wats oat GOVERNMENT OF INDIA MINISTRY OF RAILWAYS GUIDELINES ON FABRICATION OF STEEL GIRDERS FOR CONSTRUCTION/FIELD ENGINEERS BS -110 (R) March, 2016 ISSUED BY B&S DIRECTORATE RESEARCH DESIGNS AND STANDARDS ORGANISATION LUCKNOW-226011FABRICATION OF STEEL GIRDERS The fabrication of steel girder bridges is being done by various Railway Workshops as well as through trade. The fabrication is governed by the provisions of, i) ii) Indian Railway Standard specification for fabrication and erection of steel girder bridges and locomotive turn-tables. (81-2001) Indian Railway Standard Cade of Practices for metal arc welding for structural steel bridges carrying rail cum road or pedestrian traffic (Adopted 1972 Revised 2001) The officials associated with fabrication work should have thorough understanding of both the codes i & ii, However, these guidelines have been prepared for helping the field engineers associated with execution of the fabrication work through trade. It has been tried to cover various aspects which require close attention of the field engineers for ensuring quality of the fabrication work. These guidelines are just to facilitate and not to supersede the two cades. All engineers associated with fabrication are advised to understand the pravision of IRS 81-2001 and Welded Bridge Cade and take help from these guidelines Book published by RETS IRICEN “Steel Structure Fabrication for Railways” is also a very good guide for the Engineer incharge of fabrication. The workshop engineer or contractors should also have good understanding of various provisions of above Railway cades and ather related codes ITEM REQUIRING ATTENTION BY FIELDIWORKSHOP ENGINEERS DURING FABRICA: A. IN OF STEEL GIRDERS Approved Drawing to be used for fabrication: Field/Workshop Engineer associated with fabrication should have all the relevant drawings, Cades & Specifications with latest Correction Slips prior to the start of work. On the basis of structural drawings, fabrication drawings should be prepared by fabricator. Plate Girder Drawings to be checked for intermediate stiffeners whether riveted or welded Quality Assurance Programme (QAP) of Steel Girder Fabrication: + To ensure the proper quality of fabrication, Quality Assurance Plan (QAP) is prepared. QAP must indicatestage-wise manufacturing process coveringvarious steps, tests, checks & their frequency, sampling plan, authority for grant of clearance etc. for all activities from inspection and testing of raw material to trial assembly and erection. The QAP must cover following aspects.+ Brief Details of project + Contract Agreement No. + Loading Standard * Governing Specification + Drawing references + Roles and responsibilities of various agencies involved in fabrication, erection & inspection A sample QAP for 30.5m welded open web girder is given at Annexure-| QAP is to be scrutinized and approved by the inspection agency. In case of welded girder it is to be done by RDSO, as per prevailing orders. (QAP should be signed by Fabricator and Railway Officials [Minimum JAG Level] before submission to RDSO) Field Engineer should ensure that work is carried out strictly as per the approved QAP and no deviation takes place from QAP. All the stages should be studied in detail, prior to start of work. Scrutiny & Approval of Welding Procedure Spec. Sheet (WPSS) (final approval to be done by RDSO): WPSS is process sheet indicating plate/section used, welding process, type of joint, welding consumables quality, welding parameters, acceptance standard tests applicable etc. Field Engineer should ensure that welding is carried out as per approved WPSS. Performa for WPSS is given in Appendix-V of IRS B1- 2001. WPSS should be signed by fabricator and Railway Officials before sending for approval of RDSO (Annexure-|)It is to be ensured that welding consumables to be used are fram approved source and a proper record of their consumption is maintained. A sample Performa for record keeping af consumablesis enclosed as Annexure-Iil Welding Procedure Qualification Records (WPQR) (final approval to be done by RDSO): WPQR is the document indicating approval of various welders who are to be deployed for carrying aut welding work for fabrication. It containsName of the welder with photograph, qualification, experience, qualification tests and records for each welding process and joint, welding parameter. Tests are conducted by RDSO Officialfrom M&C Directorate before qualifying the welders and then approval is granted through WPQR Performa for WPQR is given in Appendix-V of IRS B1-2001. WPQR should be signed by fabricator and Railway Officials before sending for approval of RDSO (Annexure-IV) Field engineer should ensure that welding is done only by approved welders and no deviation takes placeRaw Material and Gauge Certification Inspection of Raw Materials-Passing of raw material is done on the basis of visual inspection and lab test reports far mechanical properties, chemical composition, ultrasonic examination, Charpy Impact Test etc. Rivets and other consumables like paint etc. should also be got tested from NABL Lab as per relevant codes/specification All the required test should be got dane through independent NABL Labs and compared with the mill test certificate results given by the supplier before passing the material for use Material test certificate register must bemaintained by fabricator as per Annexure available in IRS: B1-2001(appendix-IPerforma-7Jand signed by railway representative as well as fabricator. All angle/channel, rolled section to be used for open web girder fabrication shall be checked for rolling tolerance as stipulated in 1S:1852 In addition to above visual inspection shall be done to ensure that steel is free from surface defects like pitting, laminations, imperfect edges, twist, other harmful defects etc. and recorded in the register Note:- Raw Material Steel has to be as per Para 8 of IRS 81:2001, recently revised vide Correction Slip No.5 dated 30-08-2013 (Annex-V). In majority of case where service temperature does not fall below 0°C steel grade designation is E-250 Quality “B0" as per Para 8.2 of IRS B1:2001 Item requiring attention before Fabrication of Girder. F4. Inspection of Layout on template floor - Field engineer has to ensure that theTemplate floor is level. Nominal and camber layout are drawn with the calibrated steel tape. The certificate of calibration from a authorized agency should be kept in record. Squareness, diagonal measurement of layouts arealso checked. It should be remembered that tape should not be changed during the various stages of measurement Running measurement should be recorded with a long tested tape having minimum length suitable for half span/full span measurement as per the case. 4 Ibs pull is to be applied for stretching the tape.Suitable device should be used for this purpose F2. _ Inspection of Jigs, Fixtures and Master Plates -Master Gussets should be checked on nominal layout and transfer of all inter section line/points to be done with great care and accuracy. If gussets are symmetrical then 1/4" or half hole marking is to be done and same willl be transferred to complete the gusset marking. Dimensional Inspection of Jigs, Fixtures, Master Plates used in manufacture of girder should be done very carefully to ensure accuracy.It should be remembered that jigs of main members of the open web girders are fabricated on the camber length with the adoption of the field holes at nominal lengthlayaut through master gussets. F3. Layout of joints is drawn as per drawing an 1:1 scale on a level ground to check for; i) Any infringement of rivets, adjoining edges etc ii) Position of holes in master plates for jigs as per layout. ili) The bore of bushes shall initially have tolerances of - Ommto + 0.1mm Fairing of bushes with holes of master plate shall conform to tolerances of - 0.13mm using a ‘GO’ gauge of 0.13mm less than hole diameter. Bushes of jigs during service shauld be maintained within acceptable limit (D+0.4mm) which shall be checked at regular intervals. F4. Certification of Jigs, Fixtures and Master Plates-Stamping of Master Plates by the inspection official should be ensured prior to their use The jigs should be checked by fabricator and field engineerfrom time to time for their wear and tear for maintaining accuracy during work. Item requiring attention during fabrication of girder: Field/Workshop engineer should keep a watch and maintain proper record for- (i) Ensuring Use of Approved Raw Material -Onlyraw material clearedoriginallyto beused during fabrication. (ii) Ensuring use of Approved Welding Consumables-Type of consumables, source, quality, approval status, grade, suitability for fabrication as per WPSS. etc. to be frequently checked and recorded (ii) Ensuring use