Professional Documents
Culture Documents
MINISTRY OF RAILWAYS
ISSUED BY
B&S DIRECTORATE
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW-226011
Indian Railway Standard specification for fabrication and erection of steel girder
bridges and locomotive turn-tables. (B1-2001).
ii)
Indian Railway Standard Code of Practices for metal arc welding for structural
steel bridges carrying rail cum road or pedestrian traffic (Adopted 1972 Revised
2001).
The officials associated with fabrication work should have thorough
understanding of both the codes i & ii. However, these guidelines have been
prepared for helping the field engineers associated with execution of the
fabrication work through trade. It has been tried to cover various aspects which
require close attention of the field engineers for ensuring quality of the fabrication
work. These guidelines are just to facilitate and not to supersede the two codes.
All engineers associated with fabrication are advised to understand the provision
of IRS B1-2001 and Welded Bridge Code and take help from these guidelines.
Book published by RETS IRICEN Steel Structure Fabrication for Railways is
also a very good guide for the Engineer incharge of fabrication. The workshop
engineer or contractors should also have good understanding of various
provisions of above Railway codes and other related codes.
B.
Loading Standard
Governing Specification
Drawing references
A sample QAP for 30.5m welded open web girder is given at Annexure-I.
QAP is to be scrutinized and approved by the inspection agency. In case of
welded girder it is to be done by RDSO, as per prevailing orders.(QAP should be
signed by Fabricator and Railway Officials [Minimum JAG Level] before
submission to RDSO)
Field Engineer should ensure that work is carried out strictly as per the approved
QAP and no deviation takes place from QAP. All the stages should be studied in
detail, prior to start of work.
C.
D.
Records
(WPQR)
(final
E.
F.
F2.
F4.
The jigs should be checked by fabricator and field engineerfrom time to time for
their wear and tear for maintaining accuracy during work.
G.
Onlyraw
material
throughout the length shall be cleaned to ensure that the surface is free from
dust, mill scale, grease, oil and paint to ensure sound quality of weld.
ii) Full welding shall be carried out in flat position with SAW process as per
sequence mentioned in WPSS/WPQR using manipulator/special welding
fixture.
iii) The sequence of welding shall be shown in WPSS/WPQR marked as 1, 2, 3
& 4 in the order of welding.
iv) The welding should be done in proper sequence.
v) Minor welds/ Inaccessible location welds shall be made by CO2welding or
other type of weldingas per approved WPSS.
Good Working practice for prevention of distortion in welded girders:
i) By pre-bending of flange plate of welded girderusing appropriate fixture.
ii) By clamping the flange plate to fixture.
(Fixture developed by MMR Workshop is given at Annexure.VI)
Radiographic Exam.of Butt Weld Joints-Any butt welding provided as per
approved WPSS should be subjected to radiographic testing by authorized
agency only. The film should be preserved for examination, sensitivity, defect
interpretation and acceptance decision based on prescribed criteria.
Ensuring use of Approved set of Jigs & Fixtures-To permitthe
interchangeability of the components and ensure pre-stressing in open web
girders and to avoid distortion, it should be ensured that only approved Jigs &
fixture are used andproper clamping arrangement are provided in jigs/fixtures.
H.
J.
K.
WPQR as laid out in steps earlier. Field engineer should do the components
inspection and ensure all record are available before giving final inspection call
inspecting authority.
Plate girder check.
i) Overall length
ii) Bearing centers
iii) Height
iv) Girder center
v) Squareness
vi) Fairing of holes
vii) Verticality
viii)Infringement, if any
ix) Butting of compression flange.
L.
M.
Stages of Inspection in Fabrication of Bridge Girders:The important stages in a tabulated form showing various stages and
corresponding Inspection/Approval agency for Rail & Rail-cum-Road Bridge are
as shown in Annexure-VII. For ROBs, Inspection/Approval agency for all stages
will be concerned Railways.
N.
Certificates to be furnished by Railway:During fabrication, internal inspection to be done by Railways to ensure that only
RDSO approved welders carryout welding as per approved WPSS, work is as
per dimensional tolerances and other quality aspects and should satisfy itself
before sending inspection call to RDSO for Trial Assembly or Component
Inspection.Railway has to give following four certificates as mentioned in RDSO
letter No. CBS/Insp./WBG Dated 10-04-2015 (Annex.VIII) at time of sending
Inspection Call.
(i)
(ii)
(iii)
(iv)
O.
Fabrication Agency:Railway Board vide letter No. 2014/CE-III/BR/Bridge Workshops Policy dated
24-02-2014has allotted Railway Bridge Workshops as Primary Source and
Secondary Sources to all Zonal Railways. The same has been reiterated vide
RDSO Letter No. CBS/Insp./WBG dated 28-02-2014 (Annex.-IX).
S.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Railway
CR, WCR & SECR
ER, ECoR& ECR
NCR & NR
SWR & SR
NWR & WR
SCR
NFR
NER
SER
Primary Source
Manmad
Mughalsarai
Jallandhar& Lucknow
Arakkonam
Sabarmati
Lallaguda
Bogaingaon
Gorakhpur
Sini
Secondary Source
Sabarmati
Lucknow
Mughalsarai
Manmad
Manmad
Manmad
Mughalsarai
Lucknow
Mughalsarai
Check List:- Check List for fabrication of Steel Bridge Girders for three stages (i)
Prefabrication stage (ii) During fabrication and (iii) After fabrication are enclosed
as performa-I, II & III in Annex.-X for guidance of Field Engineers.
Q.
R.
Some important DOs & DONTS are given here for guidance:DOs Use proper fixtures and clamps to hold the members firmly at desired location
while welding. The clamps and fixtures must be strong enough to prevent any
distortion of the member while cooling of the welding joint. The clamps and
fixtures are only to be removed when the joint is cooled to ambient
temperature.
Do the welding work in a warm and dry place so that rain water or other
atmospheric elements may not come in contact while welding is in progress.
While welding in very cold weather pre-heat the material before welding and
apply post heating to prevent the weld joint from rapid cooling and develop
stress raiser due to sudden contraction.
Cross level of bearing plates in the welded plate girders should be checked
properly for proper sitting over bed plate.
To co-relate use of steel and welders in different members proper records
should be maintained.
Drilling of holes through approved set of jig particularly long members should
be ensured. No fabrication should be done with unapproved jig.
Drain hole in the portal girders at proper locations should be ensured.
Fairing of holes and removal of drill burrs through initial assembly should be
ensured.
Proper edge finishing with grinding/ special attention in top chord
compression members butting by end milling should be carried out
At site during the erection of girders particularly open web girders due and
adequate care should be taken to achieve the required camber values.
Camber Jacks should be provided at all the nodal points during trial
assembly.
Butting of compression members, X-levels of stringers and alignment of
stringers to be checked properly in the trial erection.
Application of paint on permanent contact surface should be ensured after
proper surface preparation visual inspection is very important tool.
The plates should be perfectly horizontal while drilling the holes to ensure
horizontal verticality of holes.
Steel with proper test certificate/ reports should be used. Commercially
available steel in the market should not be used.
Steel received from the rolling mills has generally punch heat mark numbers.
These numbers should be legibly marked again with paint for easy
10
Annexure-I
SAMPLE QUALITY ASSURANCE PLAN
30.5m Welded Open Web Girder (25T Loading-2008) as per RDSOs Drg. No. RDSO/B-11678
Name of project .....
Manufactured by ......
Workshop Address
SN
Component/
Operations
Characteristic
Check
Frequency
& type of
check
Reference
Document
Fabricators
Quality
Control
Identification
and correlation
with Mill Test
Certificate
from Supplier
e.g., SAIL,
TISCO, IISCO
etc.
As per Mill
T.C. and
tests
required by
RDSO from
Govt./NABL
approved
lab
Challan,
Mill T.C.
