STANDARD QUALITY ASSURANCE PLAN FOR ELASTOMERIC BEARINGS

1. Name of Manufacture : ………………………………………… 2. Drg. No. ; ....……………………………………..

3. Name of Project/Railway: ………………………………………………… 4. Authority (CA No./LOA No./Order No.) : ……. …………………………………

S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW Physical Test As per Manufacturer Verification Authorized From Fabricato IRC:83 Examination of Test
MATERIAL manufacturer test certificate of Inspector batches at rs record. (Part-II) & Certificates is required Test
1.1 Elastomer With values of certificate & &Challan reference appointed Random IS:3400 (as Certificate shall be furnished
( Only virgin characteristics test required document. by Zonal and at per relevant by manufacturers for
Polychloropr specified by Authorized Railway discretion test following tests.
ene (CR) is inspector of of Inspector procedure) (i) Composition
permitted & zonal Railway (ii) Hardness
preferable from Govt./ (iii) Tensile strength
grades are- NABL (iv) Elongation at Break
Neoprene approved lab (v) Compression set
WRT, (vi) Accelerated Ageing test
Bayprene (vii) Adhesion Strength
110, a) Hardness IRHD ( 60 ± 5 )
Skyprene B- IMPORTANT:
5 and Denka b) Min. Tensile 17 MPa Properties of Elastomer
S-40V) strength should be as per Table 1 of
c) Min. Elong. at 400% IRC:83
break Part-II Polychloroprene
d) Max. 35% Content 60 %
Compression Ash content
set Note: (i) No reclaimed rubber,
o
e) Accelerated 100 ± 1 c for vulcanized wastes or natural
ageing test 70 Hours rubber shall be used.
(ii) EPDM (Ethyle propylene
I) Max. Change +15% w.r.t. Dimonomer), IIR (Isobutane
in Hardness value of (a) Isoprene Copolymer), CIIR
II) Max. Change -15% w.r.t. (Chloro-Isoprene Copolymer)
in Tensile value of (b) are not permitted for
strength manufacture of bearings.
III) Max. Change -30% w.r.t.
in Elongation. value of (c) Adhesion strength test to be
conducted as per IS: 3400
(f) Adhesion Min. 7 KN/m Part XIV.
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.

Signature of Signature of
Fabricating Agency Railway Representative
 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.1 Elastomer Chemical Test As per Manufacturer Verification Authorized From Fabricato IRC:83 Examination of Test
Cont. i) Determination manufacturer test certificate of Inspector batches at rs record. (Part-II) Ash Certificates is required Test
/ Identification certificate & &Challan reference appointed Random content as Certificate shall be furnished
of polymer test required document. by Zonal per IS:3400 by manufacturers for
by Authorized Railway part XXII following tests.
inspector of and (i) Polymer Identification
zonal Railway Polychloropr (ii) Polymer content
from Govt./ ene content (iii) Ash content
NABL as per (iv) Specific gravity
approved lab ASTM-D297 (V) Ozone resistance
Identification
ii) Polymer min 60% -do- -do- of polymer Preferably test of polymer
content as per identification, polymer
ASTM D content and Ash content
iii) Ash content Max 5% -do- -do- 3677 (as per should be either witnessed
relevant test or sealed sample to be sent
(iv) Specific gravity -do- -do- procedure) to NABL LAB for
evaluation.
(V) Ozone -do- -do- Note:
resistance 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.

Signature of Signature of
Fabricating Agency Railway Representative
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.2 Mild Steel Mechanical Test As per Mill TC Mill TC and 1. Authorized One test Fabricato IS: 2062-11, Manufacturer’s test certificate
UTS, Yield Stress, & test required Challan Verification Inspecting piece per rs record E250 shall be furnished. UST shall
Elongation%, by Authorized of reference official of thickness Co- ,Quality BO be conducted for12mm
Bend test , Impact inspecting document. per heat. related is generally &above thick plates per
Zonal
test at 0 degree official of with Mill used. provision of relevant
centigrade or -20 Zonal Railway 2.Complete Railway TC & test However specification before
degree for sub- from Govt. Lab visual report. Quality C processing the material for
zero zone ./ NABL inspection. shall be manufacturing.
approved lab. used for sub
Chemical Test zero
C, Mn, Si, P, S, condition.
CE. ( As
specified in
approved
Physical Drg.).
condition i.e.
Pitting,rusting,rolli
ng defect, etc.

