{INTEGRAL COACH FACTORY, CHENNAI-38 [SCHEDULE OF TECHNICAL REQUIREMENTS FOR —_| ICF/MD/SPEC.-186 | THERMOFORMED / INJECTION MOULDED FIRE ISSUE STATUS: 01 | RESISTANT POLYCORBONATE SEATS AND BACK —_| REY. No: 02 REST FOR MRVC COACHE! DATE : 23-03-2007 IDENTIFICATION SHEET ~~ [ No. of PAGES 9 NATURE OF DOCUMENT ‘COPY NUMBER ISSUED TO ISSUED BY DY.CME/DESIGN RETURN OF COPIES In case of transfer / retirement, the holder of controlled copies shall return the same either to SSE/D/MS or to his/her successor under intimation to SSE/D/MS. NOTE 1. Controlled copy holders of this DOCUMENT are expected to bring the content of this document to the knowledge of the concerned officials who are working in his / her department /section. 2. Unauthorised copying of this document is prohibited. Prepared, verified and approved Page Nos. 9 of 9. CONTROLLED COPY HOLDERS C.COPY No. 1. CMEIQA a1 2. Dy. CC&M 02 3. AME/MPO/Fur 03 4. Design Library 04 CONTROLLED BY PREPARED BY ‘VERIFIED BY APHROVED BY al Sams aaah th et es SSE /D/MS SME/DSS__| DY.CME/DESIGN | —CDE/MECHr i 12 12. SCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND BACK REST FOR MRVC COACHES. IGE/MD/SPEC-186 Issue status: OF Rev: 02 Page 1 of 9 COPE: This specification covers technical requirements for manufacture and supply of Thermoformed /Injection moulded Fire Resistant Polycarbonate seats and back rest ‘Section A : Establishes the design requirements of material; inspection and testing for Fire Resistant Polycarbonate seats and backrest using Thermoforming, ‘process/ Injection moulded process for use in Railway passenger coaches. Section B : Establishes the manufacturing facilities of firms which make Fire Resistant Polycarbonate seats and backrest, using Thermoforming Method / Injection moulding process for use in Railway passenger coaches. REFERENCE: 1. IS: 14443: 1997 2. 1801183 3. UL94 4, 180.4580 5. 6 UIC 564-2 Appendix 11 & 15 TS 2046: 1995 Annexure M. mum requirement for the approval of Polycarbonate sheet/ granules suppliers by ICF: 1 Theprobsble original virgin material manufacturer forthe said item shall satisfy the following clauses before the final approval by ICF 1) Thematerial shall meet all the parameters mentioned in clause 2.2 of Section-A. 2) The firm shall have facilty to conduct FEA to evaluate stress condition at at various locations of the proposed thermoformed injection moulded seat & backrest taking info consideration the loading conditions mentioned. in clause No. 4.3 of ICF/MD/ SPEC..- 189. FEA can also be done by reputed agencies who are regularly undertaking such analysis and calcul- ations for Railway /Automotive application 3) They shall be in a position to offer complete technical support right from the supply of polycarbonate sheets * granules for thermoforming / injection moulding to stainless steel fabrication, assembly of the seat/backrest to the frame ,installation and service. They should also have necessary infrastructure such as design, testing facilities et.SCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND 20 24 24d 213 BACK REST FOR MRVC COACHES. ICE/MD/SPECA86 Issue status: 01 Rev. 02 Page? of 9 SECTION - ‘A’ This section of the specification covers the design requirements of material: inspection and testing for Fire Resistant Polycarbonate seats and backrest using “Thermoforming process! Injection moulded process for use in Railway passenger coaches. DESCRIPTION OF MATERIAL: The single layer 6 +s /- 00 mm Polycarbonate Fire Retardant items, coloured textured surface at one side & smooth at other side material shall be composed of Fire Retardant thermoplastic Engineering plastic resin grade of reputed make. The colour, texture and profile shall be as per approved sample of ICF. ‘The polycarbonate sheet manufacturer shall have their Logo embossed on the back side with batch number and date of manufacturing, This should be strictly ensured for tracability of raw material (polycarbonate sheet) In case of Injection moulders, the contractor shall produce a documentary evidence for the purchase of the granules from ICF approved sources only. In the absense ofthe above, the item will be rejected RESIN