Physical
condition i.e.,
Pitting, rusting,
straightness,
rolling defect,
etc.
Visual
1.0
Raw Material
1.1
Steel Plates,
Structural Section
Signature of
Fabricating Agency
Inspection details
Type of
Record
Acceptance
criteria
Remarks
10
11
Plates: IS
2062-2006,
Gr. E 250 B0,
12mm &
above thick.
Plates are
fully killed &
normalized or
control
cooled.
Sections IS
2062-2006,
Gr. E 250
B0/A
IS 20622006
Inspecting
Agency
7
Extent of
inspection
8
Verification
of reference
document
.
Railway
100%
Fabricators
record
Complete
visual
inspection
Railway
100%
Fabricators
Record
Signature of
Railway Representative
11
Approval of RDSO
1.2
10
11
Mechanical
Test as per IS
2062-2006
UTS, YS, %
El, Bend test,
Lab Test at
appvd.
Laboratory
Lab Test
Report
Railway
Raw matl.
Clearance
shall be by
Zonal
Railway
Charpy test
0
at 0 C for
plates of thks.
12mm and
above
Chemical
Analysis as
per IS 20622006
-Do-
-Do-
Railway
-Do-
-Do-
Railway
Heat/Cast
no. section
wise as per
IS 20622006
-Do-
IS 20622006 Gr. E
250 B fully
killed &
normalized
or control
cooled
-
Ultrasonic
test for 12mm
& above thi.
Plates, as per
IS 4225 or
ASTM-SA
435/435M
Dimensions
By ASN
Level II
operator
Lab Test
Report
Railway
100%
Measurement
Challan
Measurement
of Dimension
Railway
100%
Visual/
Measurement
Challan
Verification of
Reference
Document
Railway
As per
requirement
Fabricators
Record &
Zonal
Railway
Records
-
Lab test at
Govt. appvd.
Lab
Manufacturers
Test
Certificate
-Do-
-Do-
-Do-
b)
As per
specn.
Mechanical
& Chemical
Signature of
Fabricating Agency
Signature of
Railway Representative
12
-Do
Table 1,
along with
Note No. 2
of IS 20622006, Gr. E
250 B
IS 4225 or
ASTM SA
435/435M
For Rivet IS
1148 For
Bolt: IS
1367(Part ii)
& property
classes as
per relevant
Drg.
-Do
Approval of RDSO
1
1.3
2
Paints
1.4
Welding
Consumables
2.0
Manufacturing
Process
Lay out of
Components
& Joints
2.1
a) Normal
b)
Jigs
Templates
&
c)
Cutting,
Straightening,
Edge
preparation
3.0
10
11
Verification of
Manufacturers
Test
Certificate,
Inspection
Certificate,
Challan
Tests as per
Specification
Visual
Challan.,
Manufacturers
Test
Certificate
Vefification of
Reference
Document
...
Railway
Each Batch
Manufacturers
Test
Certificate
IS 102,
Contract
agreement
Paints to be
procured
from
vendors
approved by
RDSO
Lab test at
Govt. Appvd.
Lab
Challan.,
Manufacturers
Test
Certificate
Challan.,
Manufacturers
Test
Certificate
Verification of
Reference
Document
.
Railway
Random
Lab. Test
Report
IS 102
Contract
agreement
-Do-
Verification of
Reference
Document
.
Railway
As per
requirement
Fabricators
Record
Consumables
should be of
RDSO appvd.
Brand
Relevant
IS/IRS
Codes &
Approved
Drawings
IRS B12001
Clearance
by RDSO
As per
specification
and as
approved by
RDSO
Any test as
required
Dimension
Measurement
with
calibrated
steel tape &
gauges
Measurement
with
calibrated
steel tape &
gauges
Approved
Drawing
Measurement
of Dimension
RDSO
100%
Iinspection
Report of
Inspection
Official
Approved
Drawing
Measurement
of Dimension
RDSO
100%
Record of Jigs
& fixtures as
per proforma
issued by
RDSO
Visual/
Measurement
Inspection
Report of
Inspection
Official &
Fabricators
Record
Visula&
Measurement
of dimension
Railway
100%
Inspection
Report of
Inspection
Official &
Fabricators
Record
IRS B12001, IS
1852-85
Verification
IRS B1-2001
IS 9595-96
WBC-2001
Verification of
Reference
Document
RDSO
100%
Fabricators
Record
IRS B12001 IS
9595-96
WBC2001
Dimension,
Intersection
lines, pitch,
gauge, dia. Of
Holes & No. of
holes
Dimension,
Freedom from
defect
Clearance
by RDSO
Welding:
a) WPSS
Review of
WPSS
Signature of
Fabricating Agency
Signature of
Railway Representative
13
Approval of RDSO
Only RDSO
certified
welders to
be engaged
in the job.
10
Witnessing of
established
WPSS
Witnessing of
Welder
Qualification
test
Measurement
of
Temperature
Visual, DT &
NDT at
approved lab
As per code
requirement
Verification of
Reference
Document
RDSO
100%
WPQR Sheet
to be
recorded in
presence of
RDSO Rep.
IS 7310(I)74
Visual with
thermal
Chalk
As per approved
WPSS
Verification of
Reference
Document
.
Railway
Random
IRS B12001
d) Baking of
Electrode, Flux
To have
moisture free
Electrode &
Flux
Visual Check
of Electrodes
& beating
As per
Manufactures
recommendations
Verification of
Reference
Document
Railway
100%
e) Selection of
correct
Electrodes
&
Flux
Reference to
WPSS, IRS
Class, etc.
Visual
As per approved
WPSS
Verification of
Reference
Document
..
Railway
100%
f)
Current
Condition
Measurement
of Amp. &
Voltage
Visual with
Ammeter &
Voltmeter
As per approved
WPSS
Verification of
Reference
Document
Railway
Random
g) Sequence of
Welding
To control
distortion
Visual
As per approved
WPSS
Verification of
Reference
Document
.
Railway
Random
h) Provision of
Run-on & Run
off Plates
To avoid
crater defects
Visual
Verification of
Reference
Document
.
Railway
100%
Inspection
Report of
Inspection
Official &
Fabricators
Record
Inspection
Report of
Inspection
Officials &
Fabricators
Record
Inspection
Report of
inspection
official &
Fabricators
Record
Inspection
Report of
Inspection
Official &
Fabricators
Record
Inspection
Report of
Inspection
Official &
Fabricators
Record
Inspection
Report of
Inspection
Official &
Fabricators
Record
b) WPQR
c) Preheating
Signature of
Fabricating Agency
Signature of
Railway Representative
14
IRS B12001
As per list
of vendors
approved
by RDSO
IRS B12001
IRS B12001
Approval of RDSO
11
4.0
Inspection
Welding
of
5.0
Trial
Assembly
6.0
Final
Clearance
7.0
Surface
preparation by
Shot Blasting
& Metalizing
10
11
a) For Fillet
Welds: Visual,
D.P.Test Fillet
Size,
Penetration,
Leg Length,
Throat
thickness, etc.
b) For butt
Welds RT/UT
tests,
as
applicable
a) Camber on
Jack
b) Dead Load
deflection
c) Dimension
d) Fairness
of holes
e) Temporary
fasteners
f)
Infringement
g) Butting of
compression
edges
Component
completeness
st
of 1 span
after
dismantling &
nd
2 span
onwards
Surface
condition after
blasting
Visual,
Gauge &
Macro
Etching.
Visual
Inspection &
Verification of
dimension by
gauges
RDSO
100%
Fabricators
Record
Relevant
IS/IRS
Code,
Approved
Drg. &
WBC-2001
Clearance
by RDSO
Visual &
Dimensional
Approved. Drg.
