High alumina cement for structural use – Specification

Scope of IS 6452 Part B: Key Points & Specifications

• Scope: Covers requirements for packing, sampling, and delivery of cement (bulk and bagged).

• Bulk Supply:

  • Cement supply in bulk is defined as any single container with ≥ 1000 kg net mass.
  • Intermediate containers (e.g., 200 kg drums) allowed by agreement (Clause 9.3).

• Sampling:

  • Sampling methods per IS 3535:1986 (Clause 5.2).
  • Sampling size and number of bags depend on total quantity (see table below).

• Tolerance & Sampling Table (B-1):

• Referenced IS Standards (Clause 2.1 & Annex A):
  Includes standards for sand, packing bags (jute, HDPE, PP, paper), sampling, physical & chemical tests of cement.

Summary Diagram: Cement Supply & Sampling Flow

flowchart TD
    A[Cement Production] --> B{Supply Mode}
    B -->|Bulk (≥1000 kg)| C[Bulk Container Delivery]
    B -->|Bagged (<1000 kg)| D[Bagged Delivery]
    D --> E[Sampling per IS 3535]
    E --> F{Quantity of Bags}
    F -->|100-150| G[Sample 20 Bags]
    F -->|151-280| H[Sample 32 Bags]
    F -->|281-500| I[Sample 50 Bags]
    F -->|501-1200| J[Sample 80 Bags]
    F -->|1201-3200| K[Sample 125 Bags]

Use this standard to ensure correct packing, sampling, and delivery compliance for hydraulic cement.

IS 6452 Part b: Referenced Indian Standards & Key Specifications

Referenced Indian Standards (Annex A highlights)

• IS 2386: Methods of test for aggregates for concrete.
• IS 4031 (Parts 1-13): Methods of physical test for hydraulic cement.
• IS 4032: Method of chemical analysis of hydraulic cement.
• IS 650: Specification for standard sand for testing cement.
• IS 1489: Specification for Portland Pozzolana Cement.
• IS 8112: Specification for 43 Grade OPC.
• IS 12269: Specification for 53 Grade OPC.
• IS 6932: Specification for jute sacking bags.
• IS 1542: Specification for HDPE woven sacks for cement packing.
• IS 1543: Specification for polypropylene woven sacks.
• IS 13292: Specification for multi-wall paper sacks (valved, sewn, gusseted).
• IS 6933: Specification for lightweight jute bags.

Key Specifications from IS 6452 Part b

• Bulk Supply Definition: Any single container ≥ 1000 kg net mass.
• Intermediate Containers: e.g., 200 kg drums, by agreement.
• Sampling for Cement Bags:
  • Net mass per bag ≥ 50 kg.
  • Sample size depends on batch size:

Notes:

• These referenced standards ensure quality control in cement testing, packing, and supply.
• Tolerance requirements for cement mass in bags ensure consistency in packaging.

flowchart LR
    A[IS 6452 Part b] --> B[Referenced IS Codes]
    B --> C[IS 4031: Physical Tests]
    B --> D[IS 4032: Chemical Analysis]
    B --> E[IS 650: Standard Sand]
    B --> F[IS 6932: Jute Bags]
    B --> G[IS 1542/1543: HDPE/PP

IS 6452 Part b — Manufacture of Cement: Key Points

Manufacture (Clause 3.1)

• Cement is produced by fusion or sintering of aluminous & calcareous materials.
• The resulting clinker is ground without any additives except water.
• The final product must comply with the IS specification.

Packing & Delivery (Clause 9)

• Bulk supply: ≥ 1000 kg in a single bag/container.
• Intermediate containers (e.g., 200 kg drums) allowed by agreement.
• Packing materials (jute, HDPE, PP sacks, multi-wall paper sacks) per agreed IS standards.
• Tolerance on bag mass sample size per batch:

Storage (Clause 7.1)

• Store cement in weather-tight buildings.
• Ensure easy inspection access.
• Protect from dampness to minimize deterioration.