SYSTE! “The resin shall be polycarbonate based fire retardant resin. No filler shall be used in the resin system, Resin system should be approved by ICF. The manufacturer of thermoformed/Injection moulded polycarbonte items will be required to provide due authentication of the batchitype of F.R. resin sourced from the Approved manufacturer of the product against supply of each ordered quantity of polycarbonate item ‘The Engineering Thermoplastic FR in sheet form of thickness 6 mm /Granules, shall be procured from only Mis. GE Advanced Plastic, M/s. Bayer , or any other reputed polycarbonate material manufacturer duly approved by ICF along with the test certificates mentioned with Clause 2.2 PROPERTIES OF FIRE RESISTANCE Textured Polycarbonate items for seat and backrest: The Polycarbonate material should have the following. typical properties. Manufacturer can offer superior grade material (if available) without any compromise on FR properties for evaluation with test report from reputed test house (CIPET/CPRI etc.)SCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND BACK REST FOR MRVC COACHES. ice/Mb/sPEcks Issue tatu: 1 Rev@2 Page 9 [TYPICAL PROPERTIES _ UNIT [STANDARD PHYSICAL | ___|___ “\foald shrinkage on tensile Bar Flow 05-07 | % [ASTM D955 RHEOLOGICAL SSS — —_ | Density* T 1.20 gem? ISO 1183 Water absorption (23° C/sat.) 1L* 035 % DIN 53495 “Moisture absorption (23 °C /50 % RH)1L O.1S % | DIN 33498 | (Wet Vou MUR SOO"CTT2KG [6 | SNe Bom MECHANICAL OSS OO “Conpressvesengh® —SSCSC~*~S~*RSC*dSCMpws «| ASTID S| "Compressive Modulus 230 Mpa) ASTMD 095 Shear Modulus 785 Mpa | ASTMD 732 “Tensile Sess at Vield 50 mam min * o Mpa | 180327 ‘Tensile Stress at Break 50 mm /min* 65 Mpa =| = 180527 ~| Tensile Strain at Yield 50 mm /min* 6.0 % ISO 527 “Tensile Svan at Break 50 mam in® Ti % 180527 Tensile Modulus T mm fnin® 3350 ipa | 150527 | Flexural Strength at yield 2 mm /min. 90 Mpa =| ISO.178. | Flexural modulus 2mm /min.* 2300 Mpa_| 180178 Fiardness, Rockwell R™ 1S0 203972 aMpact - “Tao impact Unnoiched 80°10 42°C SE 78080710 —| Fal pact Unc —C Xe a?) ISOTROAT aad inp Noted TO aFC w ‘at | BOTROTA Taal past Nobel SIO —AFC @ war | SOTA [Charpy impact Notched TT es ign? | ISOT79IC Chay umcksicip wi" Aan S| NB |i? | ISO 1797160 | Pag Utd cpa SOTO NET) int SO TIO soc — | ftSCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND BACK REST FOR MRVC COACHES. 1CE/MD/SPEC-86 Issue states: OF Rew: 02 Page sof 9 [THERMAL — 1 “Thermal conductivity 020) Win © | DINS2612 | Coeit of LinThemep Flow23 780°C | 7S | UC |_DIN 53782 Bail presuretest125°C= 2°C* PASSES =| HBC 60695- jt = 2 | TBS a © | 180306 /Vieat B/120 OO 148 € «180.306 TFIDTIBe. 0.45 Mpa edgew.* ia ©1150 75/Be. | 120*10*4/s=100mm_ “HDT/Ae. 1.8 Mpa 130 © | ISO 75Ae. | edgew.120*10%4s=100mm, | Thermal Index. Mech. prop. with impact 120 Cc UL 7468 "Thermal Index. Mech. prop. Wo impact 1s ©) UL THR | FLAMMABILITY [94V-2 Flame Class rating 740 mm [UL [94V-0 Flame Class rating [300 [mm | CUL OF | “Glow wire Test BSC passes at* io mm | TECHS: 22 Glow wire Test 960°C. passes a* a2 mm | TEC 60095. | ‘Oxygen index LOD > 35 min, ELECTRICAL — _ — | Volume Resistivity >IE1S | Ohm-m | TEC 60093 ‘Surface Resistivity. ROA >1E 15 Ohm TEC 60093 Dielectric Strength, moi 3.2mm 170 | KVimm | TEC 60243 “Tosicity* | 25 - | NED1409 Note :-Typical values obtained to IS: 2046- 1995 (Annexure-M ) for Lexan grade Polycarbonate (Mis GE Advance Plastics) is placed at Annexure—A for the guidance of the manufacturer.SCHEDULE OF TECBNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND 30 31 32 40 50 51 52 BACK REST FOR MRVC COACHES. ICE/MD/SPEC-186, Issue status: OF Rev.: Page S of 9 ‘TYPE ACCEPTANCE: The manufacturer shall supply three textured sheets with polyethylene masking both sides to size 600 mm x 600 mm x 6 mm thickness for type acceptance testing before frst proto-type approval ofthe vendor at ICF. All the characteristies ‘mentioned in elause 2.2 shall be tested. However, the purchaser reserves the right to call for a repeat ofthe above tests at his descretion. ‘The ICF approved polycarbonate sheet / granule supplier should submit the FEA of the proposed Thermoformed! Injection moulded seat or backrest to be used for Seat manufacture to ICF to evaluate the stress condition atthe various locations of the items mentioned above, before undertaking bulk manufacture as per the Joading conditions mentioned in clause 4 3,of ICF/MDISPEC.