के य मुहर वभाग 3

संदभ- के य मह
ु र वभाग-3/ 16: आई एस – 16415 13 अ टूबर 2016

वषय- आई एस – 16415 के लए पर ण और नर ण क योजना, डॉक : एसट आई/16415/1/ सत बर 2016

स म धकार वारा अनुमो दत “ म त सीमट – व शि ट” (आईएस 16415:2015) के लए पर ण और नर ण क

योजना, एसट आई (डॉक :एसट आई/16415/1/ सत बर 2016 तुरंत काया वयन हे तु संल न है ।

(-sd/-)

(एस हडसन संह)

वै ा नक सी (सी एम डी-3)

वै ा नक ई एवं मख
ु (सी एम डी-3)(-sd/- 17.10.2016)

सभी े य/शाखा/सीईडी/एमएसडी/ कायालय को प रचा लत

त ल प: आई ट एस को बीआईएस वेबसाइट/इं ानेटप पर अपलोड करने के लए

 CENTRAL MARKS DEPARTMENT-3

Our Ref: CMD-3/16:16415 13 10 2016

Please find enclosed Scheme of Testing & Inspection, STI Doc: STI/16415/1/Sept 2016 for
“COMPOSITE CEMENT” as per 16415:2015, duly approved by Competent Authority, for
implementation.

(-sd/-)
(S.Hudson Singh)
Sc.C(CMD-3)

Head (CMD-3) (-sd/- 17.10.2016)

Circulated to All BOs/ROs/CED/MSD
ITS: for hosting on intranet please.
 Doc: STI/16415/1/Sept 2016

SCHEME OF TESTING AND INSPECTION

FOR CERTIFICATION OF COMPOSITE CEMENT
ACCORDING TO IS 16415:2015

1. LABORATORY - A laboratory shall be maintained, which shall be suitably equipped and staffed where
different tests given in the specification shall be carried out in accordance with the methods given in the
specification.

2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms
approved by the Bureau.

2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of
such checks/calibration shall be maintained.
2.2 Copies of any records and other related papers that may be required by the Bureau shall be made
available at any time on request.

3. 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):2003, IS 397(Part 2):2003 and IS 397(Part 3):2003].

3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance
with IS/ISO 9001.

4. CALIBRATION - Periodic calibration of various testing equipment’s shall be carried out and records
of such calibrations kept. The following equipment shall be calibrated at a frequency shown against each
and records kept.

Sl No. TEST FREQUENCY OF CALIBRATION

EQUIPMENT
1. Blaine’s apparatus Daily with licensee’s own Standard cement sample and monthly
with standard cement samples supplied by NCCBM.
2. Compressive Once in a month with Licensee’s own Proving Ring and the
strength Testing Proving Ring shall be Calibrated once in two years from a
machine NPL/NABL Accredited Calibrating body or NPL or NPL
accredited Proving Ring manufacturer.
3. Autoclave pressure Once in a month by licensee’s own dead weight pressure gauge
gauge tester OR once in six months from accredited calibrating body or
NPL/NABL accredited manufacturer of such gauges.
4. Vibration machine Once in a month by licensee’s own Tachometer. The tachometer
shall be calibrated once in a year from NPL/NABL accredited
outside agency.
5. Dead weight Once in four years from NABL accredited Tester (if available)
pressure gauge Lab or OEM (original Equipment manufacturer) having
Tester (if available) NPL/NABL accredited calibrator.

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5. STANDARD MARK - The Standard Mark, as given in Column (1) of the First Schedule of the
licence, shall be printed or stenciled on each bag or drum of Composite Cement or on the label
applied to it, provided the material in each bag or package to which the mark thus applied
conforms to the specification. The size of the Standard Mark shall be either 160 X 120 mm or
80 X 60 mm for packing in quantity of 50 kg and above. For other packings of lower quantity,
a photographic reduction is permitted.

5.1 MARKING – In addition following information shall be legibly and indelibly marked on each bag or
drum of cement or on the label applied to each container. The ISI Mark and the following details shall
be applied on each bag or packages in BLUE COLOUR.
a) Manufacturer’s name and his registered trade mark, if any.
b) The words ‘Composite Cement’.
c) Net quantity, in kg.
d) The words ‘Use no Hooks’ on the bags
e) Batch/Control unit number in terms of weeks, month and year of packing.
f) Best before date (that is, 3 months from date of packing).
g) Wording as ‘Cement to be tested before use if more than 3 months old from date of packing’.
h) The words ‘For EXPORT’ if required.
i) Licence Number (CM/L……..)
j) Address of the manufacturer, and
k) Percentage of fly ash and slag addition.
l) Any other marking required under current Legal Metrology Act and rules framed there under.