of Approved Welders-Checking of welders certificate, records, skill and procedure adopted for welding as per WPSS (iv)Ensuring use of Approved WPSS & Welding Parameters-Checking welding parameters and equipment used for correctness of joint preparation etc. Important Checks for Tack Welding: i) Check that top & bottom flange plate are perfectly perpendicular with reference to web throughout the length of | Section ii) Check the squarenessi.e. 90° angle between flange & web of top and battom flange plate to avoid out of squares flanges ili) Check with filler gauge throughout the length of top & bottom flange connection for uniform contact throughaut the web plate Points requiring attention during full welding: i) Thorough cleaning of tack welded member should be done with appropriate tool like wire brush, before shifting for full welding Minimum width of 75mm 4throughout the length shall be cleaned to ensure that the surface is free from dust, mill scale, grease, oil and paint to ensure sound quality of weld ii) Full welding shall be carried out in flat position with SAV) process as per sequence mentioned in WPSSIWPOR using manipulator/special welding fixture. ili) The sequence of welding shall be shown in WPSSIWPQR marked as 1, 2,3 & 4 in the order of welding iv) The welding should be done in proper sequence V) Minor welds/ inaccessible location welds shall be made by COzwelding or other type of weldingas per approved WPSS. Good Working practice for prevention of distortion in welded girders: i) By pre-bending of flange plate of welded girderusing appropriate fixture ii) By clamping the flange plate to fixture (Fixture developed by MMR Workshop is given at Annexure V1) Radiographic Exam.of Butt Weld Joints-Any butt welding provided as per approved WPSS should be subjected to radiographic testing by authorized agency only. The film should be preserved for examination, sensitivity, defect interpretation and acceptance decision based on prescribed criteria Ensuring use of Approved set of Jigs & Fixtures-To permitthe interchangeability of the components and ensure pre-stressing in open web girders and to avoid distortion, it should be ensured that only approved Jigs & fixture are used andproper clamping arrangement are provided in jigsffixtures. Item requiring attention after fabrication of girder:stacking of component should be proper and shipping markis properly stenciled on component for identification FieldiWorkshop engineer should ensure that:- While cutting the plates or other section the heat/cast mark should be transferred to all cut members while using these members for fabrication Proper record of heat mark should be maintained/ correlating it with the components of girder Visual Exam of Welds-Quality of weld, uniformity of weld bead, size of the weld weld defects e.g. under cut, blow hole, porosity, spatter, crack etc.should satisfypara 31 and Appendix C of welded bridge code Metallographic and NDT Exam of Fillet Welds-Macro etching on girder, run-an, run-off tabs for ensuring proper weld quality, Dye penetrant examination etc,should be arranged by fabricator, for independent inspectionStructural and dimensional inspection-Dimensional checkshould be carried aut by field engineer to ensure conformance to drawing dimensions including diagonal checks for squareness etc. before affering girders for final inspection Trial Assembly:for open web girder First span is always trial assembled to check whether fabrication process is proper or require any correction in jigs, workmanship or procedures to ensure regular quality output. Following important parameters are checked during trial assembly: () Camber: Camber shall be checked while the girder is supported on the nodal points on camber jacks and after releasing jacks i.e. for residual camber with girder resting on bearing ends. The camber measurements should be done with appropriate leveling instrument: Dimensional check: i) Overall length ii) Bearing centers iii) Height iv) Truss center v) Center to center distance of rail bearers vi) Center to center distance of panel points vii) Squareness viii)Alignment of the girder ix) Fairing of holes x) Verticality xi) Infringement, if any xii) Butting of compression flange Component Inspection of first span-Detailed inspection of dismantled components of trial erected span is carried out to see the integrity of components. There shauld not be any elongation of holes, tearing of edges or other defects after dismantling of trial assembly Component inspection of 2" span onwards:-Once fabrication process is found satisfactory i.e. all steps from A to J are proved during trial assembly and its component inspection, then only components of 2" span and onwards should be fabricated with the approved sets of jigs and fixture, the tested WPSS andWPQR as laid aut in steps earlier. Field engineer should do the components inspection and ensure all record are available before giving final inspection call inspecting authority. Plate girder check. i) Overall length ii) Bearing centers iii) Height iv) Girder center v) Squareness vi) Fairing of holes vii) Verticality viilInfringement, if any ix) Butting of compression flange Anti Corrosive Treatment-Surface preparation, metalizing and or painting as per applicable painting schedule should be done as per provision given in para39 of IRS:B1-2001 Stages of Inspection in Fabrication of Bridge Girders:- The important stages in a tabulated form showing various stages and corresponding Inspectian/Approval agency for Rail & Rail-cur-Road Bridge are as shown in Annexure-VIl. Far ROB's, Inspection/Approval agency for all stages will be cancemed Railways. Certificates to be furnished by Railway:- During fabrication, internal inspection to be done by Railways to ensure that only RDSO approved welders carryout welding as per approved WPSS, work is as per dimensional tolerances and other quality aspects and should satisfy itself before sending inspection call to RDSO for Trial Assembly or Component Inspection Railway has to give following four certificates as mentioned in RDSO letter No. CBS/Insp/WBG Dated 10-04-2015 (Annex VIll) at time of sending Inspection Call () Steel used for welded Bridge Girders components is of weldable quality is IS: 2062 Gr.BO fully killed and fully normalized, which has been inspected &approved by the Railways. (i) Fabrication has been done with the help of approved Jigs. (ii) Entire welding was done by approved welders using approved welding procedures (WPSS) and welding consumables.(i) Fabrication work has been inspected by our internal quality contro inspection organization including the welding and riveting. All significant defects have been rectified and final dimensions are within tolerances. Fabrication Agency:- Railway Board vide letter No. 2014/CE-II/BRIBridge Workshops Policy dated 24-02-2014has allotted Railway Bridge Workshops as Primary Source and Secondary Sources to all Zonal Railways. The same has been reiterated vide RDSO Letter No. CBS/Insp WBG dated 28-02-2014 (Annex.-IX) S.No. [Raiway Primary Source Secondary Source 7 CR, WCR & SECR Manmad Sabarmati z ER, ECOREECR Mughalsarai Lucknow 3 NCR &NR Jallandhar& Lucknow | Mughalsarai q SWR ESR ‘Arakkonam Manmad 5 NWR EWR Sabarmati Manmad 6 SCR Tallaguda Manmad T NFR Bogaingaon Mughalsarai a NER Gorakhpur Lucknow a SER Sini Mughalsarai Efforts should be made by the Open Line/ Construction Organization of the concemed Railway to get the requirement of their Railway met by primary or secondary sources. While exploring this aspect, they should advise realistic target date to requirement within the planned target date, concerned CBEs should advise the requisite Railway, their ability/ inability to supply girders within the stipulated time. Only after obtaining the confirming in writing from CBEs of bath the primary and secondary sources that they are not able to meet the request of the Zonal Railway, the concerned Railways may go to the trade for fabrication/ supply of girders. In such cases, Zonal Railway will have to ensure that the trade supplies the material within the target date given originally by Railway to the CBE of primary and secondary source RDSO will take up the inspection of the girders supplied by trade only after the certificate of the primary and secondary source i.e. CBE of primary and secandary source regarding their inability to complete the requirement within the target date is produced by the requisite Railways. Check List: Check List for fabrication of Steel Bridge Girders for three stages (i) Prefabrication stage (ii) During fabrication and (ii) After fabrication are enclosed as performa-, II & Ill in Annex.X for guidance of Field Engineers Standard QAP for Elastomeric Bearings, POT-PTFE Bearings & Expansion Joints are enclosed as