Complete
dimensional
check of
Control
Assembly
RDSO
One
complete
span
Inspection
Report of
Inspection
Official &
Fabricators
Record
IRS B12001
Clearance
by RDSO
Visual
Dimensional
& Structural
Stage clearance
Record
Verification of
Stage
clearance
Record
Inspection
Report of
Inspection
Official &
Fabricators
Record
IRS B12001
Visual
checking with
reference to
surface
preparation
Visual
checking
Approved
Fabrication
Drawing & IRS
B1-2001
Verification of
stage
clearance
records
Railway
100% by
fabricator
& Random
by Railway
Fabricators
record
-Do-
-Do-
Railway
-Do-
-Do-
IRS B12001
AppendixVII
IS: 6586
IS: 5905
IS: 2590.
Initial
inspection
by
Railways
and final
Clearance
by RDSO
Clearance
shall be
given by
Zonal
Railway
Measurement
-Do-
-Do-
Railway
Surface finish
after
Metalizing
DFT checking
15
Day to day
Girder
inspection fabrication
by Railways
with
and final
approved
inspection Jigs-100%
by RDSO
Minimum
one
reading
2
per M
Measurement
Record
1
8.0
2
Cleaning
Painting
3
&
Surface
condition
before
painting
Surface finish
after painting
DFT checking
Note:
10
11
Visual
checking .
Approved
Fabrication
Drawing & IRS
B1-2001
Verification of
stage
clearance
records
Railway
100% by
fabricator
& Random
by Railway
Fabricators
record
-Do-
-Do-
-Do-
-Do-
-Do-
-Do-
Railway
Railway
Clearance
shall be
given by
Zonal
Railway
Visual
checking
Measurement
IRS B12001
IS:104,
IS:51, IS:
2339, IS:
5666
Minimum
one
reading
2
per M
Measurement
Record
1. During fabrication, internal inspection to be done by Railways to ensure that only RDSO approved welders carry out welding as per
approved WPSS, work is as per dimensional tolerances and other quality aspects and should satisfy itself before sending Inspection call
to RDSO for Trial Assembly or components Inspection.
2. For ROBs Inspection/Approval Agency for all stages will be concerned Railways.
Signature of
Fabricating Agency
Signature of
Railway Representative
16
Approval of RDSO
Annexure-II
APPENDIX - V
(Ref. Clause 26)
Proforma for Welding Procedure Specification Sheet
Name and address of Fabricator:
Welding procedure specification No
1.
2.
Base Metal
3.
Welding Process
4.
Welding position
5.
Welding consumables
5.1
Electrode/wire
Class :
Dia
Drying method:
5.2
Flux
Class :
Type:
Drying method:
6.1
6.2
Joint preparation:
7.
Welding current:
Type:
Polarity:
8.
Welder qualification:
9.1
Welding Parameters:
17
Annexure-II (Contd)
Weld
Pass
No.
1
9.2
Electrode Curren
s/
wire t (amp)
dia.(mm)
2
3
Arc
Voltage
(volt)
4
Wire feed
speed
(m/min)
5
Travel
speed
(m/min)
6
Electrical
stickout
(mm)
7
Gas flow
rate
(litre/min.)
8
10.
11.
12.
13
14
Peening
15
16
17
Inspection of weld.
18.
18
Annexure-III
Performa for maintaining Register for consumable:
Date
Detail of Item
with
manufacturer
name
Weather
item is
approved
by RDSO
(Yes/No)
Manufacturer
test
certificate
detail.
19
Quantity
received
Quantity
consumed
Annexure-IV
Proforma for Welding Procedure Qualification Record
NAME AND ADDRESS OF FABRICATOR
1.
2.
3.
Name of welder:
4.
5.
6.
Base Metal:
7.
Welding Process:
8.
Welding position:
9.
Welding Current:
Type:
Polarity:
10
11
Welding consumables:
11.1
Electrode/wire
Class:
Dia:
Brand:
11.2
Flux
Class:
Type:
Brand:
11.3
Shielding gas:
12.
Welding parameters:
Weld
pass
No.
Electrod
e wire
dia (mm)
Current
(amp)
13.
Arc
voltag
e
(volt)
4
Wire
feed
speed
(m/min.)
5
20
Travel
speed
(m/min.)
Electrical
stick out
(mm)
Shielding
gas flow
rate
(lit/min.)
8
Annexure-IV (Contd)
14.
Test
1
Non-destructive tests:
i)
Visual examination:
ii)
iii)
iv)
Radiographic/Ultrasonic test:
Specimen No.
2
Result.
3
Destructive tests:
i)
Macro-examination:
ii)
Hardness survey:
iii)
iv)
v)
vi)
vii)
21
Annexure-V
22
Annexure-V (Contd)
23
Annexure-VI
24
Annexure-VII
Stages of inspection of Steel Bridge Girders
(For Rail and Rail-cum-Road Bridges)
(I)
(II)
(III)
Prefabrication stage :
(1) Approval of Quality Assurance Plan (QAP)
(2) Scrutiny of Welding Procedure Specifications Sheets (WPSS)
(3) Welders Qualification Test i.e. Welding Procedure Qualification
Records (WPQR)
(4) Inspection and clearance of raw material
(5) Inspection of layout on template floor (Nominal Camber)
(6) Inspection of jigs and fixtures with master plates
During Fabrication :
(1) Use of approved raw material
(2) Use of approved welding consumables
(3) Use of approved welders
(4) Use of approved welding procedures and parameters (WPDS)
Welding Procedure Data Sheet to be maintained for all welds.
(5) Fabrication with approved set of jigs
After Fabrication
:
(1) Inspection of welds
(2) Structural and dimensional inspection
(3) Trial assembly (First Girder)- Camber Values, Dimensions,
Fairness of Holes by Go-No-Go Gauge, Butting of Flange in Top
Chord.
(5) (4)
Inspection of Dismantled Components of 1st Trial Assembly
Check for elongation of Holes/Abnormal stress marks/cuts etc. &
Removal of shortcomings noted during Trial Assembly.
(7) (6)
Inspect of only components for further spans- welding inspection &
Dimensional checks.
(9) (8)
Metalizing/ Painting
Inspection/
Approval
RDSO
RDSO
RDSO
Railways
RDSO
RDSO
Railways
Railways
Railways
Railways
Railways
RDSO
RDSO
RDSO
RDSO
RDSO
Railways
25
Annexure-VIII
26
Annexure-VIII (Contd.)
27
Annexure-IX
28
Annexure-IX (Contd)
29
Annexure-X
PROFORMA -I
Check List for Fabrication-Inspection of Steel Girders
1.
Fabrication Code:
2.
3.
Fabrication Guideline:
4.
5.
------------
6.
7.
8.
(i)
Raw Materials
(ii)
Rivet/nut/bolt
(iii)
Welding consumables
(iv)
(v)
Paint
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
Raw material
(i)
(ii)
(iii)
(iv)
(v)
Visual inspection
(vi)
(vii)
HSFG Bolt
(i)
Material Specification
30
Annexure-X (Contd.)
(i)
9.
10.
(ii)
(iii)
(ii)
(ii)
31
Annexure-X (Contd.)
PROFORMA -II
Check List for Fabrication-Inspection of Steel Girders
Proforma-I completed or not (further inspection to be done after completing activities
mentioned in proforma-II)
1.
2.
3.
Welding
(i) Scrutiny of WPSSs (Done or Not)
(ii) Approval of WPQRs (Yes or No)
(iii) Welding Parameters during welding (WPDS) maintained or not
(iv) Welding done by Approved welders (Yes or No)
(v) Use of approved welding consumable (Yes or No)
Electrode: IRS: M/28
Wire & Flux: IRS: M/39
Co2wire: IRS: M/46
(vi) Internal checks of welding
(a) Visual, weld size, throat thickness, weld profile
(b) DPT/MPT and Macro Etching
(c) Ultrasonic/Radiography Testing
32
Annexure-X (Contd.)
