SPECIFICATION
WD-20-ABR-2007
INDIAN RAILWAYS
SPECIFICATION FOR COMPREG CLAMP / PACKING FOR
AIR BRAKE PIPES FOR FREIGHT STOCK OF
INDIAN RAILWAYS.
WD-20ABR2007
ISSUED BY:
RESEARCH DESIGNS & STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
LUCKNOW 226011.
March-2007. Price Rs.
SPECIFICATION FOR Compreg CLAMP FOR
AIR BRAKES PIPES FOR FREIGHT STOCK OF
INDIAN RAILWAYS
1. SCOPE
This specification covers technical requirements of wood-based Impregnated Compressed Laminates –Compreg Clamps to RDSO drawing No. WD-04058-S-01and packing for use in air brake freight stock of Indian Railways
2. DEFINITION
2.1 'MANUFACTURERS' means firm / company from whom the offer for the supply of wood-based Impregnated Compressed Laminates clamps /packing is invited.
2.2`INSPECTING AUTHORITY' means the organisation or its representative nominated by the Purchaser to inspect wood-based impregnated compressed laminates clamps /packing on his behalf.
2.3 The Research Designs and Standards organisation, Manak Nagar, Lucknow226011 is hereafter referred to RDSO.
2.4In case the manufacturers needs any clarification in respect of any clause of this specification or regarding the drawing, the Tenderer shall obtain the same from DG (Wagon) RDSO, for clarification.
3.0PARTICULAR REQUIREMENTS
3.1Manufacturers willing to supply wood-based Impregnated Compressed Laminates clamps/packing for the use of Indian Railways shall register themselves with RDSO.
3.2Manufacturers who are registered with RDSO for Compreg Board to specification No. C-9407 latest Rev. will also be permitted supply compreg clamp / packing. But such manufacturers should get their QAP for compreg clamp / packing approved by RDSO.
3.3 The manufacturer shall have adequate facilities for the manufacture, testing and quality control requirement of wood-based Impregnated Compressed Laminates clamps/packing, conforming to Annexure-1
3.4 The manufacturers shall have a well-documented `Internal Quality Assurance System' to ensure sustained quality of product being manufactured. The` Quality Assurance System' shall generally cover the following:
(i)System to ensure that correct raw material is being used.
(ii)System to ensure that wood-based Impregnated Compressed Laminates clamps/packing having manufacturing defects are identified and destroyed so that such wood-based Impregnated compressed Laminates clamps / packing are not used.
(iii) System to ensure that bought out component are strictly as per requirements laid down in the specification / drawing.
(iv)System to maintain strict control of dimensions and workmanship of components.
(v) System to test and establish that the wood-based Impregnated Compressed Laminates clamps/ packing manufactured by the firms meets all the requirements laid down in specification / drawing.
(vi) System of periodical calibration of equipment / gauges to ensure accuracy of product.
4.0MATERIAL
4.1Wood based Resin impregnated compressed laminates shall be used as board for Clamps/Packing.
- DIMENSIONS
5.1The dimension of wood-based Impregnated compressed Laminates clamps shall be as per latest revision of RDSO drawing NO. WD- 04058-s-01.
5.1 Discrepancies in dimension, if noticed, shall be brought to the notice of wagon Dte. RDSO at the developmental stage and sorted out.
- DEVELOPMENTAL INSPECTION
6.1 Developmental Inspection shall be carried out at the manufacturer’s premises at the time of registration of the firm with RDSO.
6.2The Inspecting authority shall make audit checks of the manufacturing procedure/`Internal Quality Assurance System’` to ensure that the lot offered for inspection is manufactured strictly as per `Internal Quality System’ and the manufacturer has carried out all test/inspection during manufacturing stage to ensure that Impregnated Compressed Laminates clamps / packing offered are strictly to the specification. During such audit checks, theInspecting Authority shall also see from the records of `Internal Quality Assurance` that the Raw Material used for the manufacture of wood-basedImpregnated compressed Laminatesclamps/packing against the contract is as per specification laid down.