- 189 INSPECTION METHODOLOGY : The following tests shall be done and they shall meet the requirement of this standard. VISUAL: 1. The color, surface finish & uniform thickness shall be visually inspected with accepted/approved sample on 20 % of the lot subject to a minimum of two numbers. All the samples must pass the test for the lot to be accepted. 2. The dimensions shall be checked on 20% of the lot cleared in 4.1.1 subject to a ‘minimum of two numbers. All the samples checked for dimensions shall pass 3. The test conceming flammability and Electrical should be carried out on every 5% of Polycarbonate sheet manufacture by vendor and results should meet the laid down requirements given in clause 2.2 DEVIATIONS : While submitting quotation, tenderer shall provide clausewise comments and deviations, if any, only need to be brought out clearly. ‘Non-compliance of the above stipulations would render the offers as incomplete and liable to be passed over.SCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND 60 61 62 63 70 mM nA na BACK REST FOR MRVC COACHES. ICE/MD/SPEC-186 [sue status: 01 Rev. : 02 Page 6 of 9 SECTION - B This section of the specification covers the manufacturing facilities of the firm which make Fire resistant Polycarbonate seats & backrest, using Thermoforming Method/Injection moulding process for use in Railway passenger coaches. ‘The Vendor's seeking approval with ICF to supply Thermoformed / Injection moulded Fire Resistant polycarbonate items should have back to back tie- Uup(Memorandom of Understanding (M © U) from the ICF approved principles,M/s GE Advance Plastics or M/s Bayer or any other reputed polycarbonate raw material /sheet manufacturer, to supply FR grade sheet granules to ICF. The vendors must provide the test reports of the items marked with asterisk (*) during the supply of each lot of the above mentioned product, prescribed in Clause No 2.2, of section A. They should also have necessary infrastructure such as design, testing facilities etc ‘The vendors shall also have the formal approval from the original raw material suppliers for thermoforming/Injection moulding. This approval shall be done in consultation with ICF. However, ICF reserves the right to accept / reject the approval given.ICF also reserve the right to conduct due deligence check of all approvals as submitted to ICF. ‘The vendor's shall also have a back to back tie-up or Memorandom of Understanding (M © U) with the ICF approved fabricators of stainless steel seat frame to ensure the dimensional integrity and quality of seat frame with polycarbonate sheet. Documentary evidence shall be submitted to this effect. Al vendors seeking approval with Integral Coach Factory to supply seats and backrest by Thermoforming process/Injection moulding shall full fill the requirements given below MANUFACTURING FACILITIES: PLANT & MACHINERY ‘Thermoforming / Injection moulding Machines: A)The firm shall have a vacuumipressure thermoforming machine( A process, ‘wherein a flat sheet is converted to three dimensional shape by applying heat & pressure) for the sheet .The machine platen should accommodate a minimum ‘Tool size ( Mould or Die) of | meter x 1.5 meter with a draw of min.150mm, 'B) Hot Air Drying Ovens: The drying oven should be used to Pre Dry the sheets at 120 degree centigrade for minimum 12 hours to remove the moisture in the sheetSCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND 80 81 90 on BACK REST FOR MRVC COACHES. ICF/MD/SPEC-186 status: 01 ‘The sheets should be stacked in the oven such a way to keep the minimum separation of I inch between the sheets. (C)The firm shall have necessary tools/equipment for the injection moulding of the seat! back rest. D)The firm shall submit alist of plant and machinery and testing of equipments for ICF's approval. ‘Mould: ‘The firm shall have in-house facility for manufacturing or out