PROFORMA -III
Check List for Fabrication-Inspection of Steel Girders
Proforma-II completed or not (further inspection to be done after completing activities
mentioned in proforma-II)
Fabrication Process as per BS: 110 report
1.
Finished Product
I.
II.
2.
Camber on Jack
(ii)
(iii) Dimension
(iv) Fairness of holes
(v)
Temporary fasteners
4.
33
to IS:9954)
Annexure-XI
STANDARD QUALITY ASSURANCE PLAN FOR ELASTOMERIC BEARINGS
1. Name of Manufacture
3. Name of Project/Railway
:
:
S.
No.
Component
Operation
1
1.0
2
3
RAW
Physical Test
MATERIAL
Elastomer
With values of
( Only virgin
characteristics
Polychloropr specified
ene (CR) is
permitted &
preferable
grades areNeoprene
WRT,
Bayprene
110,
a) Hardness
Skyprene B5 and Denka b) Min. Tensile
S-40V)
strength
c) Min. Elong. at
break
d) Max.
Compression
set
e) Accelerated
ageing test
1.1
Characteristic
Checks &
Tolerances
I) Max. Change
in Hardness
II) Max. Change
in Tensile
strength
III) Max. Change
in Elongation.
Frequency &
Type of check
4
As per
manufacturer
certificate &
test required
by Authorized
inspector of
zonal Railway
from Govt./
NABL
approved lab
2. Drg. No.
;
....
4. Authority (CA No./LOA No./Order No.):.
Reference
Document
Fabriactor
s quality
control
5
Manufacturer
test certificate
&Challan
6
Verification
of
reference
document.
Inspection details
Inspecting
Agency
7
Authorized
Inspector
appointed
by Zonal
Railway
Extent of
Inspection
8
From
batches at
Random
and at
discretion
of Inspector
Type of
Records
Acceptance
criteria
Remarks
9
Fabricato
rs record.
10
IRC:83
(Part-II) &
IS:3400 (as
per relevant
test
procedure)
11
Examination of Test
Certificates is required Test
Certificate shall be furnished
by manufacturers for
following tests.
(i) Composition
(ii) Hardness
(iii) Tensile strength
(iv) Elongation at Break
(v) Compression set
(vi) Accelerated Ageing test
(vii) Adhesion Strength
IRHD ( 60 5 )
IMPORTANT:
Properties of Elastomer
should be as per Table 1 of
IRC:83
Part-II
Polychloroprene
Content 60 %
Ash content
Note: (i) No reclaimed rubber,
vulcanized wastes or natural
rubber shall be used.
(ii) EPDM (Ethyle propylene
Dimonomer), IIR (Isobutane
Isoprene Copolymer), CIIR
(Chloro-Isoprene Copolymer)
are
not
permitted
for
manufacture of bearings.
17 MPa
400%
35%
o
100 1 c for
70 Hours
+15% w.r.t.
value of (a)
-15% w.r.t.
value of (b)
-30% w.r.t.
value of (c)
(f) Adhesion
Min. 7 KN/m
strength of
Elastomer to
Steel Plates
Note:- Large lot means if number of bearings are 24 & tests for Acceptance level 1 to be conducted. Small lot means if numbers of bearings are < 24 where Acceptance
level 2 tests are done. Lot size to be approved by the engineer. In large lot 2 extra bearings to be made which are consumed in destructive testing.
34
S.
No.
1
1.1
Cont.
Component
Operation
2
Elastomer
Characteristic
Checks &
Tolerances
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
5
Manufacturer
test certificate
&Challan
6
Verification
of
reference
document.
Inspection details
Inspecting
Agency
7
Authorized
Inspector
appointed
by Zonal
Railway
Extent of
Inspection
8
From
batches at
Random
3
Chemical Test
i) Determination
/ Identification
of polymer
4
As per
manufacturer
certificate &
test required
by Authorized
inspector of
zonal Railway
from Govt./
NABL
approved lab
ii)
Polymer
content
min 60%
-do-
-do-
iii)
Ash content
Max 5%
-do-
-do-
-do-
-do-
(V) Ozone
resistance
-do-
-do-
35
Type of
Records
Acceptance
criteria
Remarks
9
Fabricato
rs record.
10
IRC:83
(Part-II) Ash
content as
per IS:3400
part XXII
and
Polychloropr
ene content
as per
ASTM-D297
Identification
of polymer
as per
ASTM D
3677 (as per
relevant test
procedure)
11
Examination
of
Test
Certificates is required Test
Certificate shall be furnished
by
manufacturers
for
following tests.
(i) Polymer Identification
(ii) Polymer content
(iii) Ash content
(iv) Specific gravity
(V) Ozone resistance
Preferably test of polymer
identification, polymer content
and Ash content should be
either witnessed or sealed
sample to be sent to NABL
LAB for evaluation.
Note:
For acceptance testing level
I,
(a) Ash content on specimen
from test bearing shall be
compared with those for
specially moulded test
pieces and Max variation
permitted is 0.5%
(b)Specific
gravity
on
specimen
from
test
bearing shall be compared
with those for specially
moulded test pieces and
Max variation permitted is
0.2%
(c) For other test max. and
min. limits to be adhered.
(d) Ozone resistance can be
waived by test engineer as
per note 2 of Para
918.4.1.2 of IRC83 Part II.
S.
No.
Component
Operation
1
1.2
2
Mild Steel
Characteristic
Checks &
Tolerances
3
Mechanical Test
UTS, Yield Stress,
Elongation%,
Bend test , Impact
test at 0 degree
centigrade or -20
degree for subzero zone
Frequency &
Type of check
4
As per Mill TC
& test required
by Authorized
inspecting
official of
Zonal Railway
from Govt. Lab
./ NABL
approved lab.
Reference
Document
5
Mill TC and
Challan
Fabriactor
s quality
control
Inspection details
Inspecting
Agency
6
7
1.
Authorized
Verification
Inspecting
of reference official of
document.
Zonal
2.Complete Railway
visual
inspection.
Extent of
Inspection
8
One test
piece per
thickness
per heat.
Type of
Records
Acceptance
criteria
Remarks
9
Fabricato
rs record
Corelated
with Mill
TC & test
report.
10
IS: 2062-11,
E250
,Quality BO
is generally
used.
However
Quality C
shall be
used for sub
zero
condition.
( As
specified in
approved
Drg.).
11
Manufacturers test certificate
shall be furnished. UST shall
be
conducted
for12mm
&above thick plates per
provision
of
relevant
specification
before
processing the material for
manufacturing.
Chemical Test
C, Mn, Si, P, S,
CE.
Physical condition
i.e.
Pitting,rusting,rolli
ng defect, etc.
Ultrasonic Testing
of plates
IS:4225 or
ASTM A435
100%
(100% for12mm
& above thick
plates)
2.0 Manufacturing
Process
Dimensional
inspection
Specified
tolerances
(a) Over all plan -0,+6mm
dimension
(length &
Breadth)
(b) Thickness of 20%
M
Individual
(Max of 2mm)
internal layer
of elastomer
(c) Thickness of -0,+1mm
individual
outer layer
(d)Plan
-3mm, +0
dimension of
laminates(len
gth
2.0
&Breadth)
Visual &
Measurement
As per
approved
drawing
Measureme
nt
of
dimension
36
Manufactur
er
inspecting
agency
At
Discretion
Fabricato
rs record.
Internal
report
will
be
furnished which will be
verified by Zonal Railway
Inspector. However random
check may be done by Zonal
Railway inspector during
Manufacturing.
Note: During manufacturing
test pieces will also be
moulded
with
identical
compound
and
under
identical
vulcanizing
conditions
and
suitably
marked for identification at
the time of tests. This process
shall be open to inspection by
Railway inspecting official.
S.
No.
