Ee reece Se TT 2a area, (aa ae) \RO_, ae Rt sI0 009 GOVERNMENT OF INDIA MINISTRY OF RAILWAYS, (RAILWAY BOARD) NEW DELHI-110001 No 2003/Proj/Bangalore/2/2 (Pt) Dated’7.10.2011 Pr. Chief Engineers, All Indian Railways. Sub: Double Resilient Base Plate Assembly Fastening System. Mis Pandro! Rahee Technologies Ltd had approached Ministry of Urban Development for examination of the “Double Resilient Base plate assembly system’ fastening system of Bailastless track. The same was refereed to MOR and got examined. MoR had conveyed the approval of this system vide letter of even number dt: 12-01- 2011. Subsequently, after inter-ministerial consultations and discussions, and in terms of the requirements of the Performance Criterion for fastening systems dated 21-5-10, MOUD letter number K-14011/21/2009-MRTS dt 19-04-2011 and MoR letter of even no. dt 28-04-2011 were issued. The offered system had been found to be a modified version of an earlier version performing service in severa! metro. including Hongkong and Singapore for more than ‘8 years. However, in the modified version, had been used only from September 2009 in Dubai Metro, as per the requirements of the Performance Criterion for fastening system dated 21-05-2010 along with the clarifications issued on 18-3-11. The same was approved on the basis of the satisfactory performance of the mother system, which had Put in more than 15 years of service, but with the condition that it is to be kept under RDSO monitoring. The MoR letter no. dtd 18-03-2011 mentions that a change in any component of an approved fastening system will require the metro railways to approach the MoR for approval. Accordingly, to operationalize the approval given to the double resilient baseplate assembly system, the following is advised:- 1. A copy of the Performance Certificate of the Dubai Metro dated 28.10.2010, based on which RDSO has considered the performance of the system, is attached herewith as Annexure-1. The Metro Railways/MRTS System should verify the authenticity of the system proposed to be used by them vis-a-vis this Performance Certificate. XN . The drawings and the specification of the fastening system as used in the test assembly, which has been examined and cleared, are enclosed as Annexure-2 The Metro Railways/MRTS System should make sure that the system, if used by them, matches completely with the drawing and specifications of the test APS EDWPARDSO LETTER. DOC2 Encl: Sa RAnBlY examined by ROSO. The metro rallway/MRTS system are at liberty to carry out any tests for this as considered necessary, Before this system is installed in the track, Metro Railways/MRTS System should Satisfy themselves about their chosen fastening systova meeting the physical fom nelers requirements of the Performance Criteria, by conducting fresh tests from an independent laboratory on samples selected by Metro Railway/MRTS system, The clearance: is only for the “double resilient base plate assembly fastening system" of M/S Pandrol Limited, UK. Metro Railways/MRTS Systems should verify themselves about the credentials of the Prospective suppliers of this system, The other aspects of the Performance Criteria dated 21-5-10, such as those in paras 420), 42 (v), 4.3 etc, amongst, others be examined by metro lallways/MRTS system to ensure compliance to the requirements of Performance Criterion. 1, ae v ape! (Rajiv Chaudhry) Executive Director, Works(Pig.) Railway Board, Annexure- 1 Annexure. 2 (32 pages including Sub-Annexures 2/1 to 2/14 showing the drawings (14 pages) & 2/15 to 2/32 (18 pages) showing the specifications) Copy to: “-2-070 “femproduct Specification Title: "PANDROL' Cast Baseplates Product Specification Reference: EC-K __ IssueNos 6 Page 2 of 4 Prot Specification Material Development a,shorised by: QA Rep Dat of Hath March 3.1 Visual (Surface Irregularities) 3.1.1. Only minor surface iregularities, protrusions or cavities are permitted on the complete basepla 4.12 Note Surface oxidation of east baseplates isa nonmal permited song cof supply. Surface oxidation js not detrimental to the performance 3.2. Dimensional Accuracy ‘Ail dimensions of 'as made baseplates the appropriate Pandsol copyright drawing, 3.3. Hardness 3.3.1. Cast baseplates shal vot the baseplate or the Pandrol Rail Fastening assembly (before the addition of any costing) must be in accordance with | 11 be hardness tested to ensure that they meet the required hardness 298° 3.3.2. The method of hardness testing will be as detailed in Table 1 4. COATING Castings shall be supplied without coatings unless specially requested, 5. PACKAGING Unless otherwise specifi ‘ed on the purchase