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Indian Railway: Government of India Ministry of Railways (Railway Board)
Indian Railway: Government of India Ministry of Railways (Railway Board)
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
INDIAN RAILWAY
STANDARD SPECIFICATION
FOR
FLAT BOTTOM RAILWAY RAILS
ISSUED BY
IRST-12-96
INDEX
Cl.
No.
1.
2.
Description
Page
No.
Scope
Rail Section
3.
4.
Definition
5.
Manufacture
6.
7.
Grade,
Chemical
Composition
and
Mechanical
Properties
8.
Marking
9.
10.
11
11.
Finishing
12
12.
Testing facilities
13
13.
Qualifying criteria
13
14.
Nature of tests
14
15.
Test sample
15
16.
Chemical analysis
15
17.
Tensile Test
17
18.
21
19.
23
20.
25
21.
28
22.
29
23.
Inspection
34
24.
Method of payment
36
25.
Shipment
36
Appendix
I & II
Rail sections
III
Colour code
IV
Sketch
showing
details
of
standard
test
piece
ultrasonic testing
VI
VII
VIII
IX
for
GOVERNMENT OF INDIA
MINISTRY OF RAILWAY
(RAILWAY BOARD)
SEAL
(GOVERNMENT OF INDIA)
INDIAN RAILWAYS
STANDARD SPECIFICATION
FOR
FLAT BOTTOM RAILWAY RAILS
This
specification
was
initially
adopted
in
1934
and
of
the
three
classes
of
rails
having
ultimate
tensile strength (UTS) of 880 MPa, 1000 MPa and 1080 MPa.
1.
SCOPE
This
specification
railway rails.
process,
applies
to
flat
bottom
symmetrical
chemical
composition,
acceptance
tests/retests,
2.
RAIL SECTION
1
3.
approval of the
The approval of
master
gauges)
shall
Purchaser/Authorised
Inspecting
acceptance.
gauge
Only
Purchaser/Authorised
remain
Agency
bearing
Inspecting
Agency
in
possession
during
the
shall
the
stamp
be
of
period
the
of
of
the
valid
for
checking purpose.
Each template/gauge shall be suitably engraved with the
manufacturers name and the number of the rail section together
with such other marks as the Inspecting Agency or the purchaser
may direct.
4.
DEFINITIONS
4.1
Sequence-continuous casting
.The
pouring
begins
before
of
the
the
next
steel
cast
from
from
the
ladle
precious
into
cast
the
is
Blooms that may contain steel from more than one cast
i.e. material arising during the changeover from one cast to the
next
in
the
sequence.
Number
of
change
over
bloom
will
be
Classification of rails
and
class
based
on
tolerance
in
end
straightness
as
MANUFACTURE
5.1
made
by
basic
oxygen
continuously cast.
or
electric
arc
furnace
process
and
made by
electric
arc
mandatory.
furnace
process,
secondary
ladle
refining
is
practice
throughout
rails
meet
the
manufacturer
manufacturing
stipulations
shall,
on
process
of
request,
this
inform
to
ensure
that
specification.
the
purchaser
the
The
of
the
For
suitably
heat
The
method of
made
head
hardening,
rails
should
be
available
to
the
purchaser
and
prior
approval
of
the
the
supplier
when
inviting
tender
for
supply
ii)
of
rails
iv)
Length of rail.
v)
vi)
PROPERTIES
shall
properties
conform
given
in
to
chemical
Table
composition
1.
These
and
limits
mechanical
for
chemical
of
the
steel,
when
out
by
the
method
method,
shall
be
as
specified
in
MARKING
b)
880
Grade 1000
1000
Grade 1080
1080 HH
c)
d)
e)
8.2
Basic oxygen
ii)
Electric
Hot Stamping
Each
rail
alphabetical
or
shall
be
combined
identified
alphabetical
by
and
numerical,
numerical
code
The number of the cast from which the rails has been
rolled with letter C
ii)
iii) For rails from change over bloom, cast number should be
the preceding cast number with prefix letter B.
8.3
Colour code
III
to
distinguish
special requirements.
grade,
class,
length
and
other
template
within
the
tolerances
specified
in
this
clause.
9.1
shall
fall
within
calculated
0.5
weight
percent
shown
in
below
and
Appendix
1.5
I
percent
and
II
for
above
the
each
rail
section.
9.1.1.
:
:
+ 0.8mm
+ -0.4mm
Width of head
+ 0.5mm
Width of flange
This will be
measured 14mm
below
the rails
top.
