Portland pozzolana cement (calcined clay-based) – Specification

IS 1489 Part 2 — Scope: Key Points & Specifications

Scope Overview:

• Covers technical requirements for Portland Pozzolana Cement (PPC).
• Defines test methods, packaging, and quality control.
• Permits purchaser options (Clauses 4.1.4, 4.2, 12.4.1).
• Requires agreement between purchaser and manufacturer on some parameters (Clauses 10.2.1, 10.3).

Important Tables & Clauses:

• Average net mass per bag ≥ 50 kg.
• Bags selected randomly per IS 4905:1968.

Additional Notes:

• Rounding off test results per IS 2:1960.
• Definitions per IS 4845:1968.
• Standard sand for testing per IS 650:1991.
• Water percentage (P) for standard consistency defined in Clause 12.3.

This scope ensures uniformity in cement quality, packaging, and testing for PPC under IS 1489 Part 2.

IS 1489 Part 2 — Key References, Tables & Specifications Summary

1. Rounding Off (Clause 4.2):

• Use IS 2:1960 for rounding off test results.
• Retain the same number of significant digits as specified values.

2. Definitions (Clause 3.0):

• Follow definitions in IS 4845:1968 for terms related to this standard.

3. Water Requirement (Clause 12.3):

• P = % water for standard consistency paste (see Clause 12.3).
• Use standard sand as per IS 650:1991 for testing.

4. Tolerance on Cement Bag Mass (Clause 10.2, Annex B):

• Average net mass ≥ 50 kg per bag.
• Sample sizes depend on batch size:

• Bags selected randomly per IS 4905:1968.

Additional Notes:

• Technical committee details: Annex C.
• BIS copyright rules apply; free use allowed for implementation details.
• For detailed formulas & test procedures, refer to respective IS codes mentioned.

flowchart LR
    A[Start: Cement Testing] --> B[Check Water % (P) - Clause 12.3]
    B --> C[Use Standard Sand (IS 650)]
    C --> D[Measure Mass of Cement Bags]
    D --> E{Batch Size?}
    E -->|100-150| F[Sample 20 Bags]
    E -->|151-280| G[Sample 32 Bags]
    E -->|281-500| H[Sample 50 Bags]
    E -->|501-1200| I[Sample 80 Bags]
    E -->|1201-3200| J[Sample 125 Bags]
    E -->|>3200| K[Sample 200 Bags]
    F &

IS 1489 Part 2: Definitions (Clause 3.0)

• Reference for Definitions:
  Definitions in IS 1489 Part 2 refer primarily to IS 4845:1968 for terminology related to Portland Pozzolana Cement (PPC).

• Key Points:

  • Terms like standard consistency, initial/final setting time, fineness, and soundness are as per IS 4845.
  • Water content for standard consistency (P%) is defined in Clause 12.3.
  • Standard sand for testing conforms to IS 650:1991.
  • Final test values must be rounded off following IS 2:1960 rules.

Important Related Specifications:

Summary Table: Mass Tolerance Sample Size (Annex B, Clause 10.2)

Rounding Rule (IS 2:1960)

• Round off test results to the same number of significant digits as specified.
• Ensures uniformity and clarity in reporting test outcomes.

flowchart LR
    A[IS 1489 Part 2 Definitions] --> B[Refer IS 4845:1968]
    A --> C[Water Content for Std Consistency (P%)]
    A --> D[Standard Sand per IS 650:1991]
    A --> E[Mass Tolerance Sampling per Annex B]
    E --> F[Sample Size Based on Batch Size

IS 1489 Part 2: Key Materials Specifications & Formulas

1. Chemical Requirements for Portland-Pozzolana Cement (Table 1, Clause 6)

2. Water Requirement (Clause 12.3)

• P = % water required for standard consistency paste.
• Standard sand as per IS 650 : 1991.

3. Setting Time (Clause 7.3.1)

• False set ratio (final penetration at 5 min / initial penetration at 20 s) ≥ 50%.
• Initial and final setting times per IS 4031 (Part 5) : 1988 after false set break.

Notes:

• All test values must be rounded off following IS 2 : 1960.
• Standard sand and other materials must conform to respective IS specifications.

flowchart TD
    A[Raw Materials] --> B[Chemical Composition Check]
    B -->|Loss on Ignition ≤5%| C[MgO ≤0.9%]
    C --> D[Insoluble Material Limit]
    D --> E[Water Requirement (P%)]
    E --> F[Standard Consistency Paste]
    F --> G[Setting Time Tests]

This summary ensures compliance with IS 1489 Part 2 for cement materials.

