भारत सरकार

Government of India
रे ल मंालय
MINISTRY OF RAILWAYS

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INDIAN RAILWAY STANDARD SPECIFICATION

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FOR FLAT BOTTOM RAILS

IRST-12-2009

अनस
ु ंधान अभकप एवं मानक संगठन लखनऊ - 11
Research, Design and Standards Organisation, Lucknow-11
 IRS-T-I2-2009

INDEX
SNo. Description Page No.
1. Index 1
2. Scope 2
3. Rail Section 2
4. Templates and Gauges 2
5. Definitions 3
6. Manufacture 3
7. Information to be supplied by the Purchaser 3
8. Grade, chemical composition and mechanical properties 4
9. Marking 4
10. Sections & dimensions 7
11. Freedom from defects 10
12. Finishing 12
13. Testing facilities 12
14. Qualifying criteria 13
15. Nature of tests 13
16. Test sample 14
17. Chemical analysis 14
18. Tensile test 15
19. Sulphur print test 18
20. Brinell Hardness Test 20
21. Falling weight test 21
22. Determination of hydrogen content 23
23. Qualifying criteria tests 24
24. Inspection 26
25. Method of payment 26
26 Shipment 27

Appendix

I, II ,II-A & III Rail Sections

IV Colour Code
V Gauge for checking asymmetry
VI Sketch showing details of standard test piece for ultrasonic testing.
VII Proforma for ladle analysis of rails steel
VIII Album of macrographic prints
IX Proforma for mechanical properties
X Proforma for details of , rails offered for inspection
XI Standard test method for the determination of the plane strain fracture toughness (Kic)
of rails

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 IRS-T-I2-2009

SERIAL NO. T-12-09

This specification was initially adopted in 1934 and subsequently revised in

1939, 1950, 1953, 1955, 1958, 1960, 1964, 1988 and 1996.

The present version has been adopted in 2009 specifying the requirements of the
Prime rail and IU rails having ultimate tensile strength (UTS) of 880 MPa, 1080 MPa
CR and 1080 MPa HH .This specification also specify the requirements of special class
of rail steel such as Niobium (NB), Vanadium (VN), corrosion resistant rail steel
Copper Molybdenum (CM), Nickel Chromium Copper (NC)

1. SCOPE

This specification applies to Flat bottom Railway Rails. It specifies quality of

the steel, manufacturing process, chemical composition, acceptance tests/ retests,
qualifying criteria and other technical conditions of supply.

2. RAIL SECTION

The Section of the flat bottom rails shall be in accordance with the section
profiles shown in Appendix-I, II, IIA, III, unless otherwise specified by the purchaser.

3. TEMPLATES AND GAUGES

The manufacturer shall submit, at his own expenses, two sets of templates
(internal and external) made of stainless steel for each section of rail ordered or
contracted for as per approved drawings. Two sets of plus and minus limit gauges made
of stainless steel, in accordance with the stipulated maximum and minimum tolerances,
shall also be submitted for approval of the Purchaser or his Authorised Inspecting
Agency. The approval of purchaser or his authorised inspecting agency shall be
obtained before the rolling of rails is commenced. The templates and gauges shall be
stamped by the Purchaser/Authorised Inspecting Agency as a token of approval.

One set of templates of plus and minus limit gauges (called hereinafter master
gauges) shall remain in possession of the Purchaser/Authorised Inspecting Agency
during the period of acceptance. Only gauge bearing the stamp of the
Purchaser/Authorised Inspecting Agency shall be valid for checking purpose.

Each template/gauge shall be suitably engraved with the manufacturer’s name

and the number of the rail section together with such other marks as the Inspecting
Agency or the purchaser may direct.

4. DEFINITIONS

4.1 Sequence-continuous casting

This term is used when a sequence of casts of the same grade of steel is poured
through a continuous casting machine without interruption in flow of liquid steel into
the moulds and strands. The pouring of the next cast from ladle into the tundish begins
before the steel from the previous cast is completely poured off from tundish to the
mould, leading to an inter-mixing of some liquid steel from the two successive casts.

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 IRS-T-I2-2009

4.2 Main cast

Blooms that are known to be entirely composed of steel from the same liquid
steel melt.

4.3 Changeover, Overlap or Intermediate Bloom

Blooms that may contain steel from more than one cast i.e. material arising
during the Changeover from one cast to the next in the sequence. Number of change
over bloom will be mutually decided by manufacturer/Purchaser depending upon
casting practice adopted by the manufacturer.