order Pandrol baseplates will De strapped to pallets and shrink wrapped. Weight is not to exceed | tone (6. IDENTIFICATION ‘The baseplate will be marked with the product drawing number and other markings specified on the | Tpproprate Pandzol copyright drawing oF as agree’! BY Pandrol __--cortified:that-this component drawing related £9 assembly drawing no 1344S issue code revised on 2910Cast Baseplates Product Specification Title: PANDROL Product Specification Reference: EC-K Issue Nos 6 Page 3 of 4 Brot Speiaton ater Development Aywhorsed by: QA Rep — PMCS EHH March 7. RESPONSIBILITY FOR TESTS 7.1 Alltests detailed in paragraph 3 are the responsibility of the manufacturer and shall be carried out by the manufacturer or a mutually acceptable independent testing authority. 3.2. Pancrot however reserves the right to undertake or repeat all tests detailed in section 3 8. RECORDS |All Quality Assurance records shall be retained by the manufacturer for a minimum of seven years 9. CERTIFICATION 9.1 ‘The manufacturer will submit with each batch of baseplates (or order if agreed) a certificate of conformity and associated test results confirming that the baseplates | supplied have met the requirements of this specification and conform to the appropri Pandrol copyright drawing. been assessed and allocated an approved supplier status 9.2 For manufacturers who have jor agreement between the documentation requirements may be modified subject to pri Pandrol and the manufacturer. Issue record Supply Specification Reference: EC-K Issue 6 Fie Prprjecs\20000nubers\20051 1S0 filesiproductspees\EC-K6 Modified By: PH 06/03/2007 Supply Specification consists of 3 pages & Table 1 Last Mod No. 3091, : _ Certified that-this component drawing related to-assembly drawing no $3145. issue code _C- _revised on 22> S4 rete 22> @he) Product Specification Title: 'PANDROL' Cast Baseplates Page 4 oof 4 Product Specification Reference: EC-K Issue No: 6 Produet Specification Material Development Date of 12th Mareh Owner: Manager Authorised by: QAREP issue: 2007 ‘Table 1 Paragraph Subject National Standard (s) : BS EN ISO 6506-1 ASTM E10 ASTM 1815 33 Hardness Certified that this component drawing related.to. assembly. drawing. no 4314 revised on 28> 2010 -2s-wn Pandrol’ High Temperature EVA (6 to 10% VA) Pads Ref. DC-D Issue 5 Copy Status ‘This copy, although correct at issue will not be kept up to date. Manufactures should check Specification No. And issue code corresponds exactly to the codes on the Pandrol purchase order. PRODUCT SPECIFICATION '‘PANDROL' BRAND HIGH TEMPERATURE EVA (6 to 10 % VA) PADS: Reference: DC-D Issue 5 ‘The use of equivalent International testing Standards to those quoted is permissible subject to the agreement between the customer and Pandrol Le SCOPE ‘This specification covers the manufacture and testing of pads made from ethylene vinyl acetate (EVA) containing 6 to 10 % vinyl acetate. The pads fre used between rails and / or baseplates and the track support to provide a bearing surface and an electrically insulating layer. 2 PAD CHARACTERISTICS 2.1 Raw Material Data Sheets as published by the raw material supplier for guidance and information only ‘a, Mean Vinyl Acetate (VA) Content: 6 to 10 % by weight b, Ultra violet (UV) stabilisation: ‘The finished pads shall containing carbon black. Alternative UV stabilisers may be used subject to the agreement of Pandrol. 3. QUALITY ASSURANCE TESTING 32 Visual Inspection “The pads surface shall be clean and free fiom sinking, gassing or buming 2s agreed between Panérol and the pad moulder. elated to assembly drawing Certified that this component rawring © _ sevised on 2233-2010 no_{3/YS __ issue code __{ ae‘Pandro?’ High Temperature EVA (6 to 10% VA) Pads Ref. DC-D Issue 5 3.3. Dimensional Accuracy All samples must be in accordance with the appropriate Pandrol copyright drawing. 34 Identification All samples shall be moulded with cleatly visible identification markings as detailed on the relevant Pandrol copyright drawing. 4. RESPONSIBILITY FOR TESTS All tests detailed in section 3 are the responsibility of the moulder and shall be carried out by the pad moulder or a mutually acceptable independent testing authority. Pandrol however reserve the right to undertake or repeat all tests detailed in sections 3, 5. RECORDS ‘All Quality Assurance records shall be retained by the pad moulder available for a minimum of seven years. 