Ret CGW 0007 | Page Tot Tt (Rev. 3) SCHEDULE OF TECHNICAL REQUIREMENTS FOR DECORATIVE THERMOSETTING SYNTHETIC RESIN BONDED. LAMINATED SHEETS FOR USE IN COACHING STOCK S\No,| “issue ‘Amendment i [December, 2005 = : Wonthi¥ear of | Revision! | pac no, = Firstissue Issued By: Research Designs and Standards Organization 5 ‘Manak Nager, Lucknow - 226011 yer € ool” age 4p aw[Ret CGW O0OT| Page ZoF 17 | Date ofissue: December, 2005 | Spec. No. 6-KSt4 | (Rev.-3) j INDEX Gause DESERIPTION Page No. oar z 7 [Scape z ‘ 2 | Requirements sq 3 fTests 7 4 | Sampling and ortra for conformity [5 3] Packing 3 3 | Marking 8 ‘Ranexure “A é ‘SECTION-& - Clause Description Page No. No. 7 [Scope =] Requirements 3. | Plant, Machinery & lirastructure Requirements Z| Testing Faciites 9 5 | Gualiy Conirer Requirements 70 © | Documentation 7 - a Praining 7Refi CGW GOO | Page Tori | Date of asus: December, 2005 (Rev.=3) SCHEDULE OF TECHNICAL REQUIREMENTS FOR DECORATIVE + THERMOSETTING SYNTHETIC RESIN BONDED LAMINATED SHEETS FO! IN COAGHING STOCI — SECTION -A 0. Forewor 0.1 This schedule is intended to cover the technical to materials, constructions and tests and does not include all the necessary provisions of the contracts. 02 This schedule draws references to some of the relevant IS Specifications. Latest versions of these specifications shall be taken as references 0.3 For the purpose of deciding whether a particular requirement of the schedule is, complied with, the final value observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with the IS: 2. The number of significant places retained in the rounded off value should be the same as that o! the specified value in this schedule 1. SCOPE 1.1 This specification for decorative thermosetting synthetic resin bonded laminate! sheets for use in coaching stock consists of two sections i.e, Section-A and Section-B, SectionA covers the technical requirements, methods of sampling and tests of decorative thermosetting synthetic resin bonded laminated sheets and Section-B covers infrastructure requirements of manufacture, testing and quality control 2 REQUIREMENTS 24 Materia 2.1.1. The material shall have one side bearing the decorative surface and other sie ws beiriy roughened or given an appropriate treatment to promote adhesion to th base material 22 Colour and surface finish The colour and patter of laminated plastic sheets shall be as mentioned + RDSO Sk-90068 wit latest alteration. The surface finish shall be sem-maib2.3 Workmanship, TCH | Pas | DHT 7 ae (fou te: t 2.3.1 The laminated plastic sheets shall be ge ally smd defects, local deformation and other visual defects. 7 free from, surtehe 2.3.2 Machining test: - When operations are carried out for installation, the laminated Plastic sheets shall be capable of being sawn, milled, driled and tapped without splting or cracking, 2.3.3. permissible defects as mentioned in clauses 5.4.1 to 5.4.5'of IS: 2046-95, shall be agreed. However, the requirements given in clausos 6.4.6 to 5.4.8shall be strictly complied with, 3 Tests 3.1 The Laminated plastic sheets shall be tested for the following requirements as per test method given against them. The property requirements given below are for the COMPACT GENERAL PURPOSE FLAME RETARDANT (CGF) material 43s mentioned in IS: 2046 - 95, vases ‘S.No Property Required Test Method | aus 1 ince osc waar TIGER NOT] IS HS fous 2 | Resistance to immersion in Boiling water ! rapes Sass ea ina Cute Fof —| 1: 2040-95 fomourea | Ammen 0 | aitrng and aaron State | woe i 3 | Resnes io arreararreors—— ranean Daqees —| 1: 2046-95 rene omoute€ rome _ 7 [pinensopal SabiyarC pass [ioc Sesion Tounezor—| 1S 2046-95 [enone nastine esion —| anon 5 —fRaisants to pactsuenan oy [0088 Raneaie = Kot atm) aling woght eto) ins spectzaton 3 Rural stonair Pa) a anioasralis (Bey 7 —|Rnisanaato sarang watworethan 1206-5 | Rating scale _ is __| Annexure - MtSOW OF [Page o11T | Dats rae Decor 2005 Sp: WarC-KSI6 | Reu-2) : ‘8 | Resistance to colour change (Blue wool stand | in xenon are ight 6 | ms, FRauae (Minimum) page No. 7 Annexure - | | [imenciosed carbon are taht [te as; 2006 (Minimum) Rey [Annexure ‘9 [Resistanco o steam ! Lis poIe= ‘Annexure - T ASTM -D~ 423 ‘Appearance (Rating scale) 10 | Surface finish (by 60° specular gloss meter) Gloss value 11 | Resistance to spread of flame — Min, i Aopen ir at | | | ee UIC-564-2 OR {2 | Deterioration of visibly due to smoke “Appendix ~ 19 of |= ia, UIC-564-2 OR 43 [Limiting Oxygen Index — Min, 2B 1S: 13501 14 [Toxicit Less Than 1 [NCD - 1409 4. SAMPLING AND CRITERIA FOR CONFORMITY The sampling and criteria for conformity shall be as given in clauses 8, 9 sind 10) ‘of IS: 2046 - 98. Any sample sheet failing in one or more requirements ol the: specification shall be termed as defective. No defective sheet shall be found i the sample lot to be considered as conforming to the specification. 44 No.of Test: - Al the tests given in Table ~ 1 except the test of Deterioration of visibility due to smoke, Limiting Oxygen Index and Toxicity shall be carried out on each lal, The test for Deterioration of visibility due to smoke, Limiting Oxygen Index and Toxicity are type tests. The tests for Deterioration of visibility due to smoke and Limiting Oxygen Index shall be done once in six months and test for Toxicily shat! bbe done once in a year tllin house testing facilities are developed. 5. PACKING , 5:1 The material shall be supplied in packages as agreed to between the purchaser > and the supplier. 6. MARKING 6.1 Each laminated plastic sheet shall be marked suitably with indelible ink as shown in RDSO Sk.88143 with latest alteration, 4Rak CGW 007 | Page Sof 77 Rev. = 3 Hag-K6t4 | a iy yy y) RESITANCE TO IMPACT STRENGTH (by {est shall be carried out with a falling weight type consist of the following, RE-A impact nally ‘A rigid metallic base preferably with leveling screws. A specimen suppor in the shape of a hollow steel oylinder of intemal diameter 0 + 0.05mm, external diameter not less than 57mm and height not less than 25mm. The ringihole should be so situated that its axis coincides with the line of fall of the staker A evice for clamping the test specimen to hold it in position while under impact shall also be provided, ‘A woighted striker with a hardened hemispherical striking surface 12.5 1 0 05mm diameter capable of being clamped released and falling freely in the guides. The ‘spherical striking surface of the plummet shall be free from faults or any other imperfections. The line of fall ofthe striker shall be perpendicular to the sprrcimon surface and shall be concentric to the axis ofthe ring Superstructure shall consist of rigid frame with guides to adjust the height of the striker. The height of the frame shall be such that the maximum height of fall of the striker is not less than 600 + 2 mm for 3mm thickness of sheet. Trial Run: - Load the striker with weights s0 that the product of the height of fal and the combined load of weights and striker is equal to the expected impiict strength of the material under test. Hold the striker in position by the release mechanism. Operate the release mechanism so that the stiker fais. on to the specimen. If the specimens unbroken or cracked on one surface only, it shall be recorded as ‘unbroken’. If the specimen is broken or shows @ crack or tear ‘extending from one surface to the other, it shall be recorded as ‘broken Ifthe specimen breaks, test a second specimen in accordance with the forego) procedure but with an impact energy ‘S' kgf.m less than that of the blow «ppl: to the first specimen, where 'S’ is as shown in Table below. If the second specimen also breaks, test a further specimen in the same manner bul with an energy 'S’ kgim less’ than that of the blow applied to