4.4 Classification of rails

52 kg/m , 60 kg/m ,68 kg/m & ZU-1-60 rails shall be classified as class ‘A’
and class ‘B’ based on tolerance in end straightness as specified in Clause 9.4.2.

5 MANUFACTURE

5.1 The steel used for the manufacture of rails shall be made by basic oxygen or electric
arc furnace process and continuously cast. Any other method of casting shall have
prior approval of the Purchaser. For molten steel secondary ladle refining is
mandatory. The manufacturer in his offer shall furnish details of the steel making
process including refining, vacuum degassing.

5.2 The cross sectional area of the bloom shall not be less than ten times that of the rail
section to be produced.

5.3 The manufacturer shall apply the best accepted code of practice throughout
manufacturing process to ensure that the rails meet the stipulations of this
specification. The manufacturer shall, on request, inform the purchaser of the
measures adopted for ensuring the above.

5.4 For head hardening, rails should be suitably heat treated to meet the requirements of
this specification. The method of heat treatment adopted by the manufacturer
should be made available to the purchaser and prior approval of the purchaser shall
be taken before execution of the order.

6 INFORMATION TO BE SUPPLIED BY THE PURCHASER

The purchaser shall provide the following information to the supplier when
inviting tender for supply of rails according to this specification:

i) Rail steel grade (Table 1)

ii) Rail Section profile (Appendix I to III)
iii) Class of rail
iv) Length of rail.
v) Undrilled or drilled rails ends.
vi) Colour code requirements (Appendix IV)

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 IRS-T-I2-2009

7 GRADE, CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES

The steel for rails shall be of fully killed quality and shall conform to chemical
composition and mechanical properties given in Table 1. These limits for chemical
composition are applicable both for tests on ladle samples and for check analysis of
finished rails. The ladle and check analysis of the steel, when carried out by the method
specified in the relevant part of IS: 228 or any other established instrumental/chemical
method, shall be as specified in table-1.In case of any dispute, the procedure given in
the relevant part of IS: 228 shall be referred to Table 1.

8 MARKING

8.1 Brand Marks

Brand marks shall be rolled in relief on one side of the web of each rail at least
every 3.0 meters. The brand marks on the rails shall be clearly legible and shall be
rolled in letters in relief at least 20mm in height and minimum 1.0 mm above surface of
the web of the rail.

The brand mark shall include:

a) The rail section.
b) The grade of steel, i.e.
Grade 880 - 880
Grade 1080 HH - 1080 HH
Grade 1080 Cr - 1080 CR
Grade 880 Cu-MO - 880 CM
Grade 880 Ni Cr Cu - 880 NC
Grade 880 Vanadium - 880 VN
Grade 880 Niobium - 880 NB

c) Identification mark of the manufacturer

d) Month (using roman numbers) and last two digits of year of manufacture.
e) Process of steel making: -
i) Basic oxygen - O
ii) Electric - E

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 IRS-T-I2-2009

TABLE-1
Chemical Composition (percentage) Mechanical Properties

10-4% ( ppm) max

UTS (MPa) (Min)

Hydrogen content

Elongation % on
***(MPa)(Min.)

Running surface
hardness (BHN)
gauge length –
Yield Strength

5.65√So (min)
in liquid steel
Grade

by mass O
Mo (max)
Al (max)
S (max)

P (max)

V (max)

(max.)
Mn

Cr
Si
C

1.6
880 0.60-0.80 0.80-1.30 0.10-0.50 0.030* 0.030* 0.015 - - - - 880 460 10.0 Min 260**
ppm
1.6
1080 Cr 0.60-0.80 0.80-1.20 0.50-1.10 0.025 0.025 0.004 0.20 0.80-1.20 0.20 20 1080 560 9.0 320-360
ppm
1.6
1080 HH 0.60-0.80 0.80-1.30 0.10-0.50 0.030* 0.030* 0.015 - - - - 1080 460 10.0 340-390
ppm

So = Cross sectional area of tensile test piece in mm2

* 0.035 maximum for finished rail
The chemical compositions specified as above are applicable to Ladle analysis and Product Analysis. Manufacture shall ensure that chemical composition at ladle
analysis should be such that product analysis also satisfies the requirement of chemical composition as above.
** Desirable Value.
*** Frequency to be mutually agreed by purchaser and manufacturer.

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 IRS-T-I2-2009

SPECIAL RAIL STEEL TABLE 1 –Contd...