6.3During developmental Inspection, test for which facilities are available at RDSO will be conducted at RDSO. Remaining tests for which facilities are not available but available with the firm, such tests shall be carried out in the firm’s premises /sub vendor in the presence of inspecting authority.
6.4Two percent of each lot of 100 numbers wood-based Impregnated compressed Laminates clamps /packing shall be tested as per procedure given in para-8
6.5Ten percent of each lot of 100 numbers wood-based Impregnated compressed Laminates clamps/packing picked up at random shall be checked for dimensions with respect to RDSO drawing.
6.6The manner of collection and distribution of the test samples for different tests prescribed shall be at the discretion of the inspecting officer.
7.PURCHASE INSPECTION
7.1Purchase inspection shall be carried out at the premises of manufacturer who are cleared for the regular manufacture of wood-basedImpregnated compressed Laminates clamps /packing and registered with RDSO. The following procedure shall be followed for the purchase inspection: -
7.2The Inspecting authority shall make audit checks of the manufacturing procedure/`Internal Quality Assurance System’ to ensure that the lot offered for inspection is manufactured strictly as per `Internal Quality System’ and the manufacturer has carried out all test/inspection during manufacturing stage to ensure that Impregnated Compressed Laminates clamps/ packing offered are strictly to the specification. During such audit checks, theInspecting Authority shall also see from the records of `Internal Quality Assurance` that the Raw Material used for the manufacture of wood-basedImpregnated compressed Laminatesclamps/ packing against the contract is as per specification laid down.
7.3After having satisfied about the quality standards. The Inspecting Authority shall conduct the following checks from a lot of not more than 100 numbers of wood-based Impregnated compressed Laminates clamps/packing.
7.3.1One percent of each lot of 100 numbers wood-based impregnated compressed Laminates clamps/packing shall be tested as per procedure given in para-8
7.3.2 Five percent of each lot of 100 numbers wood-based Impregnated compressed Laminates clamps/packing picked up at random shall be checked for dimensions with respect to RDSO drawing.
7.4The manner of collection and distribution of the test samples for different tests prescribed shall be at the discretion of the inspecting officer / purchaser.
8. TESTS
8.1The samples shall comply with the requirements given in Table-I.
TABLE-I
S. No. / Characteristics / Requirements / Method of test1 / Sp. Gravity / 1.1 - 1.25 /
Appendix - A
2 / Water Absorption, Maximum / 5.0% for type-II / Appendix - B3 / Resistance to boiling water /
To pass the test
/ Appendix - C4 / Bending strength (kg/cm2) Minimum / Along the grain / 1200 / IS: 1658
Across the grain / 600
5 / Resistance to impact /
To pass the test
/ Appendix - D6 / Resistance to chemicals / To pass the test / Appendix - E
7 / Resistance to ageing / To pass the test / Appendix - F
8 / Resistance to spread of flame / Minimum Class B / Appendix – 4 of UIC-564-2 OR
9 / Deterioration of visibility due to smoke / Minimum Class B / Appendix – 15 of UIC-564-2 OR
10 / Limiting Oxygen Index / Minimum 28 / IS: 13501
11 / Toxicity / Less Than 1 / NCD – 1409
8.2No. of Test: -
All the test given in Table –1 except the test of Limiting Oxygen Index and Toxicity shall be carried out of each lot. The Limiting Oxygen Index and Toxicity are type tests. The test of Limiting Oxygen Index shall be done in six months and the test for Toxicity shall be done once in a year. For this purpose of these tests an authorized representative of inspecting authority shall draw a sample at the time interval mentioned above the firm shall arrange testing at reputed laboratory as decided between RDSO/ Inspecting authority and manufacturer. The cost of testing will be borne by manufacturer. The above tests may also be carried out in presence of RDSO/ Inspecting authority at firm’s premises, in case the testing facilities are available with them.