Annexure-XI, XIl & XIll for guidance of Field Engineers.Some important DOs & DON'TS are given here for guidance:- Dos- > Use proper fixtures and clamps to hold the members firmly at desired location while welding. The clamps and fixtures must be strong enough to prevent any distortion of the member while cooling of the welding joint. The clamps and fixtures are only to be removed when the joint is cooled to ambient temperature > Do the welding work in a warm and dry place so that rain water or other atmospheric elements may not come in contact while welding is in pragress. > While welding in very cold weather pre-heat the material before welding and apply post heating to prevent the weld jaint from rapid cooling and develop ‘stress raiser due to sudden contraction. > Cross level of bearing plates in the welded plate girders should be checked properly for proper sitting aver bed plate > To co-relate use of steel and welders in different members proper records shauld be maintained > Drilling of holes through approved set of jig particularly long members should be ensured. No fabrication should be dane with unapproved jig. > Drain hole in the portal girders at proper locations should be ensured > Fairing of holes and removal of drill burrs through initial assembly should be ensured > Proper edge finishing with grinding! special attention in top chord compression members butting by end milling should be carried out > At site during the erection of girders particularly open web girders due and adequate care shauld be taken to achieve the required camber values. > Camber Jacks should be provided at all the nodal points during trial assembly > Butting of compression members, X-levels of stringers and alignment of stringers to be checked properly in the trial erection > Application of paint on permanent contact surface should be ensured after proper surface preparation visual inspection is very important toal > The plates should be perfectly horizontal while drilling the holes to ensure horizontal verticality of hales. > Steel with proper test certificate/ reports should be used, Commercially available steel in the market should not be used > Steel received from the rolling mills has generally punch heat mark numbers. These numbers should be legibly marked again with paint for easyidentification. Heat mark numbers should be transferred to cut members with paints Members of the open web girders should be fabricated on the camber length with the adoption of the field holes af nominal length Cansistency of weld quality is higher in Submerged Arc Welding Process and chances af human errors are also eliminated. Therefore, welding of the girders should be done by SAW process. Whenever nat possible then only CO? welding ar MMAW maybe adapted if provided in approved WPSS. Stage inspection during fabrication should be properly ensured to avoid rejection at later stage. Skilled and qualified welders, drillers, fitter should be deployed for welding drilling and marking works. The welder should be indivisually approved by authorized agency i.e, M&C Directorate of RDSO. Selection of Angles in fabrication of cross girders and stringers of open web girders requires special attention, drooping in angles either acute or obtuse shauld not be permitted. It will cause improper sitting of sleepers on the stringers DON'T's- Use of pitted/ corraded material should not be done because it gives rise to concentration of stresses and results in paor fatigue strength Tack welds in fabrication of riveted open web girders should be avoided Do not hammer the distorted joints for rectification, It may lead to the develapment of cracks and failure of the joints Da not do the welding in chilled weather, as due to sudden cooling of welded joints they are liable to be brittle and develop cracks, The joints may also suddenly fail under dynamic loading without any prior warning Do not weld with un-controlled welding parameters, these will affect the quality of welding and make the joints weak and may yield in dynamic loading on the structure Do not weld the joint haphazardly without following the proper welding sequence. This will lead to uncontrolled and irreparable distortion, of the proper geometry of the joint. ‘Sharp notches in the member should be avoided. 10Name of project Manufactured by Workshop Address. ‘SAMPLE QUALITY ASSURANCE PLAN 30.5m Welded Open Web Girder (25T Loading-2008) as per RDSO's Drg. 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For ROB Inspection/Approval Agency fr allstages willbe conceimed Ralaays. Signature of Fang Agency Signatur of Pinay Representative 16 ‘Pppeoal of DSOAnnexure-Il APPENDIX -V (Ref. Clause 26) Proforma for Welding Procedure Specification Sheet Name and address of Fabricator: Welding procedure specification No 1. Weld joint description 2. Base Metal 3. Welding Process 4. Welding position 5. Welding consumables 5.1 Electrodelwire Class Dia Drying method 5.2 Flux Class Type Drying method 5.3.1. Shielding gas 6.0 Base Metal preparation 6.1 Joint design details: (Give sketch showing arrangement of parts, welding groove details, weld passes & their sequence etc.) 6.2 Joint preparation: 7. Welding current Type Polarity; 8. Welder qualification: 9 Welding parameters and technique 9.1 Welding Parameters: 17Annexure-II (Contd...) Weld] Electrode | Curren ] Arc Wire feed) Travel | Electrical | Gas flow Pass |s/ — wire|t (amp) | Voltage | speed speed | stickout | rate No. dia.(mm) (volt) | (m/min) | (m/min) _| (mm) (litre/min.) T 2 3 4 5 6 7 8 9.2 Welding sequence and technique: (Give sketch showing sequence and direction of welding) 10. Provision of run in and run-off tabs: 11. Cleaning of weld bead before laying next weld bead 12. Root preparation before welding ather side of groove weld: 13. Preheating and inter pass temperature: 14 Peening 15 Post weld treatment 16 Rectification of weld defects: 17 Inspection of weld 18. Any other relevant details Prepared by Signature. Designation Date (for & on behalf of Fabricator) 18Annexure-l Performa for maintaining Register for consumable: Date Detail of item Weather Manufacturer Quantity] Quantity ] Quantity | Sign of site with item is test received | consumed | balance | supervisor manufacturer | approved | certificate name | byRDSO| detail. (Yes/No) 19Proforma for Welding Procedure Qualification Record NAME AND ADDRESS OF FABRICATOR Annexure-IV 1. Description of weld joint 2. Welding procedure specification no 3. Name of welder: 4 Date of preparation of test piece: 5. Dimensions of test piece 6. Base Metal 7. Welding Process: 8. Welding position: 9. Welding Current Type Polarity: 10 Weld joint design details: 11 Welding consumables: 11.4 Electrodelwire Class Dia Brand 11.2 Flux Class Type Brand 11.3. Shielding gas: 12. Welding parameters Weld | Electrod | Current | Arc | Wire ] Travel | Electrical | Shielding pass | ewire | (amp) | voltag| feed | speed | stick out | gas flow No. | dia (mm) e | speed | (mimin.)| (mm) rate (volt) | (m/min. (litimin.) 4 2 3 4 5 6 7 8 13. Preheating and interpass temperature 2014. Results of Qualification Tests: Annexure-lV (Contd...) Test Specimen No Result 1 2 3 Non-destructive tests i) ii) ii) iv) Visual examination: Dye penetrant test Magnetic particle test: Radiographic/Uitrasonic test Destructive tests vi) vii) Macro-examination: Hardness survey’ Fillet weld fracture test Transverse tensile test Tensile strength Yield Stress Location of fracture All-weld tensile test Tensile strength Yield Stress Elongation % Guided bend test Root bend test Face bend test Side bend test Any other tests: Signature Designation Date (for & on behalf of Fabricator). 2Annexure-V GOVERNMENT OF INDIA MINISTRY OF RAILWAYS (Railway Board) INDIAN RAILWAY STANDARD SPECIFICATION FOR FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES AND LOCOMOTIVE TURN-TABLES Fabrication Specification (IRS:B1-2001) ADOPTED - 1934 REVISED = 2001 ADDENDUM & CORRIGENDUM SLIP NO. 5 Dated 30-08-2013 () Existing Para 0.3.3 is to be replaced as under: Para 03.3, RDSO's Specifications: M&CIPCN/102/2009 Epoxy zinc phosphate primer. M&C/PCN/103/2011 Epoxy micaceous iron oxide. M&C/PCN/109/2008 Polyurethane red oxide. M&CIPCN/110/2008 Polyurethane aluminium. M&CIPCN/111/2008 High bulld Epoxy paint. (i) Existing Para's 8.1, 8.2, 8.3 and 8.4 are to be replaced as under: 8.1 1S:2062, Quality “A” Grade Designation E250 as rolled semi-tilled or killed shall be used for foot-over bridges and other structures subjected to ‘non-critical loading 8.2 1S:2062, Quality “BO” Grade Designation E250 fully killed and with normalizing! normalizing rolling! controlled rolling where service temperature does not fall below 0°C, shall be used for weldediriveted girders subjected to Railway loading. Plates less than 12mm thick need not be with normalizing! normalizing rolling/ controlled roling. 