PATIL RAIL INFRASTRUCTURE PVT LTD

SLEEPER DIVISON
 Index Sheet

Chapter Title Page Nos.

No.
1. Note on Production Planning & Control 4
2. Manufacturing Process 6
2.1 Mould Preparation 6
2.2. Reinforcement 6
2.3. Weigh Batching, Concrete Mixing & Sleeper Casting 6
2.4. Steam Curing 7
2.5 Sleeper Demoulding 7
2.6. Water Curing 7
2.7. Production Cycle of Sleeper 8
2.8. Flow Chart for Manufacturing Concrete Sleepers 9
2.9. Flow Chart for Testing Sleeper 10
3. Production Planning Process 12
3.1. Orders on Hand & Delivery Period 13
3.2. Capacity of Plant 13.
3.3. Agreements 13 - 14
3.4. Manpower Availability 15
3.5. Tenders Participated 16
3.6. Planning 16
3.6.1. Reviewing of Contracts/agreements 16
3.6.2 Information Flow Chart 17
3.6.3 Standard Processes 18 – 19
3.6.4 Layout of Plant 20
3.6.5 Inventory Planning 21
3.6.6 Maintenance Schedule 21
3.7. Daily Checklist 22-23
3.8 Fortnightly Checklist 24
3.9. Weekly 25

2
3.10. Monthly 26
3.11. Risk Analysis 27
3.12. Planning Group Formation 28
3.12.1 Meeting Schedules 29 -30
4. Statutory Compliances 32 -33
4.7 Chart for Statutory Requirements 34
5. Types of Reports Generated at Factory for CHQ
5.1. Monthly Report 36 – 38
5.2. Weekly Report 39 – 40
5.3. Daily Report 41 - 42
6. Special Chapter – Indian Railway Specifications 44 - 56

3
4
 1. NOTE ON PRODUCTION PLANNING AND CONTROL

1.1. Introduction

The main objective of production function is to produce the goods and services
demanded by the customers in the most efficient and economical way.

Therefore efficient management of the production function is of utmost importance in

order to achieve this objective.

1.2. What is PPC for

Production planning and control can facilitate efficient management of the production
in the following ways.

1.3. Optimum Utilization of Capacity

With the help of Production Planning and Control [PPC] the entrepreneur can
schedule his tasks and production runs and thereby ensure that his productive
capacity does not remain idle and there is no undue queuing up of tasks via proper
allocation of tasks to the production facilities. No order goes unattended and no
machine remains idle.

1.4. Inventory control

Proper PPC will help the entrepreneur to resort to just- in- time systems and thereby
reduce the overall inventory. It will enable him to ensure that the right supplies are
available at the right time.

1.5. Economy in production time

PPC will help the entrepreneur to reduce the cycle time and increase the turnover via
proper scheduling.

1.6. Ensure quality

A good PPC will provide for adherence to the quality standards so that quality of
output is ensured.

1.7. To sum up we may say that PPC is of immense value to the entrepreneur in capacity
utilization and inventory control. More importantly it improves his response time and
quality. As such effective PPC contributes to time, quality and cost parameters of
entrepreneurial success.

5
6
2. MANUFACTURING PROCESS
Concrete Sleeper Manufacturing Process consists of six basic operations as
mentioned below

2.1. Mould Preparation

The inner sides of the moulds are cleaned by cleaning machine fixed with a wire
brush and wiped clean with a cloth. Mould End Plates are fixed to the moulds
with bolts and nuts. Mould oil is applied to the inner sides of the mould either
manually or by using mould oil spray machine. Grease is applied to the mould
end plates and Insert pockets. Inserts (shoulders) are placed in the insert
pocket and insert pins are used for fixing the inserts to the mould.

2.2. Reinforcement

Stranded High Tension Steel Wires are drawn from one end of the bench
passing through all the four moulds or (eight moulds placed four each on either
side) to the other end. The wires are held in the bench end plates by wedges &
barrels. One end plate of the bench is movable for pre-stressing of wires.
Hydraulic Jacks are used to give pre-stress to the wires upto the required
tonnage strength. Bench end plate screws are tightened. The stress bench of
four\eight moulds is now ready for casting and it is moved to the casting area on
to the vibrating blocks. Alternatively, high frequency vibrators can be fixed on
the moulds for vibration and compaction.

2.3. Weigh Batching, Concrete Mixing & Sleeper Casting

Coarse aggregates, fine aggregates and cement are weighed one after the
other in a hopper which is placed on an electronic weigh batching plant. The
electronic process control system operates the radial gates of the bins
automatically according to pre-determined quantities\weights (approved mix
design). The weighed material is transferred into a skip hoist bucket which feeds
the material into the concrete mixer. Water is released into the mixer by the
process control system at a prefixed water/cement ratio taking into
consideration the moisture content in the aggregates. After the mix is mixed to a
homogeneous mix, it is transferred into the motorized concrete distributor.

Concrete is poured by the motorized concrete distributor into the moulds which
are on the vibrating blocks in the casting area. The vibrating blocks allow the
use of low water/cement ratio and give the necessary compaction. The bench
after casting is moved to the steam chambers by a motorized trolley.

7
2.4. Steam Curing

The bench is lifted by a EOT bridge crane and placed into the steam chambers.
Each chamber can accommodate 7-8 benches. The sleepers are steam cured
in a controlled manner over a specified period (10-12 hours) starting from room
temperature to a maximum steam heat of 70°-75°C and down to room
temperature. After the concrete is set and hard, the bench is removed from the
chamber by the EOT bridge crane and placed in the demoulding area for
demoulding.

2.5. Sleeper Demoulding

The bolts on the bench end plates are unscrewed simultaneously by a machine
or alternatively the bolts can be unscrewed diagonally manually. Stress is
transferred to the concrete. The wires between the sleepers are cut either by a
diamond edge cutting machine or by a welding machine by cutting rods. The
sleepers are removed from the moulds and placed on the trolley. Finishing
operations like sleeper numbering, end painting, etc. are completed while the
sleepers are on the trolley.

2.6. Water Curing

The trolley loaded with sleepers are moved to the water curing tanks after
finishing operations and submerged in water for curing with the help of the gantry
hoists or towering crane. After water curing for 14 days the sleepers are removed
from the tanks and placed in the stacking area. They are ready for inspection and
despatch.

8
 2.7. PRODUCTION CYCLE OF SLEEPER

Moulds being
cleaned

Mould end plates

are fixed

Oiling & Greasing

of moulds

HTS Wires being

cut to length of
Wires drawn through
bench
the moulds

Wedges & Barrels

and inserts are fixed

Tensioning of drawn
Wires

Completed sleepers
Concrete Pouring moved to stack yard
Weigh Batching &
into vibrating moulds
Concrete Mixing

Moulds into steam Sleepers placed

Moulds sent back into water curing
chambers for steam for cleaning tanks
curing

De-tensioning, Finishing operations

cutting of wire Sleepers demoulded on sleeper trolleys
between moulds and placed on
trolleys

9
 2.8. FLOW CHART FOR MANUFACTURING CONCRETE SLEEPER

RAW MATERIALS

MOULDS

Special Aggregate Water HTS SGCI

Cement s IS: 383 IS: 456- Wires Inserts
Cleaning moulds &
CA1, CA2, 2000 IRS: T-46
IRS: T-40 or IS: 6006 fixing end plates
RT-381
53-S grade Sand IS: 1785

Oiling

Weigh Batching (After

Fixing inserts in pockets, driving
moisture adjustment) insert pins & applying putty

Preparation of concrete (High speed or

Feeding HTS wires through end
pan or turbine type mixture)
plates holes, fixing wedge-
barrels, tightening by hand.

