the chemical analysis and physical tests given in the specification shall be carried out. Environmental conditions to be maintained as required. 2.0 TEST RECORDS: All records of tests and analysis shall be kept in suitable forms as per Form 1 to Copies of any records or charts that may be required by BIS shall be made available at any time on request. 2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the various requirements of the specification. 3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme See [IS 397(Part 1),IS 397(Part 2), IS 397(Part 3) and IS 397(Part 4)]. 3.1 In addition, effort should be made to gradually introduce Quality Management system in accordance with IS/ISO CALIBRATION: Periodic calibration of various testing equipments shall be carried out and records of such calibrations kept. The following equipments shall be calibrated at a frequency shown against each and records kept: TEST EQUIPMENT FREQUENCY OF CALIBRATION (i) Blaine s apparatus Daily with licensee s own Standard cement and weekly with standard cement s supplied by NCCBM. (ii) Compressive strength testing machine. (iii) Autoclave Pressure Gauge Once in a month with Licensee s own Proving Ring and the Proving Ring shall be Calibrated once in two years from the accredited independent agency like NPL or Proving Ring manufacturer. Once in a month by licensee s own dead weight pressure gauge tester OR once in six months from accredited independent agency or by manufacturer of such gauges. (iv) Vibration Machine Once in a month by licensee s own Tachometer. The tachometer shall be calibrated once in a year from accredited independent agency. (v) Dead weight pressure Once in four years from NABL accredited Lab or OEM gauge tester(if available) (original Equipment manufacturer) having NPL certified calibrator.

15 Doc: STI/269/LS/2 5.0 STANDARD MARK: The standard mark as given in column 1 of the First Schedule of the license shall be printed or stenciled on each bag or package of Portland 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. 5.1 Marking: In addition, the following information shall be given on each bag or package. The information and ISI Mark shall be applied on each bag in BLACK COLOUR. (a) Name of the manufacturer and his registered trade mark, if any. (b) The words 'Ordinary Portland Cement, 33 Grade'. (c) Net Quantity in kg. (d) The words 'Use no Hooks'. (e) Address of Manufacturer. (f) Type and percentage of performance improver(s) added, in case of addition of performance improvers. (g) Batch /Control unit number in terms of the week, month 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. In such an event, the bags shall be marked as W01. W51.. etc. (ii) In addition to the 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 also apply. (h) The words FOR EXPORT, if required. (j) License Number(CM/L...). 6.0 LEVELS OF CONTROL: 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 the Standard Mark. 6.1 Each of the of cement taken for test shall satisfy the requirements of the specification. 6.2 Weighment: One filled bag from each Nozzle shall be taken at random twice in a shift of operation and weighed in case of electronic packer with recorder. In all other cases one bag from each Nozzle shall be checked once in two hours. The records shall be maintained in Form 1. 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 net mass of each bag shall be as specified subject to the tolerances as given in clause 9 of IS 269, as the case may be. Such adjustments for each nozzle shall be recorded in Form1. 2

16 3 Doc: STI/269/LS/2 7.0 RAW MATERIALS: Routine analysis of various raw materials going into the manufacture of Ordinary Portland cement,33 Grade 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 of the analysis shall be maintained as per Form Clinker analysis shall be maintained as per Form No.4. In addition, in case clinker is procured from outside, it is to be ensured that each consignment is accompanied with test certificate of clinker manufacturer. The licensee in such cases shall also test and keep records as per Form No REJECTION: A separate record shall be maintained giving information relating to the rejection of lots of 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). 9.0 PACKING: Packing and Net quantity of cement shall conforms to clause 9 of the standard. Each consignment of bags/sacks shall be accompanied with a test certificate conforming to relevant Indian Standards either from the manufacturer or from any recognized testing laboratory. Alternately, the s of bags/sacks from each consignment shall be tested by the cement manufacturer either in his own laboratory or any other recognized laboratory before they are used for packing cement. No testing would be necessary if the bags/sacks carry Standard Mark. 9.1 Colour of Bags: Any colour except red can be used. However, the colour of bags shall be in contrast to the colour of marking so that marking on the bags is clear and legible STORAGE: Storage shall conform to clause 7 of the Standard SAMPLES: The licensee shall supply free of charge, the or s required in accordance with Bureau of Indian Standards (Certification Marks) Regulation, from his factory or godowns. BIS shall pay for the s taken by it from the open market REPLACEMENT: Whenever a complaint is received soon after the material with ISI Mark have been purchased and used and if there is adequate evidence that the material have not been misused, defective material shall be replaced 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 BIS STOP MARKING: The marking of the product shall be stopped under intimation to BIS 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 BIS for any reason. The marking may be

