TDG-0009 Version No 2 0

ISO9001:2015 Document No: TDG-0009 Version No: 2.0 Effective date: 01.01.
2023
Document Title: Item Specific guidelines & Schedule of Technical Requirements for manufacture and supply of Glued Insulated Rail Joints
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Government of India – Ministry of Railways
RESEARCH DESIGNS & STANDARDS ORGANISATION
Manak Nagar, Lucknow–226011
DOCUMENT NO: TDG-0009, Ver. 2.0
DOCUMENT TITLE: ITEM SPECIFIC GUIDELINES & SCHEDULE OF TECHNICAL REQUIREMENTS

FOR MANUFACTURE AND SUPPLY OF GLUED INSULATED RAIL JOINTS.
1.0 Amendment History:
S. No. Document No Version Amendment Date Reasons for Amendment
1. TDG-0009 0.0 01.12.2001 First issue under new documentation

system
2. QC–G-7.1-9 1.0 01.12.2001 Document no. changed & contents are same
as per TDG-0009 Rev.’0’
3. TDG-0009 2.0 21.11.2022 Item Specific Guidelines, Quantity for Up-
gradation for Vendor Status and List of plant
& machineries, testing & measuring
instruments, additional essential equipments
for Re-furbishing/In-situ fabrication of glued
insulated rail joints added and updated
‘Manual for Glued Insulated Rail Joints’.
AKHILE Digitally signed

SH
by AKHILESH
KUMAR
MAHENDRA Digitally signed by MAHENDRA
KUMAR GUPTA
Date: 2022.11.21
KUMAR 16:43:40 +05'30' KUMAR GUPTA Date: 2022.11.21 17:05:34
+05'30'
ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

Prepared by Issued by Page 1 of 12
ISO9001:2015 Document No: TDG-0009 Version No: 2.0 Effective date: 01.01.2023
2.0 Purpose:
This guideline covers all technical and other requirements in context with adequate space needed for
storage of raw/finished material, manpower and plant/ machinery & equipment required for manufacture and
supply of Glued Insulated Rail Joints used for vendor registration /quality audit of vendor. This guideline
replaces the provisions of earlier guidelines issued on the subject i.e. QC–G-7.1-9 Ver.1.0 and now doc. No.
TDG-0009, Ver. 2.0 has been issued in 2022.
3.0 Scope of Application

This shall be applicable for initial capability assessment, periodic quality audit for extension of
approval, up-gradation of vendors and maintaining their approved list. In case of any variation
between the procedure/provision given in work instruction and that in the ‘Item Specific Guidelines’,
the later shall prevail. The competent authority wherever referred to in this document shall mean Principal
Executive Director/ Infra-I.
4.0 Procedure/Details
Procedure/ details is annexed.
5.0 Referenced Documents

S.No. Document Name Document No.
1. Manual for Glued Insulated Rail Joints (First Reprint-2022) or Nil
latest
2. Latest ISO Apex Documents of RDSO
6.0 Referenced Documents of External Origin

None.
7.0 Associated Records

None.
8.0 Responsibility and Authority
Activity Responsible Approver Supporting Consulted Informed

Creation, maintenanceof ED/Track / PED/Infra-I DD/XEN/ AIE/ M&C Dte. All approvedvendors/
this document Director/Track ADE concerned
/ARO through website
Compliance of directives DD/XEN/AIE/ ED/Track - - -
contained in this ADE / ARO /Director/Track
document
Requirement of ED/Track / PED/Infra-I DD/XEN/ M&C Dte. All approved
Deviation from this Director/Track AIE/ ADE vendors/concerned
directive /ARO through website

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:44:16 +05'30'

9.0 Abbreviations
RDSO Research Designs & Standards Organization

PED/ Infra-I Principle Executive Director/ Infra-I
ED/ Track Executive Director/Track Design
DD Dy. Director
XEN Executive Engineer
AIE Assistant Inspecting Engineer
ADE Assistant Design Engineer
ARO Assistant Research Officer

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:44:38 +05'30'