IS 1489 Part 2 - Manufacture: Key Points & Specifications

• Clause 4.2 & 10.2.1 / 10.3: Manufacturing details and packing materials are subject to purchaser-manufacturer agreement.
• Water for Standard Consistency (Clause 12.3):
  • P = % water required for standard paste consistency (see Clause 12.3).
  • Standard sand for testing must comply with IS 650:1991.
• Packing Material (Clause 10.2.2.3):
  • Packing material type and quality are mutually agreed upon by manufacturer and purchaser.
• Sampling & Identification (Clause 11.3):
  • Manufacturer must provide facilities and materials for sampling and identification of cement batches.
• Rounding Off (Clause 4.2):
  • Test results rounded per IS 2:1960 rules, retaining significant figures as per specified values.

Summary Table: Manufacture Requirements

flowchart TD
    A[Manufacture Process] --> B[Water % for Paste (P) per Clause 12.3]
    A --> C[Use Standard Sand IS 650:1991]
    A --> D[Packing Material - Agreement]
    A --> E[Sampling & Identification Facilities]
    A --> F[Testing & Rounding off per IS 2:1960]

This ensures quality control, standardization, and mutual agreement in manufacturing and supply of cement as per IS 1489 Part 2.

IS 1489 Part 2: Chemical Requirements for Portland-Pozzolana Cement

Key Chemical Requirements (Table 1, Clause 6):

Notes:

• Pozzolana content (x) must be between 10% and 25% by mass.
• Gypsum (natural or chemical) may be added if cement is made by intergrinding clinker and pozzolana.
• No other admixtures except approved air-entraining agents (max 1%) are allowed.
• Homogeneity of the blend must be within ±3%.

Formula for Insoluble Material Limit:

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

where (x) = % of pozzolana in the cement.

Setting Time (Clause 7.3.1):

• If false set occurs, the ratio of final to initial penetration after mixing should be ≥ 50%.
• Initial and final setting times after breaking false set must meet standard requirements per IS 4031 (Part 5).

Summary Diagram:

flowchart TD
    A[Portland-Pozzolana Cement] --> B[Chemical Composition]
    B --> C[Loss on Ignition ≤ 5%]
    B --> D[Magnesia (MgO) ≤ 0.9%]
    B --> E[Insoluble Material ≤ (100 - x)*x/100 %]
    B --> F[Pozzolana Content 10-25%]
    F --> G[Homogeneity ±3%]
    A --> H[Admixtures]
    H --> I[Gypsum allowed if interground]
    H --> J[Air-entraining agents ≤ 1%]
``

IS 1489 Part 2: Physical Requirements - Key Points

Clause 12.2 - Test Temperature:

• Physical tests should be conducted at 27 ± 2°C.
• Actual temperature during testing must be recorded.

Clause 12.3 - Water Content:

• P = Percentage of water for standard consistency paste (see Clause 12.3).
• Use Standard Sand conforming to IS 650:1991 for tests.

Rounding Off Results:

• Follow IS 2:1960 for rounding numerical test results, keeping significant digits same as specified values.

Important Tables:

For tolerance requirements on cement bag mass (Clause 10.2, Annex B).

Summary Diagram

flowchart TD
    A[Test Setup] --> B{Temperature}
    B -->|27 ± 2°C| C[Conduct Tests]
    B -->|Record Actual Temp| D[Log Data]
    C --> E[Measure Water Content (P%)]
    E --> F[Use Standard Sand (IS 650)]
    F --> G[Calculate Results]
    G --> H[Rounding Off (IS 2:1960)]

For detailed test procedures and composition, refer to IS 1489 Part 2 clauses and IS 650 for sand.

IS 1489 Part 2: Sampling Key Points

• Sampling Method: As per Clause 11.2, sampling procedures must follow IS 3535:1986.

• Sample Size Table (Annex B, Clause 10.2): Number of bags to sample depends on batch size:

• Mass Requirement: Average net mass per bag in sample ≥ 50 kg.

• Random Selection: Bags must be selected randomly (see IS 4905:1968).