17 Doc: STI/269/LS/2 resumed as soon as the deficiencies are removed or when BIS gives the permission to do so. The information regarding resumption of marking shall also be sent to BIS PRODUCTION DATA: The licensee shall send to BIS as per the enclosed Proforma1 to be authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported by them and the trade value thereof at the end of each operative year of the license. Table1. 4

18 Clause Requirement Clause IS 269:2013 Ordinary Portland Cement, 33 Grade TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of testing & Inspection) Test Details Test Method Clinker Cement Grinding Reference (FORM 4&5) (FORM 6&7) Levels of Control Cement Remarks Packing (FORM 8) Doc: STI/269/LS/2 (1) (2) (3 (4) (5) (6) 7 (8) 5. Chemical composition IS 4032 Daily composite Weekly composite Weekly Full analysis composite 5.0 Chloride content IS 4032 do This test shall also be carried out whenever there is any change in source of any raw material. Sulphuric anhydride Magnesia Insoluble residue. IS 4032 do do Daily composite do do Loss on ignition. do Alkali content IS Fineness IS 4031 (Part 2) 6.0 Soundness Lechatlier method IS 4031 (Part 3) Soundness Autoclave Method IS 4031(Part 3) 5 Laboratory Ball Mill testing is required to be done when there is change in the source of Raw material or change in design. do 1) Every alternate hour from each mill separately. 2) Daily composite do Daily composite Daily composite Daily composite do do Daily Composite See Note 1

19 Doc: STI/269/LS/2 (1) (2) (3) (4) (5) (6) (7) (8) 6.0 Setting time. IS 4031 Daily composite (Part 5) 6.0 Compressive strength. IS 4031 (Part 6) 6.0 Transverse strength IS 4031 (Optional) (Part 8) Laboratory Ball Mill testing is required to be done when there is change in the source of Raw material or change in design. do do One per shift(composite ) Daily composite Weekly composite do Weekly composite Note 1: If desired by the purchaser, the manufacturer shall carry out test for alkali content. The manufacturer shall furnish a certificate indicating the alkali content, if requested. Note 2: Limit of addition of performance improver shall be as given in Table 1 of the standard and shall be as per clause of the standard. Note 3: Composite shall be made out of hourly s for the required period (See clause 4 of IS 3535:1986 Methods of sampling hydraulic cements). Note 4: Where there is no packing silo and cement is packed directly from cement grinding mill, the frequency of tests specified for cement grinding stage would apply for the various tests to be carried out on s taken from cement mill spouts. Note 5: When asked for by agreement between purchaser and manufacturer, transverse strength value to be agreed between purchaser and manufacturer at the time of placing an order. FORM NO.. 6

20 Doc: STI/269/LS/2 DATE SHIFT Form No.1 FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE (Clause 6.2 of STI) TIME (HOURLY) HOURLY CHECK OF MASS OF BAGS NO. OF NET MASS OF BAGS BAGS FROM NOZZLES No.1, RECORDS OF CALIBRATION/DATE OF CALIBRATION OF NOZZLE(S) No.2. No.12 (1) (2) (3) (4) (5) (6) 1 st Hour 12 2 nd Hour 12 3 rd Hour 12 Form No.2 RAW MATERIAL TESTING (Clause 7 of STI) Date of receipt Date of Name of the Source of supply and Details of analysis for of material Testing Material consignment No. specified requirements. (1) (2) (3) (4) (5) Note : A separate register may be opened for each raw material. Form No.3 PRODUCTION DATA (POST GRINDING DETAILS OF PRODUCTION ACCEPTED & REJECTED FOR ISI MARK) (Clause 8 OF STI) Date/Shift Quantity Passed for ISI Marking Rejected Reasons for not marking 7

