NO. WD-12-BOXN (Rehab.

)-2006(Rev-1)

INDIAN RAILWAYS
SCHEDULE OF TECHNICAL REQUIREMENT FOR
REHABILITATION OF BOXN WAGONS
FOR
BROAD GAUGE-1676 mm

S.NO. Month/year of issue Amendment No. Revision No Pages

1. May 2006 --- --- ---
2. June 2016 --- 01 ---
3. January 2017 01 --- 01

ISSUED BY

RESEARCH DESIGN AND STANDARDS ORGANISATION

MINSTRY OF RAILWAYS, MANAK NAGAR,
LUCKNOW-226 011

June,2016 Price:
 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

Amendment No. 01 to WD –12 – BOXN(Rehab.)–2006(Rev-1) of January 2017

The following amendment is issued with the approval of the competent authority:

Clause/Para : Amended from the existing to

Contents : At S.No.-12, Annexure-III deleted
Para 1.1 : This specification covers the technical requirements for the rehabilitation of BOXN
wagons. The work involves fabrication of new side walls, end walls, replacement of
floor plate, doors, damaged under frame members. To ensure good quality of
welding, it is essential to install the wagon on manipulator for undertaking this work so
that horizontal down hand welding can be performed to the maximum extent. The top
and bottom centre pivots will also require replacement and fixing with Lock bolts.
The bogie, air brake equipment and pipes, draft gear and couplers including
uncoupling gear and brake gear of the existing wagons will be retained. In
case any of these components are missing or damaged, they will have to be
replaced.
Preferably BOXN Wagons in age group of 18-22 years should be taken up for this
rehabilitation unless condition of a particular wagon so dictates and the BOXN
wagons in age group 12-18 years should be taken up for upgraded rehabilitation
using RDSO Specification WD-16-BOXNR-2010 (Rev-1) or latest.
Rehabilitation of wagon to be taken up only if centre sill of wagon found to be in
sound condition and meeting the parameters laid down in check sheet at Annexure-I.
Para 2.2 : Deleted
Para 2.3 : Strip off side walls, end walls and floor plate completely by cutting carefully from
under frame and carry out measurement of camber.
Para 4.2 Body end wall: Complete body end arrangement shall be replaced with new one as
per RDSO Drg.No.WD-80007-S-06.Material specifications of different items are given
in the drawing. The body end complete shall be manufactured on a suitable welding
fixture to ensure down hand welding and then assembled with the under frame.
However, for assembly of corner stanchion with body side Para 4.5 will be followed
Para 5.0 : Deleted
Annexure-III : Deleted

x-x-x
 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

CONTENTS

S.No. Description Page No.

1. Scope 3
2. Work Details 4
3. Under frame repair 4
4. Wagon Body 5
5. Air Brake 6
6. Other Technical Requirements 6
7. Painting and Marking 7
8. Testing 7
9 Inspection 7
10 Annexure-I 9
11 Annexure-II 10
12 Annexure-III 11

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

INDIAN RAILWAYS
PARTICULAR SPECIFICATION
FOR
SCHEDULE OF TECHNICAL REQUIREMENT FOR
REHABILITATION OF BOXN WAGON
(FITTED WITH AIR BRAKE SYSTEM)

1.0 SCOPE
1.1 This specification covers the technical requirements for the
rehabilitation of BOXN wagons. The work involves fabrication of
new side walls, end walls (condition basis), replacement of floor
plate, doors, damaged under frame members and fitment of feed
pipe (to convert the wagon from single pipe to twin pipe). To
ensure good quality of welding, it is essential to install the wagon
on manipulator for undertaking this work so that horizontal down
hand welding can be performed to the maximum extent. The top
and bottom centre pivots will also require replacement and fixing
with Lock bolts. The bogie, air brake equipment and pipes,
draft gear and couplers including uncoupling gear and
brake gear of the existing wagons will be retained. In case
any of these components are missing or damaged, they will
have to be replaced.
Preferably BOXN Wagons in age group of 18-22 years should be
taken up for this rehabilitation unless condition of a particular
wagon so dictates and the BOXN wagons in age group 12-18
years should be taken up for upgraded rehabilitation using RDSO
Specification WD-16-BOXNR-2010 (Rev-1).

Rehabilitation of wagon to be taken up only if centre sill of wagon

found to be in sound condition and meeting the parameters laid
down in check sheet at Annexure-I.

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

2.0 WORK DETAILS

2.1 Every incoming wagon to a workshop should undergo a

comprehensive incoming examination that should identify the
repairs that need to be carried out before the wagon is turnout.
Format for the same is placed at Annexure-II

2.2 Wagons provided with single pipe shall be converted into Twin pipe
Air brake system to RDSO drawing no-WD-80007-S-12 (Sheet 1of
2) & WD-80007-S-12 (Sheet 2 of 2)

2.3 Strip off side walls, end walls (if found damaged/repaired) and floor
plate completely by cutting carefully from under frame and carry
out measurement of camber.

