PM/ IS 1489 (Part 1)/ 1/ December 2018

PRODUCT MANUAL FOR

PORTLAND POZZOLANA CEMENT – FLY ASH BASED
ACCORDING TO IS 1489 (PART 1): 2015
This Product Manual shall be used as reference material by all Regional/Branch Offices &
licensees to ensure coherence of practice and transparency in operation of certification under
Scheme-I of Bureau of Indian Standards (Conformity Assessment) Regulations, 2018 for
various products. The document may also be used by prospective applicants desirous of
obtaining BIS certification licence/certificate.

1. Product : IS 1489 (PART 1) : 2015

PORTLAND POZZOLANA CEMENT – FLY ASH
Title :
BASED
No. of Amendments : 1

2. Sampling Guidelines:
a) Ordinary Portland Cement – IS 269
a) Raw material : b) Clinker – IS 16353
c) Fly ash – IS 3812 (Part 1)
b) Grouping guidelines : Not applicable
PPC – Fly ash based – 8 kg for physical test
1 kg for chemical test
c) Sample Size :
Conformity of Raw material per the relevant Indian
Standard shall be ensured at the time of GoL/CSoL.

3. List of Test Equipment : Please refer ANNEX – A

Scheme of Inspection
4. : Please refer ANNEX – B
and Testing

5. Possible tests in a day :

(i) Insoluble Residue
(ii) Loss of ignition
(iii) Fineness
(iv) Setting time
6. Scope of the Licence :
“Licence is granted to use Standard Mark on Portland Pozzolana Cement – Fly ash based
as per IS 1489 (Part 1): 2015”.
Any other aspect required Transverse strength test is optional test as per agreement
as per the Standard between purchaser and manufacturer.
BUREAU OF INDIAN STANDARDS
Manak Bhawan, 9, Bahadur Shah Zafar Marg,
New Delhi – 110002
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ANNEX A

List of Test Equipment

Major test equipment required to test as per the Indian Standard

Sl
Tests used in with Clause Reference Test equipment
No.
1 Fineness Clause 7 Table 2 Blaine’s apparatus variable flow type
Stop watch with start-stop mechanism
Mercury for calibration
Balance, Standard weights
Standard Cement
Manometer liquid (di-butyl phthalate or light
mineral oil.)
Mercury of reagent grade or better, Pyknometer
Circular discs of filter paper of medium porosity
(mean pore diameter 7 µ).
Le-Chatelier’s flask
Constant temperature water bath to maintain
temp. within ± 0.1 ° C
2 Soundness by Autoclave Auto clave machine with thermostatic control to
Clause 7 Table 2 maintain pressure of 2.1 MPa for 3 hrs, pressure
to be attained within 1-1 ¼ hrs;
L-Shape thermometer LC 1 °C
Pressure gauge 0-42 kg/cm2 LC = 0.4 kg/cm2
Humidity chamber with temperature & RH
control 27 ± 2 °C, RH 90 to 100 %
Standard bar 308 mm, max
Bar moulds 25x25x282 mm
Length comparator with dial gauge
Mineral oil for covering moulds
3 Soundness by Le-chatelier Method Le-Chatelier’s water bath preferably with
Clause 7 Table 2 thermostatic control raising temperature from
27 ± 2 0 C to boiling in 27 ± 3 minutes
Le-Chatelier’s moulds with weights and cover
glasses minimum 8 nos.
Humidity chamber with temperature & RH
control 27 ± 2 0 C, RH 90 to 100 %
Steel scale 12" (304.8 mm)
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4 Setting time Vicat apparatus

Clause 7 Table 2
Needle for Consistency, IST& FST testings
Moulds
Stop Watch
Balance - 1000g ± 0.1g and Standard Weights
1mg to 500 gm
Gauging trowel of weight 210 ± 10 g
5 Compressive Strength Vibration machine with timer & cube mould
Clause 7 Table 2 fitting assembly 12000 ± 400 vibration per min.
Compressive Strength machine
Poking Rod , Petroleum Jelly
Proving ring with all accessories suitable for
calibration of CST machine
Tachometer
Cube Moulds 70.6 × 70.6 mm, Poking rod
Gauging trowel (210 ± 10 g)
gauging plate, stainless steel(non-perforated)
Standard sand grade 1, 2 and 3 (as per IS 650)
Curing tank of appropriate size with water
circulation arrangement
Graduated glass cylinders 150 to 200 ml
Humidity chamber with temperature & RH
Control 27 ± 2° C, RH 90 to 100 %