21 Doc: STI/269/LS/2 Date of manufacture Total loss on Ignition Insoluble Residue Form No.4 CLINKER (DAILY COMPOSITE SAMPLE) (SEE COLUMN 5 OF TABLE 1) Sio2 CaO Al203 Fe203 SO3 Mgo LSF (Lime Alumina Saturation Factor Factor) Sample Pass/Fails Disposal/Action taken if Sample fails (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Date of Grinding Fineness Form No.5 CLINKER GROUND WITH GYPSUM (DAILY COMPOSITE SAMPLE) LABORATORY BALL MILL(COLUMN 5 OF TABLE 1) Setting Initial Time Final Compressive Transverse (IST) (FST) Strength Strength (Optional) days Soundness (Lechatelier/Auto clave method) Sample/pass/fail Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7) (8) Date of Grinding Form No.6 CEMENT GRINDING (DAILY/WEEKLY COMPOSITE SAMPLES)(COLUMN 6 of Table 1) LOI IR SO3 Mgo Cao Al203 Fe203 Si02 LSF Alumina factor Fineness Soundness le/auto Setting time IST/FST Compressive strength days Transverse strength (Optional) Sample pass/fail Mode of disposal/action taken if fails (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) 8

22 Doc: STI/269/LS/2 Form No.7 CEMENT GRINDING (FOR ALTERNATE HOURLY SAMPLES) (Column 6 of Table 1) Date of Grinding Time Fineness Setting time Sample Initial Setting Time (IST) Final Setting Time (FST) Pass/Fail Mode of Disposal/Action taken if fails (1) (2) (3) (4) (5) (6) (7) Date of Packing Form No.8 CEMENT PACKING (DAILY/WEEKLY AVERAGE SAMPLE)( COLUMN 7 OF TABLE 1) LOI IR S0 3 MgO CaO A Fe 20 3 SiO 2 LSF Chloride content (1) (2) (3 ) Alkali Content (refer Note 1) Alumina factor Fineness Soundness Le/Auto Setting time IST/FST Compressive strength days... Transverse Strength test (Optional) Sample pass/fail Mode of disposal/action taken if fails (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Form No.9 S.No. Date of Calibration CALIBRATION RECORD NAME OF EQUIPMENT S.NO. (if any) Result of Calibration (Test records indicating details of Action taken if equipment found defective Remarks standard values and observed values for each equipment to be kept in proforma for which various columns be devised, as required) Note: The above records are to be kept separately for each equipment. 9

23 Doc: STI/269/LS/2 PERFORMA 1 PROFORMA FOR OBTAINING QUARTERLY PRODUCTION DETAILS Period covered * Name of Licensee CM/L No. Name of Articles (s) IS No. Grade/Type/Size 1.1 Brand/Trade/Name(s) of BIS Certification Marked Products 2. Total production of the articles(s) licensed for certification marking 2.1 Total production of the article(s) conforming to Indian Standard 3. Production covered with BIS Certification Mark and its value a) Quantity (tonne) b) Invoice sale price 3.1 Brand Name used on production covered under BIS Certification Mark 3.2 Calculation of marking fee as per agreed Rate of Marking Fee a) Unit b) Quantity covered with BIS Certification Mark *Information to be filled up by BO before forwarding to the licensee. Note : Incase a clause is not applicable, suitable remarks may be given against it. c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b) 4. Quantity not covered with BIS Certification Mark. If any, and the reasons for such noncoverage 4.1 Brand Name under with non certified goods were sold 5.0 Quantity Exported with BIS Standard Mark and its value 5.1 Brand Name under which BIS Certified goods are exported 6.0 Authentication by Chartered Accountant Name Date Signature of Authorized Signatory 10

24 Doc: STI/269/LS/2 11

25 Doc: STI/269/PACK/4 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF PACKING OF ORDINARY PORTLAND CEMENT, 33 GRADE AT BULK CEMENT TERMINAL ACCORDING TO IS 269:2013 (Fifth Revision) 1. LABORATORY: A laboratory shall be maintained, which shall be suitably equipped and staffed, where the chemical analysis and physical tests given in the specification shall be carried out. Environmental conditions to be maintained as required. 2. TEST RECORDS: All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau as per Form 1 to Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 2.2 For all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the various requirements of the specification. 3.0 QUALITY CONTROL: It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part 1), IS 397(Part 2), IS 397(Part 3) and IS 397(Part 4)]. 3.1 In addition, effort should be made to gradually introduce Quality Management system in accordance with IS/ISO CALIBRATION: Periodic calibration of various testing equipments shall be carried out and records of such calibrations kept. The following equipments shall be calibrated at a frequency shown against each and records kept: TEST EQUIPMENT FREQUENCY OF CALIBRATION i) Blaine s apparatus Daily with licensee s own Standard cement and once in a month with standard cement s supplied by NCCBM. ii) Compressive strength Once in a month with licensee s own testing machine proving ring and the proving ring shall be calibrated once in two years from the accredited independent agency or NPL or proving ring manufacturer. 1

