Portland pozzolana cement Part 1 (Flyash based) – Specification
1991 Edition

Overview of Fly Ash-Based Portland Pozzolana Cement

• Coverage: Defines manufacture, chemical and physical criteria for PPC using fly ash.
• Pozzolanic Material: Exclusively fly ash is permitted as the pozzolana.
• Terminology: Adheres to definitions from IS 4845:1968.
• Standard Consistency Water (P): Water percentage needed for standard paste consistency (Clause 12.3).
• Standard Sand: Testing sand must meet IS 650:1966 specifications.

Cement Bag Mass Sampling Table (Annex B, Clause 10.2)

• Mean net weight per bag must be at least 50 kg.
• Random selection of bags as per IS 4905:1968.

Notable Updates:

• Minimum compressive strength requirement updated from 4.0 MPa to 4.5 MPa (Clauses 4.1.2 & 4.1.3).

Rounding Rules:

• Implement IS 2:1960 guidelines for rounding test outcomes, maintaining significant figures as per standard values.

flowchart TD
    A[Fly Ash Portland Pozzolana Cement] --> B[Production & Testing]
    B --> C[Physical & Chemical Standards]
    B --> D[Cement Bag Mass Criteria]
    D --> E[Sampling Quantities Based on Batch Size]
    C --> F[Standard Consistency Water (P)]
    C --> G[Standard Sand per IS 650:1966]

Refer to the full IS 1489 Part 1 document and related IS codes for comprehensive chemical and physical specifications.

Definitions and Specifications per IS 1489 Part 1

• Scope: Manufacturing and characteristics of fly ash-based Portland pozzolana cement.
• Reference Terminology: Based on IS 4845:1968 for hydraulic cement terms.
• Standard Consistency Water (P): Percentage of water required to produce standard consistency paste (Clause 12.3.1).
• Standard Sand: Must comply with IS 650:1966 for cement testing purposes (Clause 12.3.2).
• Rounding Off: Test results rounded according to IS 2:1960.
• Sampling: Conducted randomly as per IS 4905:1968.
• Cement Bag Mass Tolerances (Annex B):

• Storage and Retesting: Cement stored over 6 months in bulk or more than 3 months in bags requires retesting (Clause 13.2).

Process Flow: Cement Consistency and Sampling

flowchart TD
    A[Start: Cement Production] --> B{Determine Water % (P)}
    B --> C[Prepare Standard Consistency Paste]
    C --> D[Conduct Physical & Chemical Tests]
    D --> E{Sample Selection per IS 4905}
    E --> F[Assess Batch Size]
    F -->|100–150| G[Sample 20 Bags]
    F -->|151–280| H[Sample 32 Bags]
    F -->|281–500| I[Sample 50 Bags]
    F -->|501–1,200| J[Sample 80 Bags]
    F -->|1,201–3,200| K[Sample 125 Bags]
    F -->|>3,200| L[Sample 200 Bags]
    G & H & I & J & K & L --> M[Verify Mass Tolerances]
    M --> N{Pass Criteria Met?}

Portland Clinker Specifications per IS 1489 Part 1

• Definition (Clause 3.2): Clinker primarily consists of calcium silicates formed by heating a uniform mix of lime (CaO), silica (SiO₂), alumina (Al₂O₃), and iron oxide (Fe₂O₃) to near fusion.

• Chemical Composition (Refer IS 269:1989, Clause 4.2): Clinker must conform to IS 269 requirements for Portland cement clinker.

• Chemical Limits for PPC Clinker (Clause 6.1, Table 1):

• Explanations:
  • LOI indicates residual carbonates or moisture.
  • MgO content influences soundness; excess MgO (>6%) may cause expansion.
  • Insoluble material reflects impurities affecting cement quality.

Insoluble Material Limit Formula:

[ \text{Maximum Insoluble Material} = x + \frac{4.0 (100 - x)}{100} ]

where x represents a specific constituent percentage (context-dependent).

This maintains clinker quality essential for durable Portland pozzolana cement.

Key Formulations and Requirements for Constituents in IS 1489 Part 1

Insoluble Material Maximum (Clause 4.0.iv)

• For Portland pozzolana cement containing x% fly ash:

[ \text{Maximum Insoluble Material (%)} = x + \frac{4.0 (100 - x)}{100} ]

• x denotes the declared fly ash proportion by mass.

Chemical Constraints (Clause 6.1, Table 1)

Physical Specifications (Clause 12.3)

• P: Percentage of water for standard consistency paste.
• Standard sand utilized for tests must comply with IS 650:1966.