Component
Operation
1
2
cont. (e) Thickness of
laminate
(f) Parallelism
of laminate
with respect
to bearing
base as
datum
(g) Hardness
during
manufacturi
ng
(h) Over all
Thickness
3.0 Final inspection
3.1
3.2
Characteristic
Checks &
Tolerances
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
Inspection details
Inspecting
Agency
7
Extent of
Inspection
8
Type of
Records
Acceptance
criteria
Remarks
10
11
10 %
1 in 100
IRHD 605
Visual &
Measurement
As per
approved
drawing
Measureme
nt
of
dimension
Manufactur
er
inspecting
agency
At
Discretion
Fabricato
rs record.
-do-
Visual and
measurement
As per
relevant drg.
&
specification
Measureme
nt
of
dimension
Authorized
Inspector
appointed
by Zonal
Railway
100%
Fabricato
rs record
&
test
report.
As per table
2 of IRC 83
Part-II
-0,+5%
Visual
examination
Dimensions of
and
bearing as per
dimensional
specified tolerances
check
as under :
a) Over all plan
dimension(l -0,+6mm
ength &
Breadth)
b) Over all
Thickness
-0,+5%
c) Parallelismof
top surface 1 in 200
of bearing
with respect
to the
bottom
surface as
datum
d) Parallelism
of one side 1 in 100
surface with
respect to
the other as
datum
Chemical &
Physical
37
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
Manufacturer
Test
Certificate
&Challan
Verification
of
reference
document.
Inspection details
Inspecting
Agency
7
Extent of
Inspection
8
Authorized
Inspector
appointed
by Zonal
Railway
From
batches at
Random
-do-
-do-
-do-
-do-
Type of
Records
Acceptance
criteria
Remarks
10
11
Fabricato
rs record.
IRC:83
(Part-II) Ash
content as
per IS:3400
part XXII
and
Polychloropr
ene content
as per
ASTM-D297
Identification
of polymer
as per
ASTM D
3677 (as per
relevant test
procedure)
Test
3.2.1
Chemical Test
i) Determination/
Identification of
polymer.
As per
manufacturer
certificate &
test required
by Authorized
inspector from
Govt./ NABL
approved lab
min 60%
max 5%
For
level
acceptance
sample
from
randomly
selected bearing of each lot
of Elastomer bearing as
prescribed in procedure in
IS3400 and IRC83 (Part-II)
shall be drawn by authorize
inspector and tested in house
lab. or in Govt./ NABL
approved laboratory for all the
5 tests. These test are in
addition to tests conducted on
specially moulded test pieces
prepared at the time of
manufacture of bearing.
38
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
Manufacturer
test certificate
&Challan
Verification
of
reference
document.
3.2.2 Elastomer
(Only virgin
Polychloropr
ene (CR) is
permitted &
preferable
grades areNeoprene
WRT,
Bayprene
110,
Skyprene B5 and Denka
S-40V)
3.2.2
Cont.
Physical Test
With values of
characteristics
specificed
As per
manufacturer
certificate &
test required
by Authorized
inspector from
Govt./ NABL
approved lab
a) Hardness
IRHD
( 60 5 )
17 MPa
b) Min. Tensile
strength
c) Min. Elong. at
break
d) Max.
Compression
set
Inspection details
Inspecting
Agency
7
Extent of
Inspection
8
Authorized
Inspector
appointed
by Zonal
Railway
From
batches at
Random
Type of
Records
Acceptance
criteria
Remarks
10
Fabricato
rs record.
IRC:83
(Part-II) &
IS:3400 (as
per relevant
test
procedure)
11
with these for specially
molded test pieces and
Max variation permitted is
0.2%
(c) For other test max. and
min. limits to be adhered.
(d) Ozone resistance can be
waived by test engineer as
per note 2 of Para
918.4.1.2 of IRC83 Part II.
Polychloroprene Content 60
%
Ash content
Note: (i) No reclaimed rubber,
vulcanized wastes or
natural rubber shall be
used.
(ii) EPDM (Ethyle propylene
Dimonomer),
IIR
(Isobutane
Isoprene
Copolymer),
CIIR
(Chloro-Isoprene
Copolymer)
are
not
permitted
for
manufacture of bearings.
Test certificate shall be
furnished by manufacturers.
(For level I acceptance
sample from each lot of
Elastomer as prescribed in
specification shall be drawn
by authorize inspector and
tested in either In-house Lab.
or in NABL/ Govt. Approved
laboratory. For level 2
acceptance, tests on specially
molded test pieces to be
done.
Tests to be done are
(i) Composition
(ii) Hardness
(iii) Tensile strength
(iv) Elongation at Break
(v) Compression set
400%
35%
39
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
3
e) Accelerated
ageing test
i) Max. Change
in Hardness
ii) Max. Change
in Tensile
strength
iii) Max. Change
in
Elongation.
(f) Adhesion
strength of
Elastomer to
Steel Plates
4
o
100 1 c for
70 Hours
+15% w.r.t.
value of (a)
-15% w.r.t.
value of (b)
Upto 15MPa
All bearing of
the lot shall be
tested.
Test to be
conducted as per
Annexure 2 of
IRC: 83 (Part-II)
acceptance value
of Ea=20%
2
1(0.2/S +0.0005)
MPa where S is
shape factor
Load testing
on
Two test
bearings.
Test to be
conducted as per
Annexure 2 of
IRC: 83 (Part-II)
Load testing
on
Two test
bearings.
3.3
Load Test on
complete
bearings
a) Axial load
test
b) Elastic
Modulus test
3.3
(c) Shear
Cont.
Modulus
test
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
Inspection details
Inspecting
Agency
7
Extent of
Inspection
8
Type of
Records
Acceptance
criteria
Remarks
10
11
(vi) Accelerated Ageing test
(vii) Adhesion Strength
IMPORTANT:
Properties
of
Elastomer
should be as per Table 1 of
IRC:83 Part-II
-30% w.r.t.
value of (c)
Min. 7 KN/m
As per
relevant drg.
and
specification
Fabricators
record.
Authorized
Inspector
appointed
by Zonal
Railway
100%
In case of
large lot
40
Fabricato
rs record.
IRC 83 PartII
S.
No.
Component
Operation
(d) Stripping
strength
test /
Adhesive
strength
test
(e)Ultimate
compressive
strength test
Characteristic
Checks &
Tolerances
Frequency &
Type of check
Reference
Document
Fabriactor
s quality
control
3
value of G for
acceptance from
0.8MPa to 1.2
MPa
Test to be
conducted as per
Annexure 2 of
IRC: 83 (Part-II)
examination for
evidence of
cracking/ peeling
both in strained
(Strain value 2.0)
and unstrained
state.
60MPa
Load testing
on
Two test
bearings.
Inspection details
Inspecting
Agency
7
Extent of
Inspection
8
Type of
Records
Acceptance
criteria
10
Remarks
11
pieces prepared at the
time of manufacture of
bearings. Note that the
bearing selected for test
will not be reused and
destructive test will be
done on sample prepared
from them.
(B) For acceptance level 2
shear modulus tests is
mustwhich will be done
on randomly selected
bearings and which after
test can be used in the
bridge.
Load testing
on
Two test
bearings for
Destructive
Test.
Ultimate
Compressive
Strength test.
There should be no failure of
steel laminate or irreversible
squeezing out of elastomer
upto load of 60MPa.
Note:- Large lot means if number of bearings are 24 & tests for Acceptance level 1 to be conducted. Small lot means if numbers of bearings are < 24 where Acceptance
.
level 2 tests are done. Lot size to be approved by the engineer. In large lot 2 extra bearings to be made which are consumed in destructive testing.
Signature of
Fabricating Agency
Signature of
Railway Representative
41
Annexure-XII
MODEL QUALITY ASSURANCE PLANFOR POT-PTFE BEARINGS
1. Name of Manufacture:
2. Drg. No.:
3. Name of Project/Railway:
S.
