WD-05-BFNS-2017

(Supersedes WD-04-BFNS-2002)

INDIAN RAILWAYS

SPECIFICATION
(TO BE READ WITH CORRESPONDING
LIST OF DRAWINGS AS PER THE TENDERED DESIGN)

FOR

BOGIE FLAT STEEL WAGON

TYPE – BFNS22.9

BROAD GAUGE

(1676 mm)

ISSUED BY

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
LUCKNOW-226 011

JUNE’2017 Price

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CONTENTS
Clause No Description Page No.
1 Scope 3
2 Definitions 3
3 Welding 3
4 Testing 4
5 Standard Specifications 4
6 Particular Requirements 4-7
7 Inspection 7
8 Drawings 7
9 ‘As Made’ Drawings, Photographs and Models. 7-8
10 Warranty/Guarantee 8
Annexure-I Method of determination of Tare weight of wagons. 9
Annexure-II Nylon brake gear bushes in the brake gear of wagons. 10

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INDIAN RAILWAYS
PARTICULAR SPECIFICATION FOR
BROAD GAUGE BOGIE FLAT STEEL WAGON
TYPE - BFNS22.9
1. SCOPE

1.1 This Specification covers the particular requirements for the manufacture and supply of
Broad Gauge Flat Steel Wagon Type ‘BFNS22.9‘ with particular details as per relevant
drawings detailed in Drg. No. WD-98057-S-01 (latest revision) of the tendered design and
and other relevant drawings as provided hereinafter in this specification and General
Standard Specification G-72 (latest revision) issued by RDSO (Wagon), Manak Nagar,
Lucknow-226011.

1.2 In case of any contradiction in the various clauses of the present specification/drawings
and General Standard Specification G-72 (latest revision), the most stringent requirement
will be applicable.

1.3 Latest alteration of all drawings and amendment/revision of all specifications referred to
in this specification shall be applicable at the time of manufacturing of wagons, unless
otherwise permitted by the Purchaser/Engineers.

2. DEFINITIONS

2.1 'Purchaser' means the President of the Republic of India.

2.2 'Engineers' means Research, Designs and Standards Organisation, Ministry of Railways,
Manak Nagar, Lucknow-226011

2.3 'Inspecting Officer' means the person, Firm or Department nominated by the Purchaser
to inspect the work on his behalf and the Deputies of the Inspecting Officer so nominated.

2.4 'Contractor' means the person, Firm or Company with whom the order for the supply is
placed and shall be deemed to include the Contractor's successors (approved by the
Purchaser), representatives, heirs, executors and administrators as the case may be unless
excluded by the terms of the Contract.

3. WELDING

3.1 General requirements and comprehensive guidance with regard to edge preparation, fit up
for welding, welding procedure and inspection of welded joints are contained in Clause 8 of
General Standard Specification No.G-72 (latest revision) which can be purchased from
Director General, RDSO, Manak Nagar, lucknow- 226011.

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3.2 Wherever welding is specified or adopted in the manufacture of the wagons or in the
fabrication of sub- assemblies and components, the manufacturer shall submit his proposed
welding procedure and sequence to the Inspecting Officer and obtain his approval for the
same. This, however, will not, in any way, reduce the contractor’s responsibility for
satisfactory execution of the contract in all respects as stipulated in Clause 8 of General
Standard Specification No.G-72 (latest revision).

4. TESTING

4.1 One ‘Pattern Wagon’ shall be manufactured by the supplier, manufacturing this wagon
first time, for carrying different tests. This wagon will be squeeze load tested at the
premises of the manufacturer in consultation with engineers, to establish design &
manufacturing quality. Required test rig for squeeze load test shall be provided by the
manufacturer.

4.2 The same wagon shall also be tested under loads as detailed in Clause 12 of General
Standard Specification No. G-72 (latest revision). Clearances found between various
members of under frame and bogies measured under tare, fully loaded, overloaded and
under no load condition, certified by Inspecting Officer shall be submitted to the engineers
by the suppliers.

4.3 The performance of air brake equipments of each wagon shall be tested with single
wagon test.

4.4 Any modification arising out of squeeze load test/ FEM shall have to be carried out by
the manufacturers. It is only after approval of the prototype, that the series production of
wagon shall be taken in hand.

5. STANDARD SPECIFICATION

All materials required for the manufacture of these wagons shall conform to the latest issue
of relevant specifications, adopted for railways-use unless otherwise specified herein.

6. PARTICULAR REQUIREMENTS

Construction drawings for wagon indicated in relevant drawings detailed in Drg. No.
WD-98057-S-01 (latest revision).

6.1 UNDERFRAME

The under frame shall conform to technical details as per relevant drawings detailed in
Drg. No. WD-98057-S-01 (latest revision) of the tendered design.

6.2 BOGIE

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6.2.1 The wagon shall be equipped with Bogie type/ details as per relevant drawings
detailed in Drg. No. WD-98057-S-01 (latest revision) of the tendered design. The anti-
pilferage device to bogie end pull rod (item 2 of SK-69597) shall be provided after
assembly of bogie with under frame.

