Hydrophobic Portland cement – Specification
1991 Edition

Scope & Essential Provisions of IS 8043

• Application Scope: Defines production, chemical, and physical criteria for hydrophobic Portland cement.
• Packaging & Mass: Cement bags nominally weigh 50 kg; tolerances comply with the Standards of Weights and Measures (Packaged Commodities) Rules, 1977.
• Sampling Procedure: Conducted randomly as per IS 4905:1968.
• Numerical Rounding: Follows IS 2:1960 regulations.

Sampling Size for Mass Tolerance (Annex C)

Referenced Standards Summary (Annex A)

• IS 269:1989 – Ordinary Portland Cement specifications
• IS 650:1966 – Standard sand for cement testing
• IS 4031 (Parts 1-13) – Physical test methods for hydraulic cement
• IS 4905:1968 – Random sampling techniques
• IS 11652 & IS 11653 – Packaging materials for cement

These details ensure compliance with quality control, packaging, and testing requirements for hydrophobic Portland cement.

Definitions and Clarifications in IS 8043

• Hydraulic cement terms are as per IS 4845:1968.
• Additional definitions specific to hydrophobic Portland cement are supplemented.
• Cement packaging mass must adhere to the Standards of Weights and Measures (Packaged Commodities) Rules, 1977.
• Tolerance levels for bag mass are detailed in Annex C.
• Sampling is conducted randomly according to IS 4905:1968.

Sampling and Mass Tolerance Table (Annex C)

• The average net mass per sampled bag must be at least 50 kg.

flowchart TD
    Batch[Batch of Cement Bags] --> Sampling[Random Sampling (IS 4905)]
    Sampling --> SampleSize[Sample Size Based on Batch]
    SampleSize --> MassCheck[Verify Average Mass ≥ 50 kg]
    MassCheck -->|Pass| Accept[Batch Approved]
    MassCheck -->|Fail| Reject[Batch Rejected or Reprocessed]

Refer to IS 4845 and other cited standards for detailed definitions and testing methodologies.

Hydrophobic Portland Cement: Composition and Manufacturing Methods

Raw Materials and Processing (Clause 4.1)

• Constituted from calcareous, argillaceous, and other silica, alumina, or iron oxide materials.
• Processed by burning at clinker temperatures.
• Clinker ground with natural or chemical gypsum.
• Hydrophobic agents added in minor amounts (not exceeding 0.5% by clinker mass), examples include:
  • Oleic acid
  • Naphthenic acid
  • Stearic acid
  • Pentachlorophenol

Chemical Composition Requirements (Clause 5.1)

• As specified in IS 269:1989 for Portland cement.

Packaging and Mass Control (Clause 1.2)

• Bag mass and tolerance must align with the Standards of Weights and Measures regulations.
• Testing results rounded off according to IS 2:1960.

Related Indian Standards

flowchart TD
    RawMaterials[Raw Materials] --> Burning[Burn at Clinker Temperature]
    Burning --> Clinker[Clinker]
    Clinker --> Grinding[Grinding with Gypsum]
    Grinding --> AddAgent[Add Hydrophobic Agent (≤0.5%)]
    AddAgent --> FinalProduct[Hydrophobic Portland Cement]

Refer to IS 269:1989 for chemical limits and detailed manufacturing standards.

Chemical Specifications for Hydrophobic Portland Cement

• Chemical requirements adhere to IS 269:1989 for 33-grade ordinary Portland cement.
• Hydrophobic additives limited to maximum 0.5% by clinker mass (e.g., oleic acid, naphthenic acid, stearic acid, pentachlorophenol).

• Clinker is burnt at prescribed temperatures, then ground with gypsum and hydrophobic agents to impart water resistance.
• Cement packaging uses materials such as HDPE, PP, or jute sacks per relevant IS codes.

flowchart LR
    RawMaterials --> ClinkerProduction
    ClinkerProduction --> Grinding
    Grinding --> AddGypsum
    AddGypsum --> AddHydrophobicAgent
    AddHydrophobicAgent --> HydrophobicCement
    HydrophobicCement --> Packaging

Hydrophobic cement complies chemically with IS 269 with added hydrophobic agents ensuring moisture repellency.

Physical Characteristics of Hydrophobic Portland Cement

• Physical properties such as soundness and setting times conform to IS 269:1989 standards for ordinary Portland cement.

• Compressive strength benchmarks (from IS 269):

• Packaging and mass tolerances abide by Standards of Weights and Measures (Packaged Commodities) Rules, 1977.
• Test result rounding follows IS 2:1960.

flowchart TD
    Cement[Hydrophobic Portland Cement] --> PhysicalTests[Physical Requirements]
    PhysicalTests --> Soundness[Soundness (IS 269)]
    PhysicalTests --> SettingTimes[Setting Time (IS 269)]
    PhysicalTests --> Strength[Compressive Strength (IS 269)]
    PhysicalTests --> Packaging[Packaging & Mass Tolerance]

Refer to IS 403 (Parts 1-13) for detailed physical test procedures.