• Facilities (Clause 11.3): Manufacturer must provide labor/materials for sampling and identification.

• Independent Testing (Clause 12.4.1): Purchaser can request samples before/after delivery for testing as per IS 1489.

Summary Diagram: Sampling Process

flowchart TD
    A[Batch of Cement Bags] --> B[Random Selection per IS 4905]
    B --> C[Sample Size per Batch Size Table]
    C --> D[Sampling as per IS 3535]
    D --> E[Testing & Identification]
    E --> F{Purchaser Requests Independent Test?}
    F -- Yes --> G[Sample taken before/after delivery]
    F -- No --> H[Standard testing]

This ensures representative sampling and compliance with quality standards.

Manufacturer's Certificate - IS 1489 Part 2 (Clause 9)

Key Specifications:

• Certificate Content:

  • Confirmation that cement conforms to IS 1489 Part 2.
  • Percentage of pozzolana present in the cement.
  • Declaration that pozzolana content will not vary more than ±3% from the declared value.

• Timing:

  • Certificate must be furnished within 10 days of dispatch.

Relevant Details from IS 1489 Part 2

Sampling Table for Cement Bags (Annex B, Clause 10.2)

Notes:

• Cement bags must be selected randomly as per IS 4905:1968.
• The manufacturer must also ensure proper storage to avoid deterioration (Clause 7.5).

flowchart TD
    A[Manufacturer Produces Cement] --> B[Tests Cement for Compliance]
    B --> C[Determines % Pozzolana]
    C --> D[Furnishes Manufacturer's Certificate within 10 days]
    D --> E[Certificate Includes:]
    E --> E1[Compliance Statement]
    E --> E2[Declared % Pozzolana ±3%]
    E --> E3[Batch & Sampling Info]

This ensures traceability and quality assurance as per IS 1489 Part 2.

IS 1489 Part 2: Packing and Marking Summary

• Clause 10.2.2:

  • Packing for export cement is done in bags or drums.
  • Average net mass per bag/drum is as agreed between purchaser and manufacturer.
  • No fixed standard weight; flexibility based on agreement.

• Clause 10.2.2.3:

  • Packing material type is mutually agreed between supplier and purchaser.
  • No prescribed packing material in the code; depends on buyer-supplier contract.

Key Points:

• No fixed formula or table for packing weights or materials in IS 1489 Part 2.
• Agreement-driven packing specifications ensure suitability for transport and handling.
• Marking on bags/drums should follow purchaser requirements (usually includes cement type, weight, manufacturer info).

Typical packing weights (industry practice, not IS mandated):

flowchart LR
    A[Manufacturer] -->|Agree packing| B[Packing Material Type]
    A -->|Agree net mass| C[Bag/Drum Weight]
    B & C --> D[Packing & Marking]
    D --> E[Export/Delivery]

Summary: IS 1489 Part 2 leaves packing and marking details flexible, emphasizing purchaser-manufacturer agreement for export cement.

IS 1489 Part 2 — Sampling and Identification Facilities

Key Clauses Summary:

• Clause 11.3: Manufacturer/supplier must provide all facilities (labour, materials) for sampling, packing, and identification of cement samples.
• Clause 11.2: Sampling methods must follow IS 3535:1986.
• Clause 11.1.2: If testing is delayed beyond one week, samples must be stored in airtight containers.

Sampling Procedure (per IS 3535:1986):

• Samples should be taken from different bags or bulk supply to represent the batch.
• Use clean, dry tools and containers for sampling.
• Label samples clearly with identification details (batch number, date, source).

Identification Facilities:

• Provide proper packing materials to avoid contamination or moisture ingress.
• Maintain clear traceability of samples for testing and record-keeping.
• Ensure airtight storage if delay in testing occurs.

Practical Checklist for Sampling Facility:

flowchart TD
    A[Start Sampling] --> B[Select Representative Bags/Batch]
    B --> C[Use Clean Tools]
    C --> D[Collect Sample]
    D --> E[Pack in Airtight Container]
    E --> F{Testing within 1 week?}
    F -- Yes --> G[Send for Testing]
    F -- No --> H[Store Airtight until Testing]

Note: Always refer to IS 2:1960 for rounding off test results as per Clause 4.2.

This ensures compliance, traceability, and preservation of sample integrity per IS 1489 Part 2.