the second specimen Continue this sequence of operations until a specimen does not break. vi) If the first specimen does not break, test a second specimen bul with an impact energy’'S' kgf.m greater than that of the blow applied Twenty test specimens shall be subjected to test and no specimen shal! be struck more than once. 4Ref COW G00T | Page 7 of 1 | Date of sue: December, 2005 | Spec. No. C-KSia (fev. —3) ‘Table: - Relation ship between increment of energy for trial run and energy of biow immediately - preceding increment. [—Eneray of Blow immediately | Preceding increment. Increment (S) of energy for | Trial run (kgf) “| ‘Greater than 056 0:28 up to and including 0.56. Not less than 0.28 0.14 0.014 0.14 up fo and including 0.279 (0.056 + 0.014 } (0.07 up to and including 0.139 10.035 up to and including 0.065 (0.028 + 0.008 0.14 + 0.006 Less than 0.035 Not greater than 0.007 PAGE tN. Rane sh BREF[RE Caw OUT Pace BOTT Dae fase: Bacar 2005] See. C-KS14 | (Rev. =3) 1 24 3a 32 33 34 38 36 37 38 39 SECTION-B SCOPE This section covers the infrastructural requiremenis fo, enue decodes thermeseting synthetic esi bonded laminated rie rreoaeNG sock REQUIREMENTS All vendor seeking registration with ROSO shall comply all the requirements mentioned below. PLANT, MACHINERY AND INFRASTUCTURE REQUIREMENTS The manufacturers shall have adequate space and a covered aren with cemented floor to accommodate the following, a) Damp free place for storage of raw materials b) Independent manufacturing area for decorative thermosetting syniticty resin bonded laminated sheets. ©) Inspection area The firm should have at least one number Two chamber oll heated dryer. ‘The firm should have at least one number boiler of adequate capacity. ‘The firm should have at least one number Vessel for resin and lu manufacturing, ‘The firm should have at least one number hydraulic press with die arrangement to manufacture decorative thermosetting synthetic resin bonded laminated sheets of adequate size with adequate margin of trimming. ‘The firm should have at least one No, Dryer of adequate capacity. ‘The firm should have at least one No. cutting power press/machine, The firm should have at least one No. Sanding machine along wi dust collection unit and control panel ‘The firm should have at least one No. Air compressor.(Rev. 3) REE CGH OOOT Page BOTT [Dat af eso, Decora A 4 44 42 43 44 45 46 47 48 49 4.10 ant 4.12 4.413) 4.14 4.18 TESTING FACILITIES: The fim should have at least one No. El ‘The firm should have atleast one No. Tens! ‘The firm should have atleast one No. hot water vessel (With specimen holder) ‘The firm should have atleast one No. water vessel (With specimen holder) ‘The firms should have at least one No. Resistance to surface wear machine. The firms should have at least one No. Impact testing machine (Falling wot method). The firms should have at least one No. Dimensional stability machine (Two No Conditioning chamber). ‘The fies should have at least one No. Hot air oven (Drying oven}-(Cap.501-?°C ‘The fins should have at least one No. Hot plate The fims should have the apparatus required for testing resistance to dry heat The fis should have the apparatus required for testing resistance to steam The firms should have the apparatus required for testing resistance to colour change in xenon arc light and enclosed carbon arc light, The firms should have atleast one No. Gloss meter (60° specular gloss meter) The firm should have in-house testing facilities for conducting type test tr Resistance to spread of flame, Limiting Oxygen Index, Deterioration of vsitity due to smoke and toxicity w.e.f 30-08-2006. Till such time, firm should arrange testing at reputed laboratory as decided between IR/Inspecting Authority manufacturer. The cost of testing will be bome by the manufacturer. The firm should have the following instruments, a) Vernier calipers with Digital display ') Micro moters with Digital display ©) Measuring scale d) Measuring tape 2) 90° Angles 4 f) Flatness table (with 600 ineter straigen S.S. bar) 9) Thermometer hh) HydrometerJ Ref; CGW 0001 | Page 10 fT | — Bate of asus: December, 2005 | Spee. Woc-Ks14 (Rev.