6.3 COUPLER AND DRAFT GEAR

6.3.1 The wagon shall be equipped with High tensile Centre Buffer Coupler, High Capacity
Draft Gear and other associated assemblies/ sub components/ operating/ interfacing
equipment as per relevant drawings detailed in Drg. No. WD-98057-S-01 (latest revision) of
the tendered design.

6.3.2 Coupler operating mechanism shall be positioned as per relevant drawings detailed in Drg.
No. WD-98057-S-01 (latest revision) of the tendered design.

6.4 AIR BRAKE

6.4.1 The wagon shall be equipped with single/twin pipe graduate release Air Brake equipment to
RDSO Specification with latest revision/amendment as mentioned in relevant drawing
detailed in RDSO index Drg. No. WD-98057-S-01 (latest revision) of the tendered design.

6.4.2 Pipes and pipe joints consisting of Brake pipe and Branch pipes shall be as per relevant
drawings detailed in RDSO index Drg. No. WD-98057-S-01 (latest revision) of the tendered
design.

6.4.3 The complete air brake equipment including the pipes and joints shall be fitted on Pattern
wagon as per the relevant drawing detailed in RDSO index Drg. No.WD- 98057-S-01(latest
revision) of the tendered design and offered to the ‘Engineers ‘ for approval. The Contractor
shall be obliged to carry out any modifications on the layout of the air brake equipment, if
found necessary, by the ‘Engineers’.

6.4.4 Brake block force shall be checked at the time of prototype testing, with the necessary
facilities, equipments etc. being provided by the manufacturer. Any modification required
after testing, shall be ensured by the manufacturer.

6.4.5 Contractor shall proceed with the bulk production of the pipes and joints only after the
final approval of fitment and layout of pattern wagon equipment, as mentioned above.

6.4.6 During the bulk production of wagons, the Contractor shall ensure that the complete air
brake equipment is fitted on the wagon correctly as per the dimensions shown in the layout
drawing. Special care must be taken with regard to the clamping arrangement of pipes to
under frames besides securing of clamps with pipe and tack welding of nuts with
bolts.

6.5 BRAKE GEAR

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6.5.1 The wagon shall be equipped with brake gear in accordance with the arrangement
shown in relevant drawings detailed in RDSO index Drg. No. WD-98057-S-01 (latest
revision) of the tendered design. The contractor shall also ensure for correct
functioning of the brake gear components.

6.6 SIDE BRACKET WITH LINK, SIDE STANCHIONS AND FLOOR PLATE
ARRANGEMENT

6.6.1 SADDLE & FLOOR PLATE ARRANGEMENT

Wagons shall be provided with longitudinal trapezoidal pockets for loading of coils as per
relevant drawings detailed in Drg. No. WD-98057-S-01 (latest revision) of the tendered
design. The Contractor shall also ensure that the floor drain holes are suitably located to
clear the Air brake equipment, Pipings, under frame brake gear components and all
the bogie members.

6.6.2 SIDE STANCHIONS

Wagons shall be equipped with collapsible side stanchions on both side of wagon along with
Stanchion brackets and Rests as per relevant drawings detailed in Drg. No. WD-98057-S-01
(latest revision) of the tendered design.

6.6.3 STOPPERS

The wagon shall be equipped with Adjustable stoppers to prevent longitudinal shifting of
coils as per relevant drawings detailed in Drg. No. WD-98057-S-01 (latest revision) of the
tendered design.

6.6.4 SIDE BRACKET WITH LINK

These wagons shall be equipped with side bracket with link on both side of wagon as per
relevant drawings detailed in Drg. No. WD-98057-S-01(latest revision) of the tendered
design.

6.7 PAINTING AND MARKINGS

6.7.1 The surface preparation and painting of the wagons shall be as indicated in Clause 11 of
General Standard Specification No. G-72 (latest revision) read with latest amendments. In
addition with the provision in Clause-11 the underframe members shall be grit/shot blasted
and painted as per painting schedule given in Specification No.G-72 (latest revision)) read
with latest amendments.

6.7.2 Precautions before and after painting shall be observed as detailed in para-11.2.2,
11.2.3 and 11.2.4 of specification no. G-72 (Latest Revision).

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6.7.3 The marking other than those indicated in Clause –11 of General Standard Specification
No. G-72 (latest revision) read with latest amendments shall be as per relevant drawings
detailed in Drg. No. WD-98057-S-01(latest revision) of the tendered design.

6.7.4 The tare weight of the wagons shall be marked in tonnes upto one decimal place, as
determined by the method detailed in Annexure - I.

6.7.5 The standard plates shall be attached on the underframe sole bars at diagonally opposite
corners as per relevant drawings detailed in Drg. No. WD-98057-S-01(latest revision) of the
tendered design. One plate on one side of underframe shall be in English and the other shall
be in Hindi.

6.7.5 Railways initials to be marked will be intimated later. The mechanical code shall be
stenciled and stamped at the locations shown in relevant drawings detailed in Drg. No. WD-
98057-S-01(latest revision) of the tendered design.