Pouring concrete & vibrating with vibrators (9000 RPM)

Filling cubes for concrete testing Removing insert pins Tensioning
Tightening bolts

Steam from Steam curing as per approved

boiler steam-curing cycle

Testing concrete cubes for release strength

& de-tensioning & loosening end plates

Wire cutting at ends

De-moulding & putting over trolleys, final wire

cutting flush with end surface, preliminary
checking, end painting, writing Batch Nos. and
Date of casting

Water curing along with cubes

14 days – for main line sleepers.

28 days – for turnout sleepers.

Taking out from curing tanks, checking dimensions,

distance between two outer inserts and at rail seat,
Slope, Toe gap etc. & stacking by putting wooden
battens

Testing concrete cubes, SBT of sleepers End painting & Dispatch

Checking electrical resistance (Loading as per RT-2468)

10

RAW MATERIALS
 ²

 

11
12
3. PRODUCTION PLANNING PROCESS

Production at each and every plant has to be planned keeping the following in view

3.1. Orders on Hand and Delivery Period

3.2. Capacity of the Plant: Like Availability of plant and machinery,

Benches & Moulds etc.

3.3. Agreements

3.4. Man Power availability

3.5. Tenders Participated

13
3.1. Orders on Hand and Delivery Period

Production schedule in a month is to be planned in such a way that no order should

go beyond original Delivery period. Also priority should be given for Railway orders.

Production should be planned in combination of P & C in all shifts depending on the

order book and infrastructure availability.

3.2. Capacity of the Plant

100% facility should be utilized

Planning should be done considering the following facilities

 no. of benches & moulds available

 Capacity of the batching plant

 no. of steam chambers and their capacities

 no. of water curing tank and their capacities

3.3. Agreements

The following agreements have to be executed before the start of the production:

3.3.1. Labour Agreement

3.3.2. Crusher Agreement

14
 3.3.1. Labour Agreement

 Labour agreements in all other plant with different production capacities.

Production per shift is calculated

 If the existing labour agreements are not covering the entire quantity of
targeted production per shift incentives are to be awarded for each extra
bench production to get the required production.

 Production planning is to be done as follows.

Y = target production as per the infrastructure availability (In Benches)

X = target production per shift as per labour agreement (In Benches)

Z = incentive production (Benches)

P = No of P&C sets in production

F = Multiplication factor for converting P&C sets in to BG Benches.

(This factor is considered as per the Labour agreement)

Option 1: Only BG production

X+Z=Y

Option 2: In combination with P&C

P*F + [X+Z- (P*F) ] = Y

No. of P& C Benches in terms of BG Benches No. of Benches

3.3.2. Crusher Agreement

Crusher agreement plays a major role in our production planning. The crusher
agreement shall be made as per the following

X = Production target in terms of BG sleepers per month

Y = required quantity of aggregates in cft

Y = X * 4.0 * 1.15

4 cft of aggregates is considered per BG sleeper.

And an extra 15% quantity must be included to take care of the requirement of
any unforeseen events.

Also the ratio of supply of Aggregates must be

15
 70% - 20 mm and 30 % -10 mm

3.4. Manpower Availability

A detailed standard Organizational chart is enclosed herewith.

ORGANISATION CHART

GENERAL MANAGER

ASST. GENERAL MANAGER, MGR. ADMN. & A/C

PERSO
NNEL
MGR.
Sr. Officer (Admn. &
A/c’s)
PRODN. MGR. MGR. QC UTILITY DEPT.
MAINT. MGR. PURCHASE &
STORES
INCHARGE
Lab Incharge 1 Officer Officer (A/c’s)
Asst. Mgr. Maint. (Admn.)

Prodn.
Engineers
(2)
Lab Sr. Officer Purchase.
Analyst. (Stores) Officer
2
Cook/Helper - 1
Inspection &
Dispatch Stores Officer
Prodn. –3
Supervisors (6) Office Boy – 1
Elect. Maint. Maint.
Supervisor Supervisor

Boiler
Attendant – 3 Purchase & Driver -1
Dozer Driver - Stores Asst. -2
Fabricators – 2
3

Note: The above organization chart is for the conventional method

For the long line method the organization chart is under finalization

16
3.5. Tenders Participated

While planning the production for a particular month we have to consider the quantity
which is likely to be awarded in that particular month for which we have participated
in a Tender. Normally Tender finalization takes approximately 4 to 6 months.

It is recommended that to have 5 to 10 % of targeted production can be considered

towards this anticipated quantity in the production planning

3.6. PLANNING

The following factors have to be considered in the planning process:

3.6.1. Review of Contracts / agreements

Execution of all contracts well within the available delivery period is most important
to avoid LD charges. Moreover Railways considers past performance while awarding
the new orders. In order to improve our business prospective and increase our
market share we need to complete all our contracts within available delivery period.

Contracts / Agreements have to be monitored on daily basis and, if necessary

corrective measures are to be taken immediately. If any deviation is occurred from
the planning it has to be brought to the notice of the higher management.

17
 3.6.2. Information Flow Chart

Production department
– plant

Data compilation
at plant

Plant 2 Plant 3

Receipt of
Letter to respective Data at CHQ
Rly. For DP extn., - Operations

Report of Operations
Department

EC MD CFO VP-I VP-II AUDIT

FEED BACK OF RESPECTIVE

VP

18
3.6.3 STANDARD PROCESSES

Time & Motion Study Per Bench For All Sleepers

Sl. Standard
no. Particulars of work M-S
1 DEMOULDING SECTION
a Bench shifting & lifting from steam chambers to demoulding bay 2-29
b Bench end bolt releasing 1-43
c Barrel & wedges removing 0-41
d Mould end plate bolts releasing 2-40
e Loosening of sleepers 1.40
f Wire cutting by ARC welding 3.33
g Mould end plates lifting 0-34
h Bench pushing to demoulding trolley 0-15
i Demoulding of sleepers 2-08
j Insert hole cleaning 1-10
k Batch No. writing 0-42
TOTAL 17.35
2 Process section
a Mould end cleaning 1.07
b Insert pocket cleaning 2-44
c Mould surface cleaning 2-28
d Mould surface oiling 3-32
e Greasing of Insert pocket & Insert fixing 3-13
f Insert pin fixing 1-57
g Mould end plate bolting 5-25
h Fresh wire cutting 1-51
i Wire threading 3-34
j Barrel & Wedges fixing 2-01
k Wire tensioning 1-20
TOTAL 29.57
3 Casting section
a Cement & Aggregate from bin to weigh batcher 0-43
b Skip bucket travel from bin to mixer (up/dn) 0-44
c Aggregate mixing in mixer 1-03
d Concrete pouring from mixer to concrete bucket 0-13
e Concrete bucket travel to bench (up/dn) 1-50
f a)Vibrator bolt fixing 1-40
b)Vibration of moulds 2-45
g Vibrator bolt releasing 1-11
h Bench trolley travel from ed to steam chamber 0-34
i Insert pin removing 0-49
j Bench shifting to steam chamber 1-51
TOTAL 13-38
4 Steam curing process 11.00.00
19
 Grand total in hours 12.6.49

Notes:

The following are the few points to be considered before arriving standard process
time:

a) Except few, most of the above readings recorded at various units are
almost matching can be considered as standard time. But, where the variation
is more, bench mark is to be taken from minimum reading as standard one,
which is to be adopted in other units.

b) Where the process duration is more, we can go for some creativity for
reducing the same. The same was discussed during the previous core group
meeting at Anara on 12.08.06; suggestion from our unit is to make change in
the fixing of end plate system. Trials are under process @ Tirumangalam &
kaipadar units, and hope to introduce the same after successful trial.

c) We want to continue the time study of the process with more number
readings, to concentrate more on focused areas to improve productivity further.
To fix the standard process time second lowest reading is considered

Standard process time is 12 hrs, 6 minutes & 49 seconds.