Ultrasonic
Testing of plates IS:4225 or
100% ASTM A435
(100% for12mm
& above thick
plates)

2.0 Manufacturing Dimensional Visual & As per Measureme Manufactur At Fabricato IRC 83 Part- Internal report will be
Process inspection Measurement approved nt of er Discretion rs record. II & as per furnished which will be
 Specified drawing dimension inspecting drawing verified by Zonal Railway
tolerances agency Inspector. However random
(a) Over all plan -0,+6mm check may be done by Zonal
dimension Railway inspector during
(length & Manufacturing.
Breadth) Note: During manufacturing
(b) Thickness of ±20% test pieces will also be
M
Individual (Max of 2mm) moulded with identical
internal layer compound and under
of elastomer identical vulcanizing
(c) Thickness of -0,+1mm conditions and suitably
individual marked for identification at
outer layer the time of tests. This process
(d)Plan -3mm, +0 shall be open to inspection by
dimension of Railway inspecting official.
laminates(len
gth

Signature of Signature of
Fabricating Agency Railway Representative
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
2.0 &Breadth)
cont. (e) Thickness of ±10 %
laminate
(f) Parallelism 1 in 100
of laminate
with respect
to bearing
base as
datum
(g) Hardness IRHD 60±5 Visual & As per Measureme Manufactur At Fabricato IRC 83 Part- -do-
during Measurement approved nt of er Discretion rs record. II & as per
manufacturi drawing dimension inspecting drawing
ng agency
(h) Over all -0,+5%
Thickness
3.0 Final
inspection

3.1 Visual Dimensions of Visual and As per Measureme Authorized 100% Fabricato As per table All bearings to be visually
examination bearing as per measurement relevant drg. nt of Inspector rs record 2 of IRC 83 inspected for absence of any
and specified tolerances & dimension appointed & test Part-II defects in surface finish,
dimensional as under : specification by Zonal report. shape or any other
check Railway discernible superficial defect.
a) Over all plan -0,+6mm Also after load testing, during
dimension(l visual examination of bearing
ength & no defects should be noticed
Breadth) in surface finish, shape or
b) Over all -0,+5% other noticeable superficial
Thickness defects.
c) Parallelismof 1 in 200
top surface Authorised inspector has to
of bearing carry out 100% dimensional
with respect check for item a) & b) and
to the random check for item c)&
bottom d) to be done till full
surface as satisfaction.
datum
d) Parallelism 1 in 100
of one side
surface with
respect to
the other as
datum

Signature of Signature of
Fabricating Agency Railway Representative
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.2 Chemical &
Physical
Test
3.2.1 Chemical Test As per Manufacturer Verification Authorized From Fabricato IRC:83 Test certificate shall be
i) Determination/ manufacturer Test of Inspector batches at rs record. (Part-II) Ash furnished by manufacturers.
Identification of certificate & Certificate reference appointed Random content as For level I acceptance
polymer. test required &Challan document. by Zonal per IS:3400 sample from randomly
by Authorized Railway part XXII selected bearing of each lot
inspector from and of Elastomer bearing as
Govt./ NABL Polychloropr prescribed in procedure in
approved lab ene content IS3400 and IRC83 (Part-II)
ii) Polymer content min 60% -do- -do- as per shall be drawn by authorize
iii) Ash content max 5% ASTM-D297 inspector and tested in house
(iv) Specific gravity Identification lab. or in Govt./ NABL
v) Ozone of polymer approved laboratory for all the
resistance -do- -do- as per 5 tests. These test are in
ASTM D addition to tests conducted on
3677 (as per specially moulded test pieces
relevant test prepared at the time of
procedure) manufacture of bearing.
For Level II acceptance
tests on specially moulded
test pieces to be done.
Tests to be done for
(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 Govt./NABL LAB for
evaluation.
For Level-I Acceptance
additional test will be,
(a) Ash content on specimen
from test bearing shall be
compared with these for
specially moulded test
pieces and Max variation
permitted is ± 0.5%

