Doc: STI/269/6 · Doc: STI/269/6 August 2013 3 7.0 RAW MATERIALS: Routine analysis of various raw materials going into the manufacture of Ordinary Portland cement, 33 Grade shall

Doc: STI/269/6 August 2013

1

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 9. 2.1 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 9001.

4.0 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

sample and weekly with standard cement samples 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 (if available)

Once in four years from NABL accredited Lab or OEM (original Equipment manufacturer) having NPL certified calibrator.


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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 1st 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 t he 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 sample 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.


3

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 2.

7.1 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.4.

8.0 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 quant ity 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 samples 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.

10.0 STORAGE: Storage shall conform to clause 7 of the Standard.

11.0 SAMPLES: The licensee shall supply free of charge, the sample or samples

required in accordance with Bureau of Indian Standards (Certification Marks) Regulation, from his factory or godowns. BIS shall pay for the samples taken by it from the open market.

12.0 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.

13.0 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


4

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.

14.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed

Proforma-1 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……….


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Test Details

Levels of Control Test

Method Clause Requirement

Clause Reference Clinker (FORM 4&5)

Cement Grinding (FORM 6&7)

Cement Packing(FORM 8)

Remarks

(1) (2) (3)

(4) (5) (6) (7) (8) 5.0

Chemical composition Full analysis

- IS 4032 Daily composite sample

Weekly composite sample


5.0

Chloride content Sulphuric anhydride Magnesia Insoluble Residue. Loss on ignition. Alkali content

-

- - - - -

IS 4032 IS 4032 -do- -do-

-do- IS 4032

-

- - - - -

- Daily composite

sample -do- -do- -do- -

-do- - - - - -

This test shall also be carried out whenever there is any change in source of any raw material. - - - - See Note 1

6.0

Fineness - IS 4031 (Part 2)

Daily clinker ground with Gypsum (Clinker taken hourly. A composite sample of the day is mixed with gypsum at the laboratory ball-mill and tested).

1) Every alternate hour from each mill separately.

2) Daily composite sample

Daily composite sample

Soundness - Le-chatlier method IS:4031 (Part 3)

-do- Daily composite sample


6.0

Soundness - Autoclave Method IS 4031:(Part

-do- -do- Daily Composite sample

IS 269:2013 Ordinary Portland Cement, 33 Grade

TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of testing & Inspection)


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(1) (2) (3) (4) (5) (6) (7) (8) 6.0 Setting time. - IS 4031

(Part 5) -do- a) Hourly sample

b) Daily composite sample


6.0 Compressive strength. - IS 4031 (Part 6)


-do-

6.0 Transverse strength (Optional)

- IS 4031 (Part 8)

-do- Weekly composite sample


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 4.1.1. Note 3: Composite sample shall be made out of hourly samples 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 samples 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. ……….


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DATE SHIFT TIME (HOURLY)

NO. OF BAGS

NET MASS OF BAGS FROM NOZZLES No.1, No.2…. No.12

RECORDS OF CALIBRATION/DATE OF CALIBRATION OF NOZZLE(S)

(1) (2) (3) (4) (5) (6)

Form No.1 FORMAT FOR MAINTENANCE OF TEST RECORDS

WEIGHMENT CONTROL AT PACKING STAGE (Clause 6.2 of STI) HOURLY CHECK OF MASS OF BAGS

Form No.2 RAW MATERIAL TESTING

(Clause 7 of STI) Date of receipt of material

Date of Testing

Name of the Material

Source of supply and consignment No.

Details of analysis for 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

1st Hour

12

2nd Hour

12

3rd Hour

12


8

Date of Grinding

Fineness Soundness (Le- chatelier/Auto clave method)

Setting Time Final (FST) Compressive

Strength 3 7 28 …days…

Transverse Strength

(Optional)

Sample/pass/fail Disposal/Action taken if sample

fails

(1) (2) (3) (4) (5) (6) (7) (8)

Date of Grinding

LOI IR SO3 MgO CaO Al2O3 Fe2O3 SiO2 LSF Alumina factor

Fine- ness

Sound- ness Le/Auto

Setting time

IST/FST

Compressive strength

3 7 28 …days…

Transverse Strength (Optional)

Sample pass/fail

Mode of disposal/action taken if sample fails

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18)

Form No.4 CLINKER (DAILY COMPOSITE SAMPLE) (SEE COLUMN 5 OF TABLE 1)

Date of manufacture

Total loss on Ignition

Insoluble Residue

SiO2 CaO Al2O3 Fe2O3 SO3 MgO

LSF (Lime Saturation Factor)