20

- 17M:35S
3.6.4. LAYOUT OF PLANT

3.6.5. Inventory Planning

21
  Cement, Wire, inserts are the main input raw materials and a constructive
inventory planning is to be done in order to avoid any production losses due
to raw material shortages.

 Minimum 15 days inventory is to be maintained at each plant.

 This 15 days is arrived as per following calculation

Average lead time - 8 to 10 days

PO must be released when the stock reaches minimum stock level.
Minimum stock level - Raw materials required for 15 days production.

3.6.6. Maintenance Schedule

 Preventive maintenance of all machineries must be done on every alternate

weekly off.

 Repair and preventive maintenance of Benches and moulds must be done on

every weekly off.

 Maintenance of Boiler must be done on every weekly off.

 All maintenance reports must be prepared and updated as per the enclosed
formats and must be kept near by each machine duly mentioning next
maintenance date

22
 3.7.
DAILY CHECKLIST
(BEFORE START OF PRODUCTION)
Plant Name:
Department:

Shift: I II III

Electrician -
Mechanic -
A Name of machinery - Mixer units
SL Particular to be verified Condition Action Taken Remarks
1 Mixer and hopper motor
2 Doors (mixer, Hooper , aggregates
3 Wire rope & hopper wheels
4 Break set & break drum
5 All cable connections & opera-switches
6 Water valves IN and Out
7 Gear box chain and sprocket
8 Air cylinder
9 Electronics Display
B. Name of machinery -Converter & Vibrator
1 Vibrator operating switch
2 Vibrator cover & Nut bolt
3 Cables and Base plate
4 Converter starter & change over
5 Converter slip ring
6 Converter foundation and safety cover
C. Name of machinery - Concrete conveying
bucket
1 Motor & gear box foundation
2 Tyre coupling ,Bolts & Keys
3 Relay contactors & operating switch
4 Conveying cables
5 bucket doors & Gears
6 Wheels and Nut bolts
D. Name of machinery - Air compressor
1 Compressor motor & pulley
2 Air filter & air stocking tank
3 Oil level & Pressure Gauge
4 Pressure switch & Cut off
5 Main switch & Head
E. Name of machinery - EOT Crane
1 Motor & gear box foundation
2 Tyre coupling ,Bolts & Keys
3 Hoist gears and break set
4 Wire rope and pulleys & Tackle hooks
5 Wheel and bearings
6 Relay contactors & operating switch
7 Chain procket and chain
23
 Action
SL Particular to be verified Condition Taken Remarks
F. Name of machinery - Boom scraper
1 Motor and cables
2 gear box foundation and chain sprocket
3 Both wire rope & pulleys
4 Rivers forwared motor and switch
5 Clutch & Break
G. Name of machinery - Bench trolley
1 Motor & gear box foundation
2 Tyre coupling ,Bolts & Keys
3 Trolley wheel and bearing
4 Cable and contactor & operating switch
H. Name of machinery - Demo-and Loading
trolley
1 Trolley wheel and bearing
2 Wheel gauges
3 Trolley lines
4 Nut and bolts & pedestal
I. Name of machinery - Tension machine
1 Hydraulic jacks
2 Hydraulic hose pipe & Nipples
3 Dial gauge
4 Motor and starter

After checking the Machineries hand over to Production In charge

Special Remarks (if any): _______________________________________

___________ _________________
Date Production Incharge

24
 3.8.
FORTNIGHTLY CHECKLIST
PREVENTIVE MAINTENANCE SCHEDULE MACHINERIES

Plant Name:
Department:

Shift: I II III

FORTNIGHTLY MONTH OF Jan-'08

Sl Name of No/ Set of
No machinery Machinery SCHEDULE DATE DUE Date
1 Gantry - No-1 1 No 04.01.08 19.01.08 04.02.08 20.02.08
2 Gantry - No-2 1 No 08.01.08 23.01.08 08.02.08 23.02.08
3 Gantry - No-3 1 No 07.01.08 25.01.08 07.02.08 25.02.08
4 Gantry - No-4 1 No 10.01.08 26.01.08 11.02.08 26.02.08
Demoulding
5 hoist 1 No 05.01.08 22.01.08 05.02.08 22.02.08
6 Casting trolley 2 Set 12.01.08 28.01.08 12.02.08 28.02.08
Tension
7 machine 1 No 03.01.08 19.01.08 04.02.08 19.02.08
8 Concrete bucket 1 No 02.01.08 17.01.08 02.02.08 18.02.08
9 Generator set 1 No 11.01.08 24.01.08 11.02.08 24.02.08
10 Air compressor 1 No 13.01.08 28.01.08 13.02.08 28.02.08

Special Remarks (if any): _______________________________________

___________ _________________
Date Production Incharge

25
 3.9.
WEEKLY
PREVENTIVE MAINTENANCE SCHEDULE MACHINERIES

Plant Name:
Department:

Shift: I II III

WEEKLY MONTH OF April-'08

Sl Name of machinery No/ Set of
No Machinery DUE DATE
1 Mixer machine 1 Set
2 Skip bucket 1 Set
Electronic weigh
3 bacher 1 Set
4 Converter 2 No
06.04.08

13.04.08

20.04.08

27.04.08

04.05.08

19.05.08

25.05.08
11.05.08
5 Vibrator 8 No
6 Boiler 2 No
8 EOT- Crane 1 Set
Boom scraper & Air
9 comp 1 No
7 Steam chamber 12 Nos
8 Factory lighting E

Special Remarks (if any): _______________________________________

___________ _________________
Date Production Incharge

3.10.
26
 MONTHLY
PREVENTIVE MAINTENANCE SCHEDULE MACHINERIES

Plant Name:
Department:

Shift: I II III

Monthly MONTH OF Mar-'08

Sl Name of machinery No/ Set of

SCHEDULE
No Machinery DATE DUE DATE
1 Loading trolley 12 Nos 18.03.08 18.034.08
2 Demoiulding trolley 2 Nos 10.03.08 10.04.08
3 Cube testing machine 1 No 28.03.08 27.04.08
4 Sleeper testing machine 1 No 17.03.08 17.04.08
Welding & cutting machine(Air
5 cool) 1 No 27.03.08 27.04.08
Rail lines(Gantry-mol, Cast, &
6 Carri Rmt 03.03.08 03.4.08
7 Fire extinguisher 3 Nos 26.03.08 26.04.08
8 Cement weighing machine 1 No 19.03.08 19.04.08
9 Mortor cube 1 No 21.03.08 21.04.08
10 Sieve shaker 1 No 22.03.08 21.04.08
11 Lathe machine 1 No 24.03.08 20.4.08
12 Servo stabilizer 1 No 23.03.08 23.04.08
13 Factory lighting 30.03.08 27..04.08
14 Water pumps 4 Nos 25.03.08 25.04.08

Special Remarks (if any): _______________________________________

___________ _________________
Date Production Incharge

27
3.11. Risk Analysis

In the plant time to time Risk Analysis has to be done in co - ordination with CHQ
and necessary forecasting has to be done.

Risk Analysis is to be done mainly in the following areas

3.11.1 Raw materials

 Inventory
 Lead time of the input raw materials
 Labour problems / Breakdowns arising at Raw material supplier factories
 Seasonal changes which effects the supply of Sand and metal

3.11.2. Work force

From time to time, possibly once in 15 days, meeting has to be conducted with staff
and workers and necessary important information has to be brought to the notice of
the management.