Grade
Chemical Composition (percentage) Mechanical Properties

hardness (BHN)
on gauge length
max by mass O

Yield Strength

Elongation %
10-4% ( ppm)

UTS (MPa)
liquid steel

– 5.65√So
Mo (max)

Hydrogen
content in
Al (max)

Nb (max)

Running
S (max)

P (max)

V (max)

surface
(max.)

(Min)

(Min)

(min)
Mn

Cr
Si
C

0.60- 0.80- Min

NIOBIUM (NB) 0.10-0.50 0.030* 0.030* 0.015 - - - 0.04 - 1.6 ppm 880 540 10.0
0.80 1.30 260**
0.60- 0.80-
VANADIUM (VN) 0.10-050 0.025* 0.030* 0.015 - - 0.20 - 20 1.6 ppm 880 630 9.0 Min 260
0.80 1.30

CORROSION RESISTANT RAIL STEEL

Grade
Chemical Composition (percentage) Mechanical Properties

Hydrogen content in
10-4% ( ppm) max

liquid steel (max.)

UTS (MPa) (Min)

Elongation % on

Running surface

hardness (BHN)
gauge length –
Yield Strength

5.65√So (min)
(MPa)(Min.)
by mass O
Mo (max)
Al (max)
S (max)

P (max)

min
Mn

Cu

Ni
Cr
Si
C

Copper- Molybdenum 0.60- 0.80- 0.10- 0.030 0.2- 0.25-

0.030* 0.015 - - - 1.6 ppm 880 460 10.0 260
(CM) 0.80 1.30 0.50 * 0.3 0.35
Nickel Chromium
0.60- 0.80- 0.10- 0.030 0.50- 0.3- 0.25-
Copper 0.030* 0.015 0.25 - 1.6 ppm 880 520 10.0 260
0.80 1.30 0.50 * 0.65 0.4 0.40
(NC)

So = Cross sectional area of tensile test piece in mm2

* 0.035 maximum for finished rail
The chemical compositions specified as above are applicable to Ladle analysis and Product Analysis. Manufacture shall ensure that chemical composition at ladle
analysis should be such that product analysis also satisfies the requirement of chemical composition as above.
** Desirable Value.

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 IRS-T-I2-2009

8.2 Hot Stamping

Each rail shall be identified by a numerical, alphabetical or combined alphabetical

and numerical code which will be distinctly hot stamped at least once every 4.0m on the
web in figures and letters at least 15mm high from which following information can be
obtained:

i) The number of the cast from which the rails has been rolled with
letter ‘C’
ii) Number of the strand.
iii) For rails from change over bloom, cast number should be the preceding
cast number with prefix letter ‘B’.

8.3 Cold Punching

8.3.1 Following should be cold punched on one of end face of each rail
a) Inspecting Agency Id and Group ID
b) Shift No in which product inspected
c) Date of Inspection

8.3.2 For IU rails

In addition to marking mentioned in this Specification, the letter “IU’ (Industrial
Use grade) as the case may be in 15 mm size shall be stamped on both end faces
of rails.

8.4 Colour code

Rails shall be painted as per colour code given in Appendix-IV to distinguish

grade, class, length and other special requirements. Paint of good quality should be used
with the prior approval of the Inspecting Agency.

9 SECTIONS AND DIMENSIONS

Each section of rails shall be accurately rolled to its respective template within the
tolerances specified in this clause.

9.1 Permissible Variations in Dimensions

The tolerances in sectional dimensions shown here under shall be allowed,

provided,

For Prime quality rail the actual weight computed by weighing short pieces of
rails, not less than 300mm each in length, shall fall within 0.5 percent below and 1.5
percent above the calculated weight shown in Appendix I, II and III for each rail section.

For IU Rail the actual weight computed by weighing short pieces of rails not less
than 300 mm each in length is not less than the calculated weight shown in Appendix I
,II, II-A & III of this specification for each section of rail by more than 1.5%.

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 IRS-T-I2-2009

9.1.1 Tolerances in sectional dimensions (For Prime Quality rails)

Dimention Tolerance Remarks

Overall Height of +0.8 mm
Rails -0.4 mm
Width of Head + 0.5mm This will be measured 14mm below the rails top
Width of flange + 1.0mm For section less than 60Kg/m
+1.2 mm For sections 60kg and above
-1.0 mm
Thickness of web +1.0 mm This will be measured at the point of minimum
-0.5 mm thickness
Verticality/Asymmetry + 1.2mm Measured by gauge shown in App. V)
Flange The base of the rail shall be true and flat, but a slight concavity not
exceeding 0.40mm shall be permissible.
Fishing surface The standard template for rail fishing surface shall not stand away
from the contour of web by more than 1.20mm and the clearance at
the fishing surfaces shall not exceed 0.2mm at any point.