Alumina Factor

Sample Pass/Fails

Disposal/Action taken if Sample fails

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Form No.5 CLINKER GROUND WITH GYPSUM (DAILY COMPOSITE SAMPLE)

LABORATORY BALL MILL(COLUMN 5 OF TABLE 1) Initial(IST)

Form No.6 CEMENT GRINDING (DAILY/WEEKLY COMPOSITE SAMPLES)(COLUMN 6 of Table 1)


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Form No.7

CEMENT GRINDING (FOR HOURLY SAMPLES) (Column 6 of Table 1) Setting time Date of Grinding Time Fineness

Initial Setting Time (IST)

Final Setting Time (FST)

Sample Pass/Fail

Mode of Disposal/Action taken if sample fails

(1) (2) (3) (4) (5) (6) (7)

Form No.8 CEMENT PACKING (DAILY/WEEKLY AVERAGE SAMPLE) COLUMN 7 OF TABLE 1)

Date of Packing

LOI IR S03 MgO CaO A1203 Fe203 SiO2 LSF Chloride content

Alkali Content(refer Note 1)

Alumina factor

Fine- ness

Sound- ness Le/Auto

Setting time IST/FST

Compressive strength 3 7 28

…days...

Transverse Strength (Optional)

Sample pass/fail


(1) (2) (3)

(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 standard values and observed values for each equipment to be kept in proforma for which various columns be devised, as required)

Action taken if equipment

found defective

Remarks

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


10

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 non-coverage

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 Authorized Signatory Name Date


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Doc: STI/269/LS/2 August 2013

1

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


2.0 TEST RECORDS: All records of tests and analysis shall be kept in suitable

forms as per Form 1 to 9. 2.1 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 9001.

4.0 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 sample

and weekly with standard cement samples 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 like 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 weight pressure

gauge tester(if available) Once in four years from NABL accredited Lab or OEM (original Equipment manufacturer) having NPL certified calibrator.


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 1st 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 t he 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 sample 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.


3

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 2.

7.1 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.4.

8.0 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 samples 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.

10.0 STORAGE: Storage shall conform to clause 7 of the Standard. 11.0 SAMPLES: The licensee shall supply free of charge, the sample or samples

required in accordance with Bureau of Indian Standards (Certification Marks) Regulation, from his factory or godowns. BIS shall pay for the samples taken by it from the open market.

12.0 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.

13.0 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


4

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.

14.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed

Proforma-1 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……….


5

Test Details Levels of Control Test Method Clause Requirement

Clause Reference Clinker (FORM 4&5)

Cement Grinding (FORM 6&7)

Cement Packing (FORM 8)

Remarks

(1) (2) (3)

(4) (5) (6) 7)

(8) 5. Chemical composition

Full analysis - IS 4032 Daily composite

sample Weekly composite sample


5.0 Chloride content Sulphuric anhydride Magnesia Insoluble residue. Loss on ignition. Alkali content

-

- - - -

IS 4032 IS 4032 -do-

-do- -do- IS 4032

-

- - - - -

- Daily composite

sample -do- -do- -do- - -

-do- - - - - - -

This test shall also be carried out whenever there is any change in source of any raw material. - - - - See Note 1

6.0 Fineness - IS 4031 (Part 2)

Laboratory Ball Mill testing is required to be done when there is change in the source of Raw material or change in design.

1) Every alternate hour from each mill separately.

2) Daily composite sample


Soundness - Le-chatlier method IS 4031 (Part 3)



6.0

Soundness - Autoclave Method IS 4031(Part 3)

-do- -do- Daily Composite sample

IS 269:2013 Ordinary Portland Cement, 33 Grade

TABLE 1 LEVELS OF CONTROL (Para 6 of the Scheme of testing & Inspection)


6

(1) (2) (3) (4) (5) (6) (7) (8) 6.0 Setting time. - IS 4031

(Part 5) Laboratory Ball Mill testing is required to

be done when there is change in the source of Raw material or change in design.

One sample per shift(Composite sample)


6.0 Compressive strength. - IS 4031 (Part 6)


-do-

6.0 Transverse strength (Optional)

- IS 4031 (Part 8)

-do- Weekly composite sample


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 4.1.1 of the standard. Note 3: Composite sample shall be made out of hourly samples 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 samples 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. ……….


