C.0 SPECIFICATION OF MATERIAL
C.1 SPECIFICATION FOR FISHPLATES:
i) Steel of fishplates shall conform to IRST-I.
ii) The dimensions of fishplate shall conform to relevant drawing of the glued joints.
C.2 SPECIFICATION FOR HTS BOLTS & NUTS.
HTS bolts and nuts shall comply with the following specifications.
i) Bolts: Hex bolts shall be as per IS: 1363 conforming to property clause 10.9 of IS; 1367.
ii) Nuts: Hex nuts shall be as per IS 1363 conforming to property clause 12 of IS: 1367.
C.3 SPECIFICATION FOR PUNCHED WASHERS,
Steel of Punched Washers shall conform to IS.2062.
C.4 SPECIFICATION OF INSULATING BUSHES/SLEEVES, LINERS AND END-POSTS
The insulating components viz. bushes/sleeves, liners and end-posts shall be made with the following materials in the premises of manufacturer as per the procedure indicated under para C.5.2
C.5.1 GLASS-CLOTH CARRIER REINFORCEMENT:
Glass-cloth carrier reinforcement shall Conform to IS: 11273:1992 clause 4 5 type C for the properties not covered below:
a) Nominal weight: 360 + 36 gm/sq. m
b) Nominal thickness: 300 ± 30 microns
Ends per inch : 15.5 ±2.5 %
Picks Weave per inch: 14 ± 2.5 % plain
C.5.3 DIMENSIONS OF FINISHED PRODUCT .
The liners end-posts and bushes/sleeves shall be given final finish conforming to the dimensions shown in the relevant drawings.
C.5. 4 QUANTITY PER JOINT
C 5 4.1 Quantity of raw material required for insulating components per 52kg G3(L) type glued joint, with 6 mm. thick end-post drawing, shall be approximately as under:
C.5 4.2 Quantity of raw material required for G3(S) type joints can be obtained by reducing proportionately.
C.6 SPECIFICATION AND QUANTITY REQUIRED OF GLUE
The tangential shear strength of glue is claimed to be about 120 kg/sq. cm by the manufacturer.
i) The glue, as developed by M/S Ciba-Geigy of India Ltd. for prefabricated type glued joints, consists of Araldite XY 27 and Hardener XY 28 to be mixed in the proportion of 100.40. The approximate quantity of combined adhesive required for 52 kg rail joint is 1.4 kg for G3(L) and 1 kg for G3(S) type joints. The quantity cm be estimated proportionately in case of rail joints for other sections of rail.
ii) Similarly, the glue developed by M/S C1BATUL Ltd. for prefabricated type glued joints, consists of resin Lapox A-83 and hardener Lapox K-83 to be mixed in the proportion of 100:40. The approximate quantity of combined adhesive required for 52 kg rail joint is 1.4 kg for G3(L) and 1 kg for G3(S) type joints. The quantify can be estimated proportionately in case of rail joints for other sections of rail.
APPROVED SUPPLIERS OF MATERIALS FOR GLUED JOINTS
D.1 STEEL FISHPLATES:
1. M/S Lauls Ltd., 33-B, N I T Faridabad
2. M/S Laxmi Iron and Steel Works Pvt. Ltd.,206 Acharya Jagdish Chandra Bose Road, Calculta-700017
3. M/S Partap Rajasthan Special Steel Ltd., '' Road No.6, V.K. Industrial Area, Jaipur 302013
D. 2 H.T.S. BOLTS & NUTS:
1. M/S G.K.W, Fasteners division, 97, Andul Road, Howrah-3
2. M/S Precision Fasteners Ltd. New India Centre, 17 Cooperage Road, Bombay.
3. M/S Kumar Industrial Corporation 797 lndustrial Area-B, ,Ludhiana
4. M/S Lakshmi Precision Screws. Hissar Road Rohtak.
1. M/S CIBA-GEIGY of India Ltd. Esplanade House 29 H Somani Marg, Bombay-400001
2. M/S SIP Industries Ltd., 11.6 Dr. Radhakrishnan Sakai III - Floor Mylapore Madras-600004
3. M/S C1BATUL Ltd., P.O. AtuI, Distt. Balsad (Gujrat) - 396 020
D.4 GLASS CLOTH CARRIER (WOVEN ROVINGS)
1. M/S FGP Ltd., 9-Wallace Street,Bombay-400 001.
2. M/S U. P. TWIGA Fibre Glass Ltd. Twiga House 3, Community Centre East of Kailash, New Delhi-110 065
D.5 PROSPECTIVE SUPPLIERS FOR SAND BLASTING MACHINES
1. M/S Shotblasting & Metal Spraying (P) Ltd., 509 Arun Chambers Tardoo Road, Bombay-400034
2. M/S William Jacks & Co (India) Pvt. Ltd. P.O. Box 335, Hamilton House, Graham Road, Bollard Estate Bombay-400 001
D.6 PROSPECTIVE SUPPLIERS FOR TORQUE SPANNERS
1. M/S Mekaster, 908 Ansal Bhawan, 16 Kasturba Gandhi Marg, New Delhi
2. M/S Indiana Trade Links, Sultanwind Road, Opp. Octroi Post, Amritsar (Panjab)
PRO FORMA FOR QUALITY ASSURANCE PROGRAMME
S. No. ITEM OBSERVATION
MATERIAL (To be recorded for each section of rail for each supply)
i) Rail Section:
ii) Condition of Storage
iii) Ultrasonically tested
iv) Availability of Test Certificate
vi) Quantity in hand
b) FISHPLATES (To be recorded for each drg. of fish plate for each supply )
i) For which rail section and dig. No.
ii) Condition of storage
iii) Source of supply:
iv) Availability of Certificate if material conforming to IRS T-l
v) If conforming to template approved by RDSO
vi) Holes position w.r.t. centre line of rail hole (measured with the help of template)
ix) Quantity in hand
c) HTS BOLTS AND NUTS (To be recorded for each supply)
i) Source of supply
ii) Availability of certificate for material conforming to specifications,
iii) Marking on bolts & nuts
iv) Storage facility
v) Quantity in hand
d) FIBRE GLASS (WOVEN ROVINGS) (To be recorded for each supply )
i) Source of supply
ii) Condition of Storage
iii) Quantity in hand
e) INSULATING COMPONENTS END POST (To be recorded per 100 Nos.)
i) Size and shape variation , if any
ii) Thickness variation, it any
iii) Glue used for making and ratio:
iv) Whether Roughened properly before use
v) Quantity in hand
e) Rails and fishplates are first cleaned with wire-brush and then rail, fishplates and Bolts & Nuts are cleaned with Acetone or Benzene
f) Resin and Hardener weighed separately in the ratio prescribed by the firm and stirred properly before use.
g) Method of application of glue and putting the insulating components and fibre glass cloth are according to Manual of Instructions.
h) End pressure is given at the joint after insertion of end-post in position duly soaked in glue.
i) Bushes are inserted in rail-holes duly dipped in glue. Sleeves are inserted around bolts.
j) Bolts are inserted without difficulty and tightened in stage of 35 kg-in torque upto 105 kg-in torque initially (Central bolls are to be tightened first).
k) Final tightening is checked after 20 min. with 105 kg-m torque.
l) Oozed out glue is applied around the fishplates to fill the fillets.
m) Insulation resistance is checked immediately after making the joints
n) Joints are not disturbed before 24 his. at room temperature.
IV) OBSERVATIONS AT THE TIME OF (To be recorded for each joint to be tested with the joint No.)
TESTING THE JOINTS
a) The slots are cut properly and rounded.
b) Eccentric loading is not applied.
c) Load is applied without jerks
d) Loading is stopped when crack appears at the joints.
e) Value of load applied at appearance of crack or completion of testing
f) Insulation resistance is recorded after pull-out test and then the joint is immersed in water for 48 hours for wet insulation resistance test
g) Insulation value obtained
a) Availability of Required drawing, specification, literature etc.
b) Display of Board for identification of resin and Hardener with their prescribed ratios
ANNEXURE - G