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Rdso Guideline Fabrication PDF
Rdso Guideline Fabrication PDF
Introduction :
Foot over bridges over the Indian Railways are used by pedes trian traffic
to cross the Railway track safely.
1.1
ii)
1.2
1.3
Cutting of steel:
IRS BI 2001 (Fabrication Specification) Para 17 s tipulates as under:
17.1 Flame cutting by mechanically controlled torch/torches s hall be
accepted. Provided the edge as given by the torch is reasonable clean
and s traight, plates may be cut to s hape and beams and other s ections
cut to length with a gas cutting torch, preferably oxyacetylene gas should
be us ed.
17.2 All flame cut edges shall be ground to obtain reasonably clean
square and true edges . Draglines produced by flam e cut s hould be
removed.
1.4
1.5
1.6
Lay out :
i)
ii)
1.7
Drilling of holes :
Quality of fabrication s hall be improved if jigs are us ed during fabrication.
Drilling of the com ponent may be done through jigs . All burrs left by the
drill and s harp edges of the holes shall be rem oved.
1.8
1.9
ii)
iii)
iv)
All cons umable shall be s tored and handled with care and in
accordance with the m anufacturers recomm endations .
Riveting :
i)
ii)
the s urface. Driven rivets when s truck sharply on the head with the
110-gm. rivet tes ting hammer, shall be free from movement or
vibration.
23.6 All loose and burnt rivets and rivets with cracks badly formed
eccentric or deficient heads s hall be cut out and replaced.
Permissible deviation of driven rivets shall be as per Annexure-III.
Rivets s hall also be cut out when required for the examination of
the work. Actual method of cutting out s hall be approved by the
Engineer. Recouping and caulking shall in no circums tances be
resorted to.
23.8
iii)
1.10
All defective rivets and loose rivets shall be m arked on their heads
with paint and prom ptly replaced. Rivets in any com ponents should
be tes ted 100% in shop by a respons ible supervisor and maintain
the record of the same.
1.11
Inspection Stages :
(a)
Before fabrication
(b)
During fabrication
(c )
After fabrication
(a)
Before Fabrication :
Quality As surance Plan s hall be prepared and got approved.
Raw m aterial s uch as channels and plates etc. to be ins pected
as per s pecificatio n m entioned agains t each items and rolling
Mark Certificates .
Lamination, piping, pitting rolli ng defects and Straightness of
m aterial to be checked before fabrication.
During Fabrication :
Lay out, jigs and fixtures and profile to be checked.
Welding by qualified weld ers as per approved WPSS.
Welding parameters are to be set & checked during welding.
Riveting by qualified and s killed personal with approved work
ins tructions.
(c )
After Fabrication :
Verify rolling Mark num ber of steel s ections us ed for fabrication,
from Certificate issued by manufacturer. Check the regis ter
m aintained by firm.
Surface defects shall be checked vis ually.
Qualify of welds with respect to specified s izes , length and any
vis ual defects .
Quality of rivets to be checked visually and with the help of
riveting hamm er.
Dye Penetration Tes t for Welds
Leading dim ensions i.e. overall length, hole dimens ions, end
finishing etc. s hall be checked. For this purpos e detail
m eas urement sheet s hall be prepared for.
1.12
Connection Details :
Some of the connection details comm only us ed in fabrication of FOB has
been s hown as Annexure-IV.
ANNEXURE-I
(Ref. Clause 26)
1.
5.2
Flux
5.3.1
6.0
6.1
Shielding gas
:
Base Metal preparation :
Joint design details
:
(Give sketch showing arrangement
of parts, welding groove details, weld
passe s & their sequence etc.)
Joint preparation
:
Welding current
:
Type :
Polarity
Welder qualification
:
Welding parameters and technique:
Welding Parameters
:
6.2
7.0
8.
9.
9.1
:
:
:
Class
:
Dia
Drying method
Class
Dia
Drying method
Weld
Pass
No.
Electrodes/
w ire dia.
(mm)
Current
(amp)
Arc
Voltage
(volt)
9.2
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
:
:
:
:
:
Wire
feed
speed
(m/min)
5
Trav el
speed
(m/min)
Electrical
stick out
(mm)
Gas flow
rate
(litre/min.)
ANNEXURE-II
1.
Description of Weld
Welding procedure specification no.
Name of welder
Date of preparation of test piece
Dimensions of test piece
Base Metal
Welding Process
Welding position
Welding Current
10.0
11.0
11.1
11.2
Flux
11.3
12.0
Weld
Pass
No.
1
13.0
14.1
Shielding gas
Welding parameters
Electrodes/ Current
Arc
w ire dia.
(amp)
Voltage
(mm)
(v olt)
2
3
4
Preheating and interpass temperature:
Results of Qualification Tests:
Test
1
Non-destructive tests
i)
Visual examination:
ii)
Dye penetrant test:
iii)
Magnetic particle test:
iv)
Radiographic/Ultrasonic test:
Destructive tests:
i)
Macro-examination:
ii)
Hardness survey:
iii)
Fillet weld fracture test:
iv)
Transverse tensile test:
Tensile strength
Yield Stress
Location of fracture
v)
All-weld tensile test:
Tensile strength
Yield Stress
Elongation %
vi)
Guided bend test:
Root bend test
Face bend test
Side bend test
vii)
Any other tests
:
:
:
:
:
:
:
:
: T ype :
Polarity :
:
:
Class :
Dia
:
Brand :
Class :
Type :
Brand :
:
:
Wire feed
speed
(m/min)
5
Trav el
speed
(m/min)
6
Specimen No.
2
Electrical
stick out
(mm)
7
Shielding gas
flow rate
(lit/min.)
8
Result
3
Signature ____________________________
Designation ____________________________
Date
____________________________
(for & on behalf of Fabricator)
Fax 91-0522-2450398
E-mail : edbs@ rdso.railnet.gov.in
No. CBS/FOB
I.
II.
III.
226011
Government of India-Ministry of Railways
Research Design & Standards Organisation
Lucknow- 226011
Dated
-03-2008