9.1.2 Tolerances in sectional dimensions (for IU rails)

Dimension Tolerance Remarks

Overall Height of +2.0 mm
Rails -1.0 mm
Width of Head +2.0mm This will be measured 14mm below the rails top
-2.0mm
Thickness of web +2.0 mm This will be measured at the point of minimum thickness
-1.0 mm
Width of flange +1.5 mm
-2.0mm
Flange The base of the rail shall be true and flat, but a slight concavity not
exceeding 0.40mm shall be permissible.
Fishing surface The standard template for rail fishing surface shall not stand away
from the contour of web by more than 1.20mm and the clearance at
the fishing surfaces shall not exceed 0.2mm at any point.

All other requirements as regards variation in dimensions, length and

falling weight test shall be as per Prime Quality rail (Para 9.1.1).

9.2 Length of rails

The standard length of rails shall be 13m or 26m. However, in case rails are to be
procured in longer lengths, the same shall be prescribed by the purchaser.
The manufacturer shall be entitled to supply in pairs short lengths up to 10% by
weight of the quantity contracted for or ordered. Such shorter lengths shall not be less
than 10.0 m in lengths for standard length of rails of 13m and shall not be less than 24 m

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 IRS-T-I2-2009

in lengths for standard length of rails of 26m. The short lengths shall be in multiples of
1.0m.

Type of Rail Tolerance in length

Prime Quality Rail +20 mm -10 mm
IU Grade +30 mm -30 mm

9.3 End Squareness

The deviation from square in both horizontal and vertical directions shall not
exceed 0.60 mm on a length of 200mm.

9.4 Straightness

9.4.1 The straightness of the whole rail shall be judged by naked eye but in case of
doubt or dispute, the affected portion shall be checked using 1.5 meters straight edge.
The maximum permissible deviation shall be 0.7mm measured as the maximum ordinate
on a chord of 1.5m. Wavy, kinky and twisted rails shall not be accepted.

9.4.2 End Straightness

The tolerances for end straightness shall be as indicated in Table 2 and as

illustrated in figure 1 and 2.
Table –2
Sl. Straightness Tolerance
No Class ‘A’ rails Class ‘B’ rails I U Grade rails
1. Horizontal Deviation of Deviation of Deviation of 1.5 mm
0.5 mm 0.7 mm measured as maximum
measured as measured as ordinate from the chord
maximum maximum of 1.5 meters standard
ordinate from ordinate from straight edge
the chord of the chord of
2.0 meters 1.5 meters
standard straight standard
edge. straight edge
2. Vertical Deviation of Deviation of Deviation of 1.5 mm
a) Up sweep 0.4 mm 0.5 mm measured as maximum
measured as measured as ordinate from the chord
maximum maximum of 1.5 meters standard
ordinate from ordinate from straight edge.
the chord of the chord of
2.0 meters 1.5 meters
standard straight standard
edge. straight edge.
b)Down NIL NIL NIL
Sweep

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 IRS-T-I2-2009

L= Length of straight edge specified in Table 2

d= Maximum tolerance specified in Table 2.

Fig.1 TOP VIEW OF HORIZONTAL TOLERANCE AT RAIL ENDS

Fig.2: SIDE VIEW OF VERTICAL TOLERANCE AT RAIL ENDS

Any rail not complying with these requirements may be rectified once by the
Manufacturer and offered for re-inspection.

10 FREEDOM FROM DEFECTS

10.1 The rails shall be free from all detrimental defects such as cracks of all kinds,
flaws, piping or lack of metal etc. having an unfavorable effect on the behavior of the rail
in service.

10.2 The absence of harmful internal defects shall be ensured by the continuous on-line
ultrasonic examination. This examination shall be carried out for all rails under the
responsibility of the manufacturer to the satisfaction of the Inspecting Agency.

10.3 The manufacturer in his offer shall furnish the detailed method of on-line
ultrasonic testing of rails to be followed by him. The limits of permissible defects for
ultrasonic testing of rails shall be as follows and the standard test piece shall be as shown
in appendix-VI.