Signature of Signature of
Fabricating Agency Railway Representative
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
(b)Specific gravity on
specimen from test
bearing shall be compared
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.
3.2.2 Elastomer Physical Test As per Manufacturer Verification Authorized From Fabricato IRC:83 Test certificate shall be
(Only virgin With values of manufacturer test certificate of Inspector batches at rs record. (Part-II) & furnished by manufacturers.
Polychloropr characteristics certificate & &Challan reference appointed Random IS:3400 (as (For level I acceptance
ene (CR) is specificed test required document. by Zonal per relevant sample from each lot of
permitted & by Authorized Railway test Elastomer as prescribed in
preferable inspector from procedure) specification shall be drawn
grades are- Govt./ NABL by authorize inspector and
Neoprene approved lab tested in either In-house Lab.
WRT, or in NABL/ Govt. Approved
Bayprene laboratory. For level 2
110, acceptance, tests on specially
Skyprene B- a) Hardness IRHD molded test pieces to be
5 and Denka ( 60 ± 5 ) done.
S-40V) b) Min. Tensile 17 MPa
strength Tests to be done are
c) Min. Elong. at 400% (i) Composition
break (ii) Hardness

Signature of Signature of
Fabricating Agency Railway Representative
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.2.2 d) Max. 35% (iii) Tensile strength
Cont. Compression (iv) Elongation at Break
set (v) Compression set
o
e) Accelerated 100 ± 1 c for (vi) Accelerated Ageing test
ageing test 70 Hours (vii) Adhesion Strength
i) Max. Change +15% w.r.t.
in Hardness value of (a) IMPORTANT:
ii) Max. Change -15% w.r.t. Properties of Elastomer
in Tensile value of (b) should be as per Table 1 of
strength IRC:83 Part-II
iii) Max. Change -30% w.r.t.
in value of (c)
Elongation.
(f) Adhesion Min. 7 KN/m Adhesion strength test to be
strength of conducted as per IS: 3400
Elastomer to Part XIV.
Steel Plates
3.3 Load Test
on complete
bearings
a) Axial load Upto 15MPa All bearing of As per Fabricators Authorized 100% Fabricato IRC 83 Part- For both Acceptance Level 1
test the lot shall be relevant drg. record. Inspector rs record. II & Acceptance Level 2, all
tested. and appointed 100% bearings to be
specification by Zonal Checked for axial load tests
Railway as per Para 918.4.1.1(3),
check for misalignment of
plates, poor bonding of
elastomer and laminated
steel plate, surface defect,
low stiffness etc. Variation in
stiffness of any one bearing
shall not be larger than 20%
of mean of measured values.
b) Elastic Test to be Load testing In case of Note:-
Modulus test conducted as per on large lot For acceptance level l sample
Annexure 2 of Two test from randomly selected
IRC: 83 (Part-II) bearings. bearing of each lot (for
acceptance value destructive testing) of
of Ea=±20% elastomeric bearing as
2
1÷(0.2/S +0.0005) prescribed in procedure of IS:
MPa where “S “is 3400 & IRS:83 (Part –II) shall
shape factor be drawn by authorized
inspector and all test mention
from (b) to (e) are to be got
done either in house lab or in

Signature of Signature of
Fabricating Agency Railway Representative
 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Type of check Document s quality Records criteria
Tolerances control Inspecting Extent of
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.3 (c) Shear Test to be Load testing Govt./NABL approved lab.
Cont. Modulus conducted as per on (A) These tests are in addition
test Annexure 2 of Two test to tests conducted on
IRC: 83 (Part-II) bearings. specially moulded test
value of G for pieces prepared at the
acceptance from time of manufacture of
0.8MPa to 1.2 bearings. Note that the
MPa bearing selected for test
will not be reused and
(d) Stripping Test to be Load testing destructive test will be
strength conducted as per on done on sample prepared
test / Annexure 2 of Two test from them.
Adhesive IRC: 83 (Part-II) bearings.
strength examination for (B) For acceptance level 2
test evidence of shear modulus tests is
cracking/ peeling mustwhich will be done
both in strained on randomly selected
(Strain value 2.0) bearings and which after
and unstrained test can be used in the
state. bridge.

(e)Ultimate 60MPa Load testing

compressive on Ultimate Compressive
strength test Two test Strength test.
bearings for There should be no failure of
Destructive steel laminate or irreversible
Test. 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 Signature of
Fabricating Agency Railway Representative