Testing Hydrophobicity as per Annex B of IS 8043

Quantitative Evaluation (Clause 6.6, B-1.1)

• Prepare samples by taking 5 g of fresh 33-grade OPC and hydrophobic cement each.
• Spread samples uniformly in a 15 cm diameter Petri dish as a thin layer.
• Condition samples at ≥99.9% relative humidity and 27 ± 2°C for 24 hours.
• Determine mass loss on ignition by heating to 550°C.
• Acceptance requires hydrophobic cement's ignition loss to be ≤ 30% of that recorded for ordinary Portland cement.

Qualitative (Floatation) Test

• Hydrophobic cement exhibits floatation due to water-repellent additives.
• Physical and chemical requirements follow IS 269 and IS 8043 clauses.

flowchart LR
    SamplePrep[Prepare 5 g Samples] --> Spread[Spread in 15 cm Petri Dish]
    Spread --> Condition[Condition at ≥99.9% RH, 27±2°C, 24 hrs]
    Condition --> Ignite[Ignite at 550°C]
    Ignite --> MassLoss[Measure Mass Loss]
    MassLoss -->|≤ 30% of OPC| Accept[Accept Hydrophobic Cement]
    MassLoss -->|> 30% of OPC| Reject[Reject Sample]

This testing ensures the cement's resistance to moisture uptake compared to ordinary Portland cement.

Storage, Sampling, Testing, and Rejection Procedures for Hydrophobic Cement

• Storage must maintain dry and moisture-free conditions as per IS 269:1989 to preserve hydrophobicity.
• Random sampling follows IS 4905:1968.
• Hydrophobicity testing utilizes Annex B protocols.
• Physical testing adheres to IS 403 (Parts 1-13):1988.
• Sampling methodology based on IS 3535:1986.
• Standard sand for testing per IS 650:1966.

Rejection Criteria

• Cement failing hydrophobicity or physical property tests as per IS 269 and Annex B must be rejected.

Sampling Size for Mass Tolerance (Annex C)

• Average net mass per bag must be ≥ 50 kg.

flowchart TD
    Storage[Proper Storage] --> Sampling[Random Sampling (IS 4905)]
    Sampling --> Testing[Test Hydrophobicity & Physical Properties]
    Testing --> Decision{Pass Tests?}
    Decision -->|Yes| Accept[Accept Cement]
    Decision -->|No| Reject[Reject Cement]

Summary: Employ IS 269 for handling hydrophobic cement, random sampling per IS 4905, conduct hydrophobicity testing per Annex B, and apply batch sampling criteria from Annex C for quality control.

Manufacturer’s Certification According to IS 8043

• Manufacturers must confirm compliance with IS 8043 standards and issue a certificate of conformity within 10 days of shipment (Clause 8.1).
• Certificates must include the total chloride content (% by mass) present in the cement (Clause 8.2).
• Test references include IS 269:1989 (chemical specs), IS 3535:1986 (sampling), and IS 403 (Parts 1-13):1988 (physical testing).

Chloride Limits per IS 269:1989

flowchart LR
  Manufacturing[Manufacture Cement] --> Testing[Perform Tests per IS 269 & IS 403]
  Testing --> Confirm[Confirm IS 8043 Compliance]
  Confirm --> Chloride[Measure Chloride Content]
  Chloride --> Certificate[Prepare Certificate of Conformity]
  Certificate --> Dispatch[Dispatch Cement and Certificate Within 10 Days]

The manufacturer's certificate is crucial for traceability and quality assurance, confirming compliance with durability and safety norms.

Packaging, Marking, and Delivery Conditions in IS 8043

Packaging Protocols

• Packaging materials must be mutually agreed upon by manufacturer/supplier and purchaser (Clause 9.2.2.3).
• Commonly utilized materials include:
  • HDPE woven bags (IS 11652:1986)
  • Polypropylene woven bags (IS 11653:1986)
  • Jute sacks (IS 2580:1982)
  • Multi-wall paper sacks with valves (IS 11761:1986)
  • Lightweight jute union bags (IS 4905:1968)

Labeling Requirements

• Bags may carry the Standard Mark (Clause 9.1.1).
• Marking typically features:
  • Manufacturer’s name
  • Cement grade
  • Net weight
  • Batch or lot number
  • ISI certification mark, where applicable

Delivery Considerations

• Delivery must conform to applicable standards referenced in the annex (Clause 2.1).
• Sampling and physical tests refer to IS 3535 and IS 403.
• Packaging must protect cement from moisture and damage during transit.

flowchart TD
    Manufacturer[Manufacturer] --> Packaging[Packaging Material (Agreed)]
    Packaging --> Marking[Marking (Standard Mark, Details)]
    Marking --> Delivery[Delivery]
    Delivery --> Protection[Protection from Moisture and Damage]

Refer to respective IS specifications for detailed packaging and testing requirements.