Head : 1.5 mm dia through hole

Web : 2.0 mm dia through hole
Web & foot junction : 2.0 mm dia through hole
Foot : 0.5mm deep, 12.5mm long and
1.0mm wide notch (inclined at 20o with vertical
axis)

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 IRS-T-I2-2009

All Flash Butt Welds executed by the manufacturer for welding of rails in to long
panels shall be subjected to ultrasonic testing along with other acceptance criteria as per
provisions of Manual for Flash Butt Welding of Rails .

10.4 EDDY CURRENT TESTING:

The manufacturer should have eddy current testing covering bottom area of the
rail as also the top surface and sides of surface head. The ECT probes should cover
complete area of rail bottom and at least 80% area of top surface and sides of the head.
The system should be capable of detecting the defects more than or equal to 0.5 mm
depth and more than 10 mm long.

10.5.1 SURFACE QUALITY

10.5.1.1 Surface quality for Prime Quality Rail

10.5.1.2 Hot marks

Depth of rolling guide marks anywhere on the rail should not exceed 0.5mm. A
maximum of two guide marks are allowed per rail. The width of each rolling guide mark
should not exceed 4.0mm.

Depth and width of guide marks must conform to the following:

Depth Minimum width Maximum width

mm mm mm
0.5 1.5 4.0
0.4 1.2 4.0
0.3 0.9 4.0

10.5.1.3 Cold Marks

Depth of longitudinal or transverse cold formed scratches anywhere on the rail

should not exceed 0.5mm.

10.5.1.4 Seams

Rails with seams greater than 0.2 mm in depth are not acceptable and shall be
ground. On the running surface of the rail, dressing shall be limited to 0.3mm deep and
in other places; it shall be limited to 0.5 mm deep.

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 IRS-T-I2-2009

10.5.2 Surface Quality for IU rail

The rails shall be of uniform section throughout and shall be generally sound and
free from twists, cracks and major surface defects.

The following maxima of dimensions of surface defects in the rail shall, however,
be acceptable:-

Type of Location Permissible dimensions of

defect defects
Seams (a) Table of rails, side of the head of rail, Up to 3mm in depth
bottom and side of the foot of rail
(excepting middle third of the foot).
(b) Middle third of the bottom surface of Up to 2mm in depth
the foot of the rail.
Scabs Table of rail and side of the head of the 75 mm x 25 mm not to
rail. exceed 3 mm in depth.

Number of scabs shall not be more than 3 in the standard rail lengths and shall be
separated from each other by at least six times the length of the scab. There shall be no
scab within 200mm from the end of the rail.

10.5.3 Protrusions

All protrusions in the head or foot of the rail shall be ground to match the parent
contour. Protrusions on web greater than 1.5mm high and 20mm square shall be ground.
All protrusions affecting the fitment of the fishplate shall be ground.

10.6 During examination on the inspection banks, any shrinkage cavity, inclusion &
segregation visible to the naked eye shall result in rejection of such rail or cutting out
of the defective portion and re-examination.

10.7 Any operation carried out either in the hot or cold state with the object of hiding a
defect is strictly forbidden.

11 Finishing

11.1 Cold straightening shall be effected by means of gradual pressure without impact.
The rails may be roller straightened only once in each direction. The markings must
be protected from the action of the straightening rolls.

11.2 The rails must be cut to length when cold. Burrs shall be removed without any
perceptible beveling of the section.

12 TESTING FACILITIES

The manufacturer shall, at his own expense, supply all templates and gauges,
prepare and supply test pieces and sample of steel, sample rails and drillings, and supply
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 IRS-T-I2-2009

labour and apparatus/equipment, for testing which may be required by the Inspecting
Agency for carrying out all the tests and render reasonable assistance in execution of such
tests as desired by the Purchaser/Inspecting Agency.

13 QUALIFYING CRITERIA

The following test shall be done for each rail section, grade and class after any
change in the process of manufacture which may affect the results or annually for first
three years after adoption of the revised specification. If results of these three years are
consecutively found satisfactory, this frequency may be relaxed to three years by
Purchaser. The test shall be undertaken by the supplier to demonstrate compliance with
the qualifying criteria. If so desired, the purchaser /Inspecting Agency should be provided
all facilities to check the sample and witness the test.

a) Residual stress measurement.

b) Fracture toughness measurement
c) Fatigue test

The samples for these tests shall be collected from finished rails. These samples
shall not be subjected to any further mechanical or thermal treatment. The tests shall be
carried out by an accredited/recognised laboratory approved by the purchaser and the test
results shall be reported to the purchaser. The purchaser shall have access to all test
records, calibrations and calculation which contribute to the final results.