8.3RDSO may draw the sample for quality check at its discretion and firm shall arrange testing of these samples in a reputed outside laboratory as decided between RDSO and manufacturer. Testing charges shall be borne by the manufacturer.
8.4 The samples shall be collected from wood based Impregnated compressed boards for testing the Bending strength ,Resistance to ageing ,Resistance to boiling water and Resistance to impact test as given in Table-1.
8.5The sample shall be collected for remaining tests as per given in Table-1.
8.6If the wood-basedImpregnated compressed laminates board is procured from RDSO approved source, the testing clause will not applicable.
- MARKING
Each wood-based Impregnated Compressed Laminates clamps/packing should be legibly marked with the following particulars: -
1)Name of manufacture / Initials
2)Month and year of manufacture. ( in the format mm/yy)
10.PACKING
10.1The wood-based Impregnated compressed Laminates clamps /packing shall be securely packed in cardboard boxes so that there is no damage during transit. Packing drawing to be approved by RDSO.
10.2Contractor shall also ensure wood-based Impregnated Compressed Laminates clamps/packing are adequately packed before dispatch to prevent damage in handling and storage.
11.WARRANTY/GUARANTEE
11.1 The warranty /guarantee period will be 30 months from the date of delivery or 24 months from the date of commissioning whichever is earlier.
APPENDICES
A.Determination of specific gravity:
Specimen of size 40mm X 40mm X t*, free from major defects shall be taken and specific gravity determined using standard method by taking weight in air and in water at the temperature of 271 C.
BDetermination of water absorption:
Specimen of size 40mm X 40mm X t* with cut edges, shall be weighed and kept suspended in distilled water at the temperature of 271 C for 24 hrs. It shall then be removed, surface and edges dried in folds of blotting paper and weighed. Increase in weight expressed, as percentage of original weight shall give water absorption. Water absorption shall not be more than 7.5% for type-I and 5% for type-II.
CResistance to boiling water:
Specimen of 100mm X 100mm X t* with cut edges, smoothened with fine emery shall be taken for test. Measure the thicknesses of specimen at the centres of its four edges and with the external edge of the micrometer anvil approximately 5mm from each edge (Fig.1). Mark the measuring points so that the subsequent measurement can be made in the same places. It shall then be kept suspended in boiling distilled water at 1001 C for 8 hrs. Then the specimen shall be transferred from boiling water and kept submerged in water at the temperature of 271 C for one hour. Specimen shall be removed and dried in folds of blotting paper. Measure the thickness at measuring points already marked. Calculate the percentage increase in thickness at measuring points and their average shall be taken as percentage increase in thickness. It shall also be examined for any delamination, deterioration of surface appearance, appreciable softening, etc. The specimen have passed the test if:
i)It does not show any of the defects mentioned above.
ii)The increase in thickness is within the 10% of original thickness.
DResistance to impact
Specimen of size 300mm x 300mm x t* is supported in a suitable square as per Fig.-2 given below. The steel ball of 1 kg. is dropped from a height of 2 metres by a suitable device to strike the board within 25mm from its centre. Test shall be repeated on 2 more specimens. After the test, the specimen shall not develop any cracks in or around the area of impact or on the under surface or show any defects such as delamination, split etc. This test is applicable only for thicker section of 10 mm and above.
E.Resistance to chemicals
Specimens each size of 40mm X 40mm X t* shall be kept immersed separately in following solutions, in clean glass beakers for 24 hours,
(i)In dilute hydrochloric acid (5 vol. Of conc. HCL to IS: 265-1962 in 100 vol. of distilled water),
(ii)Sodium carbonate solution (1% by weight),
(iii)Soap solution (1% by weight of soap to IS: 285-1964 in distilled water) and
(iv)Detergent solution (1% by weight distilled water at 27 1 C)
The specimens when withdrawn and examined shall not show any surface defects like checks, splits, blisters, warps discolouration, overlap, gap, open joints etc.