8.3 1S:2062, Quality “C” Grade Designation £250 fully killed and with normalizing’ normalizing rolling’ controlled rolling ensuring impact properties at (-) 20°C shall be used for sub-zero temperature areas for weldediriveted girders subjected to Railway loading. Plates less than 12mm thick need not be with normalizing! normalizing rolling/ controlled rolling, 22Annexure-V (Contd...) NOTE: 1. In case Rolled Steel Section confirming to 1$:2062 Quality “BO” ‘or “C” are not available in market, CAO(CVCBE may permit use of steel confirming to 1S:2062 Quality “BR” on case to case basis by satisfying himself about non availabilty of quality "BO" or c 2. In case Rolled Steel Section confirming to 18:2062 Quality “BR’ is also not available in market, CAO(C)CBE may permit use of steel confirming to 1S:2062 Quality “A” on case to case basis, by satisfying himself about non availabilty of quality “BR’. 8.4 High tensile steel shall comply in all respects with the requirement of 18:2062 Grade Designation E 410 Quality 80 or C (copper bearing quality) for the welded work. (ii) Existing Para 39.2. Para 39.2.3(b) Finishing Coat ‘Two finishing coats of red oxide paint to 18:13607 with colour/shade to be specified by Zonal Railway or of any other approved paint shall be applied ‘over the primer coats. One coat shall be applied before the fabricated stee! work leaves the shop. After the steel work is erected at site the second finishing coat shall be applied after touching up the primer and the finishing coat if damaged in transit. Note: (i) The colour/shade of finishing coat should be generally maching with the Smoke Grey colour/shade No. ISC 692 mentioned in IS:5- 2004. (ii) The coloure/shade can be changed by CBE as per the local regirements. (b) is to be replaced as under: BY ORDER (AK.Dadarya) Executive Director(B&S) LUCKNOW Dated: 30-08-2013 23Annexure-VI LommxS0mm STRIP WELDED = — ON 40MM THICK PLATE TO - PROVIDE PREBENDING TO FLANGE PLAN 40mm THICK PLATE CLAMPED WITH FLANGE —_ ctamp—- {4 GAP REDUCED BY CLAMPS 1OmmxSOmm STRIP WELDED. ON 40mm THICK PLATE TO PROVIDE PREBENDING TO FLANGE PLATE OF GIRDER | | WEB OF GIRDER SIDE VIEW IMPROVED DESIGN OF FIXTURE 24Annexure-VIl Stages of inspection of Steel Bridge Girders (For Rail and Rail-cum-Road Bridges) (| Prefabrication stage: Inspection’ Approval (i) Approval of Quality Assurance Plan (QAP) RDSO (2) Scrutiny of Welding Procedure Specifications Sheets (WPSS) RDSO () Welders Qualfication Test Te. Welding Procedure Qualfcation | pogo Records (WPQR) (@) Inspection and clearance of raw material Railways () inspection of layout on template floor (Nominal Camber) RDSO (6) inspection of jigs and fixtures with master plates RDSO ()__| During Fabrication (i) Use of approved raw material Railways (2) Use of approved welding consumables Railways (8) Use of approved welders Railways (@) Use of approved welding procedures and parameters (WPDS)| Railways Welding Procedure Data Sheet to be maintained far all welds. () Fabrication with approved set of igs Railways (ii)__| After Fabrication (i) Inspection of welds RDSO (2) Structural and dimensional inspection RDSO @) Tral_assembly_(First_ Gider} Camber Values, Dimensions, | _ RDSO Faliness of Holes by Go-No-Go Gauge, Butting of Flange in Top Chora, () Inspection of Dismantied Components of 1* Trial Assembly —| RDS Check for elongation of Holes/Abnormal stress marks/cuts etc. & Removal of shortcomings noted during Trial Assembly. (7) Inspect of only components for further spans- welding inspection & | _ RDSO Dimensional checks. (@) Metalizing/ Painting Railways Note: 1. During fabrication, internal inspection to be done by Railways to ensure that only RDSO approved welders carry out welding as per approved WPSS, work is as per dimensional tolerances and other quality aspects and should satisfy itself before sending Inspection call to RDSO for Trial Assembly or components Inspection For ROB's Inspection/Approval Agency far all stages will be concemed Railways 25Annexure-VIll ‘rire bor 24sosso} scones} sare Seer area y-2$200) 431203) sear iPod ate Are TE Berpaxor.aso2 28088 ‘HET 226011 Ea ert evalam Goverment fdas ofRaays ‘Research Design & Standards Orgeniaation eet ‘iesnaw 220017 No, CBSINSPWBG Dated: (0-04-2018 Chief Bridge Engineer 1. Central Railway, Mumbai CST-400 001 2, Eastern Railway, Fai Place, Kolkata-700 001 3, East Central Railway, Hazipur-844 101 4. East-Coast Railway, Bhubaneshwar-751 016. 5, Northem Railway, Baroda House, New Delhi-t 10 001 6. North-Central Raiway, Allahabad-211 001 7. North Eastern Railway, Gorakhpur-273 001 8. North-Western Railway, Jaipur-802 001 8. Northeast Frontier Railway, Maligaon, Guwahat-781 081 10. Southern Railway, Park Town, Chennai-600 003. 14. South Central Railway, Rail Niayam, Secunderatad-600 371, 42. South East Central Railway, Bilaspur-495 004. 13. South Eastem Railway, Garden Reach, Kokkata-700 043. 14. South-West Railway, Hubli80 023, 15. Western Railway, Mumbai-400 020. 46. WestCentral Railway, Jabalpur-482 001 Sub: Fabrication — Inspection of Stee! Bridge Girders. Ref: 1. This Office letter of even number dated 12-09-2013. 2. Para 27 of IRS ‘Welded Bridge Code. RDSO has been entrusted to undertake the inspection of Steel Bridge Girders as per Para 27 of IRS; Welded Bridge Code. In order to ensure proper Quality of the fabrication work of the Steel Bridge Girders, Quality Assurance Plan (QAP) is finalized among the user Zonal Railways, Fabricating Agency and RDSO, accordingly the responsibilty to ensure different quality checks from pre-fabrication to post fabrication stages are stage wise indicated clearly. Some cases have come to notice, where Railways are not diligently following the inspection on their part as per approved QAP during fabrication of Steel Bridge Girders. In order to ensure the Quality of Steel Bridge Girders while offering the girder to RDSO for final inspection itis desired that an undertaking by Railway Officer should be submitted:~ Undertaking by Railway Officer (minimum JAG Offcen}:- Itis certified that- @ Stee! used for welded Bridge Girders components is of weldable qual is IS: 2062 Gr.B0 Tully killed and fally normalized, which has been inspected & approved by the Railways. (@ Fabrication has been done with the help of approved Jigs. (ii) Entire welding was done by approved welders using approved welding procedures (WPSS) and welding consumables. 26wy Annexure-VIll (Contd. Fabrication work has been inspected by our internal quality contro/mspection organization including the welding and riveting. Al! significant defects havo been rectified and final dimensions are within tolerances. \dly convey to all concerned officials that Inspection call without above undertakings. will not be considered. Bea 1 a ped (AK Dadarya) Executive Director(B&S) For Director General Copy to — 1” Chief Administrative Officer (Constn ) 1. Central Railway, ChhatrapatShivaji Terminus, Mumbai ~400 001. 2. Eastern Railway, Fairlie Place, Kolkata-700 001 3. East Central Railway, MahendruGhat, Patna-800 004 4, East-Coast Railway, Bhubaneshwar-755 001 5. Northern Railway, Kashmere Gate, Dethi- 110 008 6 North-Central Railway, Allahabad-211 001 7. North-Eastern Raliway, Gorakhpur- 273 001 8. NF. Raiiway, Maligaon, Guwahati-761 011 8. North-Western Railway, Near Jawahar Circle, Malviya Nagar Jaipur-302 006. 10. Southern Railway, 183, EVR Periyar, High Road Egmore, Chennai -600 008. 11, South Central Railway, Rail Nilayam, Secunderabad-500 371. 12. South East Central Reiiway, Blaspur-495 004 13. South-Easiom Raiway, Garden Reach Kolkata-700 043 14, South-Western Railway, 18, Basaveshwara (Millers) Road, Bangalore-560 046. 15, Wester Railway, Churchgate, Mumbai-400 020. 16. West-Central Raihvay, Jabalpur-482 001. |. Chiet Workshop ManageriDy. Chief EngineerExecutive Engineer(Bridge Engineering Workshops):- 4. Central Railway, Manmad. 2 EC Railway, Plant Depot, Mughalsarai 3. Northern Raibway, Jalandhar. 4. Northern Raiiway, Charbagh, Lucknow. 5 N.E-Railway, Gorakhpur Cant. 6 NF. Railay, New Bongaigaon, 7 Southern Railway, Arakkonam. 8. South Central Raiway. Lataguda, 8. South Eastem Railway, Sin. 40. Western Railway, Sabarmatl Managing Director, Rail Vikas Nigam Ltd., Plot No. 25 1% Floor, B-Blok, August Kranti Bhawan, Bhikaji Cama Place, New Delhi-1 10066, Managing Director, Dedicated Freight Corridor Corporation of India Ltd., 8" Floor, Pragati Maidan, Metro Station Building Complex, New Delhi ~ 110001. pana =~ pol lis (AK .Dadarya) Executive Director(B&S) For Director General a7Annexure-IX weacer sre ear — Yat Hfarera AK.Dadarya rear oiftenes othe Hw VTE enland Pea / yor Ge eee “wer — 220001 Executive Director/B8S. Government of India-Ministry of Railways Research Designs & Standards Organisation Lucknow. 