In case any sample fails to meet the requirement laid in the qualifying criteria the
manufacturer shall review its process of manufacturing within six months to eliminate
any shortcomings and fresh qualifying criteria test shall be undertaken under intimation
to the Purchaser.

14 NATURE OF TESTS

All tests shall be carried out as per latest version of reference specifications
mentioned in this document.

14.1 ACCEPTANCE TESTS

14.1.1 Following acceptance tests shall be conducted for Grade 880, 1080 CR ,
880 CM, 880 NC, 880 VN & 880 NB Rails:
a) Chemical Analysis
b) Tensile Test
c) Sulphur Print
d) Hardness test (for information and record)
e) Falling Weight Test
f) Hydrogen content
g) Inclusion Rating Level

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 IRS-T-I2-2009

14.1.2 For Grade 1080 Head Hardened (1080 HH) Rails all the tests stipulated in Para
14.1.1 above shall be conducted except tensile test and hardness test, prior to heat
treatment. Following tests shall be carried out after heat treatment:

a) Tensile Test
b) Hardness Test
c) Macroscopic Test

14.2 The choice of the test sample location within the cast and strand shall normally lie
with the manufacturer. The test sample position within the bloom/rail shall be
selected at the discretion of the Inspecting Agency.

14.3 The initial test pieces and also the samples intended for retest must not be taken
from the change over or intermediate blooms. Tests will only be carried out on these
blooms when part or the whole of the adjacent cast has been withdrawn as not
conforming to specification, or for supplying supplementary information, if required
by the purchaser.

14.4 The test methods and the conditions, under which the tests are carried out, shall
conform to the standard in force in the country of manufacture, in so far as they are not
defined in the present specification.

15 TEST SAMPLE

15.1 The samples drawn for preparation of the test pieces shall be marked and stamped
under the supervision of the Inspecting Agency.

15.2 If during the preparation of test pieces, any marks have been removed, they shall
be replaced on the actual test pieces in the presence of the Inspecting Agency.

15.3 The test pieces shall be machined in the cold state and must not be subjected to
any cold or hot working or heat treatment except for stress relieving treatment at 100o C
for two hours for tensile test pieces at the option of the manufacturer.

16 CHEMICAL ANALYSIS

16.1 The manufacturer shall, at his own expense, make a complete ladle sample
analysis of each cast from which the rails are to be rolled and shall submit an
authenticated copy of the results to the Inspecting Agency in the proforma at Appendix-
VII. The percentage of each specified element shall conform to the limits specified in
table-1 of clause 7.

16.2 Extent of test (Product)

For casts ≤ 150t, one test per cast.

For casts > 150t, two tests per cast, one sample taken from first half
of the cast and the other from the second half and different
strand.
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 IRS-T-I2-2009

16.3 If chemical analysis of any cast fails to conform to the provisions of clause 7, the
cast shall be subjected to the retest as per provisions of clause 16.4.

16.4 Retest

Two additional chemical analyses shall be made. If both analyses pass, the casts
shall be considered as complying with clause 7. If one or both of the analyses fail, the
cast shall be rejected.

16.4.1 If a cast does not satisfy the conditions of the specification, the intermediate
metal belonging to preceding and succeeding cast shall be rejected or subjected to a
retest.

16.5 The chemical analysis for specified elements shall also be made either from
drillings taken from a hole drilled in the rail, or by spectrography or any other approved
method from the position shown (in fig.3), rolled from the same cast or from the tensile
test piece or piece selected by the Inspecting Agency and the percentage of each specified
element shall be within the range specified in table 1 of clause 7.

10 to 15 mm.
C/L OF RAIL
A

10 mm Ø
A
15 to 17 mm.

SECTION AT A-A

Fig. 3A for drilling Fig. 3B for Spectrography

A 10 to 15 mm.
C/L OF RAIL

A
15 to 17 mm.

SECTION AT A-A

Fig. 3C for drilling Fig. 3D for Spectrography

Fig. 3 Location Of Sample For Chemical Analysis

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 IRS-T-I2-2009

17 TENSILE TEST

17.1 For 880,1080 CR , 880 CM, 880 NC, 880 VN, And 880 NB grade Rails:

17.1.1 Nature of Tests

The manufacturer shall determine the tensile properties of the steel in accordance
with the requirements of IS: 1608. Such tests shall be made on standard test pieces
taken from position shown in figure 4.