10.0 ITEM SPECIFIC GUIDELINES

(i) Glued Insulated Rail Joints are to be procured from RDSO approved sources. In this context latest Apex
ISO document procedure is to be followed for initial registration / quality audit / approval of the firms.
(ii) In case, firm approved for manufacturing of Glued Insulated Rail Joints to one drawing, desires to develop
the product to other drawings, the requisite inspection gauges will have to be approved by RDSO. After
getting satisfactory internal test reports, the samples will be drawn and tested at firm’s works. If test
results on samples found satisfactory, the firm would be considered for inclusion in the “List of RDSO
Vendors for Developmental Orders” as per the provisions of latest ISO apex documents.
(iii) Up-gradation from “List of RDSO Vendors for Developmental Orders” to “List of Approved Vendors” shall
be as per procedure mentioned in RDSO’s latest ISO apex documents. Consideration (Minimum Quantity)
for up-gradation to “List of Approved Vendors” is as under:
S. No. Item (Minimum Quantity) Remarks

Category Unit Min. Qty. for up Initial Quantity to
gradation be Inspected by
RDSO
1. 52 kg Rail Nos. 500 200 200 nos. of each type of
Section drawings in minimum two
Category installments (Preferably of equal
2. 60 kg Rail Nos. 500 200 size of lots) will be inspected
Section initially by RDSO and future
Category inspection would be done by
Zonal Railway/RITES. The
sampling size shall be as
specified in the Manual.

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:44:56 +05'30'

SCHEDULE OF TECHNICAL REQUIREMENTS

For manufacture of Glued Insulated Rail Joints
1.0 Requirements: The vendors seeking approval shall comply all the under mentioned
requirements:
a) General and manufacturing facilities: Adequate area (covered area and

uncovered area) shall be available for installation of all plants & requirements
including testing equipment. It should not be less than 600 square meter for new
vendors.
b) Material: The requirement of material for fabrication of glued joints is given in

Annexure-B of the Manual for Glued Insulated Rail Joints. Rail, Fishplate and HTS
Bolts & Nuts shall be procured from RDSO approved sources.
c) Specification: The material shall be procured as per the specification given in

Annexure-C of the Manual for Glued Insulated Rail Joints.
2.0 Minimum Facilities & Machineries required for fabrication, manufacturing & testing
of Glued Insulated Rail Joints:
SN Description Capacity Min. facilities

/Equipment
considered
essential
1. Gantry Crane /Hydra crane Facilities 2T (min.) 1No.
2. Rail cutting machine Hex saw/circular saw/Band - 1No.

Saw
3. Drilling machine with required drill bits - 1No.
4. Electric Grinder - 2Nos.
5. Protective Goggles - 2Nos.
6. Sand blasting equipment with compressor 10HP 1No
7. Jigs for assembly of joint (Fig. -4 of Manual) - 4Nos.(min.)

8. Pullout strength testing Jig complete with 1No. 200T 1No.
200T or 2Nos. of 200T capacity Hydraulic Jack &
Pressure Gauge (as per guidelines shown in fig. 100T 2Nos.
2 & 3 of the Manual for Glued Insulated Rail
Joints)
9. Straight edge 1meter long with15mm notch 1m 1No.
10. Steel Brushes (Stiff) - 2Nos.
11. Steel pans about 30cm diameter for mixing - 2Nos.
AKHILE Digitally signed by

SH AKHILESH KUMAR
Date: 2022.11.21
16:45:28 +05'30'
KUMAR

12. Steel brush (Round) attachment of electric - 2Nos.

grinder
13. Split washer rollers - 2Nos.
14. Receptacle (to clean tools etc.) - 1 No.
15. Torque wrench 105Kg- m 1No.
16. Pair of scissors for cutting of glass- cloth - 1No.
17. Files (round & flat) - 1set
18. Spanner/adjustable spanners suitable for - 1set
tightening of HTS bolts &nuts
19. Weighting balance with set of suitable weights - 1set

20. Chamfering tool with bolts & nuts (fig.-1 of - 2sets(min.)
manual)
21. Templates of fishplates duly approved by RDSO - 2sets
22. Vernier Calipers (min.15cm), Steel Scales, Steel - 1set

