cap ‘WD-14-ABR-2007 (Supersedes WD-14-ABR-2000) GOVERNMENT OF INDIA MINISTRY OF RAILWAYS ‘SPECIFICATION FOR NON-ASBESTOS: ‘TYPE COMPOSITION BRAKE BLOCKS FOR FREIGHT STOCK OF INDIAN RAILWAYS WD-14-ABR-2007 ISSUED BY RESEARCH DESIGNS AND STANDARDS ORGANISATION MINISTRY OF RAILWAYS LUCKNOW February, 2007 PRICE: RS. eb !8WD-14-ABR-2007 ‘SPECIFICATION FOR NON-ASBESTOS ‘K’ TYPE COMPOSITION BRAKE BLOCKS FOR FREIGHT 243 214 215 216 247 218 ‘STOCK OF INDIAN RAILWAYS SCOPE This specification covers the technical requirements of non-asbestos ‘K’ type composition brake blocks for application on freight stock of indian Railways. These brake blocks have a high co-efcient of fction and called‘ type brake blocks REQUIREMENTS GENERAL ‘K’ type brake blocks have an average co-efficient of friction of approximately 0.25. The ‘K’ type composition breke blocks shall be non interchangeable with cast iron as well as low friction composition brake block (‘'Type) already in use on freight stock. The parameters for freight stock using K’ type brake blocks are given inthe Annexure. ‘The composition of the material and the manufacturing process for series production of ‘K’ type composition brake blocks must alvays conform with that of the composition brake blocks for which ‘approval has been given by RDSO and no change shall be made in the composition and drawing against which approval has been granted. The use of asbestos is prohibited. The use of Lead and Zinc in the metal state or in the form of compounds is not allowed. The same apples to all other components, if in the form of powder, particles or gas produced during the use of the brake blocks, which may constitute a danger to health, ‘The composition of the material constituting the brake block must be chosen so as to give the best balance between: - ~ the braking characteristics, = the wear and service life of blocks, = wear on the running surface of the wheels, ~ _ the effect on adhesion between the rail and whee! The characteristics laid down in this specification must be maintained for the complete usable thickness ofthe braking materia ‘The supplier will advise the detailed procedure for disposal of usedleondermned composition brake blocks and will also associate with railways to set up faciities for disposal of used/condemned composition brake blocks ob 822 224 222 223 224 225 23 234 232 233 24 244 242 243 WD-14-ABR-2007 FRICTION ‘As far as possible the co-efficient of fiction must be independent of the inital breking speed, the state of beddingyin of the brake block, the spectic pressure as well as the temperature and atmospheric condifions. The tolerance bands of the instantaneous and average coefficient of friction shall be as per ‘Annexure-ll ofthis specification. The definition of the fricfon co-efficient is given in Annexure- I During bedding in the coefficient of friction must not vary by more than +15% from the value obtained when bedding: is complete. Under the influence of dampness ie. under wet conditions, the average coefficient of fiction must not vary by more than +15% in relation to the value obtained during braking when dry with other conditions remaining the same. ‘ter prolonged braking flowed by braking to a stop, paticulaty high temperature oocurs (maximum 375°C on the opposing friction surfaces). The average coefficient of friction must not vary, withthe ‘other conditions remaining the same, by more than + 15 % in relation to the value obtained during ‘braking in the cold and dry state GEOMETRICAL CHARACTERISTICS ‘The controling dimensions of brake blocks shall conform to the requirements given in the RDSO drawing No. WD-00006-S-01 with latest Alt. placed at AnnexureV. The constructional features of the brake block must enable them to wear down to a thickness of 410mm, including the back plate, without the latter or the securing components with the brake head, ‘coming into contact with the running surface of the wheel Weight of Brake Biock shall be shown in the drawing MECHANICAL, PHYSICAL AND CHEMICAL CHARACTERISTICS ‘The various elements making up the brake blocks must be spread uniformly in the body ofthe block. ‘There must be no pitting, lakes or other defects. The material must not aitack the opposing fiction surface or give rise tothe formation of metalic inclusions. ‘The blocks must not cause more serious heat damage to the wheels (hot spots, cracks, flaking) than ‘would be caused by cast ron blocks used in the similar way on the similar wheels. “The values of density, hardness, compression modulus, cross breaking strength, acetone extract, ash content (loss on ignition) and back plate pul off strength must be given for acceptance purposes.244 248 25 254 252 253 34 344 34.2 343 WD-14-ABR-2007 ‘The brake block and its back plate mu be designed to withstand the forces likely to occur during service. The durability of assembly can t_ checked withthe test arrangement shown in Appendix 6 of UIC 541. 