7

DATE SHIFT TIME (HOURLY)

NO. OF BAGS

NET MASS OF BAGS FROM NOZZLES No.1, No.2…. No.12

RECORDS OF CALIBRATION/DATE OF CALIBRATION OF NOZZLE(S)

(1) (2) (3) (4) (5) (6)

Form No.1

FORMAT FOR MAINTENANCE OF TEST RECORDS WEIGHMENT CONTROL AT PACKING STAGE (Clause 6.2 of STI)

HOURLY CHECK OF MASS OF BAGS

Form No.2 RAW MATERIAL TESTING

(Clause 7 of STI) Date of receipt of material

Date of Testing

Name of the Material

Source of supply and consignment No.

Details of analysis for 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

1st Hour

12

2nd Hour

12

3rd Hour

12


8

Date of Grinding

Fineness Soundness (Le- chatelier/Auto clave method)

Setting Initial Time Final (IST) (FST) Compressive

Strength 3 7 28 …days…

Transverse Strength

(Optional)

Sample/pass/fail Disposal/Action taken if sample

fails

(1) (2) (3) (4) (5) (6) (7) (8)

Date of Grinding

LOI IR SO3 Mgo Cao Al203 Fe203 Si02 LSF Alumina factor

Fine- ness

Sound- ness le/Auto

Setting time

IST/FST

Compressive strength

3 7 28 …days…

Transverse strength (Optional)

Sample pass/fail


(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18)

Form No.4

CLINKER (DAILY COMPOSITE SAMPLE) (SEE COLUMN 5 OF TABLE 1) Date of manufacture

Total loss on Ignition

Insoluble Residue

Sio2 CaO Al203 Fe203 SO3 Mgo LSF (Lime Saturation Factor)

Alumina Factor

Sample Pass/Fails

Disposal/Action taken if Sample fails

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Form No.5 CLINKER GROUND WITH GYPSUM (DAILY COMPOSITE SAMPLE)

LABORATORY BALL MILL(COLUMN 5 OF TABLE 1)

Form No.6 CEMENT GRINDING (DAILY/WEEKLY COMPOSITE SAMPLES)(COLUMN 6 of Table 1)


9

Form No.7

CEMENT GRINDING (FOR ALTERNATE HOURLY SAMPLES) (Column 6 of Table 1)

Setting time Date of Grinding Time Fineness Initial Setting Time (IST)

Final Setting Time (FST)

Sample Pass/Fail

Mode of Disposal/Action taken if sample fails

(1) (2) (3) (4) (5) (6) (7)

Form No.8 CEMENT PACKING (DAILY/WEEKLY AVERAGE SAMPLE)( COLUMN 7 OF TABLE 1)

Date of Packing

LOI IR S03 MgO CaO A1203 Fe203 SiO2 LSF Chloride content

Alkali Content(refer Note 1)

Alumina factor

Fine- ness

Sound- ness Le/Auto

Setting time IST/FST

Compressive strength 3 7 28

…days...

Transverse Strength test (Optional)

Sample pass/fail


(1) (2) (3)

(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 standard values and observed values for each equipment to be kept in proforma for which various columns be devised, as required)

Action taken if equipment found defective

Remarks

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


10

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)


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)



4.1 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 Authorized Signatory Name Date


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Doc: STI/269/PACK/4 August 2013

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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


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 9.

2.1 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 9001.

4. 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 sample and once in a month with standard cement samples 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.


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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 1st 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 t he 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.


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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.3.

8.0 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 samples 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.


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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.

10.0 STORAGE: Storage shall conform to clause 7 of the Standard.

11.0 SAMPLES: The licensee shall supply, free of charge, the samples 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 samples taken by it from the open market. 12.0 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.

13.0 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.

14.0 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.

15.0 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.

16.0 PRODUCTION DATA: The licensee shall send to BIS as per the enclosed proforma-1 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.


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Form No. 1 FORMAT FOR MAINTENANCE OF TEST RECORDS

WEIGHMENT CONTROL AT PACKING STAGE HOURLY CHECK OF MASS OF DRUMS

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


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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

Form No. 8 & 9 ORDINARY PORTLAND CEMENT 33 GRADE

(PHYSICAL TEST REPORT) (Tests done at factory or at pre-declared lab)

(At receipt stage and at bulk packing terminal)

Date Batch No.

Test Report Soundness Compressive Remarks

No. Strength

Transverse Strength (optional)

LC AC 3 7 28 Days

days Days


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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)

TEST DETAILS LEVELS OF CONTROL

Clause Requirements Test Method Frequency Remarks

Clause Reference

5.0 Loss on ignition IS 4032 One sample 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 pre- declared 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-

(Le-chatlier 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.


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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)


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)



4.1 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

Doc: STI/269/6 · Doc: STI/269/6 August 2013 3 7.0 RAW MATERIALS: Routine analysis of various raw materials going into the manufacture of Ordinary Portland cement, 33 Grade shall

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