No.
Component
Operation
1
1.0
2
RAW
MATERIAL:
Cast Steel
(CS)
1.1
Characteristic
Checked
3
Physical Test
UTS, Yield
Stress,
Elongation%,
Reduction of
Area,
Impact test at 0
degree
centigrade or -20
degree for subzero zone
Micro Exam;
Hardness test
Chemical Test
C, Mn, Si, P, S,
Cr, Ni, Mo, Cu ,V
Frequency
Reference
& Type of
Document
check
4
5
As per Mill
Mill TC and
TC & test
Challan
required by
RDSO/Auth
orized
inspecting
official of
Zonal
Railway
from Govt.
Lab ./
NABL
approved
lab
Fabriactors
quality
control
6
1.Verification
of reference
document.
2.Complete
visual
inspection.
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
RDSO/Auth One
integral
orized
Test piece
Inspecting
per heat
official of
Zonal
Railway
Ultrasonic
Testing
(On cast steel
100% before &
after load Test
100%
42
Type of
Records
Acceptance
criteria
Remarks
9
Fabricator
s record
Co-related
with Mill
TC & test
report.
10
IS:1030
Cast steel
shall
generally
comply with
Grade 280520W or 340570W
(Grade/class
as per
relevant
approved
Drg.).
11
Manufacturers test certificate
shall be furnished. UST shall
be conducted as per provision
of relevant specification before
processing the material for
manufacturing. UST after load
test shall also be carried out.
IS:9565
Level-III
S.
No.
Component
Operation
1
1.2
2
Mild Steel
Characteristic
Checked
3
Mechanical Test
UTS, Yield
Stress,
Elongation%,
Bend test ,
Impact test at 0
degree
centigrade or -20
degree for subzero zone
Chemical Test
C, Mn, Si, P, S,
CE.
Frequency
Reference
& Type of
Document
check
4
5
As per Mill
Mill TC and
TC & test
Challan
required by
RDSO/Auth
orized
inspecting
official of
Zonal
Railway
from Govt.
Lab ./
NABL
approved
lab.
Fabriactors
quality
control
6
1. Verification
of reference
document.
2.Complete
visual
inspection.
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
RDSO/Auth One test
piece per
orized
thickness
Inspecting
per heat.
official of
Zonal
Railway
Type of
Records
Acceptance
criteria
Remarks
9
Fabricato
rs record
Corelated
with Mill
TC & test
report.
10
IS: 2062-11,
E250 ,Quality
BO is
generally
used.
However
Quality C
shall be used
for sub zero
condition.
( As specified
in approved
Drg.).
11
Manufacturers test certificate
shall be furnished. UST shall
be conducted as per provision
of relevant specification before
processing the material for
manufacturing. UST after load
test shall also be carried out.
Physical
condition i.e.
Pitting,rusting,roll
ing defect, etc.
Ultrasonic
Testing of plates
(100%)
1.3
Stainless
Steel (S.S.)
Physical Test
UTS, Yield
Stress,
Elongation %,
Hardness
Chemical Test
C, Mn, Ni, Cr, P,
S, Si, Mo
100%
As per Mill
TC & test
required by
RDSO/Auth
orized
inspecting
official of
Zonal
Railway
from Govt.
Lab ./
NABL
approved
lab.
Mill TC and
Challan
1. Verification RDSO/Auth
of reference orized
document.
Inspecting
official of
2.Complete
Zonal
visual
Railway
inspection.
IS:4225 or
ASTM A435
Fabricato
r records.
Stain less
steel shall
conform to
AISI
316L/xO2Cr1
7Ni12Mo2 of
IS:6911
Or
(Grade/class
As per
relevant
approved
Drg.).
43
S.
No.
Component
Operation
1
1.4
2
PTFE
(confined &
dimpled )
1.5
Elastomer
( Neoprene
WRT/
Bayprene
110 or
equivalent/D
enka
Characteristic
Checked
3
a) Tensile
strength
b) % of
Elongation At
break.
c) Dimensional
Stability
d) Resistance to
heat
e) Durometer
Hardness
f) Specific
Gravity.
g) Density
h) Electric
strength (
Proof test)
i) Appearance
and finish
Physical
properties
f)
g)
h)
i)
j)
k)
Hardness
(IRHD)
Minimum
Tensile
strength
(MPa)
MinimumElo
ngation at
break (%)
Max.
Compression
set (%)
Accelerated
ageing
Max. change
in hardness.
Frequency
Reference
& Type of
Document
check
4
5
As per
Manufacturer
manufactur
test certificate
er
&Challan
certificate &
test
required by
RDSO/Auth
orized
inspecting
official
from Govt.
lab./ NABL
approved
lab
Fabriactors
quality
control
6
1. Verification
of reference
document.
As per Mill
TC & tests
required by
RDSO/Auth
orized
Zonal
Railway
inspecting
official from
Govt.lab/
NABL
approved
lab
Verification
of reference
document.
Manufacturer
test certificate
&Challan
2.Complete
visual
inspection.
.
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
RDSO/Auth One test pc
orized
for Full Lot
Inspecting
of supply
official of
Zonal
Railway
RDSO/Auth
orized
Inspecting
official of
Zonal
Railway
44
From each
batch at
Random
Type of
Records
9
Fabricato
rs record.
Acceptance
criteria
10
Grade A of
BS:3784
or
equivalent
(Grade/class
as per
relevant
specification /
approved
Drg.).
Fabricato
rs record.
IRC:83
(Part-III) &
(Part-II) and
IS:3400 (as
per relevant
test
procedure)
Remarks
11
Manufacturers test certificate
shall be furnished. Sample
from each lot of PTFE shall be
drawn by authorize inspector
and tested in Govt./NABL
approved laboratory.
S.
No.
Component
Operation
Characteristic
Checked
3
Max. change
in tensile
strength.
m) Max. change
in elongation
Frequency
& Type of
check
4
Reference
Document
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
Type of
Records
Acceptance
criteria
Remarks
Fabriactors
quality
control
6
10
11
As per Mill
TC & tests
required by
RDSO/Auth
orized
Zonal
Railway
inspecting
official from
Govt.lab/
NABL
approved
lab
Manufacturer
test certificate
&Challan
Verification
of reference
document.
RDSO/Auth
orized
Inspecting
official of
Zonal
Railway
From each
batch at
Random
Fabricato
rs record.
IRC:83
(Part-II) &
IS:3400 (as
per relevant
test
procedure)
As per Mill
TC & tests
required by
RDSO/Auth
orized
Zonal
Railway
inspecting
official from
Govt.lab /
NABL
approved
lab
Manufacturer
test certificate
&Challan
Verification
of reference
document.
RDSO/Auth
orized
Inspector
appointed
by Zonal
Railway
One test pc
for full lot of
supply
Fabricato
rs record.
IS:410,
CuZn37 (HB)
l)
1.6
Brass
sealing Ring
(20mm wide
x 2mm
Thick)
Chemical Test
iv)
Ash
content shall
not exceed
5%
v) The raw
elastomeric
( polychloroprene)
content of the
compound
shall not be
lower than
60%.
vi)
Sp.
Gravity
Physical
properties
(i) Tensile
strength
(N/mm2),
(ii) Elongation %
(iii) Bend test
(iv) Vickers
Hardness
Chemical Test
Cu ,Pb, Fe and
total Cu+Pb+Fe&
Remainder Zn
45
Or
(Grade/class
As per
relevant
approved
Drg.).
S.
No.
Component
Operation
1
1.7
2
Bolts & Nuts
Characteristic
Checked
3
Physical
properties
(i) Tensile
strength (MPa)
(ii) Hardness
(BHN)
(iii) Head sound ness test
(iv) Depth of
decarburization.