4 , back plate must not become detached from the composition material The brake blocks must not reduce the adhesion between the wheel and rail to an unaoneptable degree compared with that normally obtained from vehicles fitted with cast iron brake blocks. ‘MARKING ‘The marking on back plate and clamp of 3ch brake block shall be as per Drawing No. WD-00006-S-01 with latest Alt placed annexure IV. ‘These marks shall be punched in such nanner so that the block can be identified even after being fully wom in service, ‘The condemning limit shal be marked | orange colour on the side of brake block, manufactured to drawing no. WD-00006-S-01, with lates! ACCEPTANCE PROCEDURE FOR NEW SUPPLIER: - The tenderer seeking to supply brake blocks to Indian Railways must have a technical collaboration with an foreign manufacturer who has experience in manufacturing rail road brake blocks. The foreign collaborator must have complete manufacturing and tes facilities including full scale Dyntamometer for, manufacturing and testing of brake blocks. The collaborator will have to give detailed information including type acceptance test data run and their verification procedure as per clause 2.2 and other details in accordance with clause no 2.4.3. The test on dynamometer wil be carried out by the collaborator as per test scheme given in annexure-V. ‘The condition of foreign collaboration is sticty applicable for those companies, which are not inthe business of manufacturing friction composition materials for industri use. However, the companies, which are in the business of friction composition material for industrial use and have established all the requisite manufacturing and testing facilites including full scale rail dynamometer for indigenous ‘manufacture of the Railway brake block and are following a quality assurance plan to the satisfaction ‘of RDSO may be exempted by RDSO from the requirement of foreign collaboration. Such firms should submit dynamometer test results after testing of samples on their own dynamometer. ‘The firm cleared for regular supply of “L’ type composition brake block for freight or coaching or Loco ‘may also manufacture the type brake block. The first lot shall be manufactured in presence of RDSO officials, Sample of brake biocks will be drawn by the RDSO representative for dynamometer testing at RDSO. Hef 18344 315 31.6 347 34.8 31.9 3.4.10 att 34.12 34.13 34.14 31.15 3.1.46 WD-14-ABR-2007 The tenderer will have to produce adequate evidence from their collaborator in support of good perforriance of the collaborator and adequate experience in manufacture and supply of composition brake blocks for Rail Road application. ‘The tenderer shall also submit a copy of approval certificates issued to their collaborator by any of raliroads for composition brake blocks. The tenderer shall submit a copy of memorandum of understanding (MOU) joiny signed by the tenderer and collaborator The tenderer shall submit list of past supplies made by their collaborator to different railroads along with specifications followed for manufacture and supply of brake blocks. ‘The tenderer shall submit the list of plant and equipment available along with capacity, no. of such ‘equipments, manufacturer name ete available with collaborator. ‘The tenderer shall submit detailed drawing of the brake block in line with clause 2.3 for approval of RDSO. The tenderer will have to submit from the collaborator, the results of dynamometer test of samples. carried out by the collaborator according to test scheme indicated in Annexure V. The detais of {fiction properties as per clause 2.2 and other details of test results in accordance with clause 2.4.3 shall also be furnished. The information in para 3.1.1 to 3.1.10 should be presented together with a request for type acceptance test by RDSO. The supplier wil submit six number of brake blocks for type aoneptance test on RDSO's brake dynamometer and samples will be tested as per Test Scheme given in Annexure-V The testing charges will be paid by the supplier. During the tests, the blocks must not reveal any sign of combustion, formation of faking, sweating of the binding material, permanent grating or other defect. ‘The wear should be uniformly distributed over the entre depth of the block, it should be as low as possible and be largely independent of the type of brake load application. The specific wear value of ‘each brake block