6 Transverse Strength Test Moulds

Clause 7, Table 2
Planetary Mixer, Standard Sand
Jolting Apparatus, Scraper, Demolding device as
per IS 4031 (Part 8)
7 Drying shrinkage Balance with weights
Clause 7, Table 2 Trowel
Length comparator
Flow table and Accessories
Beam mould- 25 x 25x 282 mm
Humidity and Temperature control cabinate.
8 IS 1489 (Part 1) : 2015 General equipments for Cement testing
a) To control humidity & temperature 1. Humidity chamber with temperature & RH
in lab control 27 ± 2°C, RH 90 to 100 %
2. Suitable arrangement to demonstrate
maintenance of temp. of 27 ± 2 ° C & RH 65 ±
5% constantly
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b) For cement Sampling Mixing trays –adequate size including trays of 24

partitions for keeping hourly samples
c) To control the residue of cement Sieves of size (300, 212, 150, 90, 75 & 45µ)

d) To measure temperature Thermometers

e) Lab ball mill (motorized) To grind the clinker, slag & gypsum sample in lab
ball mill for testing
f) To weigh the material 1. Platform type balance
2. Electrical balance
3 Weight box with weights (1 mg - 500 g)
9 General test equipments for chemical testing
Clause 6 , Table 1 of IS 1489 (Part 1) : 2015
Muffle Furnace with thermostatic control,
Range 0 – 1200° C
Oven with thermostatic control 0-300° C
Heater and hot plate
Distillation Assembly
Crucible: Platinum or Porcelain / silica
Filter paper (no 1,40,41,42)
Desiccators with cover & Desiccant
Water bath
pH meter/paper
Glassware - volumetric flask -0-250 ml, beaker 0-
250 ml, measuring cylinder 0-50,100,500, 1000
ml, burette 0-25/50 ml, conical flasks-
0-250 ml, pipette 0-5,10, 25, 50 ml
All chemicals required for complete chemical
analysis of cement
Tongs including platinum tipped tong
Wire gauge with asbestos sheet at the middle
Washing bottle
Mortar mixer- 4.75 l
Glass thermometer
All required chemicals as per IS 4032 for Portland
slag cement, Ordinary portland cement and
Portland clinker testing.

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10 Fly ash testing [ clause 4.1 of IS 1489 (Part 1) : 2015 and IS 3812 (Part 1) : 2013]
Chemical Test Chemicals and glassware as per IS 1727 and
IS 4032, Flame photometer
Loss on ignition Muffle furnace
Crucible (Silica /Platinum)
Weighing balance
Fineness Blain Apparatus
Permeability cell , Disk, Plunger, Filler paper
U-Tube manometer with manometer liquid
Stop watch with Stop-Start mechanism
Standard sample
Mercury for calibration
Pycnometer, Thermometer
Residual on 45µ sieve 45µ sieve
Balance
Oven
Soundness by autoclave Same as cement above
Lime reactivity 50 mm cubes moulds
Planetary mixer , paddle, mixing bowl, scrapper
Flow table and Accessories
Tamping rod
Trowel etc
Compressive strength 50 mm cube moulds
Planetary mixer , paddle, mixing bowl, scrapper
Flow table and Accessories
Tamping rod
Trowel etc

The above list is indicative only and may not be treated as exhaustive.

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ANNEX B

SCHEME OF INSPECTION AND TESTING

1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped

(as per the requirement given in column 2 of Table 1) and staffed, where different tests given
in the specification shall be carried out in accordance with the methods given in the
specification.

1.1 The manufacturer shall prepare a calibration plan for the test equipments. The following
equipments shall be calibrated at a frequency shown against each and records kept.