226011 Phone/Fax No.0522-2453098 No. CBS/INSP/WBG Chief Administrative Officers (Construction) Chief Bridge Engineers 1. Central Railway, Mumbai CST-400 001 2. Eastern Railway, Fairlie Place, Kolkata-700 001 3. East Central Railway, Hazipur. 4, East-Coast Railway, Bhubaneshwar. 5. Northern Railway, Baroda House, New Dethi- 110 001 6. 7, a. North-Central Railway, Allahabad North Eastern Railway, Gorakhpur-273 001 North-Western Railway. Jaipur. Northeast Frontier Railway, Maligaon, Guwahati-781 061 10. Southern Railway, Park Town, Chennai-600 003. 11. South Central Railway, Rail Nilayam, Secunderabad-500 371 12. South East Central Railway, Bilaspur ; 13, South Eastern Railway, Garden Reach, Kolkata-700 043 14. South-West Railway, Hubli 15. Western Railway, Mumbai-400 020, 16. West-Central Railway, Jabalpur. © ‘Sub: Nomination of Bridge Workshops-Secondary source. Ref: Railway Board's letter No. 2014/CE-IIVBR/Bridge Workshops Policy dated 24.02.2014. Railway Board vide their letter under reference have conveyed that with the approval of Board (ME) it has been decided that primary source as well secondary source of different Zonal Railways would be as under: S.No. Railway Primary source _ Secondary Source 1 | CR, WCR & SECR | Manmad Sabarmati 2 | ER, ECoR & ECR | Mughalsarai Lucknow 3_| NCR.NR Jallandhar & Lucknow | Mughalsarai 4_|[SWR.SR Arakkonam Manmad 5 [| NWRWR Sabarmati Manmad 6 [SCR Lallaguda Manmad 7__ [NER Bogaingaon ~~) Mughaisarai 8 [NER Gorakhpur Lucknow ~| 9 | SER Sini Mughalsarai | 28Annexure-IX (Contd...) 2.0 Further Railway Board has also ordered that RDSO will take up the inspection of the girders supplied by trade only after the certificate of the primary and secondary Source, .¢ CBE of primary and secondary source regarding their inability to complete the requirement within the target date is produced by the requisite railways. The above atrangement will be effective from 01.04.2014 3.0 Zonal Railways are advised to take suitable action in order to comply with the Railway Board's order. 4.0 Copy of Railway Board's letter under reference in enclosed for necessary action by Zonal Railways. DA: As above ee (AK Dadarya) Executive Director/B&S Copy to: The General Manager (Con.), Northeast Frontier Railway, Maligaon, Guwahati- 781 061 Il. Director, indian Railways Institute of Civil Engineering, Pune-410 001 Ill, Executive Director, Civil Engg./B&S, Railway Board, Rail Bhavan, New Delhi- 110 001 'V. Chief Work Shop Managers! Dy.Chief Enginners/Executive Engineers- Bridge / Engg. Work Shop Central Railway, Manmad E.C. Railway, Plant Depot, Mughalsarai N.Railway, Jalandhar Cantt. N.Railway, Charbagh, Lucknow N.F Railway, New Bogaigaon S.Railway, Arakkonam 4 2 3 4 5. N.E.Railway, Gorakhpur Cantt 6 F. 8. S.C.Railway, Lalaguda 9. SE Railway, Sini i 10. W.Railway, Sabarmati \ ui’ yen pre DA: As above [agi (A.K.Dadarya) Executive Director/B&S 29eakoena Annexure-X PROFORMA -I Check List for Fabrication-Inspection of Steel Girders Fabrication Code: IRS Welded Bridge Code Fabrication Specification: IRS:B1-2001 Fabrication Guideline: RDSO Report No. BS:110 HSFG Bolt Guideline: RDSO Report No. BS:111 Approved drawing No. ———--—~ Components of QAP (For Model QAP Refer BS-110) i) Raw Materials ii) Rivetinut/bolt iii) Welding consumables iv) HSFG Bolts (Bolts, Nuts, Washers and ferrules) (v) Paint (vi) Manufacturing process (Refer BS-110) (vii) Nominal/ Camber layout on template floor Vill) Jigs‘fixtures (layout and jigs not required fabrication is to be done by CNC system) ix) Welding activities and inspection (WPSS WPQR and WPDS) (x) Welding by approved welders (xi) Trial Assembly (First Girder) (xi) Detailed component inspection and clearance thereof Raw material i) Steel to IS: 2062 quality BO fully killed and normalized (i (ii) Heat mark on plates and name manufactures (ii) Mill Test Certificate available or not/Properties satisfactory or atherwise (iv) Testreport from NABL if any (v) Visual inspection (vi) Rolling and cutting tolerance as per 1S:1852 6 (vii) Any dispensations fram competent authority i.e. CAO(C)/CBE for change of quality of steel or in drawing HSFG Bolt (i) Material Specification 3010 (i) Annexure-X (Cont (a) Bolt : 1S:3757 (ii) (ii) (b) Nut 1S: 6649 and (C) Washer: 1S: 6623 Test report (Manufacture) Test report, NABL, if any Stud shear connector (0) (ii) Material BS: EN 1SO:13918 Ferrule broken or not Approval of Template Floor Layout (nat applicable if CNC machine is used) (a) Nominal Layout (b) Camber Layout (c) Appraval of master plates (i) (ii) (ii) (iv) wy) (vi) wii) Gusset Plates on nominal layout Members on camber length Distance over intersection paints Transference of intersection linins Symmetry and inter changeability Pitches/Gauge lines w.rt intersection points. Dia of holes and No. of hales 31Annexure-X (Cont PROFORMA -II Check List for Fabrication-Inspection of Steel Girders Proforma-| completed or not (further inspection to be done after completing activities mentioned in proforma-I!) 1. Use of approved raw material 2. Fabrication with approved of jigs or CNC 3. Welding (i) Scrutiny of WPSSs (Done or Not) (ii) Approval of WPGRs (Yes or No) (ii) Welding Parameters during welding (\WPDS) maintained ar not (iv)Welding done by Approved welders (Yes ar No) (v) Use of approved welding consumable (Yes or No) Electrode: IRS: M/28 Wire & Flux: IRS: M/39 Cogwire: IRS: M/46 (vi) Internal checks of welding (a) Visual, weld size, throat thickness, weld profile (b) DPTIMPT and Macro Etching (c) UltrasoniciRadiography Testing 32Annexure-X (Cont PROFORMA -IIl Check List for Fabrication-Inspection of Steel Girders Proforma-II completed or nat (further inspection to be done after completing activities mentioned in proforma-I!) Fabrication Process as per BS: 110 report 1. Finished Product |. Welding inspection (dane or due) (a) Visual, weld size, throat thickness, weld profile (b) DPTIMPT and Macro Etching (c) UltrasoniciRadiography Testing Use of approved set af jigs/CNC system 2. Structural and Dimensional Inspection (as per drawing) | Trial Assembly (1** girder) (a) Parameters to be checked (i) (ii) (ii) (iv) wy) (vi) Camber on Jack Dead Load Camber Dimension Fairness of holes Temporary fasteners Infringement, if any (vii) Butting of compression edges (b) Camber (an jack and residual) to be recorded in case of open web girders Measurements as per drawing of components. Surface Preparation (IS:9954) Metalizing/Painting of girder as per para 39 of IRS;B1 (Sa 2" to 1S:9964) 33‘STANDARD QUALITY ASSURANCE PLAN FOR ELASTOMERIC BEARINGS 4. Name of Manufacture 3. Name of ProjectRalinay 2. dig Ne. 4 Authorty (CA No/L.OA No Orde No): Annexure-X1 pa | —CRRETETSTE EGET B | RTETETE | FUBTRES™-| —FSBRETON GHGS —| Type G7 REESE aR No. | “Operation | “checks 8 | Typeatchtek] Oocumert [squat Reeords | “cntena m= Tolerances | 7 contol [REpESInG | Ee ‘Rgerey | inspection 7 = cu 5, su a 1 RW TT Fe Wares] THERIOT | RABNTET am —— Faas IRURS_— Earanavon a Te MATERIAL mmanutcurer [testcenteate [of Inspector [bates at |rsvecord. | (Panis | Corutates required Test 141 |Basomer | wer aves ot |eetfene& | Echatan |retrence | sppontes | Random {s3a00(as_| Ceres shal be mishea Conyurgin | charasersics — [teteeques ocumere. |byzonal | anda perrelevart | bymanutcres or Palyherpr | Spected byauthorses ce aeton ex folowing tests. ne (ORs inipecorof otinspecor provedie) | ()Campostion permed & onal alway (0) Haaness Pretrable ‘fom bow! {i Tenale srength (ates ae nage (i) Bongaton at Beak Neoprene approved lab (Compression set Wer (i) feceleraes Povng test Baypiene (i) Aaeson Senger tie ) Hardness | IRHDCOD:25) ‘Skype 8 be oRraNT: Sand enka |) Mn. Tensie | 17a Propertes of Bastomer say) Srengin shouldbe as per Tale tof J) Mn Beng. at | 400% ines break Parc Palyehloroprene 4) hax a4 Cortente a0 Compression ‘an corer 5% Pod Nate: () No reclaimed rubber Je) Hcetrated | 1002 1%e r Nwlenzed wastes or naira Soenatest | Hour rbber shat be used (G) EPDM (Bhile propylene 0 Mn camge |si8 are Sistem) 8 (eobane inrness | vue of Irene "Cope CR Wy Mac change | -T5% wrt (Cheresoprene” Copan) Infensie | ale of) Senet pemitea or Srengih manutacure ofbeanngs. ty Max hange | 90% wt inGengaton. | aie of) ‘Adhesion sength tet to be anducted a5 per IS: 3400 (oAineson — | Min.7 Ken Fare xiv Strength of Bosamerto Sheet Paes Tafe- Large at Tans number obenings ae 224 Eesti Pacpianee val Tobe condudd. Shalat ans WRINBWS of Beaings are CT where RSapanoe level ess ae done, Lat sizeto be approved bythe enginer-Inarge at 2 era bearings to be made ubih are consumed in destructive ting. 34SEA —CRSTSCTET SIS] RSRTEY RATES FSETSSTS] —FSBESTEN GESTS Ty RSET rena No. “Operation | “checks a | Type at check] Document |S quaty Rteords | "enters Tolerances ‘onerel PSBENNG[ Bterr ‘Agerey” | inspection 