Tapes of various sizes, Inner & Outer caliper
and Filler gauges in mm
23. Megger 100 Volt DC for testing insulation - 1No.
resistance in dry condition
24. An Ammeter capable of measuring current upto - 1No.
micro amperes for insulation resistance in wet
condition
25. Electric heaters in winters to maintain - Nos. as required
temperature above 200C in the shed required
for hardening of glue in 24 hrs.
26. Proving ring duly calibrated by NPL or NCCBM, 200T 1No.
required for in house calibration of pressure
gauge used in pull out strength test unit.
27. Rubber hand gloves - Nos. as required
Additional essential equipments for Re-furbishing/In-situ fabrication of glued

insulated rail joints
28. Portable power pack 3KW 1No.
29. Mechanical/ Hydraulic tensor - 1No.
30. Brushes for glue application - Nos. as required
31. Rail jumpers - 2Nos.
3.0 Fabrication /Assembly: Fabrication /Assembly of joints is to be done as per clause 2.1
and 2.3 of the Manual for Glued Insulated Rail Joints.
AKHILE Digitally signed by

SH AKHILESH KUMAR
Date: 2022.11.21
16:45:43 +05'30'
KUMAR

4.0 Maintenance of Records: Records in respect of fabrication of Glued Joints should be

maintained in the Proforma as given in Annexure-G of the Manual for Glued Insulated Rail
Joints.
5.0 For sample drawl of the Glued Insulated Rail Joints, four sample of Glued Insulated Rail
Joints (either of 60kg/52kg rail section) of the design for which firm is approved shall be
required to be manufactured for inspection.

by AKHILESH
SH KUMAR
Date:
KUMAR 2022.11.21
16:46:01 +05'30'

PROFORMA
(To be filled in by manufacturer of Glued Insulated Rail Joints)
1.0 GENERAL INFORMATION
1.1 Name of the firm :------------------------------
1.2 Address:
(a) Head office : -------------------------------
(b) Works : ------------------------------
(c) Nearest Railway Station. :--------------------
(d) Distance of Works from nearest Railway Station in km :-------------
1.3 Factory Area (in Sq.m.)
(a) Covered :---------------------
(b) Uncovered :---------------------
(c) Is the factory site in your name or on rental basis?:-----------

(Support with documents).
1.4 SSIC/ NSIC/ MSME Registration No. (Enclose Copy) :
1.5 (a) Telephone/Fax Numbers:
(i) Head office: Telephone :-------------------

Fax
(ii) Works’ premises: Telephone :--------------------

Fax
(b) E-mail Address :--------------------
1.6 Power availability:
(a) Capacity allotted in general :-------------------
(b) Stand-by generator & its capacity (if available) :------------------
(c) Name the party/person in whose name the power is :--------------

sanctioned and your agreement with the party
/person (Support with reasonable documents)
1.7 Name of any other units located in the above premises. :-----------------

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:46:20 +05'30'

1.8 Man-power management:
(a) Managerial Staff :--------------------
(b) Shop Floor Engineers/supervisions. :--------------------

(Their number, names, qualification & service experience)
(c) Laboratory in-change whether full or part time :------------------------

(Indicate his/her name, qualifications & service experience)
(d) Inspection & quality control staff :---------------------

(Give their names, qualification & service experience).
(e) Workmen:
(i) Highly skilled :------------------------------
(ii) Semi skilled :------------------------------
(iii) Un-skilled :------------------------------
2.0 TECHNICAL INFORMATION
2.1 Water Curing Tank:
(i) Size :
(ii) Capacity: (Nos. of GIRJ put in water curing tank):
(iii) Over ground / Underground :

(Strike which is not applicable)
2.2 Source of supply of raw material:
Steel Fishplates conforming to IRS/T-1

HTS Bolts & Nuts
Glass cloth carrier/ Woven Roving
Glue (Resin & Hardener)
(Resin & Hardener shall be of the one firm
as prescribed ratio by the firm)
Washers
Release Agents

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:46:35 +05'30'