found by weighing should not exceed 5 odkw hr. ‘The blocks tested on the dynamometer must meet the requirements given in para 2.2 of this specification On successful completion of the dynamometer testing at RDSO, the brake biocks shall undergo field tials. The field trial shall be carried out in two phases. The first phase shall consist of field trials of 1500 imported brake blocks, On successful completion of the field trials of imported brake SLBWD-14-ABR-2007 blocks, 1500 indigenously manufactured brake blocks shall under go the field trials in second phase. The supplier has to submit the drawing as per clause 2.3 and QAP as per clause 3.2.2 for ‘approval before undertaking manufacture of these brake blocks. The imported! indigenously manufactured brake blocks will be supplied for field tial only after inspection by RDSO. 3.1.47 Six samples out of 1500 inital indigenously manufactured brake block shall be picked up by the ROSO to under take full-scale dynamometer test of any two samples. The supplier shall arrange this testing of blocks on his ownMvith collaborator. Alleratvely the supplier may send the brake block for testing at RDSO at his own cost. This test will be carried out as per Test Scheme given in Annexure. 31.18 Based on the technical evaluation after field trial of 1500 Nos. of brake blocks further action will be taken for series production of composition brake blocks. 3.1.19. The inspection during series production and supply will be cerried out as per clause 4 32 FOR SUPPLIER ALREADY CLEARED FOR INDIGENOUS SUPPLY 3.2.1 The supplier shall submit detailed drawing of the brake block in ine with clause 2.3 for approval of RDSO. 3.22 The supplier shall get his Quality Assurance Plan approved by RDSO before undertaking manufacture of the brake blook. The Quality Assurance plan must contain the detais of process of manufacture, process controls and quality records maintained. The QAP must also contain the aoceptable readings ofthe following parameters along with the method of testing a) Compression modulus. b) _Cross-braking strength ©) Acetone extract. 2) Ashcontent.(Loss on ignition) e) Hardness. £) Density. g) Back plate pul off strength. bh) Anyother tests 3.23 The supplier shall undertake full-scale dynamometer test (as per Annexure V) on the brake blocks Under supply to Indian Railways at intervals as per QAP approved by RDSO. For this purpose requisite samples shall be picked up by RDSO and the supplier shall arrange testing of the blocks. ‘Altematively the supplier may send the block for testing at RDSO at his own cost. To maintain quality, RDSO at ther disretion may pick up samples at ay time for testing at RDSO dynamometer. 3.24 Theiinspection during series production and supply will be carried out as per Claus 4. Geb /4WD-14-ABR-2007 4. INSPECTION 4.1. For New Supplier - 4.1.1 The inspection of the brake block shall be carried out by Director General / RDSO or his authorised representative af the premises ofthe supplier. 4.1.2 Theinspection will be caried out as per the following procedure: i) iv) ” vii) vii) ‘Supplier to submit pre-nspection report for the lots offered for inspection as per the approved QAP of the firm. Supplier to ensure traceability of each block to its parent mix batch number & heat No. etc. The inspector shall inspect the qualty records maintained by the supplier for the entire lot Each lot offered for inspection shall consist of 2000 brake blocks or part thereof. The lot No. shall represent the mix, batch numbers and heat No. out of which these brake blocks have been manufactured 2% of every offered lot of 2000 nos. brake blocks wil be selected at random and checked for dimensional accuracy. Dimensions are to be checked as per approved drawing of manufacturer. However, itis to be ensured that blocks from diferent mix batches will be taken up for inspection. ‘Two brake block selected at random from the above lot shal be tested forthe following 2) Compression modulus. b) —_Cross-braking strength ) Acetone extract. d) Ash contents or (loss on ignition), e) Hardness. f) Density ‘The block shall be aovepted based on acceptable readings given in the RDSO approved QAP of the supplier. The method of testing shall be as gven in UIC 541-4-0R or as per the method of testing followed by manufacturer indicated in their approved QAP. ‘Two brake block selected at random from the same lot to be tested for back plate pull of strength and accepted based on acceptance values specified in approved QAP ofthe firm, ‘Two brake block selected at random will be subjected to any other test to be included in the QAP of the firm as decided by the manufacturer and RDSO. 4.1.24. The brake blocks shall conform to the requirements mentioned in the QAP ofthe firm and approved by RDSO. If any of the samples selected as per para 4.1.2 fail to meet the requirements of any ofthe requirements, double the quantity of samples stipulated in clause 4.1.2 shall be selected for tests. If during rtesting any ofthe brake blocks fal to meet the requirements of any of the tests the entire lot (of brake blocks offered for inspection shall be rejected and brake blocks shall be rendered unserviceable 44.2.2. The rejected lot shall be destroyed. 