7 z 0 77 I emer — ores Te Fe Marea | Verein | Rabonred | Fam —— Fabien | RO Eaninatan ot — Ter fon. 1)" Datemnaton |manutacurer |testceretonte |ot Inspector” [barnes ae |rsrecor. | (Pati) Ash | Cerbtests Is requred Test iterateaton | certeate 2 | 8Chatan reference | appontee | Random Contert as | Certtcate shal be Umishea otpalymer | testrequred tocumere. | ByZonal per iss40o | by" manufactures or byAaorses Pa Par Xxi | flowingteste Inspec of na () Pelymer eriteaton tonal alway Polpeloropr |) Poles conten fom Got! ene conte |) Ach content NAB aspen | Sect gravty approved lab ‘Ashan207 | (V) Oroneresstance ldeneteston 5) Peter | in so oo tpatymer | Pretrbly test of palmer content. Seper | entteaten polymer cote ‘Betw0 —_ |'nd Ash content shoud be J) Ash contet [Mans so oo SerT (asper | ether winessed or Seales relearttes | Sample tbe sen to NABL 0) specif grauty A o procedue) | {AB br evaiaton Ne J) orene A oo For acceptance testing level [3 Aeh content on specimen ‘fom tet bearing shall be Compared wi thse br Spesally Moulded test pieces and Max variation ermitedis 205% specie gravy on Speamen “tom test Beanng shal be compares ftth those. br speaally ‘moulded test peces and Max varaten permed Is rook le) For eter test max. and tn. tobe aahered la) Ozone resixance can be Stave bytes engineer as per note. 2 of Pare Sia.ai 2 ofioed par 35pO | —CRATETSTE Fea B | RETR | FUBTRTS™-| WSBT GIS | Type a7 ReneSaRET aR No. | “Operation | “checks 8 | Typeatehtek] Oocumert [squat Reeords | “cntena m= Tolerances | 7 contol [REpESInG | Ee ‘Rgerey | inspection 7 ul su ca Tia Sel — | Mecha Test [As pera TO [MATTE and ROTI OTe | Fas] ISIE TT | WaRUROTETs ATCE Urs. Weld Suess, | Stestrequred | Chatan”” | Veriton | mapecing [piece per [re record | E260 hal be Lmihed: UST shal Bangaion. by Athorzea otrekrence|ogearer” [tniness | Co ‘ualtyB0 |e conduaed. Yelm Bendtest-rrpact | inapecang ocumert | SMe0t |oeveat. [related |i generaly | above. th plates per testatdaegre | ofl of 2 tran tat [uses provaon of reve ‘erage o-20_| Zhai Railway 2.comeiae | Pateay Tres [However | Specteston bese degee tr | fom Gow Lb ‘sual repor. | Quay |posessng the material tr ieorone Nast inspecton. crate | anutacug, approved ib tied sub Chenin Test rer G33, dion ce Cs Spestedin spprved Pia condion oa) Ping rusting rl nade UsrasorieTestg ofplaes Is4228 or 100% STi As (100% fr12men Eaove tick pias) pan] BReTaNT — Par Fe TE TTP Farieas | ROR Pa] Hema —Tepot we Process |inspecson Measurement | approved at ot [er Dsorton frarecard|lléasper™ |tmisned "wach ‘wil be Species Saang | derenson” | inspecting rowing | ented by" Zonat "Rainy olernces soeney Fedor However random f) Over aptan “0s ‘dvenion (engin fresh) ) Tees 0f 20%, lndaal | Qvax"“ot2mm) check may be done by Zona Faiway. inspector dung anus. Nate Daring manutactung test pieces wl also be trovded wih “denea fampound "and. “under intemal ye tester ideraeal ‘aleaning fTaehness of -0.+tmen fndens and sutaly ‘nai trated for idetifeston at ter yer the te oftess Ts process jean Simm, 40 Stallbe open to nspeton by ‘ianson of Paimay inspecting offea Taranateste| * 20 | $reaam)ape ‘Operation TRESS ‘Ghecke & Tolerances Feary, Type aheck Rater Document Fae Salty Fapesion aaa ‘oneal FEpESIPG ‘eeney Ct brspeaton Tp Reeords cae z T <0 77 ey wane ‘aminate |p aratetsm ttn Sin respect fobeaing base ae ‘tum ca) artness ‘sing ‘manutatt "3 ) Over at ‘ines Far +n 100 RHO e0ss 996% sual & Measurement sper seproved hang Messureme Pied tdvenson Manutotur Inspecting aeney, Deen Feiato ferecord 1c 89 Pare a asper rowing to 70 a Bal speci tual nd mensional heck ) Over a plan ‘dmensond eng rena) ) Over a Thncness ) Paralelso top surtace ‘tbeanng hrespea| aun ) Paral ‘tone se sures aah especie the other a| ‘au Dimensions of fearing 2 et fpectedtalerances under ote 038% tin 200 tin 100 aval and sper relator : Secitozion Messureme Pied tdmension ‘Aaarzes inspects apportes By zonal Peay 100%, Fiato fe record as report. Aspertable aorikees Pai ‘Al bearings to be vsually inspected br absence of any (debate in sure th Shape or any. ether ‘scemble superteal detect ‘Aso ater ad testing. ring ‘sal examination of bearing no defects should be noted im swrace ts, shape. or ther notoeabe’ supefela dees ‘Aahorsed inspector has to cary at {00% dimensional heck ‘br term 2) 8b) and Fandom ches fr tem 32) tobe dene tt stcten re Frypical 37pO | —CRATETSTE Fea B | RETR | FUBTRTS™-| WSBT GIS | Type a7 ReneSaRET aR No. | “Operation | “checks 8 | Typeatehtek] Oocumert [squat Reeords | “cntena m= Tolerances | 7 ‘coneral RRBEING | tere ‘Rgerey | inspection 7 = cu 7H Ter sat chemical Test | As pee Menutcurer |veateaton | astoried [rom [rabies [incss [rest centeate shall be )"Geteminston! |ranuacurer | Tes or inspector” bates ae |revecord. | (Pati) Ash | tmished by manutctes Wdertesion of [cerfene & | Certeate |retrence | sppontes | Random fontertas” | For level" acceptance palmer [testrequres | Bchasan’ | documere, by Zana per 183400 | sample fom randonty byasthonses Pinay an xxil | Ssectea bearing of ene lot inipecor fom ina ot Gasomer "beareg 35 Boxe Nast Polpelorpr | presented procedure. Spproves ob ene content| SSa00 and” i089" (Parl) 5) ote caren | min 80% rs a szper | shal be aun by auhorze fs) aateoneme [max ‘AStiLD297 | apector and teste house 6) Specie grty Wenafeaton |iap orm Govt! NABL ozone ctpotymer | Spproved abaratory fra he resbtance rs a aspet | Phase. These tet ae ASTMD | action totes conducted on S877 asper | Sealy mouse est pices relevanttest | prepared at the tine of procedae) | fanutacue ofbeaning Fer Level ll acceptance tests on spedaly moulded test piecesto be cone Testeto be done or () Palmer entation (Palmer cortert () Achcontere (0) Speco gauty {) Orone resistance Preferably test of polymer erteaton. polymer orert Sha. Pah content shoud. be her wknessed: or salad Sarl to be “sent to Gomes Lal” er ‘salute, For Lavell Acceptance sddivonaltes wa be, |) Aen ‘ontrt on specimen om tet bearing shall be Compared wi these br Spesally Moulded test pieces and Max variation permitedis 205% eySpecite gravty on Speamen "fom tes beanng shal be compared 38ape ‘Operation TRESS ‘Ghecke & Tolerances Feary, Type aheck Rater Document Fae Salty ‘oneal Fapesion aaa FEpESIPG ‘eeney Ct brspeaton Tp Reeords cae z T <0 7 Tes Br SSay Trolded test peces and Max waraton permated Is pre fe) For ther test max. and mts tobe aahered (Ozone resistance can be waived bytes engicer a5 per note. 2 of Pare Bie.ai 2 ofioes Par Poljchlotoprene Contente 60 * an content 5% Nate: () No vealed rubber ‘leaned wastes of ‘tral ber shat be sea © EPDM (Bye propylene monomer) (enbuane”—tsoprene Sopa). (Chor eopene opotyner) are not pemned ‘oe ‘manufacture ofbeacngs. 329] Cont aT (Calon Palyehorpr ne (ORs ermited & prebrable (pads ae Neoprene Wer Baypiene 0 Skyprene 8 Sana Denk $40\) Pasa Tat VW aes of chargers Speciteed 2) Hardness Min Tense svengh yan ong at ‘rea vax ‘Cerpresson Fe manufacturer centeate & est requrea byAaorses inspector fom Govt Nas approved lab 'RHD (oes) {Tea oot 26% aT test ourteate Bohaian an of retrence ocumer. aaa inspector apportes By zonal Peay Farr aches at Fandom Tae reecord TRO (ars 153800 Gs perrlevant procedure) Tes ate shal be funished by manutetwe's (or ial aoeptance Sample fom each lat of sstomer as. presored in Spesteaton shal be draun By authorize ispecor and tested in eer mouse Lab tri NABL Gow Spproved Faboratry. For feel 2 acceptance tests on Spesally Modded ‘test pleces tbe (hone Teststobe done are ( Campostion (0) Haaness (i) Tenate engin (i) Bongaton at Beak (a.compression set 39pO | —CRATETSTE Fea B | RETR | FUBTRTS™-| WSBT GIS | Type a7 ReneSaRET aR Operation | “cheeks | Typeet check] Oocumere |"s quai Reeords | “cntena m= Tolerances | 7 contol [REpESInG | Ee ‘Rgerey | inspection = cu ca ey Resweraed POE wr Oy Related Roane 1 Jgengiest_ [TO Hours (a) Aaeson Senger Max Change | H8% ut inariness_| alu f(a) bar oRraNT: ioe Orange [5% wee Proper of | Bastomer inTenaie | aie of) ‘ould be as per Table T of Srengih ine Parc lyMax: Change | 20% wt ‘a satue oF) ongstin co aabeson | Mn.7 Ken ‘Aabesionseengh test tbe Suengt of Conducted as per IS: 3400 Easomerto Fare xiv Stel Paes TaITESOT camelete scatnes Aiatioad | Upo 15MFa | Atbeaingot | Asper Fabricators | Aahorzed [100% | Fabicato | R089 Par: | For bt Aoceptance Level 1 oe elt shalibe | reiavartdy. recor | specter ferecord | 8 fecetnce Level 2 a rested md apportes 00% bexings to be Specitesion By zonal Checked Yr aa oad tests Paiaay 3 per, Pa 18410), Shed isatgnment of Pistes, "poor bending. of Eastomer “and aranated Steel ple, aurce dee iow sites ets Varian Sess of any one Bearing Shall ot be lager than 2055 Stmean ofmessired vas, yeasic | Testtobe Lead testing hreaseof fete diustest | conducedasper [on lagetee For acceptance