&
Chemical Test
Frequency
Reference
& Type of
Document
check
4
5
As per Mill
Manufacturer
TC & test
test certificate
required by &Challan
RDSO/Auth
orized
inspecting
official
from
Govt.lab/
NABL
approved
lab
Fabriactors
quality
control
6
Verification
of reference
document.
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
Authorized
As per
Inspector
relevant
appointed by specificatio
Zonal
n
Railway
Type of
Records
9
Fabricato
rs record.
Acceptance
criteria
10
IS:1364 &
IS: 1367
(property
class 8.8)
Or
(Grade/class
as per
relevant
approved
Drg.).
Remarks
11
Test certificate shall be
furnished by manufacturer.
One sample for each lot of
Bolts & Nuts supply shall be
drawn by authorize inspecting
official of Zonal Railway and
tested in Govt./NABL approved
laboratory.
C,P & S
Dimensional
check as per
specification
1.8
Adhesive for
bonding
PTFE
Peel of strength
1.9
Paint
Verification of
Manufactures
Test Certificate,
Inspection
Certificate,
Chalan
Visual &
Measureme
nt
As per Mill
TC & test
required by
Zonal
Railway
inspection
official from
Govt./
NABL
approved
lab.
Visual
Manufacturer
test certificate
&Challan
Verification
of reference
document.
Zonal
Railway.
One
sample per
lot.
Fabricato
rs record.
Manufacturer
test certificate
&Challan
Verification
of reference
document.
Zonal
Railway.
Each Batch
Fabricato
rs record.
46
Adhesive for
bonding
PTFE to
backing
plates shall
produce a
bond with a
minimum peel
strength of
4N/mm width
when tested
in accordance
with BS:5350
( Part C9)
As per
relevant
Specification
S.
No.
Component
Operation
Characteristic
Checked
1
2.0
2
Manufacturin
g Process
2.1
a) plan
dimension
b) individual
height of
the
componen
t
c) Thickness
of
elastomeri
c pad
Check after
attachment
of stainless
steel plate
a) Flatness
b) Surface
Finish
NDT test
2.2
2.3
2.4
DP test on
welding of
the top plate
and bearings
after load
test
Hardness
a) On
major
steel
compon
ents
b) On the
hard
facing
zone
Frequency
& Type of
check
4
Reference
Document
5
Fabriactors
quality
control
6
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
Type of
Records
Acceptance
criteria
Remarks
10
11
Dimensional
inspection
Visual &
Measureme
nt
As per
approved
drawing
Measureme
nt
of
dimension
Manufactur
ersinspecti
ng official
100 %
Fabricato
rs record.
Internal
report
shall
be
furnished, However random
check may be done in
presence of Zonal Railway
inspecting official.
Dimensional
inspection
Visual &
Measureme
nt
As per
approved
drawing
Measureme
nt
of
dimension
Manufactur
ers
inspecting
official
100%
Fabricato
rs record.
Internal
report
shall
be
furnished, However, random
check may be done in
presence of Zonal Railway
inspecting official.
DP Test, weld
Size , visual
DP Test of
weld, visual
& gauge
As per
approved
WPSS &Drg.
Visual
inspection &
verification
of dimension
by gauge.
Manufactur
ersinspecti
ng official/
Zonal
Railway/RD
SO
Fabricato
rs record.
IS:3658 -1981
As per drg.
and relevant
specification
Fabricators
record
&
check.
Manufactur
er
inspecting
official/
Zonal
Railway
Fabricato
rs record.
IRC 83 PartIII
Internal
report
will
be
furnished, however, random
check will be done in presence
of
Railway
representative
inspecting authority.
Firm should keep the records
of hard facing and submit the
same to inspection official at
the time of inspection
Hardness tester
measureme
nt
47
100%
100%
S.
No.
Component
Operation
Characteristic
Checked
1
2.5
2
Corrosion
Protection
a) Grit
Blasting
b) Zn
metalizin
g
c) Painting
Assembly
a) Paralleli
sim
b) Overall
Height
2.6
2.7
Marking
2.8
Tolerance of
fit between
different
component
of bearing
a) Piston
Cylinder
b)Elastomeri
c pad &
Cylinder
c) Guide &
Adjacent
compone
nt
d) Pin &
Cylinder
Dimensional
Inspection
Dimensional
Inspection
Fabricators
quality
control
6
Inspection details
Inspecting
Extent of
Agency
Inspection
7
8
Type of
Records
Acceptance
criteria
Remarks
10
11
As per drg.
and relevant
specification
Fabricators
record
&
check.
Manufactur
er
inspecting
official/
Zonal
Railway
100%
Fabricato
rs record.
IRC 83 PartIII
Internal
report
shall
be
furnished. However,total DFT
shall be checked randomly
from the finished store in
presence
of
inspecting
authority of Zonal Railway.
As per drg.
and relevant
specification
Measureme
nt
of
dimensions .
Manufactur
er
inspecting
official/
Zonal
Railway
100%
Fabricato
rs record.
IRC 83 PartIII
IRC 83 PartIII
Fabricators
record.
Manufactur
ers
inspecting
official/
Zonal
Railway
100%
Fabricato
rs record.
IRC 83 PartIII
As per
relevant Drg.
Measureme
nt
of
dimensions .
Manufactur
ers
inspecting
official/
Zonal
Railway
100%
Fabricato
rs record.
IRC 83 PartIII
Frequency
& Type of
check
4
Reference
Document
Visual and
measureme
nt
Visual and
measureme
nt
Visual and
measureme
nt
Signature of
Fabricating Agency
Inspection records to be
furnished. However random
checking may be done inpresence
of
inspecting
authority of Zonal Railway.
Signature of
Railway Representative
48
Annexure-XIII
STANDARD QUALITY ASSURANCE PLAN FOR EXPANSION JOINTS
1. Name of Manufacture
3. Name of Project/Railway
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
1
1.0
2
RAW MATERIAL
1.1
Mechanical Test
UTS, Yield Stress,
Elongation%, Bend
test , Impact test at
0 degree
centigrade or -20
degree for sub-zero
zone
Refere
nce
Docum
ent
5
Mill TC
and
Challan
2. Drg. No.
4. Authority (CA No./LOA No./Order No.)
Fabriactor
s quality
control
6
Inspection details
Inspecting
Agency
Extent of
Inspection
1. Verification Authorized
of reference
Inspecting
document.
official of
2. Complete Zonal
Railway
visual
inspection.
One test
piece per
thickness
per heat.
......
.
Type of
Records
Acceptance
criteria
Remarks
10
11
Fabricato
rs record
Corelated
with Mill
TC & test
report.
IS: 2062-11,
E250
,Quality BO
is generally
used.
However
Quality C
shall be
used for sub
zero
condition.
( As
specified in
approved
Drg.).
Chemical Test
C, Mn, Si, P, S, CE.
Physical
condition i.e.
Pitting,rusting,rollin
g defect, etc.
Dimensional Check
;
:
Length
Width
Thickness
Dia
Ultrasonic Testing
of plates
(100% for12mm &
above thick plates)
1.2
Physical Test
With values of
characteristics
specified
100%
As per
manufacturer
certificate & test
required by
Authorized
inspector of
zonal Railway
Manufa
cturer
test
certifica
te
&Challa
n
Verification
of reference
document.
49
Authorized
Inspecting
official
appointed
by Zonal
Railway
From
batches at
Random
and at
discretion
of Inspector
Fabricato
rs record.
IS:4225 or
ASTM A435
IRC:83
(Part-II) &
IS:3400 (as
per relevant
test
procedure)
Examination of Test
Certificates is required. Test
Certificate shall be furnished
by manufacturers for
following tests.
(i) Composition
(ii) Hardness
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
2
grades areNeoprene WRT,
Bayprene 110,
Skyprene B-5 and
Denka S-40V)
n)
Hardness
o)
p)
q)
r)
Min. Tensile
strength
Min. Elong. at
break
Max.