IS 1489 Part 2: Testing Key Points

1. Testing Temperature (Clause 12.2)

• Physical tests should be conducted at 27 ± 2°C.
• Actual test temperature must be recorded.

2. Independent Testing (Clause 12.4)

• Testing can be performed independently by purchaser or third party.
• Final test values must be rounded as per IS 2:1960 rules (same significant figures as specified values).

3. Setting Time (Clause 7.3.1)

• For cements showing false set: [ \text{Ratio} = \frac{\text{Final penetration after 5 min}}{\text{Initial penetration after 20 s}} \times 100 \geq 50% ]
• Testing per IS 4031 (Part 14):1989 and setting time per IS 4031 (Part 5):1988 after breaking false set.

4. Chemical Requirements (Table 1, Clause 6)

Summary Diagram: Testing Flow

flowchart TD
    A[Sample Preparation] --> B[Temperature Control 27±2°C]
    B --> C[Physical Tests]
    C --> D{False Set?}
    D -- Yes --> E[Calculate Penetration Ratio]
    E --> F[Break False Set & Test Setting Time]
    D -- No --> G[Standard Setting Time Test]
    F & G --> H[Chemical Tests per IS 4032]
    H --> I[Result Rounding as per IS 2:1960]
    I --> J[Compliance Decision]

Note: Always refer to relevant IS test methods (e.g., IS 4031 series) for detailed procedures.

IS 1489 Part 2 - Rejection Criteria for Cement

Key Clauses on Rejection (Clause 13)

• Clause 13.1: Cement shall be rejected if it fails to meet any specification requirement.
• Clause 13.2: Cement stored in bulk at the mill for more than 6 months or in bags with vendors for more than 3 months after testing must be retested before use and rejected if it fails specifications.

Summary Table: Rejection Conditions

Additional Notes

• Retesting ensures cement quality is maintained despite storage duration.
• Refer to IS 269:1989 and IS 4031 (Parts 1-14) for detailed test methods.
• Sampling and testing must comply with IS 3535 and IS 4905.

Related Specification Reference

In brief: Cement failing any test or stored beyond specified durations without retesting must be rejected to ensure structural safety and durability.

IS 1489 (Part 2) : 1991 — List of Referred Indian Standards

This standard refers to several key IS codes related to cement and packaging, summarized below:

Notes:

• These referenced standards cover cement specifications, testing methods, sampling, packaging materials, and terminology.
• For rounding off test results, IS 2:1960 rules apply.
• Cement storage and retesting guidelines are in Clause 13.2.

This list ensures harmonized quality control and testing for blended cements under IS 1489 Part 2.

flowchart LR
    A[IS 1489 Part 2] --> B[Cement Specifications]
    A --> C[Testing Methods]
    A --> D[Sampling Procedures]
    A --> E[Packaging Standards]
    B --> IS269["IS 269: Ordinary Portland Cement"]
    C --> IS4031["IS 4031: Physical Tests"]
    C --> IS4032["IS

Tolerance Requirements for Mass of Cement Packed in Bags (IS 1489 Part 2)

• Average Net Mass:

  • For 50 kg bags: Average net mass ≥ 50 kg.
  • For 25 kg bags: Average net mass may be 25 kg with tolerances as per 10.2.1.1.

• Sample Size Based on Batch Size (Annex B, Clause 10.2):

• Selection: Bags are selected randomly as per IS 4905:1968.

• Tolerance Limits (Clause 10.2.1.1):

  • Typically ±1% of the nominal mass.
  • No bag should be underweight below the tolerance limit.

Summary:

• Average net mass must not be less than the declared mass.
• Sample sizes increase with batch size to ensure quality control.
• Random sampling ensures representativeness.

flowchart TD
    A[Batch Size] --> B{Batch Size Range}
    B -->|100-150| C[Sample Size = 20]
    B -->|151-280| D[Sample Size = 32]
    B -->|281-500| E[Sample Size = 50]
    B -->|501-1200| F[Sample Size = 80]
    B -->|1201-3200| G[Sample Size = 125]
    B -->|Above 3200| H[Sample Size = 200]
    C & D & E & F & G & H --> I[Random Sampling per IS 4905]
    I --> J[Check average net mass ≥ declared mass]
    J --> K[Check individual bag tolerance ±1%]

This ensures compliance with IS 1489 Part 2 for cement packing mass control.