=3) 4.16 The firm should have arrangement for periodic 5a 52 53 5A 54 986 87 38 instruments. oF PAGE No, F QUALITY CONTROL REQUIREMENTS 2 andthe pred tr in:the ss" ne ‘The firm should have acquired ISO: 9001- which the approval is sought should be certification for manufacture and supply. ‘The Quality manual of the firm for ISO: 9001- 2000 should cleatly indicate at amy stage the control over manufacturing and testing of the said railway product There should be a system to ensure the traceability of the product from aw ‘material stage to finished product stage. Tho system should also facibtate 1 identity the raw material composition from the finish product stage. It should be ensured that there is a Quality Assurance Plan for the product detailing the following various aspects: Organisation chart Process flow chart Stage inspection details from raw materials stage to finish product stay Various parameters to be checked and level of acceptance of such parameters indicated and method to ensure control over them, + Disposal system of rejected raw material and components, ‘There should be at least one fulltime technologist having a minimum bacnelor s degree in relevant field with experience of at least § years or a persin wih diploma in relevant field with 12 years experience. He should be free from dey to-day production, testing and quality control responsibilities, He should be ‘mainly responsible for development of a product, analysis of products, contro! over raw material, and corrective action in case of difficulties in achieving the parameters. Ensure that the incharge of the Quality Control Section is having a qualification of ‘minimum bachelor's degree in the relevant field and has a minimum of ' yu experience. Altematively he should be a diploma holder with minimum oi years experience. He should be actively involved in day-to-day activites 0 Quality contro stage inspection / compliance of QAP ete. The firm must ensure that proper analysis is being done on monthly basis study the rejections at various intemal stages and itis documented, The firm should ensure that latest version all the relevant specifications. 1S. standards are available with the fr,Rat COW 0001 | Page TT OFT | Date of ssue: December, 2005 | Spec. Wp.'C-Ks14 6. 64 et 62 63 64 6s 66 7A (Rev. = 3) a DOCUMENTATION Pee a, Jo OM. Firm shall maintain folowing documentsiecofg ge A well documented Quality Pian. Incoming raw materia register with Test Cerificates references of suppliers ans internat test results Stage inspection results including finished products results. c Records of internal rejection and its analysis vis-a-vis action plan, Records of final products inspection by extemal agencies (like RDSO), Non Conformity Reports and case analysis as well as action taken thereof. Records for maintenance of diesimoulds, Ensure that proper systems are avaiable for dealing with customer complaint TRAINING Training needs should be identified for all concerned officials and regular turns shall be organised and imparted on maintenance of machines, quality assurance safety parameters etc,‘Corrigendum stip No.1 of January 2006 to C:KS14 “Schedule of Technical a it hermotsting sheets handed laminate ah acm in oneling stoke se yw) age Sable paene, So" fom one Read No 84s flows sone rere Ye Resistance to colour change (Blue wool standard Property Required Value Test Meshod Ia Xenon Are 6 IS: 2046-95 N Light (Min) Or Inenclosed Carbon 5 Is: 2046.95. 0 are Light (Min) Ss Xo The test method for Resistance to spread of flame should be read as “Appendix-¢” in place oF Appendix-11” of UIC-564-2 OR