Compression
set
Accelerated
ageing test
Frequency &
Type of check
4
from Govt./
NABL approved
lab
Inspecting
Agency
Extent of
Inspection
Type of
Records
Acceptance
criteria
Remarks
10
11
(iii) Tensile strength
(iv) Elongation at Break
(v) Compression set
(vi) Accelerated Ageing test
(vii) Adhesion Strength
IMPORTANT:
Properties of Elastomer
should be as per Table 1 of
IRC:83
Part-II
Polychloroprene
Content 60 %
Ash content
Note: (i) No reclaimed rubber,
vulcanized wastes or natural
rubber shall be used.
(ii) EPDM (Ethyle propylene
Dimonomer), IIR (Isobutane
Isoprene Copolymer), CIIR
(Chloro-Isoprene Copolymer)
are
not
permitted
for
manufacture of bearings.
400%
35%
o
100 1 c for 70
Hours
(f) Adhesion
strength of
Elastomer to Steel
Plates
Chemical Test
vii) Determination/
Identification of
polymer
Min. 7 KN/m
Ash content
Inspection details
17 MPa
+15% w.r.t.
value of (a)
-15% w.r.t.
value of (b)
ix)
Fabriactor
s quality
control
IRHD ( 60 5 )
viii) Polymer
content
Refere
nce
Docum
ent
5
-30% w.r.t.
value of (c)
As per
manufacturer
certificate & test
required by
Authorized
inspector of
zonal Railway
from Govt./
NABL approved
lab
min 60%
Verification
of reference
document.
Manufa
cturer
test
certifica
te
&Challa
n
Max 5%
50
Authorized
Inspecting
official
appointed
by Zonal
Railway
From
batches at
Random
-do-
-do-
-do-
-do-
Fabricato
rs record.
IRC:83
(Part-II) Ash
content as
per IS:3400
part XXII
and
Polychloropr
ene content
as per
ASTM-D297
Identification
of polymer
as per
ASTM D
3677 (as per
Examination
of
Test
Certificates is required Test
Certificate shall be furnished
by
manufacturers
for
following tests.
(i) Polymer Identification
(ii) Polymer content
(iii) Ash content
(iv) Specific gravity
(V) Ozone resistance
Preferably test of polymer
identification,
polymer
content and Ash content
should be either witnessed
or sealed sample to be sent
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
3
(iv) Specific gravity
Review of WPSS
Verification
Witnessing of
established WPSS
Witnessing of
Welder
Qualification test
Visual, DT &
NDT at
approved lab
c) Preheating
Measurement of
Temperature
d)
Baking
of
Electrode, Flux
e) Selection of
correct
Electrodes & Flux
b) WPQR
Refere
nce
Docum
ent
5
Fabriactor
s quality
control
Inspection details
Inspecting
Agency
Extent of
Inspection
7
-do-
Type of
Records
Acceptance
criteria
10
relevant test
procedure)
-do-
IRS B12001 IS
959596
WBC2001
As per
code
require
ment
Verification
of
Reference
Document
RDSO
100%
Fabricato
rs
Record
IRS B1-2001
IS 9595-96
WBC-2001
Verification
of
Reference
Document
RDSO
100%
IS 7310(I)74
Visual with
thermal Chalk
As per
approv
ed
WPSS
Verification
of
Reference
Document
Authorized
Inspecting
official
appointed
by Zonal
Railway
Random
To have moisture
free Electrode &
Flux
Visual Check of
Electrodes &
beating
As per
Manufa
ctures
recom
mendati
ons
Verification
of
Reference
Document
Authorized
Inspecting
official
appointed
by Zonal
Railway
Random
Reference to
WPSS, IRS Class,
etc.
Visual
As per
approv
ed
WPSS
Verification
of
Reference
Document
Authorized
Inspecting
official
appointed
by Zonal
Railway
100%
WPQR
Sheet to
be
recorded
in
presence
of RDSO
Rep.
Inspectio
n Report
of
Inspectio
n Official
&
Fabricato
rs
Record
Inspectio
n Report
of
Inspectio
n
Officials
&
Fabricato
rs
Record
Inspectio
n Report
of
inspectio
n official
&
Fabricato
rs
51
IRS B1-2001
IRS B1-2001
As per list of
vendors
approved by
RDSO
Remarks
11
to
NABL
evaluation.
LAB
for
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
f)
Current
Condition
Measurement of
Amp. & Voltage
IN Process
Inspection
Finished
expansion
joint
inspection
Visual with
Ammeter &
Voltmeter
(a)
Angle Profile
Size, thickness
Dia , profile
(b)
Anchorage
Size by Gauge,
(c)
Profile
Length, width,
thickness
As per drawing
(d)
Weld check
(e)
Stud
Dia& length of
stud Length,
(f) Dimensional
Check
width, thickness
As per drawing
(g)
By line dori
Straightness
check
(a) Dimensional
check
Length, width,
thickness
As per drawing
(b)
By line dori
Size by gauge
Straightness
check
Refere
nce
Docum
ent
5
Fabriactor
s quality
control
Inspection details
Inspecting
Agency
Extent of
Inspection
As per
approv
ed
WPSS
Verification
of
Reference
Document
Authorized
Inspecting
official
appointed
by Zonal
Railway
Random
Concer
n
specific
ation &
drawing
s
Visual
&
dimensional
verification
w.r.t.
concern
specification
& drawings
Firm &
Authorized
Inspecting
Official
nominated
by Zonal
Rly
100% by
Firm &
random by
Zonal Rly
Authorized
Inspecting
Official of
Zonal
Rly/RDSO
100% by
Zonal
Rly/RDSO
Authorized
Inspecting
Official of
Minimum
20% by
Zonal
Visual &
dimensional
verification
w.r.t.
concern
specification
& drawings
52
Type of
Records
Acceptance
criteria
Remarks
9
Record
Inspectio
n Report
of
Inspectio
n Official
&
Fabricato
rs
Record
10
11
Fabricato
n record
maintain
ed
by
Firm
IRS B1-2001
S.
No.
Component
Operation
Characteristic
Checks &
Tolerances
Frequency &
Type of check
(c)
Painting
Process
Verification of
Manufacture s Test
Certificate
Inspection
Certificate, Challan
(a)
6
Packing
&Dispatch
(b)
(c)
Note:- 1.
2.
Welding
check- by
gauge/DPT
Marking of
expansion
joints
Clamping of
joints
packing o f
expansion joint
Refere
nce
Docum
ent
5
Fabriactor
s quality
control
6
Material
Size, length
Dia etc.
Visual
Verifica
tion of
Manufa
cture s
Test
Certific
ate,
Challan
Verification
of reference
document
Verification
of reference
document
Inspection details
Type of
Records
Acceptance
criteria
Remarks
10
11
Each Batch
Fabricato
rs record
As per
relevant
Specification
Each Batch
Fabricato
rs record
As per
relevant
Specification
Inspecting
Agency
Extent of
Inspection
7
Zonal
Rly/RDSO
8
Rly/RDSO
Authorized
Inspecting
Official of
Zonal
Rly/RDSO
Authorized
Inspecting
Official of
Zonal
Railway
Zonal
Railway
100% by
Zonal
Rly/RDSO
Paint should be as per IRS:
B1:2001 or as per contract
conditions as applicable
If there are any studs in the approved drawing, performa as per BS-115 issued by RDSO may be referred for suitable changes.
If there are Bolts & Nuts in the approved drawing, then add Para 1.3 in this QAP as given for Bolts & Nuts in Para 1.7 of QAP of POT-PTFE Bearings (Anex.-XII)
Signature of
Fabricating Agency
Signature of
Railway Representative
53
Annexure-A
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hammer Test
Required
Signature of
Fabricating Agency
Progress
Signature of
Railway Representative
54