Fig .4 LOCATION OF TENSILE TEST PIECE

R R

G
P

Fig . 5 STANDARD ROUND TENSILE TEST PIECE

Three sizes of the standard test piece, as shown in fig.5 are given in table 3, any of
which may be adopted.
Table-3

Diameter Area of cross Gauge length Parallel length Radius at

section Shoulder
D mm A mm2 G mm P mm R mm
20.64 333.33 100 120 18
14.56 166.67 75 90 13
10.00 78.50 50 55 10

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 IRS-T-I2-2009

17.1.2 Extent of Tests

For casts ≤ 150t, one test per cast.

For casts > 150t, two tests per cast, one sample taken from first half
of the cast and the other from the second half and different
strand.
17.1.3 Results to be obtained

The tensile strength obtained shall not be lower than the minimum value given in
table 1, clause 7. Should the test piece break outside the middle half of the gauge length ,
it may be discarded and such breaks should not be considered as a failure of the test. A
fresh test or fresh tests may be made by the manufacturer with a test piece or test pieces
taken from rail from the same cast from which the discarded test piece was taken.

17.1.4 Retests

When the first tensile test does not give satisfactory result, three retests shall be
made. The two retests shall be made on any of the rails from the same strand and the
third retest on any of the rails from another strand of the same cast.

The check tests must not be carried out on rails produced from intermediate
blooms of a sequential continuous cast.

If all the three retests are satisfactory, all the rails of the cast shall be accepted.

If any of the two retests from original strand does not give satisfactory result and
the third retest from the other strand gives satisfactory result, all the rails of the original
strand shall stand rejected and rest of the rails of the cast shall be accepted.

If third retest does not give satisfactory result, further retest shall be made strand
by strand as above up to 50% of strands.

For sequential continuously cast material, in the event of rejection or withdrawal

of rails from one or more strands of a cast, the rails rolled from the change over blooms
between the ends of these strands of the previous and next cast in the sequence shall
either be deemed not to comply with the requirements or shall be subjected to retest
which shall be carried out, one on rail from the strand represented by the original test and
the other from another strand. In the event of failure of either of these retests, rails
rolled from change over blooms shall be rejected.

17
 IRS-T-I2-2009

17.2 For 1080 HH (Head Hardened ) Grade Rails

17.2.1 Nature of Test

The manufacturer shall determine the tensile properties of the steel in accordance
with the requirements of IS: 1608.
Such test shall be made on standard test pieces taken from position as shown in fig.6
given below.

10mm

Figure -6

The diameter of the test piece shall be 6 mm with gauge length 3.54D or 21 mm.

17.2.2 Extent of Tests

One test per 1000 meter of heat treated rail from one heat.

17.2.3 Results to be Obtained

The minimum tensile strength after heat treatment shall not be less than 1080 MPa
with a minimum elongation of 10% and 0.2% proof stress shall be measured and record
maintained. If the test piece breaks outside the middle half of the gauge length, it may be
discarded and such breaks shall not be considered as failure of the test. A fresh test or
fresh tests may be made by the manufacturer with a test piece or test pieces taken from a
rail from the same lot from which discarded test piece was taken. If the tests fail to meet
the above requirements, the rails may be retreated at the option of the manufacturer and
such rail may be retested as above.

18 Sulphur Print Test

18.1 For Grade 880/1080 Cr/1080 HH /880 CM/ 880 NC/ 880 VN & 880 NB Rails

18.1.1 Nature of test

A Baumann-type impression is obtained by the application of bromide paper,
previously impregnated with a solution of Sulphuric acid, to the clean rail sections drawn
from a location within the cast at the discretion of the Inspecting Agency.

The sections intended to be used for these tests are cold sawn and are then
sufficiently cleaned on one surface in order to eliminate completely all machining marks
and to obtain a sharp impression.

18
 IRS-T-I2-2009

The initial samples and also those intended for the retests must not be taken from
rails of changeover blooms. Tests will only be made on these rails when part or whole of
the adjacent cast has been withdrawn as not conforming to specification.

18.1.2 Extent of Tests

Sulphur print tests shall be carried out at the rate of one each per cast for
casts ≤ 150 t and two per cast for casts > 150 tones.

18.1.3 Results to be Obtained

The prints obtained must not reveal macrographic defects more marked than those
of the limit prints shown in (or equivalent to those shown in) the album of macrographic
prints given in Appendix-VIII.