Local environment effects like political, administrative, public unrest etc…

3.11.3. Stacking area

We have to keep a track of stacking area utilization of sleepers as chocking of

stacking area will effect the production.

Dispatches are to be monitored. If the Railways are not taking delivery of the
Sleepers it will effect in chocking of stacking area. So Risk analysis in this area to be
mead and informed to the CHQ from time to time for necessary action.

3.11.4. Breakdown

From time to time life span of all machineries has to be assessed and necessary
replacements / repairs to be made. While assessing the same analysis has to be
made how it is going to effect the production and the report must be submitted to the
management immediately.

28
 3.12. Planning Group Formation

At each and every plant a Planning group must be formed consisting of the
following Members

1. CGM/GM of the plant

2. Production in-charge
3. Stores in-charge
4. Quality/Inspection in-charge
5. Dispatches in-charge

The planning group must meet on every Monday (if Monday is Holiday next day)
for the weeks production, Dispatches, Raw material planning etc.. and a report
must be sent to the respective Vice Presidents.

The meeting schedules are attached herewith.

Every Month by 25th the planning group must send the necessary indent to the
CHQ Purchase department for the next month’s production.

3.12.1 Meeting Schedules

29
Core Team Meeting: Twice in a Month for review of Fortnight and Monthly
performance and cost. The meeting is conducted as per nominated quorum at
factory level.

TO,

All the Core Team members,

This is to inform that future Core Team Meeting’s will be conducted between 11 AM
and 12.30 Pm on every 2nd and 17th of the month.

Agenda for the same shall be as mentioned below, unless and until there is change
in the program, which will be informed in advance.

Strictly no phone calls shall be entertained during meeting hours. When you come
for the meetings, each one of you must come prepared with proper Data to be
effective and useful.

Article I. AGENDA

 Reviews by CGM

 Achievements and loss of production during last fortnight /month

against plan made.

 Production Plan for next Fortnight / month.

Article II. Action plan for improving quality

Section II.1 Review on quality of sleepers-1. Human error 2.
Dimensional 3. Handling
Action taken, with achievements/result

 Review on standard cost for previous fortnight/month-with reasons

for -ve variance if any. Action plan for reducing cost for next fortnight/month

 Review on Research and Development in the last fortnight/month-

advantages and dis-advantages / Action plan for R&D for the next
fortnight / month

 Other General Discussions.

30
Article III.

Core Group Meeting: This meeting is conducted at every Quarter to discuss

about standardization and implement the new technology and systems in
production Process to increase the capacity of the plant. – To reform the
production process/technology.

TO,

All the Core Group Members,

Sleeper Division.

Sub:- Core Group Meeting – Reg.

Ref:- Core Group review meeting - @ dated

With reference to above, 4th CG review meeting is planned at Tirumangalam unit,

meeting fixed on--- & --- of -07 (two days only)

Article IV. AGENDA

 Reviews on developments after 3rd CG meeting based on the decision taken.

 New systems to be introduced next half year of

 Effectiveness & results of R&D initiatives / new MIS reports.

 Initiations taken to control of human errors.

The above are some of the important topics planned for the meeting. Meeting will be
chaired by our Vice President and the following members are asked to participate in
meeting.

Manager (Admin) - RCS-TMQ

Manager (Works) - RCS-TMQ
Manager (Utility) - Mazda
GM (Project execution) - CHQ
Manager (Works) - RCS Bilaspur
Quality Control Incharge - Anara
Purchase Officer - RCS-TMQ
Incharge (R&D) - RCS-TMQ

Apart from above any interim meeting on emergency will be called by the
Management as and when necessary.

31
32
4. STATUTORY COMPLIANCES OF FACTORY

4.1. Central Excise

Records to be maintained

 Stock Register of Cement, Inserts, HTS Wire, PVC Dowels, Mould-Inputs &
Capital Goods.
 Stock Register of Finished Goods (Rly. & Pvt. Separately)
 Despatch Register of Finished Goods
 Waster & Scrap Register
 CENVAT Credit Book & PLA
 Return (ER-1): Monthly (giving all Excise details of the relating month
including service tax)
 Payment of ED & Cess: on every 5th. of the following month by the mode of
CENVAT, Service Tax & PLA.
 Submission of status of Escalation/De-escalation within every six months (in
concern of Prov. Assessment)
 Rate of interest towards late payment: @13% p.a.

4.2. Sales Tax

Records to be maintained:

 Taxable materials – Receipt Register (State & Central), VAT Register, Way-
bills & Form ‘C’ Register
 Sales – bill details register (State & Central)
 Details of production & dispatch of our product as well as any of taxable
materials (State & Central)
 Details of Deferment
 Payment of Sale Tax & VAT as per clearance of goods by mode of
appropriate challans (State & Central) – Generally used Praroopo -5 – Rule –
7A, 7-Rule-4(1) & 8, & Praroop -17 – Rule – 20 (2) (a) & Challan filled in Form
-10, Form -9 & Form -34
 Assessment of Sales Tax – yearly (submitting the through details relating to
taxable inputs & outputs along with documentary evidence.
 Return is submitted on every quarterly along with all details.

4.3. Service Tax

Records to be maintained:

 Input Service Tax Register

 Payment of Service Tax & Cess on GTA services: On every 5th.of the
following month
 Return (ST-3): on every six month (Apr-Sep & Oct-Mar)
 Rate of interest towards late payment: @13% p.a.
33
4.4. Pollution Department

Records to be maintained:

 Concerning File for Slp. Plant & Crusher separately

 Renewal of Water & Air consent for Slp. Plant & Stone Crusher separately -
every year
 Renewal Charges: Rs.4000/- for Slp. Plant & Rs.1000/- for Crusher.

4.5. Mining Department

Records to be maintained:

 Production Journal Register (details of Prod. Of Boulders, Labours, Period &

Wages)
 Stock Journal Register of Metal (Metal receipts & consumption of metals)
 Sale Journal Register (Receipt of Metals as per Royalty slips)
 Submission of monthly details, half yearly & yearly details (Jan-Dec) in Form –
10, 11 & 12 respectively & Form – 8 for requisition of Royalty books along with
paid challan.
 Assessment of Royalty on every six months
 Apply for Quarry – Lease after every 5 years (prevailing lease is valid upto
Apr-2012) but request should be submitted 3-4 months before expiry of the
existing quarry lease – period.
 Presently royalty – rate is @Rs.30/- cu. Mtr. On boulders & @Rs.40/- per cu.
Mtr. On metals, however, we are paying on metals.

4.6. Explosive Department

Records to be maintained:

 Details of purchase, consumption & stock of explosive materials

 Submission of monthly report of explosive status.
 Renewal of explosive – licence after every 2 years.