Note : 1. For each calendar year the first week shall be counted as 7 days from 1 st of January
and subsequent weeks numbered serially accordingly. The bags shall be marked as
W 0l/MM/YY…… W 51/MM/YY……. etc.
2. Label mentioned at 5 and 5.1 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.
3. For bulk packing units all cement of one consignment received shall constitute a batch.
Batch mixing may be permitted for those packing units which are extended packing
terminals of the same cement manufacturer, subjected to packing units obtaining test
certificates from the manufacturer and keeping proper records. If the cement is received
from different manufacturers (licensees) batch mixing is not permitted. Adequate care shall
be taken to prevent/preempt mixing of cement even of the same grade.
4. In case cement manufacturer and packing bulk terminal unit belong to the same
management name of the original manufacturer and/or his trade mark or BIS
Certification marks need not be given on the bag/drum/packing.
5. If the cement for packing is not from the same manufacturer the source details (CM/L
number) shall be indicated on the bag.
6. The colour of the bag (other than Red) and background colours should be in contrast to
the colour of the Standard Mark and details so that the markings are conspicuous.

6. LEVELS OF CONTROL - The tests, as indicated in Table 1,2 & 3 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 licence shall be marked with
certification mark of the Bureau.

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6.1 Weighment – One filled bag from each nozzle shall be taken at random twice in a shift of operation
and weighed in case of electronic packers with recorders. In all other cases one bag from each nozzle
shall be checked once on two hours. The records shall be maintained in Form 1. The weighing
and packing machines shall be adjusted as and when necessary in such a way that net
quantity of each bag shall be in accordance with the tolerances given in AnnexB or clause 10.1.1
and 10.2 of IS 16415: 2015. Such adjustments for each nozzle shall be recorded in Form 1 under
remarks column.

7. RAW MATERIALS - Routine analysis of various raw materials going into the manufacture of
Composite Cement 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 and of the
Physical composition of the mixtures shall be maintained.(See form 2). The conformity of all the raw
materials shall be in accordance with clause 4 of IS 16415: 2015.
This clause is not applicable to packaging of Composite Cement at bulk cement terminal.

8. In respect of all other clauses of the specification, the factory shall maintain appropriate controls and
checks to ensure that their product conforms to the requirements of the specification.

9. HOMOGENEITY – Homogeneity of the mixture in a consignment shall be guaranteed within the

stipulated percent of slag and fly ash addition. Percentage of slag and fly ash addition may vary
depending on the raw material and this need not be declared every time. However Percentage of slag
and fly ash addition shall be marked on the bags/package accordingly.

10. 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.(See Form 3)

11. PACKING – The Cement shall be packed in bags specified in clause 10 of IS 16415: 2015. A test
certificate either from the manufacturer or from any recognized testing laboratory shall be received
along with each consignment. Alternatively the samples of bags from each consignment shall be tested
by the cement manufacturer either in his own laboratory or any other BIS recognized laboratory before
they are used for packing cement. No testing would be necessary if the bags carry BIS Certification
Mark. The bags shall be in good condition at the time of packing.

12. 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.

13. REPLACEMENT - Whenever a complaint is received soon after the goods with Standard Marks have
been purchased and used, and if there is adequate evidence that the goods have not been misused, the
material under complaint is to 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.

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 Doc: STI/16415/1/Sept 2016

14. In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by
the consumers against products 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.

15. STOP MARKING – The marking of the product shall be stopped under intimation to the
Bureau if, at any time, there is any difficulty in maintaining the conformity of their product to
the specification, or the testing equipment goes out of order. The marking may be resumed
under intimation to the Bureau as soon as the defects are removed.

15.1 The marking of the product shall be stopped immediately if directed to do so by the 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.

15.2 If packing unit is instructed by the Bureau to stop marking due to the failure of the samples,
such instruction will automatically apply to the manufacturer of the cement, as per relevant
stop marking guidelines. An undertaking to this effect is to be obtained from the bulk
packers and the cement manufacturer.

16 PRODUCTION DATA –The licensee shall send the production details to BIS as per the
enclosed Proforma-1, at the end of each quarter of the operative period. The proforma to be
submitted at the end of each operative year shall be authenticated by a Chartered Accountant
authenticating the statement of quantity produced, marked and exported by him and the trade
value thereof.

Table 1 …..