Manufacturer's Certificate (Clause 8)

• Must accompany the supply certifying compliance.

flowchart LR
    A[Raw Materials: Aluminous + Calcareous] --> B[Fusion/Sintering]
    B --> C[Clinker]
    C --> D[Grinding (Water only)]
    D --> E[Cement (IS Compliant)]
    E --> F[Packing (Bulk or Bags)]
    F --> G[Storage (Weather-tight)]
    G --> H[Delivery with Manufacturer's Certificate]

This summary captures essential manufacturing, packing, storage, and delivery requirements per IS 6452 Part b.

IS 6452 Part B: Key Requirements Summary

1. Referenced Standards (Clause 2.1 & Annex A)

• Testing sand: IS 650 - Specification for standard sand.
• Sampling methods: IS 3535 - Methods of sampling hydraulic cements.
• Physical & chemical tests: IS 4031 (Parts 1-13) & IS 4032.
• Packaging specifications: IS 13292 (HDPE sacks), IS 1480 (jute bags), IS 9842 (PP sacks), IS 1489 (paper sacks).

2. Sampling & Testing (Clause 6.4 & 5.2)

• Independent testing required.
• Sampling as per IS 3535:1986.
• Sample size based on batch size (see Table below).

3. Tolerance for Cement Mass in Bags (Foreword & Clause 9.2)

• Each bag net mass ≥ 50 kg.
• Bulk supply: single container ≥ 1000 kg or agreed intermediate containers (e.g., 200 kg drums).

Summary:

• Follow IS 3535 for sampling.
• Use specified sample sizes for quality control.
• Packaging and testing follow referenced IS codes.
• Bulk supply defined by weight for delivery arrangements.

flowchart LR
    A[Purchase Agreement] --> B{Supply Type}
    B -->|Bulk ≥ 1000 kg| C[Bulk Supply]
    B -->|Intermediate Containers| D[By Agreement]
    C --> E[Sampling as per IS 3535]
    D --> E
    E --> F[Testing per IS 4031 & IS 4032]
    F --> G[Compliance Check]

This ensures cement quality and packaging meet IS 6452 Part B requirements.

IS 6452 Part b: Sampling Key Points

• Sampling Procedure:
  As per Clause 5.2, sampling must follow IS 3535 : 1986 methods for cement.

• Random Selection:
  Bags selected for sampling should be randomly chosen as per IS 4905 : 1968 to ensure representativeness.

• Facilities & Responsibility:
  Per Clause 5.3, the manufacturer/supplier must provide all facilities, labor, and materials for sampling, packing, and identification.

• Timely Testing:
  According to Clause 6.4.3, tests on samples should be done as quickly as possible after sampling.

Typical Sampling Formula (from IS 3535):

For bulk cement, the number of bags to sample (n) from a lot size (N) can be approximated by:

[ n = \sqrt{N} ]

• Minimum sample size per bag: 500 g to 1 kg (for testing)
• Samples must be mixed thoroughly to form a composite sample.

Summary Table:

flowchart TD
    A[Start: Cement Lot] --> B[Randomly select bags (IS 4905)]
    B --> C[Take sample from each bag (IS 3535)]
    C --> D[Mix samples to form composite]
    D --> E[Pack and identify samples]
    E --> F[Test samples quickly]
    F --> G[Report results]

IS 6452 Part B — Testing Key Points

1. Testing Temperature (Clause 6.2)

• Physical tests must be conducted at 18 ± 2ºC to ensure consistency and reliability.

2. Independent Testing (Clause 6.4)

• Testing should be independent to avoid bias.
• Manufacturer must provide cement samples free of charge for testing.

3. Cost of Testing (Clause 6.4.2)

• If cement fails the standard: Manufacturer bears the cost.
• If cement passes the standard: Purchaser bears the cost.
• Unless otherwise specified in the enquiry/order.

4. Non-Compliance (Clause 6.3)

• Procedures for handling non-compliance are outlined but not detailed here.

Summary Table: Testing Temperature and Cost Responsibility

This ensures fair testing practices and clear responsibility for testing costs.