34
 4.7. CHART FOR STATUTORY REQUIREMENTS
S.N Description PF Act Factory Act ESIC Act Bonus Act Labour Act
o. Reqd./N Reqd. Reqd./N if Reqd. Reqd./N if Reqd. Reqd. if Reqd./ if Reqd.
ot Reqd. No. of ot Reqd. No. of ot Reqd. No. of /Not Reqd Not No. of
(√/)` copies (√/) copies (√/) copies Reqd. . No. Reqd. copies
(√/) of (√/)
copie
s
1 Memorandum √ 2 √ 1 √ 1 
of Articles
2 Land Lease √ 2 √ 1 √ 1  √ 1
Deed
3 Company's √ 2  √ 1  
PAN Card
4 VAT & CST √ 2 √ 1   
Registration
Copy
5 Central Excise √ 2    
Registration
Copy
6 Bank Name & √ 2  √ 1  
Account No.
7 List of √ 2 √ 1   
Directors
8 List of √ 2    
Employees
details
9 Test Reports of  √ 1   
Machineries
from the
Government
approved
Agency
10 Machinery &  √ 2   
Building layout
plan as per
Factories Act
duly approved
by authorised
Agency
11 Power of √ 2 √ 1 √ 1  √ 1
Attorney to the
Authorised
person with
signatures of
all the
Directors

Note: For Udvada Plant ESIC is not applicable. As per the rule, ESIC is applicable for such factories which come under
the span area of 08 K.M. from the ESIC hospital. Here ESIC hospital is in Vapi and it is 10 K.M. away from the
factory

35
36
 5.1 MONTHLY REPORT

Details of Production Target Achieved & Production Loss for the year
NAME OF THE UNIT:
Working Weekly Paid Lay Total Prodn Target Prodn. In Target Achieved Details
Month
Days Off Holiday Off Days Target Achieved Loss % BG CR P&C Total
April
May
June
July
August
September
October
November
December
January
February
March
Total

For

General Manager

Details of Production Loss for the Year

Month Raw Material Shortage Breakdowns Labour problems Others Total

slow
Cement Wire Inserts Metal Mech Elect shortage work

April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Total
%

37
 CRUSHER PERFORMANCE REPORT FOR THE MONTH OF.
Unit:-.
Agreement Date :-
Validity of Agreement:-.
Whether
Receipt maintenance of
Reasons Payment
Outstand s during equipment and
for s during
Target Achieved ing as on the replacement of
shortfall in the
01.08.07 month spares carried out as
supply month
(in Rs.) per agreement during
the month.
(In
cft.) (In cft.) Total Rate. Amount

For Rayalaseema Concrete Sleepers Pvt.

Ltd.,

Manager (Admn)

NAME OF THE UNIT:

Details of Rejection for the year 2007-08
Dim/ IC
Month I/S Crack TG+/- RS+/- LG+ EB SBT EHC Other Total Taken Rej %
April
May
June
July
August
September
October
Total

38
 Additions or Deletions of the plant and Machinery for the month:
NAME OF THE UNIT: Date:

Statement showing details of Additions / Transfer / Disposal of P&M made during the month

Sr.No. Date Name of the Firm Type of Make / Qty. Details

Machine Capacity Additions Transfer Disposal







Other Details to be furnished for :-

1. Additions made :-

2. Transfers made :-

3. Disposals made :-

STAFF STATUS OF ALL UNITS FOR THE MONTH OF

STRE NEW RECRUITS

NGTH STRENG DURING THE INTER UNIT TRANSFER DETAILS DAT
AS TH AS MONTH E OF
OTHER
PER PER JOIN
TERMIN FACILITI
PREVI CURREN UNIT RESIG /
ATED / ES
OUS T EMPLOY EMPLOY TRANS NED/ RESI
SUSPEN
MONT MONTH EE DEP EE DEPT FERRE TRF GN
DED
H NAME TT. NAME T. D TO

39
 5.2 WEEKLY REPORT

Weekly Statement to be submitted to CHQ latest by 11.00 am every Saturday

Bills raised and submitted in the Railways :-

Bill Recd
Order /Sub.
Type Details Bill No. Date Qty Amount date
90% Claims :-
Outstanding as on Monday:-

Bills submitted during the

week :-

10% Claims :-
Outstanding as on Monday:-

Bills submitted during the

week :-

100% Claims :-
Outstanding as on Monday:-

Bills submitted during the

week :-

Other Suppl. Claims :-

Outstanding as on Monday:-

Bills submitted during the

week :-

40
 Weekly Statement to be submitted to CHQ latest by 11.00 am every Saturday

Payment Receipt Details from the Railways :-

Order Bill
Type Details No. Date Qty Mode of Payment Details of
EFT Amt.
/Ch. Date Passed Deductions
90%
Claims

10%
Claims

100%
Claims

Other
Suppl.
Claims

5.3 DAILY REPORT

PATIL RAIL INFRASTRUCTURE PVT. LTD.-UDVADA
41
 MANAGEMENT INFORMATION SYSTEM
(A) Sleeper Production Details:-
DATE:

Description Target A B C Total Month This Order Agst Bal

Shift- Shift- Shift- Year Qty Order
I II III
BG
P&C
Prodn in BG
Benches
Prodn in P&C
Benches
Total Prodn in
Benches

Note:
Shift RM Labour Mach 2-3 P&C Others Total Remarks
B/D Moulds
A Shift-I
B Shift-II
C Shift-III
Total

(B) Sleeper Despatch Details:

Description Today Month This Agst Party Today Month Cumm Bal
Year Order
BG
Grand Total
P&C 1 in 16 (Rly)
P&C 1 in 12 (Rly)

(C) Sleeper Stock Details

In Ready for Awaiting Ready for Rejected MF
Description Total
Process Inspection Certification Despatch Sleepers Sleepers
BG 0 0 0 0 0 0 11356
Grand Total 0 0 0 0 0 0 0
P&C 1 in 8.5
0 0 0 0 0 0 0
(Rly)
P&C 1 in 12
0.00 0.00 0 0 0 0 0.00
(Rly)

(D) IC Obtained Details -

Descri IC Date Batch Nos Details of Passed Rej Un- Previous Total
ption No. Sleepers
From / To / Usable ET MF Offered Offered
Date Date
Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil 0

42
(E) Sleeper Inspection Status :-
Description SBT Check Dimension FTC Reasons for Rejections
Normal (CS-156) 0 0 0

(F) Bill Submission Details :-

Bill No. Date Qty Amount IC No. 90% 10% 100% REMARKS

(G) Raw Material Details :-

Material OB Recei Consump Transfer CB Basic Rate Receipt
pts tion Details
Wire (3 Ply) (Mt) 0 0 0 0 0
Spl. Cement (Bags) 0 0 0 0 0
SGCI Insert (Nos) 0 0 0 0 0
PVC Dowels (Nos) 0 0 0 0 0
M. S. Round (Kgs) 0 0 0 0 0
Metal (20mm) (Cft) 0 0 0 0 0
Metal (10mm) (Cft) 0 0 0 0 0
Sand 0 0 0 0 0

(H) Bank Transaction Summary :-

Excise/
Bank Opening Receipts Receipts Supplier Drawing Closing
Sales Others
Name Balance Sales HQ/Other Payment for Exp Balance
Tax
0 0 0 0 0 0 0
Op. Bal. Recpt. Payment Cl.Bal.
Cash on
0 0 0 0
Hand

(I) Excise Balance (CENVAT & PLA):

Debits
Opening Cash CENVAT Other Closing Passed
Record for Date
Balance Deposit availed Debits Balance Bill No.
Despatch Amount
PLA 0 0 0 0 0 0
Cenvat Total
0 0 0 0 0 0
Book Amount 0
Grand
0 0 0 0 0 0
Total
Note:-

Target for Aug - 08 0

Total Working Days 0
Total Weekly Off 0 For Patil Rail Infrastructure Pvt. Ltd
Total Paid Holidays 0
Total Days 0
Authorized Signatory

43
44
INDIAN RAILWAY SPECIFICATION

FOR

PRETENSIONED PRESTRESSED
CONCRETE SLEEPERS

(BROAD GAUGE AND METRE GAUGE)

(THIRD REVISION-MAY-1996)
SERIAL No.T-39-85

45
0. Foreword

0.1. This standard specification (first revision) was adopted by the Indian Railways
in May 1985 after the draft was finalized by the Sub committee of Track
Standards Committee.

0.2. The present revision has been taken up with a view to incorporate
modification found necessary as a result of use of the specification both by
the manufacture and user.