Sl. No. TEST EQUIPMENT FREQUENCY OF CALIBRATION

1. Blaine’s apparatus Daily with licensee’s own Standard cement sample and
monthly with standard cement samples supplied by
NCCBM.
2. Compressive Once in a month with Licensee’s own Proving Ring and
strength Testing the Proving Ring shall be Calibrated once in two years
machine from a NPL/NABL Accredited Calibrating body or NPL
or NPL accredited Proving Ring manufacturer.
3. Autoclave pressure Once in a month by licensee’s own dead weight pressure
gauge gauge tester OR once in six months from accredited
calibrating body or NPL/NABL accredited manufacturer
of such gauges.
4. Vibration machine Once in a month by licensee’s own Tachometer. The
tachometer shall be calibrated once in a year from
NPL/NABL accredited outside agency.
5. Dead weight Once in four years from NABL accredited Tester (if
pressure gauge available) Lab or OEM (original Equipment
Tester (if available) manufacturer) having NPL/NABL accredited calibrator.

2. TEST RECORDS – The manufacturer shall maintain test records in various formats,
Form 1 to Form 20 for the tests carried out to establish conformity.

3. LABELLING AND MARKING – Labeling and marking shall be as given below:

3.1 STANDARD MARK - The Standard Mark, as specified by BIS, shall be printed or
stenciled on each bag or drum of Portland Pozzolana Cement – Fly ash based or on the label
applied to it, provided the material in each bag or package to which the mark thus
applied conforms to the specification. The size of the Standard Mark shall be either 160 x
120 mm or 80 x 60 mm for packing in quantity of 50 kg and above. For other packing
of lower quantity, a photographic reduction is permitted.

3.2 MARKING - As per the requirements of IS 1489 (Part 1): 2015.

3.2.1 In addition to above, following marking shall also be marked:
a) Name of original manufacturer of cement with BIS licence number in case of
repacking unit.

b) Any other marking required under provisions of Legal Metrology Act, 2009 and
Legal Metrology (Packaged Commodities) Rules, 2011 framed thereunder.

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3.2.2 All the information including BIS Standard Mark except Manufacturers Registered
Trade Mark shall be applied on each bag in RED COLOUR.

3.2.3 Marking of variable parameters on cement bags which are changing with production
schedule and done online (such as Date of manufacturing/Week number/Batch number,
MRP, Percentage of addition of Pozzolana) is permitted in BLACK COLOUR. However, all
such marking shall be conspicuous.

Note :
1. For each calendar year, the first week shall be counted as 7 days from 1st of January
and subsequent weeks numbered serially accordingly. The bags shall be marked as
W 0l/MM/YY…… W 51/MM/YY……. etc.
2. Label mentioned at 3.1 and 3.2 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.
3. The colour of the bag and background colours should be in contrast to the colour of
the Standard Mark and the details so that the markings are conspicuous.

4. CONTROL UNIT –

4.1 For manufacturing units of Portland Pozzolana Cement: 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
maintained in accordance with clause 2 above.

4.2 For packing of Portland Pozzolana Cement at bulk cement terminal: The tests, as
indicated in Table 2 attached and at the levels of control specified therein, shall be carried out
on the whole packing of Portland Pozzolana Cement and appropriate records maintained in
accordance with clause 2 above.

4.2.1 For bulk packing units as per clause 4.2, all cement of one consignment received shall
constitute one batch.

4.2.2 Batch mixing may be permitted for packing units, which are extended packing terminals
of the same cement manufacturer (licensee) subject to packing units obtaining test certificates
from the manufacturer and keeping proper records. If the cement is received from different
units of the same manufacturer (different licensees) batch mixing of cement is not permitted.
The Batch integrity shall be ensured at all stages of packing and the packer shall maintain
appropriate controls and checks to ensure that there is no chance of mix up of different
batches. Adequate care shall be taken to avoid spoilage during handling, packing and
storage.

4.2.3 If bulk packing unit is instructed by BIS for suspension of licence due to the failure of
the samples, such instruction will automatically apply to the original manufacturer of the
cement, as per relevant suspension of licence guidelines. An undertaking to this effect shall
be obtained from the bulk packers and the original cement manufacturer.

4.2.4 Test Certificate of each original batch of cement shall be obtained from the supplier and
test results recorded. On the basis of tests and inspection, the decision regarding conformity
or otherwise of the consignment/batch to a given requirement shall be taken.