F.Resistance to ageing
(i)Dry Heat Test: -
3 specimens of size 200mm x 100mm x t* shall be kept in an air oven at 70 + 1deg.C for 168 hours followed by cooling at 27 +1 deg. C for 3 hours. They shall be examined after the above test. The specimens are considered to have passed the test if no surface defects likely to mar the aesthetic value or protective coating or no warping could be seen.
(ii)Ageing test: -
3 specimens of size 200mm x 100mm x t* with all four edges smoothly trimmed shall be subjected to seven cycles successively, each cycle consisting of the following operations:
a)Age at 70 +1deg. C for 8 hours in an air oven
b)Immerse in cold water 27+1 deg C for 16 hours.
After completion of 7 cycles the specimen shall be dried in folds of blotting paper and examined.
The aged specimen shall not show any surface defects likely to mar the aesthetic value or protective coating or warping.
t* = refers to thickness of the actual component in mm.
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Annexure-1
1.Requirements
The vendor seeking approval of impregnated compressed laminates shall comply all the requirements mentioned below.
1.1General and Manufacturing facilities
1.1.1There should be a provision of covered area, with adequate space underneath for storage of raw material.
1.1.2The firm should have resin manufacturing plant with at least one number of resin kettle of adequate capacity.
1.1.3The firm should have resin impregnation plant of adequate capacity.
1.1.4The firm should have at least one boiler of adequate capacity with all its accessories.
1.1.5The firm should have at least one number four daylight heavy duty hydraulic hot press to manufacture floor boards of final size 800 mm x 500 mm x 55 mm with adequate margin of trimming. The press should have heating and cooling facilities with temperature, pressure and time control.
1.1.6The firm should have indirectly heated drying chamber for drying the veneer.
1.1.7The firm should have at least one number of heavy duty double dimension saw.
1.1.8The firm should have a small machine shop consisting of thickness planer, drilling machine etc.
1.1.9The firm should have weighing machine, platform type, for measuring up to 200 kg. of weight.
1.2Testing Facilities: - The firm should have the following testing facilities.
1.2.1The testing lab should be air conditioned to control the temperature and humidity.
1.2.2The firm should have an electronic balance.
1.2.3The firm should have hot water bath complete with thermostatic controller and thermometer. The controller should be calibrated once in three month.
1.2.4The firm should have one universal testing machine of 5 t capacity.
1.2.5The firms should have facility for impact testing as per Appendix ‘D’.
1.2.6The firm should have a chemical laboratory for conducting test to resistance to chemicals as per Appendix ‘E’ of this STR.
1.2.7The firm should have at least one hot air oven for checking resistance to ageing with thermostatic controller and thermometer. The controller should be calibrated once in three months.
1.2.8The firm should have facility for conducting test for resistance to spread of flame as per Appendix – 4 of UIC – 564-2 OR.
1.2.9The firm should have the following instruments:
a)Vernier caliper with digital display
a)Micro meter with digital display
b)Moisture meter with digital display
c)Thermometer with digital display
d)Hydrometer
e)Measuring scale
f)Measuring tape
1.2.10The firm should have arrangement for periodical calibration of all the gauges & instruments.
1.3 Quality Control Requirements
1.3.1 There should be a system to ensure the traceability of the product from raw material stage to finished product stage. The system should also facilitate to identify the raw material composition from the finish product stage.
1.3.2 The firm must ensure that there is a QAP for the product detailing various aspects:-
•Organisation chart
•Process flow chart
•Stage inspection details from raw materials stage to finish product stage
•Various parameters to be checked and level of acceptance of such parameters indicated and method to ensure control over them.
•Disposal system of rejected raw material and components.
1.3.3 The firm should have acquired ISO: 9001-2000 certification and the product for which the approval is sought should be broadly covered in the scope of the certification for manufacture and supply.
1.3.4The firm must ensure that proper analysis is being done on monthly basis to study the rejections at various internal stages and it is documented.
1.3.5The firm should ensure that all the relevant specifications, IS standards are available with the firm.
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