IS 6452 Part b — Storage of Cement: Key Points

Storage Requirements (Clause 7.1)

• Cement must be stored in a weather-tight building to prevent moisture ingress.
• Storage should allow easy access for inspection.
• Protect cement from dampness to minimize deterioration.

Bulk and Packaging (Clause 9.3)

• Bulk supply: Any single container with ≥ 1000 kg net cement.
• Intermediate containers (e.g., 200 kg drums) allowed by agreement.
• Packing materials (jute, HDPE, PP sacks) as per IS standards and mutually agreed.

Sampling & Tolerance (Foreword & Clause 9.2)

• Sample size depends on total bags:

• Net mass per bag ≥ 50 kg.

Summary Table: Storage & Packaging

flowchart TD
    A[Receive Cement] --> B[Store in Weather-tight Building]
    B --> C[Ensure Easy Inspection Access]
    C --> D{Packaging Type?}
    D -->|Bulk ≥1000kg| E[Bulk Storage]
    D -->|Intermediate| F[Drum Storage]
    D -->|Bagged| G[Store in Bags ≥50kg]
    E & F & G --> H[Protect from Moisture & Deterioration]

This ensures cement quality is maintained per IS 6452 Part b.

Manufacturer's Certificate (IS 6452 Part B) - Key Points

• Clause 8.1:
  The manufacturer must ensure cement conforms to IS 6452 standards and, upon request, provide a certificate of conformity to the purchaser or their representative.

• Storage & Inspection (Clause 7.1):
  Cement must be stored in weather-tight buildings to prevent dampness and allow easy inspection.

• Packing & Supply (Clause 9.2 & 9.3):

  • Cement bags must meet agreed packing material standards (jute, HDPE, PP sacks, etc.).
  • Bulk supply is defined as a single bag/container ≥ 1000 kg or agreed intermediate containers (e.g., 200 kg drums).
  • Sampling sizes for mass tolerance testing are specified:

Summary for Manufacturer's Certificate

• Must certify compliance with IS 6452.
• Certificate includes confirmation of physical and chemical conformity per referenced IS standards.
• Certificate is issued on demand and accompanies the cement delivery.

flowchart TD
    A[Manufacturer] --> B[Ensures Cement Meets IS 6452]
    B --> C[Issues Manufacturer's Certificate]
    C --> D[Purchaser/Representative]
    A --> E[Stores Cement Properly]
    E --> B

References: IS 6452 Clauses 7.1, 8.1, 9.2, 9.3; IS 4031 series for testing.

IS 6452 Part b: Packing and Marking - Key Points

Packing Material (Clause 9.2.2.3)

• Packing material is mutually agreed between manufacturer and purchaser.
• Cement for export may be packed in bags or drums with net mass per unit as agreed (Clause 9.2.2).
• Bulk supply: Any container ≥ 1000 kg net mass is considered bulk (Clause 9.3).

Marking (Clause 9.2.2.2)

• Mark each bag/drum with:
  • "FOR EXPORT"
  • Net mass of cement per bag/drum
• Use indelible ink for marking.

Tolerance & Sampling (Foreword & Clause 9.2)

• Net mass per bag ≥ 50 kg.
• Sample size depends on total bags:

Referenced Standards for Packing Materials

• Jute, HDPE, PP woven sacks, multi-wall paper sacks specifications.
• Sampling and testing methods for cement quality.

flowchart TD
    A[Manufacturer & Purchaser Agree] --> B[Packing Material]
    B --> C{Packing Type}
    C -->|Export| D[Bags or Drums]
    C -->|Bulk| E[Containers ≥ 1000 kg]
    D --> F[Mark "FOR EXPORT" + Net Mass]
    E --> F

Summary: Packing and marking must follow purchaser agreement, clear export marking, and sample size for mass tolerance per IS 6452 Part b.