+ 0.1mm
for
section
Thickness of web
+ 1.2mm
for sections
- 1.0 mm
7
+ 1.0mm
This will be
- 0.5mm
Verticality/Asymmetry
+ 1.2mm
concavity not
0.40mm
exceeding
shall
be
permissible.
Fishing surface
rail
contour
1.20mm and
fishing
exceed
9.2
Length of rails
The
standard
length
of
rails
shall
be
13
metres.
short
lengths
shall
be
in
multiples
20.0 mm
10.0mm
of
1.0m.
8
9.3
End Squareness
9.4.1
Straightness
The
9.4.2
End Straightness
Straightness
Class A rails
Tolerances
Class
Deviation
of
rails
1.
Horizontal
Deviation of 0.5mm
0.7mm
measured as maximum
2.
measured as maximum
standard straight
standard straight
edge.
edge.
Deviation of 0.4mm
Deviation of 0.5mm
Vertical
a) Up sweep
measured as maximum
b) Down Sweep
measured as maximum
standard straight
standard straight
edge.
edge.
NIL
NIL
9
10
10.1
flaws,
piping
or
lack
or
metal
etc.
having
an
10.2
The
absence
of
harmful
internal
defects
shall
shall
be
carried
out
for
all
rails
under
be
This
the
10.3
The
manufacturer
in
his
offer
shall
furnish
the
by
him.
The
limits
of
permissible
defects
for
Web
Foot
Surface Quality
10.4.1
Hot marks
The width of each rolling guide mark should not exceed 4.0mm.
11
Minimum width
mm
Maximum width
mm
0.5
0.4
0.3
1.5
1.2
0.9
4.0
4.0
4.0
10.4.2.
Cold Marks
Depth
of
longitudinal
or
transverse
cold
formed
10.4.3
Seams
dressing
shall
be
limited
to
0.3mm
deep
and
in
other
10.4.4
Protrusions
ground
to
match
the
parent
contour.
Protrusions
on
affecting
the
fitment
of
the
fishplate
web
All
shall
be
ground.
10.5
During
examination
on
the
inspection
banks,
any
10.6
11
FINISHING
11.1
Cold
gradual
straightening
pressure
without
shall
be
impact.
effected
The
rails
by
may
means
be
of
roller
11.2
12
Burrs shall
TESTING FACILITIES
The
manufacturer
shall,
at
his
own
expense,
supply
all
templates and gauges, prepare and supply test pieces and sample
of
steel,
sample
rails
apparatus/equipment
Inspecting
Agency
for
for
and
drillings,
testing
carrying
which
out
and
may
all
supply
be
the
labour
required
tests
and
by
and
the
render
13
QUALIFYING CRITERIA
rail section,
criteria.
If
so
desired,
the
purchaser/Inspecting
a)
b)
c)
Fatigue test
d)
These
samples
shall
not
be
subjected
to
any
further
13
calculation which contribute to the final results.
14 NATURE OF TESTS
B.
a)
Chemical analysis
b)
Tensile test
c)
Sulphur Print
d)
e)
f)
Hydrogen content.
a)
Chemical analysis
b)
Tensile test
c)
Sulphur Print
d)
e)
f)
Hydrogen content.
C.
I.
Tensile test
b)
Hardness test
c)
Macroscopic test
14
14.2
The test
14.3
The initial test pieces and also the samples intended for
to
specification,
or
for
supplying
supplementary
14.4
15
TEST SAMPLE
15.1
shall
marked
Inspecting Agency.
and
stamped
under
the
supervision
of
the
15.2
any marks
15.3
16
16.1
CHEMICAL ANALYSIS
complete ladle sample analysis of each cast from which the rails
15
are to be rolled and shall submit an authenticated copy of the
results to the Inspecting Agency in the proforma at Appendix- VI.
The percentage of each specified element shall conform to the
limits specified intable-1 of clause 7.
16.2
16.3
16.4
Retest
If
with clause 7.
shall be rejected.
16.4.1
If
cast
does
not
satisfy
the
conditions
of
the
16.5
The
chemical
analysis
for
specified
elements
shall
16
17.1.3
Results to be obtained
than
piece break outside the middle half of the gauge length , it may
be
discarded
and
such
breaks
should
not
be
considered
as
Retests
made on any of the rails from the same strand and the
third
retest on any of the rails from another strand of the same cast.
The
produced
check
from
tests
intermediate
must
not
blooms
be
of
carried
out
sequential
on
rails
continuous
cast.
If
all
the
three
retests
are
satisfactory,
all
the
original
strand shall stand rejected and rest of the rails of the cast
shall be accepted.