76/8WD-14-ABR-2007 42 For supplier already cleared for indigenous supply :- 4.2.1 The inspection of the brake block shall be carried out by Director General / RDSO or his authorised representative atthe premises of the supplier. 4.22 The inspection will be carried out as per the following procedure: i) Supplier to submit pre-inspection report for the lots offered for inspection as per the approved QAP of the fir, ji) Supplier to ensure traceabilty of each block to its parent mix batch number & heat No. etc. il) The ingpector shal inspect the quality records maintained by the supplier fr the entre lt iv) Each lt offered for inspection shall consist of 2000 brake blocks or part thereof. The lot No. shall represent the mix, batch numbers and heat No. out of which these brake blocks hhave been manufactured. \)__ 1% of every offered lot of 2000 nos. brake blocks will be selected at random and checked for dimensional accuracy. Dimensions are to be checked as per approved drawing of ‘manufacturer. However it is to be ensured that blocks from different mix batches will be taken up for inspection. vi) One brake blocks selected at random from the above lot shall be tested forthe following: @) Compression modulus. b) —_Cross-braking strength ©) Acetone extract ) Ash contents or (loss on ignition). e) Hardness, f) Density. The block shall be accepted based on acceptable readings given in the RDSO approved QAP of the supplier. The method of testing shall be as given in UIC 541-4-OR or as per the method of testing followed by manufacturer indicated in their approved QAP. vi) One brake blocks selected at random from the same lot to be tested for back plate pull off strength and accepted based on acceptance values specified in approved QAP of the firm. vii) Two brake blocks selected at random wil be subjected to any other test to be included in the QAP of the fim as decided by the manufacturer and RDSO. 4.22.1. The brake biocks shall conform to the requirements mentioned in the QAP of the firm and approved by RDSO. If any of the samples selected as per para 4.2. fal to meet the requirements of any of the requirements, double the quantity of samples stipulated in clause 4.2.2 shall be selected for tests. If during testing any ofthe brake blocks fal to meet the requirements of any of the tests the entire lot ‘of brake blocks offered for inspection shall be rejected and brake blocks shall be rendered ‘unserviceable 4.2.2.2. The rejected lot shall be destroyed. ab /861 62 WD-14-ABR-2007 TESTING FACILITIES i) Suppliers shall have complete faciltes/gauges for checking of brake blocks according to dimensional tolerances shown on the drawing, ii) Suppliers shall have adequate feces for determining the characteristics as laid down in pata 4.1.2 (vi) / 4.2.2 (vil. The equipment used for testing shall be able to give output in print out form ofthese parameters for maintenance of record, The supplier shall have in house full-scale dynamometer facilites to test the brake block as per test scheme laid down in Annexure-V. The frequency of testing samples on Dynamometer should be as laid down in the QAP approved by RDSO. The supplier shall submit test results to RDSO. PACKING ‘The brake blocks shall be securely packed in cardboard boxes so that there is no damage to brake blocks during transit This shall be got approved from RDSO along with drawing, Firm having collaborator, Packing should be in accordance with the recommendations of the collaborator. This shall be too got approved from RDSO along with drawing. WARRANTY The waranty on account of manufacturing defect shall be 24 months from the month of supply or duly ie cycle ie.time taken in reaching the wear limit ofthe brake block, whichever is eater. qb 18WD-14-ABR-2007 /ANNEXURE-| PARAMETERS FOR FREIGHT STOCK S.No. Particulars _ DATA 1 ‘Maximum axle load (Tone) Poy 2. No. of wheels per_ wagon 08. 