26 2 Doc: STI/269/PACK/4 iii) Autoclave pressure gauge Once in a month by licensee s own dead weight pressure gauge tester or once in six months from accredited independent agency or by manufacturer of such gauges. iv) Vibration machine. Once in a month by licensee s own tachometer. The tachometer shall be Calibrated once in a year from accredited independent agency. v) Dead wt pressure gauge Once in four years from NABL accredited Tester (if available) Lab or OEM(original Equipment manufacturer) having NPL certified calibrator. 5.0 STANDARD MARK: The Standard Mark, as given in Column (1) of the First Schedule of the licence, shall be printed or stencilled on each bag or on the label applied to the container, provided always that the material in each bag or container to which the mark is thus applied conforms to every requirement of the specification. 5.1 Marking: In addition the following information shall be given on each bag or on the label applied to each container. The information and ISI mark shall be applied on each bag in BLACK COLOUR. (a) Name of the Packer and his registered trade mark, if any. (b) Name of the manufacturer and his registered trade mark, if any. (c) The words 'Ordinary Portland Cement, 33 Grade'. (d) Net Quantity in kg. (e) The words 'Use no Hooks'. (f) Address of Manufacturer. (g) Type and percentage of performance improver(s) added, in case of addition of performance improvers. (h) Batch /Control unit number in terms of the week, month 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. In such an event, the bags shall be marked as W01. W51.. etc. (ii)in addition to the 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 also apply. (j) The words FOR EXPORT, if required. (k) License Number of Manufacturer and Packer(CM/L...). Label mentioned above shall be attached to the seal of the container. The seal shall be of such a design that it shall automatically get destroyed on opening. Note: In case cement manufacturer and packing bulk terminal unit belong to the same industry name of the original manufacturers and/or his trade mark, BIS certification mark licence no. need not be given on the bag.

27 Doc: STI/269/PACK/4 6.0 BATCH: For the purpose of this scheme all cement of one consignment received shall constitute one batch. 6.1 Only ISI Marked Ordinary Portland Cement, 33 grade shall be used for packing. At a particular time only one batch of cement shall be packed. Another batch of cement shall be packed only after completion of packing of the first batch. At all stages of packing, the packer shall maintain appropriate controls and checks to ensure that there is no chance of mixing two different batches of the cement. 6.2 Test Certificate of each original batch of cement shall be obtained from the supplier and test results recorded. 7.0 LEVELS OF CONTROL: The tests, as indicated in Table 1 attached 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 2.0 above. All the production which conforms to the Indian Standards and covered by the license shall be marked with the Standard mark. 7.1 On the basis of tests and inspection, the decision regarding conformity or otherwise of the control unit to a given requirement shall be made. 7.2 Weighment: 12 filled bags shall be taken at random every hour in each shift of operation and weighed and appropriate records maintained (See Form 3 for record). The bags shall be so chosen for weighment that bags from each nozzle are taken for weighment. Records of such weighment shall be as per Form No REJECTIONS: A separate record shall be maintained giving information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no circumstances be stored together with that conforming to the specification. 9.0 PACKING: Packing and Net quantity of cement shall conform to clause 9 of the standard. Each consignment of bags shall be accompanied with a test certificate conforming to relevant Indian Standards either from the manufacturer or from any recognized testing laboratory. Alternately, the s of bags from each consignment shall be tested by the p a c k e r either in his own laboratory or any other recognized laboratory before they are used for packing cement. 3

28 Doc: STI/269/PACK/4 9.1 Colour of Bags: Any colour except red can be used. However, the colour of bags shall be in contrast to the colour of marking so that marking on the bags is clear and legible STORAGE: Storage shall conform to clause 7 of the Standard SAMPLES: The licensee shall supply, free of charge, the s required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988 as subsequently amended, from the factory or go downs. The Bureau shall pay for the s taken by it from the open market REPLACEMENT: Whenever a complaint is received soon after the material with Standard Mark has been purchased and used, and if there is adequate evidence that the material has not been misused, defective material shall be replaced 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 the conformity of the product to the Indian Standard shall be with the Bureau In the event of any damages caused by the material bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be responsible in such cases STOP MARKING: The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the deficiencies are removed under intimation to Bureau The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of markings shall also be sent to the Bureau PRODUCTION DATA: The licensee shall send to BIS as per the enclosed proforma1 to be authenticated by a Chartered Accountant or by the manufacturer by giving an affidavit/undertaking, a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the license. 4