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4.3 WEIGHMENT – One filled bag from each nozzle shall be taken at random twice in each
shift of operation and weight checked in case of electronic packers with recorders. In all other
cases one filled bag from each nozzle shall be checked once in two hours. The records shall
be maintained in Form 1. The bag shall be so chosen for weighment such that bags from each
nozzle are taken for weighment. The weighing and packing machines shall be adjusted as and
when necessary in such a way that net quantity of each bag shall be in accordance with the
tolerances given in Annex B and clause 10.1.1 of IS 1489 (Part 1) : 2015. Such adjustments
for each nozzle shall be recorded in Form 1 under remarks column.

4.3.1 For packing of Portland Pozzolana Cement in bulk cement terminal weighment of
hourly check of mass of drums also shall be done in addition to weighment of bags
mentioned in para 4.3 above. The records of weighments shall be maintained in Forms 12
and 14.

4.4 RAW MATERIALS

4.4.1 Routine analysis of various raw materials used in the manufacture of Portland
Pozzolana 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 of the
analysis and of the Physical composition of the mixtures shall be maintained in Form 2.
This analysis is not applicable for Packing Units of Portland Pozzolana Cement at bulk
cement terminal.

4.5 HOMOGENEITY - Homogeneity of the mixture in a consignment shall be ensured

within the stipulated percent of fly ash addition. Percentage of Pozzolana addition shall
be declared every time and marked on the bags/package.

4.6. PACKING - The Cement shall be packed in bags as specified in clause 10 of

IS 1489 (Part 1): 2015. A test certificate either from the manufacturer or from any
recognized testing laboratory shall be received along with each consignment of bags.
Alternatively the samples of bags from each consignment shall be tested by the cement
manufacturer either in his own laboratory or any other BIS recognized laboratory before
they are used for packing cement. No testing would be necessary if the bags carry BIS
Certification Mark. The bag shall be in good condition at the time of packing.

5. LEVELS OF CONTROL - The tests as indicated in column 1 of Table 1 and the levels of
control in column 3 of Table 1, shall be carried out on the whole production of the factory
which is covered by this plan and appropriate records maintained in accordance with clause 2
above.

5.1. PRODUCTION DATA - The licensee shall send to BIS a statement of quantity
produced, marked and exported by him and the value thereof at the end of each quarter of the
operative period as per the enclosed proforma and shall also submit these details to BIS at
the end of the operative year duly authenticated by a Chartered Accountant.

6. REJECTIONS – Disposal of non-conforming product shall be done in such a way so as to

ensure that there is no violation of provisions of BIS Act, 2016.

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Table 1 – Levels of Control (Grinding/Packing Unit)

(1) (2) (3)

TEST DETAILS Test equipment RECOMMENDED LEVELS OF CONTROL
Clause Requirement Test Methods requirement Number Frequency Remark
Clause Reference R: required (or) of sample Cement Cement Packing
S: Sub- Grinding/Blending
contracting
permitted
4.1 Pozzolana 4.1 IS 1489 (Part 1) R One One sample shall be tested from each supplier once in a week
IS 1727 as per IS 3812 (Part 1). No further testing required if
accompanied with test certificate or ISI marked.
4.2 Portland Cement Clinker 4.2 IS 1489 (Part 1) R One Daily composite sample shall be tested for complete
IS 4031 requirement as per IS 16353. No further testing required if
IS 4032 accompanied with test certificate or ISI marked.
4.3 Ordinary Portland 4.3 IS 1489 (Part 1) - - OPC shall be ISI marked and shall be accompanied with
Cement IS 269 manufacturer certificate. If OPC is produced in the same
factory, records as per relevant SIT shall be maintained.
6 Table 1 Chemical Requirement
i) Insoluble residue 6 IS 1489 (Part 1) R One Daily Composite Weekly -
IS 4032 sample composite sample
ii) Magnesia 6 IS 1489 (Part 1) R One Daily Composite Weekly -
IS 4032 sample composite sample
iii) Total Sulphur content 6 IS 1489 (Part 1) R One Daily Composite Weekly -
calculated as sulphuric IS 4032 sample composite sample
anhydride (SO3)
iv) Loss on ignition 6 IS 1489 (Part 1) R One Daily Composite Weekly -
IS 4032 sample composite sample
v) Chloride Content 6 IS 1489 (Part 1) R One - Weekly This test shall also
IS 4032 composite sample be carried out
whenever there is
any change in
source of any raw
material.