6. CERTIFICATION “The pad moulder will submit with each batch of pads (or order if agreed) ‘a certificate of conformity and associated test results confirming that the pads supplied have met the requirements of this specification and conform to the appropriate Pandrol copyright drawing. For pad moulders who have been assessed and allocated an approved supplier status the documentation requirements mey be modified subject to the prior written agreement between Pandrol and the moulder. Product Specification Reference : DC-D Issue 5 WP Ref: J:echnelMechspec\pads\DC-DiS Prepared By: RJH_ 10-08-2009 Product Specification consists of 2 pages Last Mod No, 3186 Certified that this component?arawing related to assembly drawing Dale we L[SIYS tee code C2 revised on 22-09 -2 3stion A-A issue 6 PANDROL BRAND ‘e’ Series Clips Supply Specifi SUPPLY SPECIFICATION *PANDROL' BRAND 'e' SERIES RATL CLIPS Reference : A-A Issue 6 1. SCOPE ‘This. specification covers the supply requirements for resilient, rail fastenings made from spring steel bar to Pandrol copyright designs for '« series clips. andro!’ Brand Rail Clips form part of a ‘Pandrol’ Brand Rail Fastening System and hold the rail to the sleeper, baseplate or other track support. “The design end manufacture will be undertaken by companies certified to 1SO 9000: 2000. 2. RAW MATERIAL ‘The raw material shall be an alloy spring steel to BSEN 10089: 2002 Grade 368iCr7 (modified) or an equivalent approved by Pandrol. 3. QUALITY ASSURANCE INSPECTION 3.1 Raw Material ‘The steel supplier shall submit, with each batch of raw material, a cetificate detailing the chemical composition of the steel and the cast Sumber of the ingot / continuously cast bloom or billet from which it was rolled. 3.2 Dimensional accuracy ‘The clips shall conform to the dimensions detailed on the appropriate Pandrol copyright drawing and shall fit the relevant standard "Pandrol’ inspection gauges and / or direct measuring fixture. 3.3. Visual Inspection The clips shall be free from excessive burrs which may be considered harmful when handled or affect efficient assembly of the clip. Any marks Caused by the forming tools shall be smooth and free from sharp indentations. 1 Certified that this component drawing related to assembly drawing t ined on 23203-2010 no! 314S° issue code = _____ revi -2e-PANDROL BRAND ‘e’ Series Clips Supply Specification A-A issue 6 3.4 Hardness ‘An area on the surface of the underside of the clip shail be ground flat-Hardness tests shall be carried out on a hardness testing machine on this area in accordance with the current national standard. ‘Three indentations shall be made on each clip inspected and the mean of these readings shall be used to determine its hardness. ‘The clips shall be heat treated to achieve a surface hardness in the range 4 to 48 Rockwell C. 3.5 Protective Coatings Clips will be supplied with an electrostatic powder coating or a Pandrol approved alternative coating. Where clips are to be exposed to high levels of corrosion Sheradising to BS4921 class 1 or an altemative Pandrol approved coating will be recommended. IDENTIFICATION Clips will be marked with an identification code. 5. PACKAGING Clips will be supplied in Lo-lift bags. Bag weight not to exceed I tonne. » RECORDS ‘Al! Quality Assurance Records shall be available for a minimum of seven years. 7. CERTIFICATION A certificate of conformity will be supy with each consignment Confirming that the products meet the requirements of this specification {and the appropriate Pandrol copyright drawing, Issue record Product Specification Reference: A-A issue 6 WIP Ref: J:techncttechspeciclips\a-0i6 Prepared By: RJH_ 26/06/2006 Product Specification consists of pages Last Mod No. 3059) 2 Certified, that this component drawing related to assembly drawing no 3! issue code _C.__revised on _2-2.-03..2-0/0 ~27-‘PANDROL' HVN Insulators Ref. BC-H Issue 8 1 2 3a COPY STATUS This copy, although correct at issue will not be kept up to date. Manufacturers should check that the specification No. and issue code on this document corresponds exactly to the codes on the Pandrol purchase order. PRODUCT SPECIFICATION '‘PANDROL' BRAND HVN INSULATOR Reference: BC-H Issue 8 ‘The use of equivalent Intemational Standards to those quoted is permissible subject fo agreement between the customer and Pandrol. SCOPE ‘This specification covers the minimum manufacturing, and testing requirements of HVN insulators. MATERIAL SPECIFICATION ‘Raw material will be a Pandro! approved grade of heat stabilised high viscosity nylon 66 as specified below and / or detailed on the purchase order. Grade of material Pandrol material code Dupont Zytel ES1HS or ES1HSB TC Rhodia Technyl A402H1 VG Solutia Vydyne 65A EA Nilit Polynil P-240LHS RE Radici Radilon ALX14080K RJ QUALITY ASSURANCE TESTING ‘Visual Inspection and Identification “The insulators shall be clean and free from evidence of gassing or burning. The sprue and any flash shall be cleanly removed unless otherwise agreed in writing by Pandrol {All markings must be clear and as indicated on the appropriate Pancrol copyright drawing or as agreed by Pandrol. cere tng tne component brawing related to assembly Sraning no _[D1YS issue code __¢-___ revised on ee ee eee 28‘PANDROL' HVN Insulators Ref. BC-H Issue 8 32 5. 