source Aluminum Mould. Alternate material can used for mould, with the prior approval of ICF. Prototype: The firm shall have to make the first prototype seat mould, as per the drawing given by ICF and submit to design for approval, before effecting regular supply. Any subsequent changes in process parameter need designs approval TOOLS: Pre Drying air circulating oven, Thermoforming machine with Temperature control systems with Trimming & Cutting machine CAPABILITY DEMONSTRATION: The firm should demonstrate capability by producing one prototype Fire resistant Polycarbonate textured sheet for seats and back rest sample in the presence of ICF representative or their nominated inspection agency before the formal approval of the firm, ‘TESTING FACILITY: ‘The firm shall_ have in-house / tie up with outside approved test houses for testing the characterstics as mentioned in clause 2,2 of section A. ‘The firm shall have some minimum testing facilities i.e. tensile, impact, Hardness testing machines and apparatus for conducting flamability test as per clause 2.2. QUALITY ASSURANCE PLAN: “The firm must prepare a documented procedure for the manufacture of the ‘Thermoformed FR polycarbonate seat and backrest . The same shall be submitted 0 ICF for approval ‘The procedure must contain information regarding:- > the various process variables (CTQ) and its effect on various properties mentioned in clause 2.2 of section - A and methoology adopted to keep the process variable under controlSCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND 92 100 101 no 120 BACK REST FOR MRVC COACHES. ICF/MD/SPECA86 Issue status: 01 Rev. 02 Page of 9 v the properties of the sheet used, (supporting documents ie manufacturing certificates from FR manufacturer.) > the type of Thermoforming machine the tools/Die used in the preparation of the FR. sheet , Flow chart of Thermoforming manufacturing process-certified by original supplier of Polycarbonate material the various stages of tests done on the raw material, work in progress and finished product . and > any other relevant information vy “The firm shall have a system for traceability of the FR sheet should be traced to @ finished product. Similarly each finished product shall be traced back to the drum of resin from which it was manufactured, 10: The firm shall have ISO 9000 -2000 series certificate WARRANTY + “The contractor shall offer free replacement warranty for five years for any damage to the subject item, from the date of commissioning of the seat assembly at ICF PACKING: The Fire Resistant Polycarbonate Textured sheets for seats cum back rest shall be supplied in properly packed condition so as to avoid any damage during transit, handling and storage. Bio-degradable packing material shall be used. If any plastic material is used for packing, the thickness of the packing material shall not be less than 25 microns, MARKING: “The manufacturer's logo shall be embossed on the masking side of the items for traceability. The batch number, identification number for traceability and date of manufacture shall be made available on each and every item, The manufacturing certificate of batch no must be provided from original manufacturer.SCHEDULE OF TECHNICAL REQUIREMENTS FOR THERMOFORMED / INJECTION MOULDED FIRE RESISTANT POLYCORBONATE SEATS AND BACK REST FOR MRVC COACHES. TYPICAL VALUES OF LEXAN GRADE POLYCARBONATE (GE ADVANCE PLASTICS) TO IS:2046- 1995 (Annexure-M) ICE/MD/SPPC-186 Issue status: O1 Rev. : 02 Page of 9 Annexure — A [Chemical Resistance est Method - 15:2046:1985 Annexure M [Datta E shit | Lean Group Chemicat mean deta] Rating € Cr Seupt Restore | 1492-1485 7 Gatfee Room i Group2 fee Reem | 008.01 5 Group? Cartes 80 | 01ST 3 ‘Group NaOH [030-034 5 Hyroger Group tycroasn | 0.10-022 5 Groups Shoe Poish | O56 a ‘Group 4 GiticAed | 0-08-01 3 Goss retention % Levan, Mean Group Chemical | “Gloss Rating Retention) Supt Recions | 2528 i Coffe Room fe Group? fee Roem | 001-1004 5 —_ Seg Cafes 806 | OOE-1B| Group NaoH | 954058 5 our Fyaregen | 95 04 Group Hycroaen | o.0-004 5 Groups Shoe Poish | STF 3 Group ‘ite Aeig_[700.3-1006) 5 (FOR GUIDANCE OF MANUFACTURER'S ONLY)