0.3. The signification modifications incorporated in this revision are as follows:

0.3.1. S.I. Units have been adopted.

0.3.2. Clause 3.4.2 has been provided for cases where water requires treatment
before use.

0.3.3. Definition of lot for the sleepers cast during developmental production has
been revised.

0.3.4. Clauses regarding concrete and method of casting and testing of cubes for
mix design are revised.

0.3.5. Critical and general dimensions of sleepers have been explained. A sketch
showing the different dimensions to be measured is attached as Annexure-II.

0.3.6. Flow chart for better understanding of Static Bending Test procedure has
been prepared and is attached as Annexure-IV.

0.3.7. The procedure and circuit diagram for measuring electrical resistance of
sleeper by using higher voltage and comparative bulb procedure in
manufacture’s premises is attached as Annexure-V.

0.3.8. List of specifications needed for daily use and referred to in this specification
is attached as Annexure-VI.

1. Scope

1.1. The specification covers the manufacture and supply of pretensioned

prestressed concrete sleepers for broad gauge and metre gauge.

2. General

2.1. The manufacture of sleepers shall be to the Purchaser’s drawing or two

drawings approved by the Purchaser and the production shall commence with
the prior approval of the Inspecting Officer. Any subsequent change in
material or production technique shall require prior approval of Inspecting
Officer.

46
2.2. The reference to IRS specification and drawings in this specification relates to
the latest version of these standards as amended from time to time. The
provisions of this specification shall override the corresponding provisions of
IS: Specifications. Any special requirements given in the drawings of the
sleepers will override the relevant provisions of the specifications. Annexure-
I shows the list of specifications required for manufacturing of sleepers.

3. Materials

3.1. High tensile Steel

3.1.1. High tensile steel in the form of plain wire or strand shall conform to IS: 1785
Part-I and IS:6006 respectively. It shall be procured only from BIS approved
manufacturers who shall furnish the proof of approval by BIS with the first
consignment during the currency of approval and for each fresh approval.
Each consignment of high tensile steel must be accompanied by a test
certificate showing the serial no. of coils. Each coil shall carry a tag in
accordance with the IS specifications mentioned above. In addition to the
normal tests stipulated in the IS specifications for every consignment, results
of “relaxation test” shall also be furnished once in six months. In case of
change of source the first test certificate shall include “relaxation test” results
also.

The steel shall be used for production only after ascertaining that it meets the
provisions of relevant specifications.

3.1.2. Whenever directed by the Inspecting Officer, the manufacturer shall get the
steel in stock tested at the latter’s cost.

3.2. Cement

3.2.1. Cement shall conform to Indian Railway Specification No. T- 40.

3.2.2. Each consignment of cement shall be covered by a test certificate. Each

consignment shall be stocked separately, tested in the laboratory of the plant
immediately for all relevant properties and shall be clearly identified. Cement
more than 3 months old, if free from lumps, shall be tested for physical
properties by an independent government approved laboratory or as directed
by the Inspecting Officer and may be used after his approval.

3.2.2.1. The Inspecting Officer has the right to have the cement in tested at any time
at the cost of manufacturer.

3.2.2.2. In case the source of supply of cement is changed, the mix design shall be
reviewed and modified, if necessary.

3.2.3. The cement content of the mix shall not be less than 350 Kg/cu.m/ and not
more than 480 kg.cu.m.

47
3.2.4. Super Plasticiser conforming to IS:91003 may be used with the prior approval
of RDSO. At this stage the revised concrete mix design shall also be
submitted to RDSO for approval.

3.3. Aggregates

3.3.1. The aggregates shall conform to IS:383 and shall, before use, be got tested
through an approved testing institute, and results submitted in accordance
with Appendix “A” of IS:383 to the Inspecting Officer for approval. The
aggregates shall have an abrasion and impact value suitable for wearing
surfaces. The flakiness index and elongation index shall not exceed 30%
when tested in accordance with IS:2386 (Part-I) Different sizes of aggregates
shall be stacked in different storage bins or stock piles.

3.3.2. Coarse aggregates shall be crushed stone, angular in shape and gravel shall
not be used.

3.3.3. Fine aggregate used shall be resulting from the natural disintegration off rock
and which has been deposited by streams or glacial agencies.

3.4. Control of Water

3.4.1. Water to be used in making and for curing concrete shall conform to IS:456.

3.4.2. If water needs any treatment before use, adequate storage of treated water
for daily requirement shall be made. Facilities for testing treated water shall
be provided in the plant. Treated water shall be tested daily or as directed by
the Inspecting Officer.

3.4.3. The total water content per batch shall be regulated with conform with the
ratio by weight of free water to cement required for the particular design mix
as established by preliminary tests. The total water content of a batch
includes:

Absorbed water in the aggregates;

Free water in the aggregates; and
Free water added to the mix.

3.4.4. The water to be mixed at the mixer shall be free water content required per
batch less the amount of free water in the aggregates, if wet, or plus the
amount of water the aggregates will absorb, if dry. Free moisture content
shall be determined at least once a day.

3.5. Concrete

3.5.1. The concrete shall be of controlled quality with the nominal maximum size of
aggregates limited to 20mm. Where wire spacing permits, aggregates up to
25 mm may be used. The manufacturer shall get the concrete mix design
along with the upper and lower limits of granulometric curves approved by the
Inspecting Office
48
3.5.1.1. The granulometric curves shall be plotted on semilog graph sheet once in a
week and shall be between the approved limits.

3.5.2. The concrete shall satisfy the following design parameters:

Minimum release strength after stream curing. 40 N/Sq.mm

15 days characteristic strength after water curing. 55 N/Sq.mm

Percentage of cubes with strength less than the Not more than
characteristic strength 2.5%

Co-efficient of variation Less than 10%

3.5.3. 80 cubes shall be cast, using materials proposed for regular manufacture, in
10 batches of 8 cubes each, 4 for steam curing and 4 for water curing

3.5.3.1. All the 40 cubes cured according to the proposed steam curing cycle shall
attain the specified minimum release strength.

3.5.3.2. The statistical analysis of the compressive strength values of the 40 water
cured cubes shall satisfy the design parameters of clause 3.5.2(ii), (iii) & (iv).

4. Manufacture

4.1. Moulds

4.1.1. Moulds shall be of steel and shall be of rigid construction so as to prevent any
distortions during casting of sleepers. Moulds shall not allow any appreciable
leakage of cement mortar in casting. The holes in the end plates shall be
accurately drilled for correct placement of prestressing wires.

4.2. Stretching of wires

4.2.1. The prestressing wire shall be stretched either individually or collectively by

an approved method. The tensioning force shall be as shown on the sleeper
drawing. The final force to be adopted, duly considering the losses while
stretching shall be approved by the Inspecting Officer. However, the stretching
force shall in no case exceed 75% of the minimum specified UTS of the wire.
The pretensioning force in the wire shall be applied by a tensioning device
equipped with automatic load cut off unit along with measuring gauge. The
final force shall also be verified by measuring the extension of the wire.

49
4.3. Mixing and consolidation of concrete

4.3.1. Manufacture of sleepers shall be done under a shed.

4.3.2. Batching of different ingredients shall be done by weight only. A modern,

mechanized or automatic weigh batcher shall be used for weighing
aggregates and cement. The weigh batcher shall have an accuracy of +/-3%.

4.3.3. Modern high speed mixer, pan, turbine or any other suitable type, approved
by the Inspecting Officer shall be used for mixing concrete. Concreting shall
commence within 2 hours of stressing of wires, failing which the HTS wires
shall be checked and re-tensioned, if necessary.

4.3.4. Concrete shall be thoroughly mixed and consolidated by means of vibrators of

at least 9000 revolutions/minute.