Notes:

• Rounding of test data follows IS 2:1960.
• Fly ash is the sole approved pozzolanic material.
• Chemical and physical tests ensure cement meets performance criteria.

flowchart LR
    A[Fly Ash Percentage (x)] --> B[Calculate Maximum Insoluble Material]
    B --> C[Chemical Testing]
    C --> D{Within Limits?}
    D -- Yes --> E[Approve Cement]
    D -- No --> F[Reject Batch]

This summary supports effective quality control for fly ash-based PPC.

Composition Specifications for Fly Ash-Based Portland-Pozzolana Cement (IS 1489 Part 1)

Chemical Limits (Clause 6.1, Table 1)

• Loss on Ignition measures residual carbon or moisture.
• Magnesia content impacts dimensional stability.
• Insoluble material limit depends on declared fly ash content (x).

Physical Parameters (Clauses 7 & 12.3)

• Standard consistency water percentage (P) defines water for paste preparation.
• Standard sand used in testing must meet IS 650:1966.

Additional Information:

• Test result rounding adheres to IS 2:1960.
• The fly ash content (x) is manufacturer-declared and integral to calculations.

Insoluble Material Limit Formula:

[ \text{Maximum Insoluble Material} = x + \frac{4.0 (100 - x)}{100} ]

Where:

• (x) = fly ash percentage in cement.

This ensures balanced chemical composition for quality PPC.

Chemical Parameters for Fly Ash-Based Portland Pozzolana Cement (IS 1489 Part 1)

• x denotes the declared fly ash content in cement.
• Limits on insoluble material adjust according to fly ash proportion.

Notes:

• Chemical testing performed per IS 4032:1985.
• Rounding conducted as per IS 2:1960.
• Cement batches out of compliance may be rejected (Clause 13.2).
• Fly ash must meet IS 3812 standards.

Formula for Insoluble Material Maximum:

[ \text{Max Insoluble Material} = x + \frac{4.0 \times (100 - x)}{100} ]

where x = fly ash content percentage.

Referenced Standards:

• IS 4032:1985 — Chemical analysis methods.
• IS 3812 — Fly ash quality.
• IS 2:1960 — Rounding rules.

flowchart TD
    A[Declared Fly Ash % (x)] --> B[Calculate Insoluble Material Limit]
    B --> C[Max Insoluble = x + 4.0*(100-x)/100]
    C --> D[Compare with Test Results]
    D -->|Pass| E[Accept Cement]
    D -->|Fail| F[Reject Cement]

This framework ensures chemical compliance for PPC.

Summary of Physical Properties for Fly Ash-Based PPC (IS 1489 Part 1)

Core Formulas and Standards

• Maximum Insoluble Material:

[ \text{Max Insoluble Material} = x + \frac{4.0 (100 - x)}{100} ]

where x is the declared fly ash percentage.

• Testing Conditions:

  • Ambient temperature maintained at 27 ± 2°C (Clause 12.2).
  • Actual measurement temperature must be recorded.

• Water for Standard Consistency (P): Percentage of water required to prepare cement paste of standard consistency (Clause 12.3).

• Standard Sand: Must conform to IS 650:1966 requirements.

Chemical Limits (Table 1)

Remarks:

• These limits maintain cement durability and performance.
• Consistent test temperature and water content are critical for reliable results.

flowchart TD
    A[Fly Ash PPC] --> B[Physical Testing @ 27±2°C]
    B --> C[Measure Water % for Standard Consistency (P)]
    B --> D[Use Standard Sand (IS 650:1966)]
    A --> E[Chemical Testing]
    E --> F[LOI ≤ 5%]
    E --> G[MgO ≤ 6%]
    E --> H[Insoluble Material ≤ x + 4(100-x)/100]

Key Manufacturing Aspects of Fly Ash-Based PPC (IS 1489 Part 1)

• Standard Consistency Water (Clause 12.3): The required water percentage (P) to achieve a standard consistency paste is determined as per IS 4031 (Part 4). This is essential for subsequent testing.

• Standard Sand (Clause 12.3): Sand used for testing must meet specifications of IS 650:1966.

• Packing Tolerances (Annex B, Clause 10.2): Sample sizes for quality control depend on batch volume:

• Packing Material: Selection must be mutually agreed by manufacturer and purchaser (Clause 10.2.2.3).