Referenced Indian Standards in IS 8043 (Clause 2.1 & Annex)

Additional Notes:

• Mass tolerances for cement bags are governed by the Standards of Weights and Measures (Packaged Commodities) Rules, 1977.
• Rounding of numerical results follows IS 2:1960.
• These standards collectively ensure uniformity in cement production, testing, sampling, and packaging.

flowchart LR
    IS8043 --> ChemPhysTests[Chemical & Physical Tests (IS 4030)]
    IS8043 --> Sampling[Sampling Methods (IS 3535, IS 4905)]
    IS8043 --> PackagingSpecs[Packaging Standards (IS 11652, IS 11653, IS 11761)]
    IS8043 --> MaterialSpecs[Material Specs (IS 269, IS 650, IS 12089)]

Hydrophobicity Test Protocols in IS 8043

Quantitative Test (Clause B-1.1)

• Utilize 5 g samples each of fresh 33-grade OPC and hydrophobic cement.
• Spread samples thinly in 15 cm diameter Petri dishes.
• Condition at ≥ 99.9% relative humidity and 27 ± 2°C for 24 hours.
• Determine mass loss on ignition by heating to 550°C.
• The hydrophobic cement’s mass loss must not exceed 30% of that of the ordinary Portland cement.

Qualitative Test (Floatation)

• Hydrophobic cement floats on water due to the action of hydrophobic agents like oleic and stearic acids.
• Manufactured by burning calcareous and argillaceous materials at clinker temperature, grinding with gypsum and ≤ 0.5% hydrophobic agent.

flowchart LR
    SamplePrep[Sample Preparation] --> Conditioning[Condition at 99.9% RH, 27±2°C for 24h]
    Conditioning --> Ignition[Ignite at 550°C]
    Ignition --> MassLoss[Measure Mass Loss]
    MassLoss -->|≤ 30% OPC| Accept[Accept Cement]
    MassLoss -->|> 30% OPC| Reject[Reject Cement]

This process confirms that hydrophobic cement exhibits significantly lower moisture uptake compared to ordinary cement.

Mass Tolerance Specifications for Cement Packaging in IS 8043

Key Points from Clauses 9.2, 9.2.1, 9.2.2.4 & Annex C

• Standard net mass per bag is 50 kg minimum (Clause 9.2).
• Alternative packaging of 25 kg bags allowed with agreed tolerances (Clause 9.2.1).

Sample Size for Mass Testing (Annex C)

Tolerance Limits

• No more than 5% of sampled bags can have a negative deviation exceeding 2% of the specified net mass (i.e., > 1 kg underweight for 50 kg bags).
• No bag should be underweight by more than 4% of the specified net mass (minimum 48 kg for 50 kg bags).
• The average net mass across the sample must be at least the specified mass (50 kg or 25 kg).

Tolerance Calculation Summary

• Let ( M_s ) be the specified net mass.
• Maximum permissible negative deviation per bag: ( 0.02 \times M_s ).
• Absolute maximum negative deviation: ( 0.04 \times M_s ).
• Maximum number of bags exceeding 2% negative deviation: 5% of the sample size.

Practical Guidelines

• Confirm sample average mass ≥ specified mass.
• Count bags below 98% of ( M_s ); must not exceed 5% of sample.
• No bag should weigh less than 96% of ( M_s ).

flowchart TD
    Start[Start Sampling] --> DetermineBatch[Determine Batch Size]
    DetermineBatch --> SampleSize[Select Sample Size per Batch]
    SampleSize --> MeasureMass[Measure Mass of Each Bag]
    MeasureMass --> CheckAverage{Is Average Mass ≥ Specified Mass?}
    CheckAverage -->|Yes| CheckTolerance[Check Tolerance Limits]
    CheckAverage -->|No| Reject[Reject Batch]
    CheckTolerance -->|Within Limits| Accept[Accept Batch]
    CheckTolerance -->|Exceeds Limits| RejectBatch[Reject Batch]

This ensures uniform packaging weight and compliance with regulatory mass tolerances.

Summary of Technical Committee Composition for IS 8043

• A multidisciplinary panel representing academic institutions, government bodies, cement manufacturers, research organizations, and industry associations.
• Chaired by Dr. H. C. Visvesvaraya from University of Roorkee.
• Members include representatives from Orissa Cement Ltd, The Associated Cement Companies Ltd, CPWD, Central Water Commission, CSIR Structural Engineering Research Centre, Central Building Research Institute, and others.
• Alternate members appointed for continuity.
• Member Secretary: Director (Civil), Central Board of Irrigation and Power.
• Ex-officio member: Director General, Bureau of Indian Standards.

Representative Organizations

• Ministry of Railways (RDSO)
• National Council for Cement and Building Materials
• Geological Survey of India
• Indian Roads Congress

Additional Notes on Mass Tolerance (Annex C, Clause 1.2)

• For transport loads of 20–25 tonnes, net mass tolerance is 0 to +0.5%.
• Typical bag weights:
  • Jute bags: 531 g (IS 2580:1982)
  • Double bessian bituminized bags: 630 g
  • 6-ply paper bags: approx. 400 g
  • Polyethylene lined jute bags: approx. 480 g

This committee ensures comprehensive expert input covering technical, manufacturing, research, and regulatory domains for cement standards.