If
third
retest
does
not
give
satisfactory
result,
upto 50%
of strands.
19
test
length,
piece
it
breaks
may
be
outside
discarded
the
and
middle
such
half
breaks
of
the
shall
If
gauge
not
be
was
taken.
If
the
tests
fail
to
meet
the
above
18
18.1
18.1.1
Nature of test
A
application
Baumann-type
of
bromide
impression
paper,
is
previously
obtained
by
impregnated
the
with
Tests
cast
has
been
withdrawn
as
not
conforming
to
specification.
18.1.2
Extent of Tests
21
18.1.3
Results to be Obtained
The
prints
obtained
must
not
reveal
macrographic
defects more marked than those of the limit prints shown in (or
equivalent to those shown in) the album of macrographic prints
given in Appendix-VII.
18.1.4
Retests
satisfactory
result,
further
retest
shall
be
conducted
strand by strand.
rolled from the change over blooms at the end of these strands of
the next cast in sequence shall either be deemed not to comply
with requirements or shall be subjected to retest which shall be
carried out one on the rails from the strand represented by the
22
Minimum
260 BHN
300 350
BHN
19.2
19.2.1
Nature of Test
19.2.2
Results to be Obtained
Hardness
of
rail
head
surface
after
heat
treatment
19.2.3
HV(390 BHN).
24
metal anvil.
less than 121t and the area of the base not less than 4.2 sq.m.
The metal anvil block shall be supported direct on a concrete or
masonry foundation weighing not less than 25 metric tonnes and
having an area of not less than 9.3 sq.m.
No timber or spring
The upper
One
blow
shall
be
delivered
midway
between
the
Designation
Weight of tup
Distance between
of Rail
(Kg)
52Kg/m
1270
1.20
7.60
60Kg/m
1270
1.07
8.40
20.2
Extent of Tests
Height of
test
sample
location
within
the
cast
and
The choice of
strand
shall
Inspecting Agency.
26
20.3
Results to be Obtained
20.3.1
20.3.2
The
Inspecting
Agency
shall
be
entitled
to
test
to
carry
out
any
other
test/examination/analysis
in
order
to
20.4
Retests
Test
sample
shall
be
selected
at
random
from
the
If
falling
weight
test
piece gives
unsatisfactory
result, three retests shall be made on two rails from the same
strand and one from any other strand.
If
the
third
test
from
the
other
strand
gives
from the changeover bloom at the end of the same strands of the
previous and next cast in the sequence shall either be withdrawn
or subjected to two retests, failure of either of retest shall
result
in
rejection
of
the
rails
rolled
form
the
changeover
27
21
cast
hydrogen
and
will
analysed
be
for
carried
hydrogen
content.
Estimation
out
approved
by
method
of
the
purchaser/Inspecting Agency.
Upto 2.5
Heat satisfactory
> 2.5
- 3.0
slow cooled.
> 3.0
the
molten
slag-metal
interface
or
from
spoon
holding
dry
ice
if
analysis
is
carried
out
within
48
hours
of
sampling
or
placed
in
liquid
nitrogen
if
analysis
is
to
be
of Hg.
28
21.3
Analysis of Hydrogen
A nitrogen carrier
other
method
can
be
permitted
with
the
prior
22.1
22.1.1
strain
gauge
surfaces
to
at
various
which
the
locations
strain
on
the
rail
gauges
are
surface.
attached
The
are
then
used
whilst
to
the
estimate
original
the
stresses
residual
which
stresses
are
have
taken
been
to
relieved
be
these
22.1.2
rail.
During
grinding it
29
shall
Final
cutting
corresponding
the
samples.
locations
shall
The
reading
be
of
converted
strain
to
at
the
stress
by
22.1.3
Results to be Obtained
22.2
22.2.1
22.2.2
The thickness
transverse
shall
profile,
the
test
piece
width
be
maximum
40mm
45mm
50mm
22.2.3.
31
22.2.4
Number of Tests
A minimum of 5 tests shall be performed.
22.2.5
22.2.6
Qualifying Criteria
No single KIc value shall be less than 42 MPam.
22.2.7
Invalid Values
i)
ii)
22.3
Fatigue Test
The constant amplitude fatigue test shall be carried
out in accordance with ASTM E606.
22.3.1
Test Pieces
Test temperature
20
+ 5oC
22.3.3
values
Under
shall
three-point
not
be
less
bending
fatigue
than 60kg/mm2
for
test,
880
the
stress
Grade
rails.
22.4.1
The
inclusion
rating
level,
when
examined
as
per
IS:4163, shall not be worse than 2.5 A,B,C,D (fig.2) both for
thick and thin series.