7. Inspection

7.1 The inspection of the wagon with all its fittings is to be carried out by RDSO, Wagon
Inspection Wing. The wagon manufacturer will provide all the facilities to the Inspecting
Officer.

7.2 Inspection of wagons shall be carried out as per Quality Assurance Plan duly approved by
RDSO and other documents, as applicable.

7.3 In case of dispute between the manufacturer and the purchaser regarding the interpretation
of any clause/clauses of the specification, the decisions of the ‘Engineers’ will be final and
binding on the parties.

8. DRAWINGS

The Wagon shall be manufactured strictly to relevant RDSO Drgs/ technical details as per
relevant drawings detailed in Drg. No. WD-05086-S-01 (latest revision) of the tendered
design. The drawings mentioned in the above drawing are, subject to advancement in
course of construction of these wagons and the contractor shall comply with these
amendments in the manufacturing of components. Copies of such amended drawings will
be supplied to the contractor free of cost. The drawings listed in the above drawing are
complete in all respects and any detailing, if necessary, will be done by the contractor.

9. 'AS MADE' DRAWINGS, PHOTOGRAPHS AND MODELS

9.1 DRAWINGS

9.1.1 The Contractor shall supply two copies of CDs of drawings followed in the manufacture of
the wagons for the record of Purchaser and Engineers. These CDs shall conform to the
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requirement as detailed in Clause-21 of General Standard Specification No. G-72 (Latest

Revision). The contractor shall incorporate in the above set of tracings, any deviations,
modification and relaxations granted in the course of manufacture.

9.1.2 In addition, the Contractor shall, also, supply two sets of ‘As Made' Polyster Film Tracings
(50 Micron thick matte) of drawings followed in the manufacture of the wagons for the
record of purchaser and engineers. These tracings shall conform to the requirement as
detailed in Clause-21 of General Standard Specification No. G-72 (Latest Revision). The
contractor shall incorporate in the above set of tracings, any deviations, modification and
relaxations granted in the course of manufacture.

9.2 PHOTOGRAPHS

The Contractor shall furnish to the Engineers, at the time of prototype approval, 1 no. for
every order of 100 wagons or part thereof free of cost, a 1/16 scale model made out of
steel or acrylic transparent sheet as called for in Clause 21 of General Standard
Specification No. G-72 (Latest Revision).

9.3 MODELS
The Contractor shall furnish to the Engineers, at the time of prototype approval, 1 no. for
every order of 100 wagons or part thereof free of cost, a 1/16 scale model made out of
steel or acrylic transparent sheet as called for in Clause 21 of General Standard
Specification No. G-72 (Latest Revision).

10. WARRANTY/ GUARANTEE

10.1 The Contractor shall guarantee the satisfactory performance of the wagons supplied
under the contract for a period of 30 months from date of delivery or 24 months from the
date of commissioning, whichever is earlier. However, for certain other subassemblies &
bought out items, Guarantee periods shall be as specified in their individual
specifications. For the items whose guarantee is not specified anywhere, standard
provisions as per as per Clause 5 of the G-72 (latest Revision) shall be applicable.

10.2 If during such period any defect appears or if the quality of the material becomes
unsatisfactory under conditions of reasonable service and if such defects or deterioration
will have been caused by the use of defective design or using unsuitable material or bad
workmanship in the manufacture, the Contractor shall arrange to repair and replace, as
soon as possible and at the Contractor's own cost (including all transport charges), such
replacements or additional materials or parts as are necessary.

10.3 Further should any design modification be required to be made in any part of the
equipment, the period of 24 months would commence from the date when the modified
part is commissioned in service. However, for certain other sub-assemblies and bought
out items, the period of guarantee for replaced part shall be as specified in the individual
specification of the item /sub-assembly.
***
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ANNEXURE-I

METHOD OF DETERMINING THE TARE WEIGHT OF WAGONS

All Contractors (whether equipped with weigh bridges or not in their works) will arrange to
weigh each wagon of identical design and mark individual tare weight on them by actual
weighment. The tare weight so arrived shall be deducted from the gross load to arrive at the
correct carrying capacity that shall be marked on the wagons.

Tare weight of the wagons shall also be intimated to the Engineers duly certified by the
Inspecting Officer.

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ANNEXURE –II

NYLON BRAKE GEAR BUSHES IN THE BRAKE GEAR OF WAGONS

1. Brake gear bushes of Nylon-66 shall be procured as per RDSO Specification with latest
revision and amendments.

2 Nominal dimensions of Nylon-66 bushes to be used will be same as of steel bushes, inclusive
of step sizes, outside diameter. However, the tolerances and the chamfering should be as per
Fig.1 of the STR.

3. Undersized holes should be drilled initially in the fork type support brackets or fork-end of
pull/push rods. These holes should be drilled together to the required size only after the
assembly but before the Nylon bushes are fitted therein. This will ensure that the two holes are
concentric and therefore, the pins passing through the bushes fitted therein will not tilt.

4. Steel pins used with Nylon-66 bushes shall be with fine finish machined on all contact surfaces
with the bush.

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