3.0 UNDER FRAME REPAIR

3.1 The wagon taken up for rehabilitation will have to be checked for
camber before rehabilitation. The camber of the wagon under frame
should not be sagging. Before repairing of the under frame of the
wagon it will be shot blasted or mechanically cleaned so that all
scales, rusts etc. is removed. On the basis of physical condition of
the members these will be replaced with new one as per Design
Drg. No. WD-80007-S-04.The repair work of under frame/welding
shall be carried out with the help of manipulator to ensure down
hand welding.
Generally sole bar over the doorways are found corroded. As such
a protection plate of size 3.15x295x1384 mm and material to
IS:1079 Gr `O` with Cu shall be welded on the sole bar over the
door way portion on all the wagons as shown in RDSO Drg.
No.WD-80007-S-14. When the thickness of the web of the sole bar
is reduced by more than 2 mm but less than 5 mm, then a 5 mm
thick protection plate of size 240 x 1454 mm to IS:2062 E 250
shall be welded. Before application of protection plate, sole bar
outer surface shall be thoroughly scrapped and cleaned of rust,
scale or dirt and properly dressed. On provision of protection plate,
the existing 5 mm thick door hinge packing (item-16 of Drg. No.
WD-90007-S-1) shall be replaced by a packing of suitable

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

thickness so that dimension 46 is maintained as shown in section-

ZZ of Drg. No. WD-90007-S-1.

3.2 When sole bar web thickness is found to be less than 4 mm, it
shall be replaced by a new one to Drg . No. WD-80007-S-14.
4.0 Wagon Body
4.1 Body side wall

Complete Body side arrangement including side stanchion, top

coping, side panels etc. shall be replaced with new body side
arrangement as shown in RDSO Drg.No.WD-80007-S-05. On
each side wall middle door including doorway cross bar pressing,
door way stiffener (small) should be replaced by side wall sheet
and provide additional bottom middle coping of ISMC 100 (1530
long) in the line of item-4 of Drg. No.WD-80007-S-05. Material
specifications of different items are given in the drawing. The body
side complete (with two doors opening on each side wall) shall be
manufactured separately ensuring the camber of the side wall to
match with under frame in a suitable welding fixture to facilitate
down hand welding and then assembled with the under frame as
per Para 4.5.

4.2 Body end wall: Examine the End Wall as per parameters
mentioned at Annexure- III , If the End wall qualifies on the
parameters than the same shall be retain otherwise the complete
body end arrangement shall be replaced with new one as per
RDSO Drg.No.WD-80007-S-06.Material specifications of different
items are given in the drawing. The body end complete shall be
manufactured on a suitable welding fixture to ensure down hand
welding and then assembled with the under frame. However, for
assembly of corner stanchion with body side Para 4.5 will be
followed.

4.3 Flap doors: The middle doors of side walls to be closed. On each
side wall end flap doors (2 Nos.) complete shall be replaced by a
new flap doors as shown in RDSO Drg. No.WD-90007-S-1. The
material specifications of different items are shown in the drawing.

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

4.4 Floor plate

Generally floor plates at certain location are sagged due to wide

span of floor supporting under frame members. Therefore
additional 30 Nos. cross ties of ISA 75X75X8 are provided as
shown in the drawing. Floor plate of BOXN wagon shall be replaced with
new floor plate. The size and method of welding the floor plate
with crib angle, sole bar and head stock is shown in RDSO Drg.
No.WD-80007-S-04.

4.5 Assembly of the body side, body end and under-frame

The assembly of body side/body end with the under frame shall be
with riveted/Lock bolted joint as shown in RDSO Drg. WD-80007-
S-05 and WD-80007-S-06. The assembly of body side with corner
stanchion and side wall top coping with end top coping shall be
with welded joint and welding shall be carried out on manipulator
to ensure down hand welding.
4.6 The design of top and bottom centre pivot shall be as per
drawing No. WD-85079-S-2, Item-2 & 1 respectively.
5.0 AIR BRAKE

Wagons provided with single pipe shall be converted into Twin

pipe Air brake system to RDSO drawing no-WD-80007-S-12
(Sheet 1of 2) & WD-80007-S-12 (Sheet 2 of 2)

6.0 OTHER TECHNICAL REQUIREMENTS

6.1 The camber of the rehabilitated wagon to be retained as for as
possible to close to original BOXN Wagon (6+_ 2 mm).

6.2 The Specification of the material shall be as specified in the

drawing.

6.3 The mode of fabrication for Sub-assembly and components shall

be same as indicated in latest particular specification of BOXN
wagon.
6.4 All other requirements regarding standard specifications, use of,
as made drawings etc. will be the same as indicated in latest
particular specification of BOXN wagon.
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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

6.5 The welding procedure and precautions during welding shall be

followed as detailed in annexure-VII and Clause-8 of Specification
G-72 (Latest Revision).