2.3 LIST OF ESSENTIAL EQUIPMENTS REQUIRED FOR FABRICATION AND TESTING

OF GLUED JOINTS:
SN Description Min. facilities Actual Remarks

/Equipment facilities/
considered Equipment
essential available
1 2 3 4 5
1. Gantry Crane /Hydra crane Facilities 1No
(Minimum Capacity 2T)
2. Rail cutting machine Hex saw/circular 1No.
saw/Band Saw
3. Drilling machine with required drill 1No.
bits
4. Electric Grinder 2Nos.
5. Protective Goggles 2Nos.
6. Sand blasting equipment with10HP 1No
compressor
7. Jigs for assembly of joint (Fig. 4 of 4Nos.(min.)
Manual)
8. Pullout strength testing Jig complete 1No. (200T)
with 1No. of 200T or 2Nos. of 100T or
capacity Hydraulic Jack & Pressure 2Nos. (100T)
Gauge (as per guidelines shown in
fig. 2 & 3 of the Manual for Glued
Insulated Rail Joints)
9. Straight edge 1meter long with15mm 1No.
notch
10. Steel Brushes (Stiff) 2Nos.
11. Steel pans about 30cm diameter for 2Nos.
mixing
12. Steel brush (Round) attachment of 2Nos.
electric grinder
13. Split washer rollers 2Nos.
14. Receptacle (to clean tools etc.) 1 No.
15. Torque wrench 105Kg-m capacity 1No.
16. Pair of scissors for cutting of glass- 1No.
cloth
17. Files (round & flat) 1set
18. Spanner/adjustable spanners suitable 1set
for tightening of HTS bolts &nuts
19. Weighting balance with set of 1set
suitable weights

by AKHILESH
SH KUMAR
Date: 2022.11.21
KUMAR 16:46:51 +05'30'

20. Chamfering tool with bolts & nuts (fig.- 2sets(min.)

1 of Manual)
21. Templates of fishplates duly approved 2sets
by RDSO
22. Vernier Calipers (min. 15cm), Steel 1set
Scales, Steel Tapes of various sizes,
Inner & Outer caliper and Filler
gauges in mm
23. Megger 100 Volt DC for testing 1No.
insulation resistance in dry condition
24. An Ammeter capable of measuring 1No.
current upto micro amperes for
insulation resistance in wet condition
25. Electric heaters in winters to Nos. as
0
maintain temperature above 20 C in required
the shed required for hardening of
glue in 24 hrs.
26. 200 tonnes capacity proving ring 1 No.
duly calibrated by NPL or NCCBM,
required for in house calibration of
pressure gauge used in pullout
strength test unit.
27. Rubber hand gloves Nos. as required
Additional essential equipments for Re-furbishing/In-situ fabrication of glued
insulated rail joints
28. Portable power pack 3KW 1No.
29. Mechanical/ Hydraulic tensor 1No.
30. Brushes for glue application Nos. as
required
31. Rail jumpers 2Nos.
2.4 Give a list of the relevant IRS, I.S. and ASTM specification relevant for the product
with latest versions as available with the firm.
3.0 EXPERIENCE
3.1 Indicate various types of items being manufactured in your works and the name of
the agency / client for whom it is being manufactured.
3.2 Indicate important customers for the last three years (both Govt. and non Govt.) if any,
for information furnished in your reply to 3.1.
3.3 Indicate details (contract reference, item and quantity manufactured and supplies of
important orders executed in the past three years for the following.
Indicate the inspecting agency for each
Digitally signed
AKHILES by AKHILESH
KUMAR
H KUMAR Date: 2022.11.21
16:47:13 +05'30'