3, ‘Wheel dia (mm) New 1000 mm_ Condernning 906 mm 4 No, of brake block per wheel ot 5. Brake block force ( Kg ) / block 2370 6 Max. speed (kmph) 100 7. ‘Type of brake system Air Brake job 6WD-14-ABR-2007 ANNEXURE:! DEFINITION OF CONCEPTS: ‘As far as tolerances on the co-efficient of friction are conoemed, a distinction must be made between -the instantaneous co - efficient of friction [1 a, which can be defined ,and each moment of braking, by the ratio of the braking effort Fo the total force F » Fi Fo «the average co-efficient of friction pm. which can be defined through out the duration of the brake application from the moment when 95% of the brake block force has been established until coming to a halt. The average coefficient of friction um is obtained by integration of the instantaneous coefficient of friction pa, over the stopping distances S 2 hae — 1s f pads where S20 So im) = stopping distance from the moment when 95% of the brake block force Fb has been applied untill coming to a halt m [Kg] = proportion of axle load to be braked by the wheel R [m) = Wheel radius Vseran [kgm2] = moment of inertia of test bench Lion {kgm} = moment of inertia corresponding to the portion of the axle load to be braked by the wheel according to the test programme. Fo (N) = total block force. Fr (N) = braking effort. Mu- (Nm) = friction moment of the test bench at certain wheel load and speed; determined by ‘the method specified in Appendix 1 of ORE B126/RP8 1 sam = m'R? yhlbWD-14-ABR-2007 If Iygisinot the same as | nm. The weights must be adjusted by applying a correction ofthe initial braking speed V mn to V as folows: Thom VA =K* Vico with K = bench jrob /8WD-14-ABR-2007 ANNEXURE:IIL o.a28 | NS \ 10680 78 200 SABS 0.20 =a pa a o ~==f==~Jo.175 |ZPp>20000 11 © 2 405060 80 100-120, 40160 Vv [km/h] AVERAGE COEFFICIENT OF FRICTION 21m FOR K - BLOCKS | 040 | 0.30 | / 0.10 | ‘{F320000 N | 00 a © 2% 405060 90 100120140180 V [km/h]WD-14-ABR-2007 ANNEXURE - IV BRAKE BLOCK -00006-5-0 14 16WD-14-ABR-2007 ‘ANNEXURE-V TEST SCHEME FOR TYPE ACCEPTANCE TEST FOR ‘K’ TYPE COMPOSITION BRAKE BLOCKS FOR FREIGHT STOCK. 1. Wheel Diameter 1000 mm 2. Number of brake blocks/whee! —one 3. Axle load 25 tonne 4. No.of samples to be tested —Two(minimum) Brake | Speed | Force per [Initial Remarks, application | kmh. | brake block | temp. of No. (kg) wheel tread (deg C). 1 2 4 5 6 Ditoox [60 — | 1000 Braking 10 slop until 80% surface sealed. Weigh 4 30___| 2200 24 60 : 34 100, 44 120 54 30 | 1100 64 60 74 10__ |, 84 120 |. o4 30 | 3300 50-60 | Braking to stop dry after cooling pause. 10.4 60 414 100 12.1 120 |. 12 30 | 2200 22 60 32 100 42 1200 | 52 30 | 1100 62 60 72 100 82 120 92. 30 [3300 10.2 60 112 100. /Sch 3WD-14-ABR-2007 422 120 43 30, 2200 23 60. 33 400 43 120 » 53 30 [1700 63 60 73 100 50-60 | Braking to stop dry after cooling pause. 83 120 93 30. 3300 40.3 60. 41.3 400 123 120. 13 60 3300 700-120 | Braking to stop, dry with high initial temperature | 14 100 o 100-120 | 15 30 » 120-140 16 120 n 120-140. 7 60 1100 50-60 | Braking to stop, dry after cooling pause 18 60 3300 weigh Nig 30 ‘| 1100 20-30 | Braking to stop, wet after cooling pause N20 100 | 3300 N2t 120 | 3300 N22 60 2200 N23 30. 1100 24 30 1100 50-60 | Braking to stop, dry after cooling pause vay 100 3300 26 120 3300 7 60 | 2200 28 30 1100 weigh 029 60 - 20-30 Holding braking for 20 minutes, 35kw per wheel +30 60 3300 ‘braking to stop after holding braking _ _ - Weigh a 30 | 1100 0-60 | Braking to slop, dy after cooling pause 32. 100 3300 33 120 3300 4 60 = | 2200 % 30__| 1100 | 036 60 : 50-60 Holding braking for 10 minutes, 50kw per wheel (2) | H37 60 | 3300 braking to stop after holding braking | Weigh 1b of 18Note: () (2) @) (4) WD-14-ABR-2007 1ng brake application (holding braking). aking to stop after holding braking at its initial tmp. without cooling pause. aking in wet condition with a water volume of 14 1/h for v < 120kmh. Braking in wet condition with a water volume of 22 1/h for v> 120k. During the test, interruption of maximum 3 days is permitted only before test 1.1, 1.2, 1.3, and D 29 Braking to slop when the wheel temperature during the test reaches 375° C. The folowing parameters shall be recorded / measured during the above test. 2, Wheel tread diameter before and after the test . Surface condition of brake block after the test specially in respect of grooving metalic inclusions, buming, uniform wear, over-healing et. and the wheel tyre in respect of polishing, pitting, flaking, cracking and other defects after the testis over. c. Max. lemperature reached on brake block and whee! trea for each test. d. General observations regarding smoke, smell, sparks and noise. Location of brake block, rotation of wheel with respect to brake block fited on dynamometer and location of thermocouple are shown in annexure — VI 1766/8WD-14-ABR-2007 ‘ANNEXURE - VI =~ O \ \ NU” ° WHEEL RUTATIUN & LOCAIIUN UF THERMOCOUPLE