6. oA Q)26 Dimensional Accuracy ‘All conditioned samples must be in accordance with the appropriate Pandrol copyright drawing, RESPONSIBILITY FOR TESTS |All tess detailed in section 3 are the responsibility of the moulder and shall be carried ant by the insulator moulder ora mutually acceptable independent testing authority. Pandral however reserves the right to undertake or repeat all tests detailed in sections RECORDS All Quality Assurance records shall be retained by the insulator manufacturer for 8 minimum of seven yeas CERTIFICATION | ‘The insulator moulder will submit with each batch of insulators (or order if agreed) @ Cinifiete of conformity and associated test results confirming that the insulators Supplied have met the requirements of this specification and conform 10 the appropriate Pandrol copyright drawing. For insulator moulders who have been assessed and allocated an approved supplier ftatus the documentation requirements may be modified subject to the prior written agreement between Pandrol and the moulder. Issue record Product Specification Reference: BC-H Issue 8 ‘WIP Ref, J:\Teshnel\Techspee\insu\BC-Hi8 Prepared by: RJH 16/03/2006 Product Specification consists of 2 pages Last Mod 3082 conta tat this component dng ated to assembly erating no 1319S issue code _C revised on 22.03: 10179 1” "‘PANDROL' HYN Bushes Ref. GC-C Issue 3 COPY STATUS ‘This copy, although correct at issue will not be kept up to date. Manufacturers should check that the specification No. and issue code on this document corresponds exactly to the codes on the Pandrol purchase order. PRODUCT SPECIFICATION ‘PANDROL'’ BRAND HVN BUSH Reference: GC-C Issue 3 ‘The use of equivalent Intemational Standards to those quoted is permissible subject to ‘agreement between the customer and Pandrol, 1, SCOPE ‘This specification covers the minimum manufacturing and testing requirements of HYN bushes. 2. MATERIAL SPECIFICATION Raw material will be a Pandrol approved grade of heat stabilised high viscosity nylon 66 as specified below and / or detailed on the purchase order. Grade of material Pandrol material code Dupont Zytel ES1HS or ES1HSB Tc Dow Plastics (was Monsanto) Vydyne 654 BA Nilit Polynil P-240LHS RE Radici Radilon ALX14080K RI 3. QUALITY ASSURANCE TESTING 3.1. Visual Inspection and Identification ‘The bushes shall be clean and free from evidence of gassing or burning. The sprue and any flash shall be cleanly removed unless otherwise agreed in writing by Pandrol. ‘All markings must be clear and as indicated on the appropriate Pandrol copyright drawing or as agreed by Pandrol. Certified that this componcht drawing related to assembly drawing Se ISIS issue code C_ revised on 22:0" 7019 —30—32 ‘PANDROL' HVN Bushes _ Ref. GC-C Issue 3 Dimensional Accuracy All conditioned samples must be in accordance with the appropriate Pandrol copyright drawing, RESPONSIBILITY FOR TESTS All tests detailed in section 3 are the responsibility of the moulder and shall be carried ut by the bush moulder or 2 mutually acceptable independent testing authority. Pandrol however reserves the right to undertake or repeat all tests detailed in sections 3 RECORDS ‘All Quality Assurance records shall be retained by the bush manufacturer for a minimum of seven years. CERTIFICATION ‘The bush moulder will submit with each batch of bushes (or order if agreed) a certificate of conformity and associated test results confirming that the bushes supplied have met the requirements of this specification and conform to the appropriate Pandrol copyright drawing. For bush moulders who have been assessed and allocated an approved supplier status the documentation requirements may be modified subject to the prior written agreement between Pandrol and the moulder, Product Specification Reference: GC-C Issue 3 WIP Ref, J\Technel!Techspeclbush\GC-Ci3 Prepared by: RJH. 15/01/2004 Proce Specification consists of 2 pages Last Mod 2966, 2 Certified that this component drawing related to assembly drawing no (344 C jeeue code _C revised on _22~ 6) Rel a2a Toss sured Covaelled Copy Teapnded avn “Uncontrolled Copy” Product Spec Title: Compression spring. Product Spec Reference: KC-G Issue Nos 1 L Page 1 of 2 Created by: P.Hewlett Checked by: Approved by: Date of issue: 05/09/06 COPY STATUS ‘This copy, although correct at issue will not be kept up to date. Manufacturers should check that the specification number and issue code on this document corresponds exactly to the codes on the Pandrol purchase order, ‘The use of equivalent Jnternational Standards to those quoted is permissible subject to agreement between the customer and Pandrol. 