(i) Govt. Department, Central, State and Govt. undertaking other than Railway.
(ii) Directly to the Railways.
(iii) Outside important firms.
3.4 Please specify current orders in hand on your firm (Contract reference, client, item,
quantity under manufacture and supply).
3.5 Whether you are already registered with RDSO for other P. Way items. If so, name
the item supported by documents.
3.6 Whether you are already registered with RDSO for items other than P. Way items. If
so, name the item and deptt. with which your firm is registered, support with
documents.
3.7 Indicate annual turnover of the firm.
4.0 DECLARATION:
4.1 We do here by declare that the above particulars are correct and no discrepancy
shall be found during actual investigation before and during execution of order on our
firm.
4.2 Any change in the plant and machinery and change of place of office and of works
site shall be brought to the notice of RDSO for clearance and approval.
4.3 We also declare that our concern has not been black listed by Railway, Railway
Board/ RDSO for business with the Railways.
4.4 We hereby undertake that all our equipment for manufacturing and testing as listed
above, shall be maintained in good working order at all times.
4.5 We hereby declare that the contents and the instructions of latest "ISO Apex
Documents” have been read and understood by us and our firm shall agree to
abide by all the stipulations laidtherein.
Signature
Name in full of Signing Authority
Status in the Firm,

Place :
Date : Stamp of the firm.

by AKHILESH
MAHENDRA Digitally signed by MAHENDRA
KUMAR GUPTA
SH
KUMAR GUPTA
KUMAR
Date: 2022.11.21 Date: 2022.11.21 18:29:10
KUMAR 16:47:32 +05'30' +05'30'


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ISO9001:2015 Document No: TDG-0009 Version No: 2.0 Effective date: 01.01.

Hkkjr ljdkj&jsy ea=ky;

Manak Nagar, Lucknow–226011

DOCUMENT NO: TDG-0009, Ver. 2.0

DOCUMENT TITLE: ITEM SPECIFIC GUIDELINES & SCHEDULE OF TECHNICAL REQUIREMENTS

1.0 Amendment History:

S. No. Document No Version Amendment Date Reasons for Amendment

1. TDG-0009 0.0 01.12.2001 First issue under new documentation

AKHILE Digitally signed

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

3.0 Scope of Application

5.0 Referenced Documents

6.0 Referenced Documents of External Origin

7.0 Associated Records

8.0 Responsibility and Authority

Activity Responsible Approver Supporting Consulted Informed

AKHILE Digitally signed

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

RDSO Research Designs & Standards Organization

AKHILE Digitally signed

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

10.0 ITEM SPECIFIC GUIDELINES

S. No. Item (Minimum Quantity) Remarks

AKHILE Digitally signed

KUMAR 16:44:56 +05'30'

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

SCHEDULE OF TECHNICAL REQUIREMENTS

a) General and manufacturing facilities: Adequate area (covered area and

b) Material: The requirement of material for fabrication of glued joints is given in

c) Specification: The material shall be procured as per the specification given in

SN Description Capacity Min. facilities

2. Rail cutting machine Hex saw/circular saw/Band - 1No.

7. Jigs for assembly of joint (Fig. -4 of Manual) - 4Nos.(min.)

AKHILE Digitally signed by

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

12. Steel brush (Round) attachment of electric - 2Nos.

19. Weighting balance with set of suitable weights - 1set

22. Vernier Calipers (min.15cm), Steel Scales, Steel - 1set

Additional essential equipments for Re-furbishing/In-situ fabrication of glued

AKHILE Digitally signed by

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

4.0 Maintenance of Records: Records in respect of fabrication of Glued Joints should be

AKHILE Digitally signed

ADE/Track Jt. Director/Track-VIII Printed 21.11.2022

1.0 GENERAL INFORMATION

1.1 Name of the firm :------------------------------

(a) Head office : -------------------------------

(b) Works : ------------------------------

(c) Nearest Railway Station. :--------------------

(d) Distance of Works from nearest Railway Station in km :-------------

1.3 Factory Area (in Sq.m.)

(a) Covered :---------------------

(b) Uncovered :---------------------

(c) Is the factory site in your name or on rental basis?:-----------

1.4 SSIC/ NSIC/ MSME Registration No. (Enclose Copy) :

1.5 (a) Telephone/Fax Numbers:

(i) Head office: Telephone :-------------------

(ii) Works’ premises: Telephone :--------------------

1.6 Power availability:

(a) Capacity allotted in general :-------------------

(b) Stand-by generator & its capacity (if available) :------------------

(c) Name the party/person in whose name the power is :--------------

AKHILE Digitally signed

KUMAR 16:46:20 +05'30'