4.3.5. Freshly cast sleepers shall be protected during the first stage of hardening
from adverse weather conditions.

4.4. Detensioning of wires

4.4.1. Anchoring system shall provide a device for gradual detensioning of the wires.
Back pulling of wires for releasing any wedge shall be strictly prohibited.
Detensioning of wires shall be undertaken only after the concrete has attained
a compressive strength of 40 N/sq.mm.

4.5. Curing

4.5.1. Initial curing of concrete sleeper shall be done by steam at atmospheric

pressure till the concrete attains a compressive strength of 40 N/sq.mm.
Presteaming period shall not be less than the initial setting time of cement.
Steam curing cycle shall have the prior approval of the Inspecting Officer.

4.5.2. After detensioning, the sleepers shall be cured for a further period of not less
than 14 days by submerging in water.

4.6. Supervision

4.6.1. Suitably qualified persons shall be engaged by the manufacturer for

supervising the following items at the works.

4.6.1.1. Testing of cement, cement mortar cubes, concrete cubes, concrete beams;
4.6.1.2. Calibration of testing and measuring equipment and different gauges;
4.6.1.3. Placing and stressing of prestressing wire;
4.6.1.4. Batching, mixing, placement and compaction of concrete.
4.6.1.5. Checking of the steam curing arrangement for its adequacy.
4.6.1.6. Demoulding of sleepers, water curing, stacking/loading etc.
4.6.1.7. Inserts shall be checked by suitable jigs before use by the manufacturer;
4.6.1.8. Checking electrical resistance of sleepers.
50
4.6.2. Supervisor so engaged shall maintain records as directed by the Inspecting
Officer and shall present them for scrutiny when demanded.

4.6.2.1. A site register shall be maintained in which inspecting officer shall record
observations against which compliance will be recorded by the supervisor.

4.6.2.2. Suitable records of manufacture of sleepers shall be maintained in such a

manner that it can be correlated at a later date to the sleeper laid in field.

4.7. Finish

4.7.1. All sleepers shall be free from surface defects such as water retaining
pockets, air holes or honey combed formations. The underside of the sleeper
coming in contact with ballast shall be left rough but the unevenness shall not
exceed 5mm. The ends of the prestressing wires shall be cut close to the
surface of the sleeper and in no case shall project more than 3mm from he
concrete surface. Two coats of suitable ISI mark anti corrosive paint,
approved by Inspecting Officer, shall be applied at the ends of the sleepers
after curing.

4.7.2. No touching up or finishing by cement mortar etc. shall be permitted on

concrete sleeper, after it is demoulded, except as provided in clause 4.7.3.

4.7.3. Such sleepers which are not found acceptable due to surface defects, shall be
accepted up to a ceiling of 1% of the supplies made any time during the
currency of the contract provided such sleepers are adequately treated with
epoxy compounds to the satisfaction of the Inspecting Officer. These sleepers
shall be marked as shown in Drawing No.RDSO/T-2466 before dispatch. The
rectified sleepers shall be paid for at the rates fixed by the purchaser.

4.8. Stacking

4.8.1. After the sleepers have been cured in terms of clause 4.5.2. and checked
both dimensionally and visually they shall be stacked at convenient place in
lots. The stacking of sleepers shall be done on leveled and consolidated
ground, one over another upto 25 layers. Each layer shall be separated by
wooden/concrete battens of 50mm X 50mm size of suitable lengths to avoid
any damage.

4.9. Lots

4.9.1. All sleepers cast in one shift shall form one lot.

51
 5. Inspection and Testing

5.1. The manufacturer shall supply at his expense, all the sleepers required for
tests and retests, samples of materials, labour, machine, tools, gauges,
apparatus forms of test report etc. and any other item which may be
necessary or required by the Inspecting Officer for carrying out any or all of
the checks and tests mentioned in these specifications and shall render all
reasonable assistance in conducting such checks and tests. All measuring
and testing appliances shall be got checked and calibrated according to the
schedule given in Annexure-I, through government approved agency or as
directed by he Inspection Officer. The calibration certificate shall be furnished
to the Inspecting Officer. The cost of all such checks and calibrations shall be
bone by the manufacturer.

5.2. Inspecting Officer and the Purchaser shall have free access at all reasonable
times to the works in which the sleepers are manufactured. They shall be at
liberty to inspect the manufacture of sleepers at any stage and to reject any
material supplies not confronting to the terms of the specifications and to
reject sleepers not manufactured according to approved manufacturing
process. They shall be provided with necessary assistance for inspection by
the manufacturer.

5.3. Checks and tests

5.3.1. In addition to the control checks exercised on the materials and manufacturing
process specified above, the concrete and the finished sleepers shall be
subjected to regular checks and tests, after 14 days submerged water curing,
as detailed in clause 5.3.1.1.

5.3.1.1. Visual and Dimensional check.

Every sleeper shall be visually inspected for surface finish. No sleeper

shall have surface defects except as provided in para 4.7.3.

Sleeper dimensions to be checked are listed below:

Critical dimensions are toe gap, location of inserts, distance between

inserts at rail seat, distance between outer most inserts and slope at
rail seat.

General dimensions are depth of sleeper at centre, rail seat and end of
sleeper, width of sleeper at top and bottom, length of sleeper, camber
and wind at rail seat and position of high tensile steel wires at ends.

The sketch at Annexure-II shows the dimension checking arrangement. The

dimensions shown on the sleeper drawing shall be checked by means of approved
gauges, procured by the manufacturer. (Annexure-II/A shows the gauge for
measuring toe-gap of rail seat.

52
5.3.1.2. Scale of check

Prior to stabilization of production technique

Scale of check per lot for critical dimension is 100% (hundred percent) and for
general dimensions 10% (ten percent) of sleepers produced.

a. After stabilization of production technique scale of check per lo for critical

dimensions is 10% (ten per cent) and for general dimension 1% (One
percent), but the dimensions between outer inserts shall be checked
100%.

b. Notwithstanding he provisions in (a) & (b) above, the Inspecting Officer

may decide to check the dimensions at scale higher than mentioned in
para (a) & (b) above.

5.3.2. Casting of cubes.

5.3.2.1. 15 cm size cubes shall be cast on a vibrating table conforming to IS: 2514
(1963) from random samples spread over the entire lot, out of concrete used
for casting sleepers for testing prior to transfer of prestress and 15 days.

5.3.3. Method of testing.

5.3.3.1. The cubes shall be surface dry at the time of testing. The rate of loading shall
be about 400 KN/Minute.

5.3.4. Compressive strength of concrete at transfer (release) of prestress

5.3.4.1. These cubes shall be steam cured along with sleepers in the same manner
and tested for transfer of prestress to concrete (at least one cube for every
steam chamber/3 for each long line but not less than a total of 3 in any case).

5.3.5. Test for 15 day compressive strength of concrete

5.3.5.1.1. These cubes shall not be steamed but shall be water cured for 14 days after
demoulding. Three cubes per lot shall be tested for 15 days compressive
strength of concrete. The minimum strength will represent the strength of
concrete for that lot.

5.3.6. Test for 15 day modulus of rupture of concrete

5.3.6.1. The test for 15 day modulus of rupture of concrete shall be carried out on
concrete beams of 10x10x50 cm size as specified in IS: 516. One specimen
shall be tested daily prior to the stabilization of production technique, once a
week thereafter. If any value falls below 5 N/sq. mm, the mix design shall be
reviewed.

53
 5.3.7. Tested for static bending strength of sleepers

5.3.7.1. Method of testing.

5.3.7.1.1. The tests shall be conducted in accordance with arrangement shown in

Annexure-III.

