FACT ', CHENNAL-38 INTEGRAL COACH FACTORY, Ci ICRIMDISPEC.-167A ‘SCHEDULE OF REQUIREMENTS FOR FRP PANEL —_| 1gSUE STATUS : 01 (USING POLYSTER RESIN) USED IN RAILWAY REV. No: 02 PASSENGER COACHES DATE : 07-09-2006 IDENTIFICATION SHEET ‘No.OF PAGES: 5 ‘NATURE OF DOCUMENT COPY NUMBER ISSUEDTO ISSUED BY : DY.CME/DESIGN. RETURN OF COPIES In case of transfer / retirement, the holder of controlled copies shall return the same either to SSE/D/MS or to his/her successor under intimation to SSE/D/MS. NOTE 1. Controlled copy holders of this DOCUMENT are expected to bring the content of this document to the knowledge of the concerned officials who are working in his / her department /section. 2. Unauthorised copying of this document is prohibited Prepared, verified and approved Page Nos. 5 of 5. CONTROLLED COPY HOLDERS C.COPY No. 1. CME/QA OL 2. Dy.CC&M 02 3. AME/MPO/Fur : 03, 4, Design Library 04 CONTROLLED BY | PREPARED BY VERIFIED BY | APPROVED BY eps bho SSE/D/MS SME /DSS DY.CME / DESIGN CDE/MECHSCHEDULE OF REQUIREMENTS FOR FRP PANELS (USING POLYSTER 10 1d 20 24 RESIN) USED IN RAILWAY PASSENGER COACHES, ICF/MD/SPEC-167A Issue status: O1 Rev.02 Page 1 of 5 SCOPE: This specification is divided into two sections. Section A establishes the requirements of material, testing and performance for Fibre Glass Reinforced Plastic (FRP) panels used in Railway passenger coaches. Section B establishes the technical and other requirements of firms which make Fibreglass Reinforced Plastic (FRP) panels used in Railway passenger coaches. i SEC’ A REFERENCE: avaene IS: 1998 ASTM D 792 ASTM D 2583 ASTM D-570 UIC 564-2 Appendix 4,15 NCD 1409 DESCRIPTION OF MATERIAL: i) iii) iv) ‘The material shall be composed of thermosetting polyester isopthalic resin with suitable isopthalic gel coat and E-glass stitched chopped strand mat (CSM) and stitched mat / woven roving combination or E-glass continuous filament mat-compatible with the polyester isopthalic resin system. The thickness of the finished FRP panel shall not be less than 3mm. In addition the thickness of polyester compatible gel coat (with FR properties) should be 0.4 to 0.5 mm. The colour of the base panel shall be to RAL shade No. 9018 (papyrus white), with “Distant blue” granules to the RAL shade No. 5023.The density shall be 75 to 110 spots per square ‘inch. ‘The exterior surface of the FRP finished product shall be semi gloss. Gloss value shall be between 21 to 50 measured at 60°. Approved sample for colour and surface finish can be seen with design office for guidance and reference purpose only. RESIN SYSTEM: a) ‘The resin shall be Fire retardant grade isopthalic acid based Polyester resin, No filler shall be used. Necessary additive may be used for obtaining fire retardant property inthe resin system. ‘The isopthalic FR resin shall be procured from a reputed manufacturer in sealed containers along with the test certificates. Traceability of resin should be demonstrated if called for by ICF.SCHEDULE OF REQUIREMENTS FOR FRP PANELS (USING POLYSTER RESIN) USED IN RAILWAY PASSENGER COACHES ICE/MD/SPEC-I67A Issue status: O1 Rev.02 Page 2 of 5 b) The manufacturer should provide details of the catalyst used along with the FR resin and as called for by ICF and demonstrate the test there of. 3.0 TYPE ACCEPTANCE: 34 PROPERTIES OF LAMINATE TO BE TESTED FOR TYPE TEST: ‘The RRP laminate shall have the properties mentioned in the TABLE 1 below: : TABLE 1 # | CHARACTERISTICS [REQUIREMENT | STANDARD T | Resistance to spread of | Class B IS:6746 UIC 564-2 Appendix 4 flame 2 | Toxicity 1.00 MAX NCD 1409 3_| Smoke index Class B UIC 564-2 Appendix 15 4 | Tensile strength ‘80 MPa TS 1998-62 5_| Cross breaking strength | 120 MPa 1S 1998-62 6 | Water absorption (0.5 % (MAX) ‘ASTM D-570 , 24 hours 7_| Specific Gravity. 14-15 ASTM D-792 3 | Fibre glass content| 28% min. to be| IS: 13411 Annexure-A (nin) evaluated after removing 0.5 top layer. D | Resistance to stains for [Should not show any | 1S: 2046-95 a) Acetone ° | visible changes on |__b) Black Tea surface. _| T0| Total ash content | 10 % max. = (excluding fibre glass ) 7 3.2 The first time supplier shall type test the FRP panels in the presence of ICF representatives as per clause3.1 above. Wherever the facilities for testing the above characteristics such as Toxicity and Smoke Index are not available with the firms the same shall be tested at an ICF approved Lab. The test results for Toxicity and Smoke Index shall be submitted by the firm after testing at ICF approved Labs once in a year or during quality audits. 