22.4.2
23.
23.1
INSPECTION
The
34
23.2
When a cast is
23.3
all
defective
segregated.
rails
shall
be
conspicuously
marked
and
23.4
The
analysis
of
all
casts
rolled
together
with
23.5
23.6
with
100
25mm
steel
flats
as
spacers
at
23.7
For
permitted.
lifting
rails,
single
point
slinging
is
not
between
the
lifting
point.
Lifting
of
rail
using
35
23.8
Sudden
impact
on
rails
during
loading,
unloading,
24.
METHOD OF PAYMENT
24.1
SHIPMENT
25.1
No
rail
shall
be
loaded
or
despatched
until
Import Shipment
(b)
Rail Transport
shall
be
loaded
in
wagons
in
layers
with
damaged
during
BFRs/BRHs/BRNs
expense.
shall
transportation.
be
replaced
by
Any
the
missing
bolster
manufacturer
at
in
his
36
37
38
TABLE-1
Grade
880
1000
1080
So
*
**
0.600.80
0.600.80
0.700.82
0.801.30
0.801.30
0.751.05
0.190.50
0.100.50
0.150.30
*
0.035
*
0.035
0.035
*
0.035
*
0.035
0.035
0.02
Mechanical Properties
Elongation
Hydrogen UTS
content (MPa)
% on gauge
in
(Min)
length
liquid
5.65So
steel
(min)
(max.)
3.0 ppm
880
10.0
0.02
0.25
3.0 ppm
1000
10.0
0.02
3.0 ppm
1080
10.0
Al
(max)
Mo
(max)
Running
surface
hardness
(BHN)
**
Min 260
**
300-350
340-390
Note: Any other micro alloying element can be added in grade 1000 rails with the approval of
the purchaser.
5
APPENDIX VII
Mechanical Properties
Date
Heat
No.
Dia
(mm)
Area
(mm2)
Initial
length
(mm)
gauge
Final
gauge
length
(mm)
%
Breaking
UTS
Hardness
load
(BHN)
elongation
(Kg/mm2)
(Kg)
Deflection
Result
Broken/Not
(mm)
broken
48
APPENDIX IX
Details of rails offered for inspection
49
8m
9m
10m
11m
12m
No. of rails
rejected during
internal inspection
13m
8m
9m
10m
11m
12m
8m
9m
10m
11m
Weight
of
blooms
produced
from the
heat
12m
No. of
blooms
produced
from the
heat
13m
Date Heat
No.
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AMENDMENT NO. 5
TO
INDIAN RAILWAY STANDARD SPECIFICATION
FOR
FLAT BOTTOM RAILWAY RAILS
Sr. No. T-12-96
Following Paras shall be amended to incorporate changes in specification of Head
Hardened Rails in IRST-12-96
1.
III.
2.
17.2.1
The manufacturer shall determine the tensile properties of the steel in accordance
with the requirements of IS: 1608. Such test shall be made on standard test pieces taken
from position as shown in fig.6 given below.
Contd2/-
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-2-
The diameter of the test piece shall be 6 mm with gauge length 3.54D or 21 mm.
3.
4.
Para 19.2 For Grade 1080 Head Hardened Rails shall be reworded as under:
19.2
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Figure -8
Contd3/-3-
19.2.3
Hardness Distribution
Hardness Distribution Test
6.
Minimum Mean
K1c( MPa m )
29
26
32
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Contd4/-
7.
8.
Table 1 for Rail chemistry shall be replaced with the revised Table 1 enclosed.
9.
-----------
Contd5/-
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-5TABLE-1
Grade
Mn
Si
S (max)
P (max)
Al (max)
Mo (max)
Cr
V (max)
N (max)
Hydrogen content in
liquid steel (max.)
Elongation % on gauge
length 5.65So (min)
Running surface
hardness (BHN)
Mechanical Properties
880
0.60-0.80
0.80-1.30
0.10-0.50
0.030*
0.030*
0.015
1.6 ppm
880
10.0
Min 260**
1000
0.60-0.80
0.80-1.30
0.10-0.50
0.030*
0.030*
0.015
0.25
1.6 ppm
1000
10.0
1080 Cr
0.60-0.80
0.80-1.20
0.50-1.10
0.008-0.025
0.020
0.004
0.80-1.20
0.18
0.009
20
1.6 ppm
1080
9.0
1080 HH
0.60-0.80
0.80-1.30
0.10-0.50
0.030*
0.030*
0.015
1.6 ppm
1080
10.0
300-350
320-360
340-390
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