5.3.7.1.2. The sleepers shall be loaded gradually (30-40 KN/min) up to the specified
load, which will be retained at this level for one minute for observing cracks, if
any. For the purpose, a crack is defined as one which is barely visible to the
naked eye and is at least 15mm long from the tension edge of the sleeper.
However, if crack appears at a load smaller than the specified load, that value
shall be recorded.

5.3.7.1.3. In case of ‘Moment of Residence’ (MR) test, the sleeper shall be deemed to
have passed the test if it sustains the loads specified in Annexure-III without
cracking. Sleepers shall be subjected to loading till the appearance of first
cracks.

5.3.7.1.4. In case of ‘Moment of failure’ (MF) test, the sleeper shall be deemed to have
passed the test it is able to take load beyond the specified test load.

5.3.7.2. Acceptance tests

5.3.7.2.1. Moment of failure (MF) test (for rail seat bottom)

Prior to stabilization of production technique, one sleeper for every 250

sleepers manufactured shall be tested. After the production technique gets
stabilized in testing scale shall be reduced to one sleeper for every 2500
sleepers produced.

5.3.7.2.2. Moment of resistance (MR) test (Rail seat bottom, centre top, centre bottom)

Depending on 15 day cube strength of the lot as mentioned in para 5.3.5.

The scale of testing for the lot shall be as follows:

55 N/sq.mm and above-one sleeper per lot.

Less that 55 N/sq.mm but up to 48N/sq. mm-two sleepers per lot.

a. Prior to stabilization of production technique: Sleeper to be

tested shall be subjected to rail seat bottom, centre top and centre
bottom tests.

b. After stabilization of production technique: Sleeper to be tested

shall be subjected to rail seat bottom and centre top tests only.
NOTE:
Test procedure has also been shown as a flow chart in Annexure-IV.

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 Wherever MF test is to be conducted, it shall be performed on the first sleeper
selected for testing under clause 5.3.7.2.2.
5.3.7.3. Acceptance of ‘lots’

5.3.7.3.1. All sleepers tested in accordance with clause 5.3.7.1 should pass all the
acceptance tests provided in clause 5.3.7.2 for the lot to be accepted.

5.3.7.3.2. If any of the sleepers fail in any of the tests conducted, the lot shall be
subjected to ‘retest’ as per clause 5.3.7.4.

5.3.7.4. Retest

5.3.7.4.1. MR

For every sleeper failed in acceptance tests I & II of clause 5.3.7.2.2., two
more sleepers from the same lot shall be retested as per clause 5.3.7.2.2.

5.3.7.4.2. MF

In case of failure of the sleeper in MF test as per clause 5.3.7.2.1.2 more

sleepers from the same lot shall be selected for testing in MF as per clause
5.3.7.2.1 and 5.3.7.2.2 and subjected to all relevant tests. However, if the
sleeper has passed MF test and failed in some other test MF test need not be
repeated on subsequent sleepers subjected to testing.

For acceptance of the all the sleepers tested in ‘retest’ must pass all the tests
conducted. However, sleepers failing in any static bending tests shall not be
paid for.

Also final passing of the lot is a prerequisite condition for payment for any
sleeper having passed all the relevant tests conducted on that sleeper.

Sleeper/sleepers tested for rail seat bottom failure test and passes the test,
shall be paid by the purchaser, if that particular lot passes all the relevant
retests.

NOTE

In case where more than one test value is obtained in retests. The latest value
obtained will be taken as strength of the lot for deciding the result of the lot.

5.3.8. Measurement of electrical resistance

5.3.8.1. All sleepers shall be tested as per Annexure-V for electrical resistance for
their fitness for use in track circuited area.

5.4. For inspection of concrete sleepers, officials having competency certificate

issued after due test by RDSO/Chief Track Engineer only shall be posted.

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6. Stamping And Marking

6.1. All the sleepers shall have legible permanently inscribed and painted marking
on the top as per drawing No.RDSO/T-2466.

6.2. The accepted sleepers shall bear the passing marks of the Inspecting Officer
in indelible paints. Sleepers which have been subjected to static bending
strength test up to cracking and accepted, shall in addition be marked on the top
in indelible paint with the letter ‘T’. MF tested and accepted sleepers shall bear
the making ‘MF’ in paint with yellow bands at ends.

6.3. All sleepers fit for use in track circuited area shall bear the mark ‘FTC’ at the
center of the sleeper.

6.4. Rejected sleepers shall be stacked separately by the manufacturer so as to

avoid their mixing with the accepted sleepers. Such rejected sleepers shall be
marked in the way specified in drawing NO.RDSO/T-2466.

6.5. All markings mentioned in para 6.1 to 6.3 shall be done with enamel paint of ISI
mark and shall be such as to last for at least 3 years under normal weather
conditions. Colour and quality of the paint used shall be got approved by the
Inspecting Officer. All such marking shall be done by the manufacturer at his
cost.

7. Loading And Despatch

7.1. Only those sleepers which have been passed, properly marked and accepted by
the Inspecting Officer shall be loaded for dispatch.

7.2. The loading of the passed sleepers in wagon shall be done by the manufacturer
at his cost as per the loading arrangement approved by the purchaser. The
sleepers shall be properly secured to avoid movement and displacement during
transit. The manufacturer shall be responsible to replace, free of cost, all the
sleepers which are found damaged in transit on account of defective loading.

8. Guarantee

8.1. The sleepers shall be guaranteed by the manufacturer for sound manufacture
for a period of 24 months from the date of its manufacture or for one year after
they have been put in service in track whichever is later. If during the guarantee
period any sleepers are found to develop defects attributable to bad material,
workmanship and/or dimensions requiring withdrawal from service, the cost of
sleepers and their replacement shall be borne by the manufacturer. The
defective sleepers withdrawn from service can be taken over at site by the
manufacturer for their disposal. The manufacturer shall make good the cost due
within 60 days of advice of defects. The decision of the purchaser shall be final
and binding in this regard.
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57
 ANNEXURE-V- A

SCHEDULE FOR CALIBRATION OF VARIOUS GAUGES AND

TESTING EQUIPMENTS IN THE CONCRETE SLEEPER PLANT

S.N Frequency
Equipment
o
1. 15 cm concrete cube testing machine Once in 3 months
(2000 KN capacity)
2. Cement mortar cube testing machine Once in 6 months
(500 KN capacity)
3. Sleeper Static Bend Test Machine (500 Once in 3 months or after testing
KN capacity) 250 sleepers, whichever is earlier.
4. Pre tensioning Jacks (500 KN capacity) Once a month or after casting 5000
sleepers, whichever is earlier.
5. Pretensioning load cell -do-
6. Concrete Beam Testing Machine (100 Once in 6 months
KN capacity)
7. Aggregate weight batcher Once every week or after casting
2000 sleepers, whichever is earlier
8. Cement weighing equipment -do-
9. Water Meter -do-
10. Master gauges for checking correctness Once in 6 months
of dimension measuring gauges
11. Dimension checking gauges Once every 15 days or after
inspecting 5000 sleepers,
whichever is earlier.
12. Proving rings (2000 KN, 500 KN and Once in 2 years
100 KN capacity)

Note:
1. The items referred at S.No. 1 to 6 above should be calibrated by proving rings
in the sleeper plant itself.
2. The items referred at S.No. 7 & 8 should be calibrated by dead weights and
item at S.No.9 by measuring cans which should be available in the plant.

3. The proving rings should be got calibrated from a reputed organization like the
IITs, NCCBM or NPL etc.

4. The record of calibration of all the above equipments should be maintained in

a manner that previous records can be easily connected.

5. The calibration can be done more frequently at the discretion of the Inspection
Official.

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