40 INSPECTION CRITERIA FOR ACCEPTANCE OF THE FINISHED PRODUCT AT ICF /FIRM’S PREMISES: 4.1 The manufacturer shall supply three advance laminates to size 600 mm x 600 mm. x3.5 mm thickness for testing at ICF for every purchase order.. ‘The following tests shall be carried out at ICF for every purchase order.SCHEDULE OF REQUIREMENTS FOR FRP PANELS (USING POLYSTER RESIN) USED IN RAILWAY PASSENGER COACHES ICE/MD/SPEC-167A, Issue status: OF Rev.02 Page 3 of S 42 VISUAL: 42.1. The color and surface finish shall be visually inspected on 20 % of the lot subject to a minimum of two numbers. All the samples must pass the test for the lot to be accepted 42.2 The dimensions shall be checked on 50% of the lot cleared in 4.2.1 subject to a rinjium of two numbers. All the samples checked for dimensions shall pass. 43 DESTRUCTIVE TESTING: 43.1 Specimens shall be cut from the advance samples for destructive testing at ICF as per sl. No. 4 to 8 of clause 3.1 44 — Stage inspection and final inspection will be carried out by RITES/any other ICF nominated agency at Firms premises 50 PACKING CONDITIONS: ‘The product must be supplied in an eco-friendly packing material. 60 MARKING: The manufacturer’s logo shall be embossed on the reverse side of the items. The batch number, identification number for traceability and date of manufacture shall be made available on each and every item. SECTION B 7.0 SCOPE: 7.1 This specification covers the technical and other requirements of the firm for manufacture and supply of fibre glass reinforced plastic (FRP) panels using ‘Vacuum Assisted RTM / Resin infusion (using Vacuum bag) process to obtain the required mechanical and fire retardant properties. 7.2 Allvendors seeking approval with Integral Coach Factory to supply fibre glass reinforced plastic (FRP) panels shall fulfill the requirements as given below 8.0 MANUFACTURING FACILITIES: 81 PLANT & MACHINERY 8.1.1 The firm shall have requisite machinery for Vacuum Assisted RTM process / Resin infusion (using vacuum Bag) process. The RTM machine shall be of either auto internal /external resin and catalyst mixing type with builtin provisions of high pressure system for injection head, roller, spray gun and auto vent system with solvent pump for flushing.SCHEDULE OF REQUIREMENTS FOR FRP PANELS (USING POLYSTER RESIN) USED IN RAILWAY PASSENGER COACHES ICF/MD/SPEC-167A, Issue status: O1 Rev.02 Page 4 of 5 8.1.2 PATTERNS AND MOULDS: ‘The firm should have adequate quality moulds to keep up the supply requirements. 8.2 DEMONSTRATION OF PROCESS CAPABILITY: £ 82.1. The firm should demonstrate its process capability by producing one prototype sample ofthe FRP panel successfully using Process as specified in the presence of ICE representative or their nominated inspection agency. The sample will be subjected to all type tests as specified in clause 3.1. Wherever the facilities for testing the characteristics such as toxicity and smoke index are not available with the firm, the same should be done at ICF approved labs and submit the test results to ICF. 9.0 TESTING FACILITY: ‘The firm must have in-house facility as mentioned below: Stop watch Beakers ‘Thermometer ‘Apparatus for conducting flammability test. Ford Cup for measuring viscosity. Firms can also have a Brooke Field viscometer Electronic weighing balance with least count of 0.00018 1 Ton UTM for testing tensile /cross breaking strength. Rovere 10.0 COVERED AREA: ‘The firm should have adequate covered area for working and storage of raw ‘material and work-in- progress 11.0 QUALIFIED PERSONNEL: Skilled artisans, supervisor, with specialized qualification in the manufacture of FRP products shall be available with the firm. 12.0 QUALITY ASSURANCE: 12.1 The firm must prepare a documented procedure for the manufacture of the FRP item. The procedure must contain information regarding:- > the properties of the resin used, > the type of fibre glass used and the properties of the same, > the tools used in the preparation of the laminate,SCHEDULE OF REQUIREMENTS FOR FRP PANELS (USING POLYSTER RESIN) USED IN RAILWAY PASSENGER COACHES ICF/MD/SPEC-167A Tesue status: OF Rev.02 Page 5 of § > additives added to the resin, > the various stages of tests done on the raw material, work in progress and finished product , and > any other relevant information . 12.2 The firm shall have a system for traceability of the isothalic FR resin. Bach drum of the resin should be traced to a finished product. Similarly each finished product shall be traced back to the drum of resin from which it was manufactured. 123 180: The firm shall have ISO 9000 -2000 series certificate. 13.0 REGISTRATION & LICENCES: 13.1. FACTORY LICENCE: The firm must have a factory license, 13.2 SALES TAX: Tax Payer’s index number