Manufacturing Process Flow

flowchart TD
    A[Raw Materials] --> B[Mixing & Grinding]
    B --> C[Water Addition (P% for consistency)]
    C --> D[Quality Testing using Standard Sand]
    D --> E[Packing in Bags]
    E --> F[Sampling & Weight Tolerance Checks]
    F --> G[Dispatch to Market]

Referenced Standards:

• IS 4031 (Part 4) for water consistency testing
• IS 650:1966 for standard sand
• IS 4905:1968 for random sampling

These ensure adherence to quality and compliance.

Manufacturer's Certification Requirements (IS 1489 Part 1)

• Fly Ash Content Declaration (Clause 9.1):

  • The manufacturer must certify the fly ash percentage in the cement within 10 days of dispatch.
  • The actual fly ash content should not deviate more than ±3% from the declared value.

• Drying Shrinkage Limit (Clause 7.5):

  • Average drying shrinkage of mortar bars (tested as per IS 4031 Part 10:1988) should not exceed 0.15%.

• Storage Conditions:

  • Cement must be stored in weather-tight facilities to prevent moisture ingress and quality deterioration.

Cement Bag Mass Tolerance (Annex B, Clause 10.2)

• Samples are randomly selected according to IS 4905:1968.
• Average net weight per sampled bag must be at least 50 kg.

Compressive Strength Criteria (Clause 4.5)

• Minimum compressive strength is revised to 4.5 MPa.

flowchart TD
    A[Manufacturer] --> B[Quality Verification]
    B --> C[Confirm Fly Ash Percentage]
    C --> D[Issue Certification (±3% tolerance)]
    B --> E[Bag Cement]
    E --> F[Random Sampling per IS 4905]
    F --> G[Verify Bag Mass ≥ 50 kg]
    G --> H[Dispatch Cement]

This process ensures traceability and compliance.

Packaging and Marking Requirements (IS 1489 Part 1)

• Packing Materials: Must be mutually agreed upon between manufacturer and purchaser as per Clause 10.2.2.3.

• Packing Formats for Export Cement (Clause 10.2.2):

  • Packaging can be in bags or drums.
  • The average net mass per unit (bag or drum) is to be agreed upon.

• Typical Bag Weight: Commonly 50 kg per bag, but subject to mutual agreement.

• Marking Details: Usually include:

  • Manufacturer’s name
  • Cement type and grade
  • Net weight
  • Batch identification number
  • ISI certification mark if applicable

• No fixed tables or formulas are prescribed for packaging; arrangements are flexible.

flowchart LR
    A[Manufacturer] -->|Agree on packing specs| B[Packaging (Bags/Drums)]
    B --> C[Apply Markings: Manufacturer, Grade, Weight, Batch]
    C --> D[Dispatch to Purchaser]

Summary: Packaging and marking are governed by mutual agreement, ensuring clarity and conformity.

Sampling Guidelines under IS 1489 Part 1

Sampling Process (Clause 11.2)

• Samples must be collected following the procedures in IS 3535:1986.
• Sampling is performed randomly according to IS 4905:1968.
• The manufacturer is responsible for providing personnel and facilities for sampling and sealing (Clause 11.3).

Sample Sizes Based on Batch Volume (Annex B, Clause 10.2)

• The average net weight of sampled bags must be at least 50 kg.

Additional Notes (Clause 12.4.1)

• Independent testing samples may be collected before or right after delivery.
• Testing is conducted per IS 1489 Part 1 standards following purchaser’s written request.

Sampling Workflow

flowchart TD
    A[Batch Received] --> B{Batch Size?}
    B -->|100-150| C[Sample 20 Bags]
    B -->|151-280| D[Sample 32 Bags]
    B -->|281-500| E[Sample 50 Bags]
    B -->|501-1,200| F[Sample 80 Bags]
    B -->|1,201-3,200| G[Sample 125 Bags]
    B -->|>3,200| H[Sample 200 Bags]
    C & D & E & F & G & H --> I[Random Selection (IS 4905)]
    I --> J[Verify Average Mass ≥ 50 kg]
    J --> K[Conduct Tests per IS 1489 & IS 3535]

This ensures sampling compliance with the standard.

Testing Standards for Fly Ash-Based PPC (IS 1489 Part 1)

1. Test Environment (Clause 12.2)

• Physical tests are to be performed at a controlled temperature of 27 ± 2°C.
• Actual temperature during testing must be documented.

2. Independent Testing (Clause 12.4)

• Testing should be carried out independently to avoid bias.