level sample Senenure2 at |Tuotest fom. tandemly seeded irovas Pari | beangs Beaing “ot cath Ie (or secetane vale estuaie | “tesing) “ot stereoe tastomeric beang a5 120.2750 0005) Pestbed n procedure of i Mea where 35 400 612535 (Pat i) shall Shope coe be draun by. auhonzes Inspector anda t5t meron ‘om () toe) are to be got Aine einer house ib oF Je) shear_— | Testtobe Lead testing ext NABL approve a edits | conduces.asper | on These tea aren aon test |fmnenre2of | Twotest to tests conduded on imovas (earn | besngs Specialy touded 13pO | —CRATETSTE Fea B | RETR | FUBTRTS™-| WSBT GIS | Type a7 ReneSaRET aR No. | “Operation | “checks 8 | Typeatehtek] Oocumert [squat Reeords | “cntena m= Tolerances | 7 contol [REpESInG | Ee ‘Rgerey | inspection 7 = x cu ca SET Faas prepared ate ‘eceptance fom fine. of manutocure of Soave? Bearings. "Note at the Nes Bearing selec fr tet wit nt be ceused. snd a) sting | Testtbe Lead testing eswucnve tet ail be Seeman | conducedasper | on ‘done on Sarple prepares teal | fonenre2of | Twotest fomtem ‘ese | R0-63(Partt) | beamgs, Srenah | exanmaton or (®) For acceptance level 2 ten | essence of Shear modules e585 ‘aching peelng iusttich al be done Sotnin raed fon randomly selected (Gein vabe 20) Beaings and which ater Snaunsraned fest can be used inthe sate Badge Jeuimate | etowra Loadtesting ampressve on UUtimate Compressive Ssrength test Totes Seng test beanngs or ‘here soul be no fare of Destusive steel lannate or reverse Tes Stueezing out of elastomer ipotoad 80a Wate Tage it means aber ofearngs ae 24 Bess tr Rsepancs a Tf be condiced. Stal lot means Whurbers oY beaings ave 74 where Accepiance level ess ae done, Lat sizeto be approved bythe engineer. In large et 2 extabearings tebe made which ae consumedin destruaive testing Signature of Fabricating Agency a Signature of Railway RepresentativeMODEL QUALITY ASSURANCE PLANFOR POT-PTFE BEARINGS ‘Annexure-XiL 4. Mame of Manufacture 2 dig Ne. 3. Name of ProjetRailuay 4. Authority (CANoJLOA No Order No}) SDOTerE Characters Frequency |-RETane—] FSETSGIo'Y | —Tapecion SIE —[ Type a] Recep Fas No. Operaton | “Checked | “ATypect | Document | auaity Prspecting |-exterra Records |" etteria check corwral_| "Ageney” | spection z z z T s ‘0 77 TO] RAW. Physical Tet | Fepernal[WINTC and | Tveiteaion | ROSOTAR | One ——|Fabiestor | S030 | anubce’s tea caiteae Mater: [UTS Weld | TCetest | Cratan”” | of reerence |onzed [integrate record | Caststel | shal be tunisbed. UST shall sa | "thar steet | Sees, feautecby Goaumert | pectng | Testrlece [eoctated | sat bercondueted a per proven © Eongaions, | ROSOIAAh Gaeta? | perneae uth tar | generaty | otreewantspectosion bere Reducion of | ones sf [Fee test | eompiyan | processing the, materia fr bea, Bspecing complete | Zona fener.” | Gage 220. | manutcanng UST ater ead freaetest to | fica of sua | Raiay ‘S20W or 340- | teat aha alsa becomes out degree Zina Inspection srow emgrade or 20 | Ratnay (Grades Gegee sib. | fom Gow sper ieozone te relent Mero ram; | Neal pprved Harinesstest | approved Oa). Ghemeal Te | Bo Chi. 3.P3, Nav rrasonic Testing 100% 159605 (Oneas see (eet 100% betre atarload Test a2DONE CRSTSSETTS | PREGLETGY RESETS] FSETSGIS'Y | — ape [Type a eae Fane ‘Operation | Checked | ATypect | Document | qualty | rapeaing | Eweta| Records | ceria, check coal_| "Apeney” | nepection r 7 5 7 77 Ta Steel Wesaioa Test] Fe per [HUTT and [1 Vereaton| ROSOTAR | One est | Fabieats | ISZUE TT —| AUCs Tea cane Uis.Weld “| TEMtest | onatan”” | ot reference oized pace per [rs record | E260 Guay | shal be funised. UST shall ‘Seess, ‘eauteaby Goeumert | apectng |tiawess |e" | Bois bercondueted a per proven Eongaions, | ROSOIAAh Uaecre?, | perneat) [read | generaty J etreevantspectesion bere Sendtes erzes 2.complee | oe wren at | Used processing the mater Ingactes at | napestng visual nal TCratest [However | manufac UST ater load degree teal of inepeston, | Ralway repot. | QuatyC | testshal sabe ered out emgrae or 20 | Zonal aloe uses degree sib | Raiay ‘wesub zero ieozone fom Gov. anton Ghemeal tex | Ly (is specites Chie 3.Pe3, | NABL th approved ce approved im Physical ‘conden Pring using ol ing eee rrasonic Tesingofpates 100% 1534225 0 (00%) | ASTM Aas SRE — PIRI TE a parhaT MaTT an Veen] ROSTRA| One SPE PORTER] SIN SSS | MTSE STOR Sel (5) ]UTS veld” — | TCatest | Cnatan” | oF reterene| oyized | Perdet |rrecords. | tee! shal | shal be ‘urished. Sample ‘Seess, feautecby oeamert | Rapectng Gantimnto | fom each lt of S.6 shal be Eongaion x, | ROSOIAAh inspecting ast Arann by auhrze inspecting Horunese erzes complete | ofa SHouo2cr [Saal and tesed Bspecing visual nal TNi2Mez0t | Gow mast "approved chal of inepeston, | Ralway Isxort | abortoy Zina Paimay or Chemica Test | fom Gove chi.t.Gre, | toy (Grades S8ve Nal Asper approved relevent im pprved Ba). 4BSa ORRaaT Ry Rae NT | PRT pe a ce rena we] peaien | “chet” | aijpea!| became | aaity Prgmaney emerar] Reads | “one aay Souel_| "ilzny” | fepeshen 7 z 7 a 7 7 Tepe arta er —| Wonca ene OSTA Oae espe | Fae Uae Rot — MONTES at TC Gree" Sena [roar feseuton [af eten| anes [trruum [rewe [esstee” out an anata somee Seoess® Jy tee dE sian | Seavet™| hang | & nm enh lta PTE Sal oe reed) | og | ert bspecng | otseny Soasee | ttanby motte apace a 2.conete Seo led ou SL ‘break. required by visual Zonal (Gradesclass | approved laboratory. ©) Drensenl_ | RSS0iach peton. | Panay Serer Sabiny | eed iene 4 Pesshnosto | Rapecing Speckaton fet tea = ©) Brame | nS ness rowed 1) Specite = cat, ©) Bsy wed sen Frets) ») Pepearance wrote 15] Ease sta FT| RENTER TR OSTA Fe] Fan] ROT —| rates Geapare [poteaes [otis [lseauiow [ofretene fased [osma [row [(orine [lmsied by nawaave, wert Ireieaby | halon" |Sicament |g | Retok {Part and |Ssrples fom Coch ete Bayprene | Hardness | ROSOMAUh ofteal of f3a00 (as | Eastamer as presedbed in cued Shean sal down by 110 oF (RHO) Zonal Zonal perrelevant | authorize inspecting offcial of ‘equivalent/D |g) Minimum Railway Railway test ROSO (Zonal Railway and oh Tense” | Rpeeg proce) | testein eu NABL apron Seu | Suet, tr tary | Soins s) Mma | NAL roan | SoS z ea) ) Nae Coneresson pet ) Mere ng ny We ange inhanese 44DOTEEE | CRSTaSTeTSTS | rEGUETGY | RETTERES | FSETSGTOTS | —FapeSTOTTGRSIS ype a Recep FSS ‘Operation | “Checked” | ATypect | Document |” quaity | rapsaing] Emeta| Records |" cntena check coal_| "Apeney” | nepection r 7 0 77 Tha RE intensie srength >) Me change inlongation Chemica Test | Apert |Manutacurer | veriteatn | ROSOVAH | Fomeach | Fabieate [18733 | Test _centfste _shal_be i) Aah [Testes |testoorstoate | of remrence [orsed [banat |rerecord. |(Par-I)& | Amnned by manutctuer ‘content shat eauired by | chatan | document | iepectng | Random 152400 a5 | Sample. fom eath tof core | Rosoiuh nee pervect | Bastomere as presesbed in ae wraes seal eer Specteaton Shall be aun by Sx Sonat 2 ture) | suborze nspecing offal of wither | Ranay ay procedure) | ROSO" ‘Zonal Ratway and ‘asomerc | Rapecng tested in Gow NABL approved potent | oto som Iaberatory. roprene) || Goxtabi Content ofthe | NABL compound | apm.ed statte | lowerthan 00% wp ‘cay ass ——] Pasta Par | Manctsaurer Veen | ROSOTAGY | Ove est pe | Fabicas | SAT Testor shal Fe seaing ing. |propertes Teetens |testeartest | ot resrence | orsed | rut otot [rerecord. | cuzna7 (Ha) | tmmsned by. manutctuer requedby | Schalan | document | Inspector | supply One sample’ br ll lot of Comm uide |) Tensie Oso pporte or | Seaing rng. supply shal be San [Seema orzed By zonal Gaur by" ROSOlAhonced Thiel) [Nima Sonat Pinay (Gradeklass | oral Raoway inspecting (G) Bngaton % | Ralway Peper [ottaal “and” tested mh =)Bendtest” | napectng relevent | Govenaa "approved J) lckess | eft tom ppoved [laboratory Saraness Gowiab Oa). Nase approved i chemical Test. Gu Po, Feand stl ePovFes, Remainder 2n 45DOTEEE | CNSTaSeTSTS | rEGUETGy | RETTEREE | FAETSGIO'S | —FapeSTOTTSRSIS [ype a Recep FSS ‘Operation | "Checked | ATypect | Document |” quaity [rapeaing] Emote Records |" cnena check cortrol_| “Agency” | inspection z 7 a 7 77 TEENS | PT par Wl Manctaaurer[Veifeaion | Raborired | Ae per | Fabrica TOTS — Test —ariteate shale properes Tatas |testeertente | ot remrence | nspector | reewant frsrecord | 18: 1307 | amshed by. manutactuer requiedby | Schalan | document | sppontedby] spectesto (Groperty | One samole foreach let oF (Tense Rosoiauh Bran i553) | Bots & thts suply sal be Seengn wea) | orzea aiuay drawn by author Inspecting J@)taronees” | apectng or ‘fical of Zonal allay and se teal testedin Gow MABL approved =) Head sound. | fom (Gradeetass_|faboraary. ess test Soxsabr sper fi) Depth of | NABL relent [secxburzaton. | approved pprved fe i Oa). ‘Shemical Test cras Diversion eheakas per | sual Specifoaton | Measureme ERE a PERTTI] PEPE NAT | RUT WETERBGN —| Zonal —[ ae Fa] RESTS | Tes po Sal Ee WHT tonne Fates |testeerteate | ot remrence | Ralway. | sampleper |rsrecord. |bonang |toinspectng ofa! Prre requredby | Schatan | document ict Pire® Zona backg Paimay plates shal inspecton prosice 2 teal fom ond we Goat ‘suum pea Naa Sength of approved ine wath im athentesed| in severance vain os300 an ca) Par estan} —| WaT — Pena Wereaten — [carat — esa EO Peper PS SUES as paTTRSTST Manufactures test caratemte | of rerence | Palway. rstecord [relevant Test cette Sohalan | document Speateaion Inspecson Cerise Ghatan 46DONE CRSTSSETATS | PREGLETGY RESETS] FAERIE | Rape Type a eae Fane Ne.