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vi) Alkali Content 6 - R One - - Pl see note under

Table 1 of IS 1489
(Part 2) : 2015.
7, Table 2 Physical Requirement
i) Fineness 7 IS 1489 (Part 1) R One 1. Every alternate Daily Composite -
IS 4031 (Part 2) hourly from each sample
mill separately.
2. Daily Composite
sample
ii) Soundness 7 IS 1489 (Part 1) R One Daily Composite Daily Composite -
(Le-Chatelier method IS 4031(Part 3) sample sample
and Autoclave method)
iii) Setting Time 7 IS 1489 (Part 1) R One One sample per shift Daily Composite -
IS 4031 (Part 5) (Composite sample) sample
iv) Compressive strength 7 IS 1489 (Part 1) R One Daily Composite Daily Composite -
IS 4031 (Part 6) sample sample
v) Transverse strength 7 IS 1489 (Part 1) S One Weekly composite Weekly -
(Optional) IS 4031(Part 8) sample composite sample
vi) Drying shrinkage 7 IS 1489 (Part 1) R One - Weekly
IS 4031(Part 10) composite sample
NOTES –
1. Composite sample shall be made out of hourly samples for the required period (Pl see IS 3535 Methods of sampling hydraulic cements).
If cement is manufactured using same proportion of raw materials from more than one cement mill, sample from each mill shall be tested for fineness as per the above table.
For all other parameters composite samples from all the mills shall be tested.
If cement is manufactured using different proportion of raw materials from more than one cement mill, sample from each mill shall be tested for all requirements as per the
above table.
2. For manufacturing units where there is no packing silo and cement is packed directly from cement grinding, the frequency of tests specified for cement grinding stage would
apply for the various tests to be carried out on samples taken from cement mill spouts along with weekly chloride content test.

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Table 2 Level of Control (Bulk Packing Unit)

(1) (2) (3)

TEST DETAILS Test equipment RECOMMENDED LEVELS OF CONTROL
Clause Requirement Test Methods requirement Number of Frequency Remarks
Clause Reference R: required (or) S: samples
Sub-contracting
permitted
6 , Table 1 (i) Insoluble 6 IS 1489 (Part 1) R One Each batch To be tested in laboratory at bulk
Residue IS 4032 terminal packing unit.
6, Table 1 (v) Loss on 6 IS 1489 (Part 1) R One Each batch
Ignition IS 4032
7, Table 2 (i) Fineness 7 IS 1489 (Part 1) S One Each batch -
IS 4031(Part 2)
7, Table 2 (ii) Soundness 7 IS 1489 (Part 1) S One Each batch
IS 4031(Part 3)
7, Table 2 (iii) Setting Time 7 IS 1489 (Part 1) S One Each batch
IS 4031(Part 5)
7, Table 2 (iv) Compressive 7 IS 1489 (Part 1) S One Each batch
strength IS 4031(Part 6)

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Form No. 1
FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE

Date Shift Time (Hourly) No. of Bags Net mass of bags from nozzles Remark.

Form No. 2
RAW MATERIAL TESTING

Date of receipt of Date of Name of Material Source of supply and consignment Details of analysis for specified requirements
material testing No.

Form 3
PRODUCTION DATA
(POST GRINDING DETAILS OF PRODUCTION ACCEPTED AND REJECTED FOR STANDARD MARK)
Shift Quantity Passed for Standard mark Rejected Remark

Form No. 4
Pozzolana (One sample per week) Fly ash Pozzolana
Date CHEMICAL PHYSICAL
SiO2 + SiO2 Reactive MgO Total Available Total LOI Fineness Lime Comp. Soundness Particle retained
Al2O3 + Silica Sulphur as alkali as Chloride Reactivity Strength at 28 by autoclave on 45 µ sieve
Fe2O3 SO3 Na2O Days (Optional)