29 Form No. 1 FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE HOURLY CHECK OF MASS OF DRUMS Doc: STI/269/PACK/4 Date Time (Hourly) Condition of Net Mass of Record of Drum Cement calibration of weighing scale. Date of calibration. 1st Hour 2nd Hour 3rd Hour Form No.2 FORMAT FOR MAINTENANCE OF RECORDS FOR THE CONDITIONS OF THE EMPTY DRUMS/BULKERS FOR PACKING CEMENT Date No. of empty No. of empty Reasons/Remarks Sign of firm s drums/bulkers drums/bulkers Inspector checked rejected Form No.3 FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE (Clause 7.2 OF STI HOURLY CHECK OF MASS OF BAGS Date Shift Time No. of Bags Net mass of Records of (Hourly) Bags from calibration/date Nozzles No.1, of calibration No.2. No.12 of Nozzle (s) 1st Hour 12 2nd Hour 12 3rd Hour 12 5

30 Doc: STI/269/PACK/4 Form No.4 RECEIPT OF CEMENT Date of Receipt Batch No. Supply received Test Certificate No. from Form No.5 CEMENT DESPATCH DATA FROM BULK PACKING TERMINAL Date Quantity Passed for ISI Rejected (if Reasons for not Marking any) Marking/Method of Disposal Form No. 6 & 7 TESTS DONE AT FACTORY (At Receipt stage and at bulk packing terminal) Date Batch No. LOI IR Alkali content( Refer Note 1 under Table 1 of STI) Fineness Setting Remarks Time Date Batch No. Form No. 8 & 9 ORDINARY PORTLAND CEMENT 33 GRADE (PHYSICAL TEST REPORT) (Tests done at factory or at predeclared lab) (At receipt stage and at bulk packing terminal) Test Report Soundness Compressive Remarks No. Strength Transverse Strength (optional) LC AC Days days Days 6

31 IS 269:2013 PACKING OF ORDINARY PORTLAND CEMENT 33 GRADE AT BULK CEMENT TERMINAL TABLE 1 LEVELS OF CONTROL (Para 7 of the Scheme of Testing and Inspection) Doc: STI/269/PACK/4 Clause TEST DETAILS LEVELS OF CONTROL Test Requirements Method Frequency Remarks Referen Clause ce 5.0 Loss on ignition IS 4032 One To be tested in from each batch laboratory at bulk terminal packing unit. 5.0 Insoluble residue do do do 6.0 Fineness IS 4031(Pt.2) do May be tested at bulk terminal packing unit or got tested from a predeclared approved testing laboratory if in house testing facilities are not available. 6.0 Setting time IS 4031 do do (Pt.5) 6.0 Soundness IS 4031(Pt. 3) do do (Lechatlier method) Soundness (Autoclave Method) IS 4031(Pt. 3) do do 6.0 Compressive IS 4031 do do Strength (Pt.6) 6.0 Transverse strength(optional) IS 4031(Pt.8 do do Note 1: If desired by the purchaser, the manufacturer shall carry out test for alkali content. The manufacturer shall furnish a certificate indicating the alkali content, if requested. Note 2: Limit of addition of performance improver shall be as given in Table 1 of the standard and shall be inclusive of 1 percent additives. Note 3: When asked for by agreement between purchaser and manufacturer, transverse strength value to be agreed between purchaser and manufacturer at the time of placing an order. 7

32 Doc: STI/269/PACK/4 PROFORMA 1 PROFORMA FOR OBTAINING QUARTERLY PRODUCTION DETAILS Period covered * Name of Licensee CM/L No. Name of Articles (s) IS No. Grade/Type/Size 1.1 Brand/Trade/Name(s) of BIS Certification Marked Products 2. Total production of the articles(s) licensed for certification marking 2.1 Total production of the article(s) conforming to Indian Standard 3. Production covered with BIS Certification Mark and its value a) Quantity (tonne) b) Invoice sale price 3.1 Brand Name used on production covered under BIS Certification Mark 3.2 Calculation of marking fee as per agreed Rate of Marking Fee a) Unit b) Quantity covered with BIS Certification Mark *Information to be filled up by BO before forwarding to the licensee. Note : Incase a clause is not applicable, suitable remarks may be given against it. c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b) 4. Quantity not covered with BIS Certification Mark. If any, and the reasons for such noncoverage 4.1 Brand Name under with non certified goods were sold 5.0 Quantity Exported with BIS Standard Mark and its value 5.1 Brand Name under which BIS Certified goods are exported 6.0 Authentication by Chartered Accountant Signature of Authorised Signatory Name Date 8