1, SCOPE ‘This specification covers the minimum manufacturing and testing requirements of Compression springs. 2. MATERIAL SPECIFICATION: Grade of materi ‘Raw material will be a Pandrol approved grade of steel: carbon steels: - BS2803 - 093465, 094465 and 095A65. alloy steels: - BS2803 - 735A50, 730A65 and 685455. [Alternative grades to the ones detailed above may be proposed by the manufacturer, however before being sed alternative grades must be approved in writing by Pandrol- 3. QUALITY ASSURANCE ‘TESTING Based on the manufacturer demonstrating thatthe production process and associaled tous Oe aaa ed that conformity to visual and dimensional requirements are assured, the HedUsoey of visual cone ear inspection (paragraph 3.1 and 32) may be reviewed by Pandrol and subsequently an ey oniy with Pandrol’s written permission, This review may take place at the ‘contractvordet Stage of after an agreed number of processed batches of springs. 3.1 Visual (Surface Irregularities) and Identification “The springs shall be free of burrs which may be considered harmful when! bandied. 32 Dimensional Accuracy [All dimensions of ‘springs’ (before the addition of any costing) must be i accordance with the ‘appropriate Pandrol copyright drawing. certified that this component drawing related to assembly drawing SSIS AUS inne code C__ revised on™ 7-3: 2019 -32-Teaavded saa "Uncontrolled Copy” was stamped Conoled Copy Product Spec Title: Compression spring. Product Spec Reference: KC-G Issue Nos 1 Page 2 of 2 ‘Created by: P\Hewlett Checked byy Approved by: Date of issuc: 05/09/06 Where specified by Pandrol, springs will be Sherardized to BS 4921 class 1. Local deposit thickness of ‘50 microns Min to 80 microns Max to ensure a Class 1 deposit thickness of 30 Microns with a smooth. grey and continuous finish (without lumps and runs). Alternative. coatings may be applied with the approval of Pandrol. Compression test ‘The spring will produce the designated force and its associated compression value in accordance with that stated on the Pandrol Copyright drawing, RESPONSIBILITY FOR TESTS All tests detailed in paragraphs 3.1, 3.2 and 3.3 are the responsibility of the spring manufacturer ‘and shall be carried out by the spring manufacturer or 2 mutually acceptable independent testing authority. Pandrol however reserves the right to undertake or repeat all tests detailed in section 3. RECORDS ‘All Quality Assurance records shall be retained by the manufacturer for a minimun of seven years. CERTIFICATION ‘The manufacturer will submit with each batch of springs (or order if agreed) a certificate of conformity ‘and associated test results confirming that the springs supplied have met the requirements of this specification and conform to the appropriate Pandrol copyright drawing. For manufacturers who have been assessed and allocated an approved supplier status the documentation requirements may be modified eubject to the prior written agreement between Pandrol and the manufacturer. sve rocoré Praduct Speeifiestion Reference: KC-G Issue 1 File: P\projcts(20000 numbers\20051 150 files\productspecs\echspec\ise ref KYKC-G i Prepared By: PH 05/08/2008 Product Specification consists of 2 pages Certified that this component drawing related to assembly drawing no T2AYS” issue code ___© revised on U2-83: 29/0. -33- eee cette7 aac 2. ea i Edeeiiee ~ - oduct Specification Title: Pandrol Anchor Components Product Specification Reference: LC-B Issue No: 3 Page 2 of Product Specification Owner: Senior Engineer Authorised by: QA Rep Date of issue: 17.02.09 3.5 M27 Anchor Boit Description Specification M27 Anchor bolt ‘M27 thread, Grade 8.8, galvanised or equivalent finish to (Part No. 12717) BS EN ISO 10684, 50um batch average thickness. (Based } on DIN 529 ‘Masonry and Foundation Bolts” - Type OD) 3.6 M27 *Nyloc’ Locking Nut ‘Description ‘Specification M27 Locking Nut "| DIN 985, Grade 6, fit GH, galvanised or equivalent Tish (Part No. 12791) fo BSEN ISO 10684, 50ym batch average thickness. —_| Issue record Product Speciation Reference: LC-B lsue 3 RAH 171022008, ; Last Modo. 3169 Certified that this component Grawing related to asse: by drawing no_ASI45 issue code__C____ revised on #9. 2010,