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Form No. 5
CLINKER CHEMICAL COMPOSITION (DAILY COMPOSITE SAMPLE)

Date of Total loss on Insoluble Alkali C3S C3 A C3S+ SO3 MgO Chloride Free LSF Alumina Sample Remarks
manufacture ignition residue content C2 S lime factor Pass/Fail
as Na2O

Form No. 6
CLINKER GROUND WITH GYPSUM (DAILY COMPOSITE SAMPLE)

Date of Fineness Soundness Setting time Compressive strength Sample Remark

grinding Le-Chatelier Autoclave Initial Final 3 days 7 days 28 days Pass/Fail

Form 7
CLINKER GROUND WITH GYPSUM & POZZOLANA
Date of Fineness Soundness Setting Time Compressive strength Drying Sample Mode of disposal
grinding Shrinkage Pass/ Fail or action taken if
Le-Chatelier Autoclave Initial Final 3 days 7 days 28 days sample fails

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Form 8
PORTLAND POZZOLANA CEMENT (GRINDING/ BLENDING) (Daily/Weekly Composite sample)
Date of IR MgO Total LOI Chloride Alkali Fineness Soundness Setting Compressive Transverse Drying Sample Action
grinding Sulphur Content content (Le- Time strength Strength Shrinkage Pass/Fail taken if
calculated chatelier & Initial & sample
as SO3 Autoclave) Final fails

Form No 9
PORTLAND POZZOLANA CEMENT GRINDING (For Alternate Hourly Sample)
Date of Time Fineness Setting Time Sample Mode of disposal or action taken if sample fails
grinding Initial & Final Pass/Fail

Form No 10
PORTLAND POZZOLANA CEMENT PACKING STAGE (Daily/Weekly Composite Sample)
Date of IR MgO Total LOI Chloride Alkali Fineness Soundness Setting Compressive Transverse Drying Sample Mode of
Packing Sulphur Content content (Le- Time Initial strength Strength Shrinkage Pass/ disposal or
calculated chatelier & Final Fail action taken if
as SO3 & sample fails
Autoclave)

Form No 11
CALIBRATION
Sl. No Date of Result of Calibration (Test records indicating details of standard values and Name of equipment Sl.No.
calibration observed values for each equipment to be kept in proforma for which various Action taken if equipment found (If any) &
columns be devised; as required) defective Remarks

Note : The above records are to be kept separately for each equipment.

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RECORDS TO BE MAINTAINED AS PER TABLE-2 OF SIT (BY BULK PACKING UNIT)

Form No. 12
FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE
HOURLY CHECK OF MASS OF DRUMS
Date Time (Hourly) Condition of Drums Net quantity of cement Record of calibration of weighing scale and Date of calibration.

Form No. 13
FORMAT FOR MAINTENANCE OF RECORDS FOR THE CONDITIONS OF THE EMPTY DRUMS/BULKERS
FOR PACKING CEMENT

Date No. of empty drums/Bulkers checked No. of empty drums/Bulkers rejected Reasons/Remarks Sign of firms inspector

Form No. 14
FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE
HOURLY CHECK OF MASS OF BAGS
Date Shift Time(Hourly) No of Bags Net quantity of Bags from Nozzles Records of calibration/date of calibration of nozzles

Form No. 15
RECEIPT OF CEMENTS

Date of receipt Batch No. Supply received from Test Certificate No

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Form No. 16
CEMENT DISPATCH DATA FROM PACKING

Date Quantity Passed for Standard Mark Rejected (if any) Reasons for not marking/Method of disposal

Form No 17 & 18
TEST DONE AT FACTORY (At receipt stage and at bulk packing terminal)

Date Batch No. LOI IR Fineness Setting Time Remarks

Form No 19 & 20
PORTLAND POZZOLANA CEMENT (PHYSICAL TEST REPORT) (At receipt stage and at bulk packing terminal)

Date Batch No. Test Report Soundness Compressive Strength Remarks

LC AC 3 days 7 days 28 days

Note-1: Sub-contracting is permitted to a laboratory recognized by the Bureau or Government laboratories empaneled by the Bureau.
Note-2: The control unit and levels of control as decided by the Bureau are obligatory to which the licensee shall comply with.

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