Key Formulas, Tables & Specifications from IS 6452 Part B (Methods of Physical Test for Hydraulic Cement)

1. Le-Chatelier Expansion Test (Clause 4.3)

• Water quantity: 22% by mass of cement (different from IS 4031 Part 3)
• Maximum expansion allowed:
  [ \text{Expansion} \leq 5 \text{ mm} ]

2. False Set Test (Clause 4.4.1)

• Using IS 4031 Part 14 (1989):
• False set criterion: [ \frac{\text{Final penetration (after 5 min)}}{\text{Initial penetration (after 20 s)}} \times 100 < 50% ]
• If false set occurs, initial and final setting times must be tested after breaking false set as per IS 4031 Part 5 (1988).

3. Manufacturing Specification (Clause 3.1)

• Cement must be made from aluminous and calcareous materials by fusion or sintering.
• No additives except water during grinding.

4. Bulk Supply (Clause 9.3)

• Bulk supply = containers ≥ 1000 kg
• Intermediate containers (e.g., 200 kg drums) allowed by agreement.

5. Sampling & Packaging (Foreword & Clause 9.2)

• Sample bag mass ≥ 50 kg
• Number of bags in sample depends on batch size (see table below):

Summary Diagram: False Set Test Procedure

flowchart TD
    A[Start Mixing Cement & Water] --> B[Measure Penetration at 20 sec (Initial)]
    B --> C[Wait 5 minutes]
    C --> D[Measure Penetration at 5 min (Final)]
    D --> E{Calculate Ratio: (Final /

Tolerance Requirements for Mass of Cement Packed in Bags (IS 6452 Part B)

Key Specifications:

• Net mass per bag: 50 kg minimum (also 25 kg bags allowed per 9.2.1 with tolerances).
• Tolerance on minus error:
  • Not more than 5% of bags in a sample can have a minus error > 2% of specified net mass.
  • No bag should have a minus error exceeding 4% of the specified net mass.

Sampling Table (Clause B-1):

Summary of Tolerance Limits:

• For a 50 kg bag:
  • 2% tolerance = 1 kg
  • 4% tolerance = 2 kg
• So, max allowed minus error per bag = 2 kg
• Max 5% of sample bags can have weight < 49 kg but ≥ 48 kg.

Notes:

• These tolerances comply with the Standards of Weights and Measures (Packaged Commodities) Rules, 1977.
• Bulk supply (≥1000 kg/container) and intermediate containers (e.g., 200 kg drums) are by mutual agreement.

flowchart LR
    A[Start: Cement Bags Sampling] --> B{Sample Size?}
    B -->|100-150| C[Sample 20 Bags]
    B -->|151-280| D[Sample 32 Bags]
    B -->|281-500| E[Sample 50 Bags]
    B -->|501-1200| F[Sample 80 Bags]
    B -->|1201-3200| G[Sample 125 Bags]
    C & D & E & F & G --> H[Check Bag Weight]
    H --> I{Minus Error > 2%?}
    I -->|Yes| J[Count Bags]
    J --> K{Count > 5% of Sample?}
    K -->|Yes|

Composition of the Technical Committee (IS 6452 Part B)

The Technical Committee for High Alumina Cement under Cement and Concrete Sectional Committee BDC 2 includes experts from diverse organizations:

Key points:

• Committee includes Chairman, Members, Alternates, and Secretaries.
• Members represent government bodies, research institutions, cement industries, and engineering organizations.
• Ensures broad expertise covering manufacturing, testing, research, and application of high alumina cement.

Additional Notes:

• The committee formulates specifications like:
  • Minimum alumina content: ≥ 32% by mass (IS 4032:1985 method)
  • Manufacturing process: Fusion or sintering of aluminous and calcareous materials.
  • Packaging and mass tolerance rules (e.g., ±0.5% for 25-tonne loads).

flowchart LR
    A[Chairman] --> B[Members]
    B --> C[Industry Experts]
    B --> D[Research Institutes]
    B --> E[Government Agencies]
    B --> F[Alternate Members]
    B --> G[Secretaries]

This structure ensures comprehensive standard development with multi-disciplinary inputs.