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IS 16415:2015, Composite Cement

Table 1, Levels of Control
(Para 7 of the Scheme of Testing and Inspection)
Sl Clause Raw Material Frequency Remarks
No. No.
1 4.1 Granulated Slag Weekly Granulated Slag shall conform to
IS 12089. If in-house facility for
evaluating glass content is not available
the same can be obtained from BIS
recognized lab for every consignment.
2 4.2 Fly Ash Weekly Fly Ash shall conform to IS 3812 (Part 1)
3 4.3 Portland Cement Daily Portland Cement Clinker shall conform to
Clinker IS 16353 for chemical and physical
requirement.
If manufactured in the same factory testing
for conformity as per IS 16353 shall be
maintained.
If procured from any other factory the
clinker shall be tested for chemical and
physical requirements as per IS 16353.
Laboratory ball mill testing is to be done
when there is change in source of raw
materials going into the production of
clinker.
4 4.4 Portland Cement Daily Portland Cement shall conform to IS 269
for Chemical requirement and Physical
requirement.
Portland Cement shall be ISI Marked,
however if OPC is being manufactured in
the same factory record shall be
maintained as per relevant STI.
If OPC is processed from any other factory
(licencee) test certificate for each
consignment shall be obtained and record
maintained

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 Doc: STI/16415/1/Sept 2016

IS 16415:2015, Composite Cement

Table 2, Levels of Control
(Para 6 of the Scheme of Testing and Inspection)
Test Details Levels of Control
Clause Requirement Reference Cement Cement Remarks
Grinding /Blending Packing
(1) (2) (3) (4) (5) (6)
6 Chemical requirement IS 16415
Table 2
i) Insoluble Residue IS 4032 Daily Composite sample -
ii) Magnesia IS 4032 Daily Composite sample -
iii) Sulphuric anhydride (SO3) IS 4032 Daily Composite sample -
v) Loss of Ignition IS 4032 Daily Composite sample -
vi) Chloride Content IS 4032 - Weekly composite sample
iv) Sulphide sulphur IS 4032 - Weekly composite sample
vii) Alkali Content Pl see Note in Table 2
of IS 16415
7 Physical requirement IS 16415
Table 3
i) Fineness IS 4031(Pt-2) 1. Every alternate hourly from Daily Composite sample
each mill/ blender separately.
2. Daily Composite sample
ii) Soundness IS 4031(Pt-3) Daily Composite sample -do-
i. Le-Chatelier Method
ii. Autoclave Method
iii) Setting Time IS 4031(pt-5) One Composite sample per -do-
shift.
iv) Compressive strength IS 4031(pt-6) Daily Composite sample -do-
v) Drying Shrinkage IS 4031(Pt-10) - Weekly composite sample
*
vi) Transverse strength IS 4031(Pt-8) - Weekly composite sample Pl see Note 5 below

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NOTE -1. Composite sample shall be made out of hourly samples for the required period (Pl See IS 3535 Methods of sampling
hydraulic cements).
If clinker is manufactured from more than one kiln, clinker sample from each kiln shall be tested as per the above table.
If clinker is manufactured using different proportion of raw materials such different clinkers shall be tested considering it
as separate production.
If cement is manufactured using same proportion of raw materials from more than one cement mill, sample from each
mill shall be tested for fineness as per the above table. For all other parameters composite samples from all the mills shall
be tested.
If cement is manufactured using different proportion of raw materials sample from each mill shall be tested for all
requirements as per the above table.
If blending of ingredients is adopted, sample at ‘Cement grinding/blending stage’ shall be drawn after blending all such
ingredients.

2. 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

3. For manufacturing units where there is no packing silo and cement is packed directly from cement grinding /blending
stage, 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 along with weekly chloride content test.

4. Limit of material proportion shall be as given in clause 5 of the standard.

5. When asked for by agreement between purchaser & manufacturer,the permissible Transverse strength value is to be
agreed between purchaser and supplier at the time of placing the order.

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IS 16415:2015, Packing of Composite Cement

At Packing Units
Table 3, Levels of Control
(Para 6 of the Scheme of Testing and Inspection)
TEST DETAILS LEVELS OF CONTROL
Clause Requirement Test Methods Frequency Remarks
Reference
6, Table 1 (i) Insoluble Residue IS 4032 One sample from To be tested in laboratory at packing unit.
each batch
6, Table 1 (v) Loss of Ignition -do- -do- -do-
6, Table 1 (iv) Sulphide sulphur -do- -do- -do-
7, Table 2 (i) Fineness IS 4031(Pt-2) -do- May be tested at packing unit or got tested from a pre-
declared approved testing laboratory if in house test
facilities are not available
7, Table 2 (ii) Soundness IS 4031(Pt-3) -do- -do-
7, Table 2 (iii) Setting Time IS 4031(Pt-5) -do- -do-
7, Table 2 (iv) Compressive strength IS 4031(Pt-6) -do- -do-