| Operaton | “Checked | “ATypect | Document | auaity Prapssing | Extent a Records |" ertera check coal_| "Apeney” | nepection 7 z 7 0 77 TET 3 Process 24 fplan Dimensions! |lsuars |asper | Measureme |anutcur | 100% | fabricate |1mc83 Pat- | wtemal report shal be Vamensin |inspecion” | Measueme | approved [at of |eranspect ‘tec. |Ildas per | imished, "However "random nda "= arauing | dimension ° | ng otal, raving | eheck tay. be done in height presence ef Zonal" Ralay te Inspecang ote orpenen Tikes of Sastre pat TE esses | Ome — Trae Fe Weer WRT PTO Fans | PORE Pa | Wena repeal Be Jaeacnment inspection |Measureme | approved [rt ot [ers rsvecord. |. 15:322 | imshed, “However. random ststaness "= arauing | mension | nspecing Is3tea | Oheck maybe done. Stelpiate oftal presence ef Zonal" Ralay ay Fates Inspecang ote |B) Surce Finish TROT es —] DP Tes wed OP Testo pe st —] ear Fa TSSEEE OST | Topo a Be WT Sue wal | wel usa [approved | nspecion & | ersinspect rstecord by the manufacture and thal oP testen Egauge | WPSS 80g. |vertcaton | ngomaa | 100% Glearance ll be gen by seling of ot dimension | Zonal ROS. he tp plate Bygauge. | RatwayRo find bearings 50 sterload Ts ea 3) On = Aepecarg. | Favioners [aanutscur | 100% | rabreato | aca ar | iemat report wil be maer indecent |reood [er ‘sect. | ‘mised, however, random ‘el Spesteason | Sheck. | nepecing ‘heok wlibe done presence farrpon tal! of alway. representative cme Binal inspecng author, Jb) athe aiuay Fm shoud keep the records hod othard fang and sub the ‘ong Same to Inspecsonffcal at ihe tmeofinspecion a7DORE CRSRSRTAIS | PREGLETGY RESETS] FSETCSIS'Y | — Rape GSTS [Type a eae Fane ‘Operation | Checked | ATypect | Document | qualty | rapsaing | Beta] Records | cera, check coal_| "Apeney” | nepection z 7 0 77 aaa Protection ay ce Vsuatand | Aspecarg. | Fabricators |anutiaur | 100% | Fabreato | R99 Part: | ermal report shal be Basing mmessureme | andeelane |reood& [=r ‘sect. | ‘unis, Howeveriotl OFT b) an = Spesteason | Sheck. | nepecing Bat be checked randonty tetas ‘call ‘fom the ished ‘Sore in % Zonal Dresenos of inspecting jy Pantin ata Suton of ana alles bly 2) Parte | Dimensions! — | Vsuatand | Asperdrg. | Measweme |Manutasur | 100% | Fabicat | R083 Par | During assembly al the Sim | nspecton rmessureme andeeloare [oto | =r fevecord | beanng components shouldbe |») Overat = Spesteason | mensane | inspecting checked fr proper deaniness Hite tal! and greasng of PTFE Binal Slanise Seal aursoes Patsy Fandom check shal be done Ig presence of Zonal Raiuaysispecing ashen. ag TROT aR Faas Wana TO Fane | ROBY Pal Dang teal ia specie W rood. ars record | the ‘sume component shal inspecing have to be fied on each ‘call Beanng. Binal at Tae between stores component tba a) ester Gyinder | Dimensions! | lsualand | Asper | Measureme |anutcur | 100% | Fabrieate | 2083 Pat- | nspesion recons to be pyeastomen | mepecton” | messureme [relevent Ory. [oe ot [ers ‘sect. | ‘tmsed” However random pads "= mensions | inspecting checking” may” be done hinder tal! presence f= inspecting =) cue & Zonal Stony of ona Rasy ‘ajacent aiuay compere ares Oyinder Signature of Signature of Fabricating Agency 48 Railway Representative‘STANDARD QUALITY ASSURANCE PLAN FOR EXPANSION JOINTS ‘Annexure-Xill 4. Name of Manufacture 2 dig Neo. 3. Name of ProjectRalinay 4. Authority (CANoJLOA No Order No} BORER] — Cras —eCERY ERATE] FSBTSEIS | — TS ESTON GETS TGS REET Fa Ne. ] “Operation ‘Checks 6 | Typectoneek | “ree | “squalty Records | “artent Tolerances pocum | ‘contrat | FSpeetnG | Berea mn TRaeney” | nepestion 7 + 7 7 1] RW AATERET 11 [aad stet for | Mechanical test | asperwarTes (rane |. veiteaton] pahorzea | Onetest | Fabriato | 1S:2082-11, | Manutacurers tet certfoste SeelPlaes, | UTS. eld ess, |testrequreaby [and |'ot retrence| perecuny [piece per |e reso | E250 thal be fimahed: UST shal Aeges. spice | Bongatent, Send | Ashonved | Chalan | documere | "$P*%0 | hekness | Co ‘ualtys0 |e" conducted. ri2rm Pies, chor |testmpacties at | inspecting water | ernest [related |isgeneraty | above tisk plates 25 per Lees’ Sudsete | aegree (tl of ana f. compete | nal wen a [used prousen of relevant fentgrade o-20 | Ralway tom aia | Ralway TClates [However | Speciation etre degeee br subzer | Govt Lab specton. reper. | Qvaity¢ | processing the material or fone NABL approves shal be | manufacturing. wb aed fe sb heniea! Test eo Ch, SF. 8, 0 anc, Os Paw Material to be cared by Specfedin | nomnated inspecting oft Physical Spproved” | otal Ratuay: conationi, oe) Pring resting lin get ec Length (mensional Check | tn Tainess as LUtrasonie Testing 100% fet2nen & How tines) 100% 153226 o AST Aa TZ] Sip Sealand | Paes Fe Tana Verteaion | Raed | Fam ——| Fabeas TRO an TE ‘her Easiomer rmanutaurer [urer | ofreerence |Inspecing [bates at |rsvecon | Pacing | Cemtoats srequred. Tet Componente | wi ves ot | Serene Stest test | documen” [oneal | Random 152400 @s_| Cerbteate shale umishes Contyarge, | aracensics— [requredby | cartes Spponmes_ | and at. perrelevat | bymanutacuters er Polichlorprene | Spectes ‘Aaersed — [te Byzona | sereton fos ‘lowing tests. (CR)is peated inspec ot | Chala Faiway | stispedor Procedure) | () Camposten pretrable onal alway | (e)raraness aSpa] CRaaeTeTSTE | Frey FRETS FSGS | —TSBRRTOSGRaTS | Tap RCT RS Operation ‘hecks 8 | Type oneek | “ree | squall Recores | “srtena m= Tolerances | oocum | ‘corerat | FEBECETG | Bearer ee iRgeney” | nspection cs 7 ‘a yaerare aoa Tera Sener Reoprene Wer. NBL approved {i elongation 2 Sreak Bayprene 110, wb (0) compression set Skyprene 65 and (i) eelerted Pong test Denia S00) {i Aeon Srength ) Hardness | RHO 00:5) MP ORTANT: Jo) Mn-Tenste | 17 Pa Propetes of Basomer Seength Should be a per Tale tof |p) Nn ong. ot 40% ines break Far Polyorprene Ja) hax 2% Corerte 00 Eamresson ‘ah coter > 5% se Ne: () No reamed ner. J) fecelerated | 10021070 Nleanzed wastes natural Soengtest | Hous bbe shal be use EFOM (Eile propylene Mex. change | 416% wrt Siranomer). IR (bobdane inHarness, | tle ofa) Soprene Copier CR wha Change | 18 wse {Chor boprene”Copayner) intensie [atv of) Bennet pemited. te seengn Imanutcreotbeaings. Vo Max: Change_| 30% wrt inBoogaion. | ake o(6) ‘eson seat testo be fonducted a5 per 18: 3400 (Adneson — | Min. 7 Ken Far xv Seengh of Basomerto See Fates hema! 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[Beat 2Spa] CRaaeTeTSTE | Frey FRETS FSGS | —TSBRRTOSGRaTS | Tap RCT RS No. | “Operation ‘hecks 8 | Type oneek | “ree | squall Recores | “srtena m= Tolerances | oocum | ‘cereal [PRESS | Bie ot TReerey” | tepection 7 z 7 ‘a ral ——| ROS Fayrroso J) Welding teria Aahored theelrby | Sue, length Inspecing | 100% by saigentr | Oa ce Oftiatof | nat Zonal | RimDso inyreoso 7 rarang TRSaiOR oT ——} I rea] VENToaion | Rahorzed”| Exh BAN | Fabveais | Aepar | Fa shou Beas parE Process Manufacture 5 Test an ot [of reerence | nspecing rerecord [reievane | 612001 oraeper contact enteate Nata | docimen | fiat Specieaton | condions vs aptzale nspecton cures Bana (ersten, Chan es Faiway Cette thatan aang aT an Canal — ESS RE] FTES Packing expansion tretrence | Ralway Terecord|recine dispatch Jon doaimere Specteaton Wy Clamping of sons (packing f Expanstn ot Note: 1. there are any suds inthe approved cauing, prtoma a per BS-115 issued by RDSO maybe refered fr suitable changes. 2. her are Bots & tas inthe approved drawing then add Para 1.2 inthis QAP as given fr Boks & Nasin Para 1.7 of QAP of POT-PTFE Beating (Ane Signature of Signature of Fabricating Agency 53 Railway Representative‘Annexure-A QUALITY CHECK LIST OF EXPANSION JOINT (SAMPLE) Date: ‘SNo. Description Required Progress. 1. [Size of the Edge Beam Lenath (+3, -0) mm ‘Anchor Studs Should be properly bend 3. | Straightness Throughtout the Length of the Beam (no bending) 4. _ [Proper Attachment of Splicing Plates at the end. 5. _ | Proper Welding Size of Anchor Studs. (2.9. 8mm, 45°) 6. | Seal Gap (6mm+0-1) 7. _ | Edge Beam comer should be properly round lke Fillet not Ghamfer 8.__| Angle Joint Straight with proper"V" Shape 9. | No Splatter, Primer & Final Paint Application 10. [Hammer Test Signature of Signature of Fabricating Agency Railway Representative