6.6 Tare weight of the wagon shall be determined as per standard

method.
7.0 PAINTING AND MARKINGS

The painting and markings for these rehabilitated wagons shall be

as detailed in Clause 7.7 of Schedule of Technical requirements
No.WD-11-BOXN-2001 for BOXN wagons. However, the
mechanical code, wagon no. and railway initials etc. shall remain
the same as that of the existing BOXN wagon. To distinguish the
rehabilitated wagon, ends top coping shall be painted yellow in
colour.

In order to identify the workshop that did the work of rehabilitation

on a particular wagon for times to come, an oval shaped Rehab
plate to RDSO drawing no WD-07001-S-06 (similar to the one
used by wagon builders after new manufacture of wagon) must be
rivetted/welded to the sole bar at suitable location as mentioned in
marking diagram drawing no WD-80007-S-21 identifying the name
of the workshop (UST Code allotted to the workshop may be
used), month and year of rehabilitation.

8.0 TESTING
The pattern wagon shall be tested as detailed in Clause 12 of
General Standard Specification No. G-72 (Latest Revision).
Clearance found between various members of under frame
and bogie shall be measured under tare, fully loaded,
overloaded and unloaded condition and submitted to the
Engineers through the Inspecting Officer.

9.0 INSPECTION
9.1 The entire rehabilitated wagon will be inspected and replacements
made their in along with measurements recorded in separate
measurement book. The inspection of the wagon with all its
fittings shall be done by NTXR as per extant procedure.

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

9.2 A central database of Rehab wagons is required to be created in

FMM and WISE. Till such time FMM and FOIS database are
ready, Rehab information shall be updated on current wagon
master. FOIS will be customized by adding more fields to ensure
updation of maintenance history by workshops.
9.3 Any maintenance activity on the rehab wagons should be taken up
after perusing the past rehab/maintenance details and the
maintenance input provided should be fed into the database.

9.4 Rehab wagon needs to give trouble free residual service, over
their stipulated codal life. Any major repairs/ NPOH marking, in
rehab wagons, needs, be reported to the shop which had
undertaken the rehab and these repairs also reporting CRIS to
include this in FMM and WISE. Till such time FMM is fully
functional, these repairs reports send to rebuilding Workshop and
RDSO.
*****

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

Annexure-I

Parameters of Center Sill that need to be checked/ inspected &

condition recorded before BOXN wagons are marked for being
taken-up for Rehabilitation
1. Should not be cracked at any portion.
2. Should not be patched/ repaired at any portion.

3. Should not be bent/ hogged/ permanently distorted in any portion/

part. The camber should not be less than 2 mm for considering the
wagon for upgradation.

4. The Draft Gear portion should be inspected & those wagons

should not be marked for Rehab that have hole/ pockets cut in the
center sill & the same are covered/repaired/ patched using cover/
patch plate.

5. Wagons wherein any bulging is noticed at the draft gear location

(owing to lateral shifting of the draft gear) or section thinning of
center sill at the draft gear locations is noticed, should not be
selected for Rehab.

6. The Thickness should not have reduced below 7mm.

7. Weld Joints of the Two Z section should be intact & satisfactory.

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

Annexure-II

Parameters/ Structural Members of BOXN that need to be checked/

inspected, Condition recorded & the required repairs identified
Part Of Wagon Incoming Condition Warranted Repairs
End Body
End Body Buldging
Body End Stanchion
End Body Corner Angle
Ladder
Side Body
Side Body Buldging - Both Side
Body Side Stanchion
Body Side Middle Coping
Door Way Crossbar Pressing
CBC
CBC with Yoke Pin
Knuckle with Pin & APD
Back Stop
Wear Plate (Striker casting)
Yoke Pin Support Plate
Yoke Support Plate
Uncoupling Rod Arrangement
Under Frame
Central Brake Rigging including SAB
Centre Pivot Top
Center Sill
Sole Bar - Pillar to Pillar
Sole Bar/Head Stock Patch
L/E Change - over arrangement
Main Transom/ Bolsters
Hand Brake Wheel
Hand Brake Gear with Gear Box
Head Stock
Head Stock & Sole Bar – Joint
DOOR
Door Check Spring
Door Locking Pin
Door Hinge Long/ Short
Door Hinge Foot
Door Gravity Catch/Chainless cotter
Floor
Crib angle & End angle
Floor Sheet/Floor Patch

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 NO. WD-12-BOXN (Rehab.)-2006(Rev-1)

Annexure-III

Parameters of End Wall that need to be checked/ inspected &

condition recorded before replacement with new End wall

1. Should not be damaged at any portion.

2. Should not be patched/ repaired at any portion.

3. Should not be bent/ hogged/ permanently distorted in any

portion/ part.
4. End wall sheet should not be badly corroded.
5. The stanchions should not be damaged, bent and repaired.
6. Top coping should not be damaged, bent and repaired.

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