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 Doc: STI/16415/1/Sept 2016

Form No. 1
FORMAT FOR MAINTENANCE OF TEST RECORDS
WEIGHMENT CONTROL AT PACKING STAGE
Date Shift Time No. of Bags Net mass of bags from nozzels Remark.
(Hourly)

Form No. 2
RAW MATERIAL TESTING
(To be individually maintained for each raw material)
Date of receipt Date of testing Name of Material Source of supply and Details of analysis for specified requirements
of material consignment No.

Form N0.3
PRODUCTION DATA
(POST GRINDING DETAILS OF PRODUCTIONACCEPTED AND REJECTES FOR STANDARD MARK)
Shift Quantity Passed for Standard Rejected Remark
mark

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Form No. 4
CLINKER CHEMICAL COMPOSITION (DAILY COMPOSITE SAMPLE)
Date of Total Insoluble SiO2 CaO Al2O3 FeO3 SO3 MgO LSF Alumina Sample Remarks
manufacture loss on residue Fe2O3 factor Pass/Fail
ignition

Form No. 5
CLINKER GROUND WITH GYPSUM
(DAILY COMPOSITE SAMPLE)
Date of Fineness Soundness Setting Setting Compressive Transverse Sample Remark
grinding (Lechatelier/Autoclave) Time Time strength strength Pass/Fail
Initial Final

Form No.6
CEMENT GRINDING/BLENDING
(DAILY/WEEKLY COMPOSITE SAMPLE)
Date of L I SO3 S MgO CaO Al2O3 Fe2O3 SiO2 LSF Alumina Finenes Setting Soundness Compressive Drying Transverse Sample Remark
grinding O R s Time strength Shrinkage strength Pass/Fail
I

Form No.7
CEMENT GRINDING/BLENDING (FOR ALTERNATE HOURLY SAMPLES)
Date of grinding Time Fineness Setting Time Initial Setting Time Final Sample
Pass/Fail

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Form No. 8
PACKING STAGE (CEMENT)
(DAILY/WEEKLY AVERAGE SAMPLE)

Date of LOI IR SO3 S MgO CaO Al2O3 Fe2O3 SiO2 LSF Chloride Alumina Fineness Setting Soundness Compressive Drying Transverse Sample Remark
Packing content Time strength Shrinkage strength Pass/Fail

Form No.9
CALIBRATION RECORD
Sl No. Date of calibration Calibration Record Name of Sl No. (if any)
Result of calibration Equipment

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Form No. 10
FORMAT FOR MAINTENANCE OF TEST RECORDS
WEIGHMENT CONTROL AT PACKING UNIT
HOURLY CHECK OF MASS OF DRUMS
Date Time (Hourly) Condition of Drums Net mass of cement Record of calibration of
weighing scale Date of
calibration.

Form No. 11
FORMAT FOR MAINTENANCE OF RECORDS FOR THE CONDITIONS OF THE EMPTY DRUMS/BULKERS FOR PACKING CEMENT
AT PACKING UNIT
Date No. of empty No. of empty Reasons/Remarks Sign of firms inspector
drums/Bulkers checked drums/Bulkers rejected

Form No.12
FORMAT FOR MAINTENANCE OF TEST RECORDS
WEIGHMENT CONTROL AT PACKING UNIT
HOURLY CHECK OF MASS OF BAGS

Date Shift Time (Hourly) No of Bags Net Mass of Bags Records of

from Nozzles calibration/date of
calibration of nozzles

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Form No. 13
RECEIPT OF CEMENTS AT PACKING UNIT

Date of receipt Batch No. Supply received from Test Certificate No

Form No.14
CEMENT DESPATCH DATA FROM PACKING UNIT

Date Quantity Passed for Standard Mark Rejected (if any) Reasons for not
marking/Method of
disposal

Form No. 15 & 16

TEST DONE AT FACTORY AT PACKING UNIT

Date Batch No. LOI IR Sulphide Fineness Setting Time Remarks

Sulphur (S)

Form No 17 & 18.

TEST DONE AT FACTORY AT PACKING UNIT

Date Batch No. Test Report Soundness Compressive Strength Remarks

LC AC 3 days 7 days 28 days

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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 packed (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
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
----------------------------------------------------------------------------------------------------
*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.

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