3. Sample Sizes for Mass Tolerance (Annex B, Clause 10.2)

• Sample sizes vary by batch size:

• Bags for sampling must be randomly chosen (IS 4905:1968).

4. Water Content for Testing (Clause 12.3)

• P is the percentage of water used to achieve standard consistency in cement paste.
• Standard sand complies with IS 650:1966.

Water Content Determination:

• Water percentage (P) is measured to produce paste of standard consistency.

flowchart TD
    A[Begin Testing] --> B{Is Temperature 27 ± 2°C?}
    B -- Yes --> C[Record Actual Temperature]
    B -- No --> D[Adjust Lab Conditions]
    C --> E[Select Sample Size per Batch]
    E --> F[Random Sampling per IS 4905]
    F --> G[Conduct Physical and Chemical Tests]
    G --> H[Determine Water % for Standard Consistency]
    H --> I[Report Test Results]

Refer to IS 1489 Part 1 and IS 4905 for detailed testing and sampling procedures.

Rejection Guidelines According to IS 1489 Part 1

Principal Clauses (Clause 13)

• Clause 13.1: Any cement consignment failing to meet the prescribed specifications is subject to rejection.
• Clause 13.2: Cement stored in bulk for more than 6 months or in vendor bags for over 3 months after initial testing must be retested.
  • Failure upon retesting mandates cement rejection.

Sampling and Testing References

Sampling Table (Annex B - Clause 10.2)

Summary

• Cement exceeding specified storage duration must be retested.
• Rejection is compulsory if retesting fails or original specifications are unmet.
• Sampling sizes for quality control depend on batch volume.
• Test methods defined in IS 4031 and sampling in IS 4905.

flowchart TD
    A[Cement Storage] --> B{Storage Duration}
    B -->|Bulk > 6 months| C[Retest Cement]
    B -->|Bags > 3 months| C
    C --> D{Retest Passed?}
    D -->|Yes| E[Use Cement]
    D -->|No| F[Reject Cement]
    A --> G{Initial Testing}
    G -->|Fail| F
    G -->|Pass| E

Source: IS 1489 Part 1:1991 Clauses 10.2, 12.4, 13.1

Annex A: List of Referenced IS Codes in IS 1489 Part 1 (1991)

This standard cites the following Indian Standards relevant to fly ash-based Portland pozzolana cement:

Notes:

• These standards cover materials, testing, sampling, and packaging.
• Compliance ensures consistency and quality in PPC production.
• Rounding off uses IS 2:1960 rules.
• Storage and retesting are governed by Clause 13.2.

Relationship Diagram

graph LR
A[IS 1489 Part 1] --> B[Material Specifications]
A --> C[Testing Procedures]
A --> D[Sampling & Packaging]
B --> IS269[IS 269: OPC Spec]
B --> IS3812[IS 3812: Fly Ash Spec]
C --> IS4031[IS 4031: Physical Tests]
C --> IS4032[IS 4032: Chemical Analysis]
D --> IS4905[IS 4905: Sampling]
D --> IS2580[IS 2580: Packaging]

Mass Tolerance Specifications for Cement Bags (IS 1489 Part 1)

Highlights:

• The average net weight per cement bag must be at least 50 kg (Clause 10.2.2.4, Annex B).
• Tolerances align with the Standards of Weights and Measures (Packaged Commodities) Rules, 1977, as updated.
• Sample size for evaluation depends on batch size:

• Sample bags must be chosen randomly as per IS 4905:1968.

Summary:

• Average weight in sample bags must not fall below the declared mass (usually 50 kg).
• Individual bag weight deviations are controlled under packaged commodity rules.
• Sampling size varies with batch size to ensure reliable quality assessment.

Reference Formula:

Let ( M ) be the declared bag mass (e.g., 50 kg), then:

[ \text{Average mass of sampled bags} \geq M ]

Sampling Process Flow

flowchart TD
    A[Batch of Cement Bags] --> B{Batch Size}
    B -->|100-150| C[Sample 20 Bags]
    B -->|151-280| D[Sample 32 Bags]
    B -->|281-500| E[Sample 50 Bags]
    B -->|501-1,200| F[Sample 80 Bags]
    B -->|1,201-3,200| G[Sample 125 Bags]
    B -->|>3,200| H[Sample 200 Bags]
    C & D & E & F & G & H --> I[Random Selection per IS 4905]
    I --> J[Verify Average Mass ≥ Declared Mass]