18.1.4 Retests

If Macrographic examination (Sulphur print) conducted according to 18.1.3 does

not give satisfactory results, three further samples, two from the same strand and one
from the other strand shall be tested.

If all the retests are satisfactory, all the rails of the cast shall be accepted.

If any of the two retests from the original strand does not give satisfactory result
but the third retest from the other strand gives satisfactory result, all the rails of the
original strand shall stand rejected and rest of the rails of the cast shall be accepted.

If the third retest from the other strand does not given satisfactory result, further
retest shall be conducted strand by strand.

For rails from sequential continuously cast blooms, in the event of rejection or
withdrawal of rails from one or more strands of a cast as a result of macrographic test, the
rails rolled from the change over blooms at the end of these strands of the next cast in
sequence shall either be deemed not to comply with requirements or shall be subjected to
retest which shall be carried out one on the rails from the strand represented by the
original test and the other from any other strand. In the event of failure of either of these
retests, the rails rolled from change over blooms shall be rejected.

18.2 Inclusion Rating Level

18.2.1 The inclusion rating level, when examined as per IS: 4163, shall not be worse
than 2.5 A, B, C, D thin or 2.0 A,B,C,D thick. Reporting for a parameter is to
be in either thin series or thick series.

18.2.3 This test shall be done once every day at random .The record of the test results
shall be communicated to purchaser.

19
 IRS-T-I2-2009

18.3 Macro-Structure Test (For 1080 HH grade Rails)

One macro structure test of hardened layer per 1000 meter of heat treated rails
shall be performed. Macro structure of heat affected zone shall confirm to figure 7.

b
a,c 10 mm

a b 15 mm
c

Figure -7

19 Brinell Hardness Test

19.1 For 880/1080 CR ,880 CM, 880 NC, 880 VN & 880 NB Rails

19.1.1 Nature of Test

For carrying out this test, impression shall be made on the running tread of a test
piece drawn at the discretion of the manufacturer. The test shall be performed in
accordance with IS: 1500.

19.1.2 Extent of Test

Test on 10% of the casts shall be carried in case of 880 grade rails and 1080 grade
rails for the purpose of records and for any corrective action as required. The hardness
values should preferably be as under:

Grade 880 rails Minimum 260 BHN

Grade 1080 HH 340 - 390 BHN
Grade 1080 Cr 320- 360 BHN

Results of the test should be average of five observations on the same test piece.

19.2 For 1080 Grade (Head Hardened) Rails

19.2.1 Nature of Test:

The hardness test on the rail head surface shall be carried out for 10% of rails, at
one end of the rail (after removing the decarburised surface), at regular interval of heat
treatment and the hardness should be in the range of 340-390 BHN for 1080 HH Grade
Rails. In case of non-conformance of any rail, 9 consecutive rails on either side of the
rails having non- conformed value shall be checked for hardness in the sequence. Rails
20
 IRS-T-I2-2009

not meeting the hardness stipulations maybe retreated only once at the option of the
manufacturer and such rails may be retested as above.”

19.2.2 Results to be obtained:

Hardness of rail head surface after heat treatment shall be within Brinell Hardness
No. 340 to 390.

2
2
2 mm 5 10
10 15 2 mm
15
25 51mm
35

45
20 m m
m 20 m

Figure -8 Hardness Distribution

19.2.3 Hardness Distribution Test

The hardness distribution test shall be conducted on transversely cut rail
sections as shown in figure 8. Hardness value at any point shall not exceed 390BHN.
The cross sectional hardness distribution of heat treated rails shall slope towards the
inside. No sharp drop in hardness should be present. The hardness at 10 mm below, the
rail head table at centre shall be 340 BHN minimum.
The hardness at 15 mm below, the rail head table at centre shall be between 315-325
BHN.

19.2.4 Extent of Test:

One hardness distribution test per 1000 m length of heat treated Rail shall be
performed.

19.2.5 Microstructure :

Test piece for microstructure should be taken from the top of rail head. Test piece
should be polished, etched and viewed under microscope X100 and X500 magnification.
The microstructure shall be fine pearlite without formation of any martensite and
Bainite. One test per 1000m of heat treated rail from one heat to be carried out.

20. FALLING WEIGHT TEST

20.1 Nature of Test

20.1.1 Falling weight test piece 1.5 meters long shall be cut from a location as per
choice of the Inspecting Agency. For heat treated rails, the sample shall be taken after
heat treatment. The test piece shall be placed in horizontal position with the head up on
two iron or steel supports resting on a solid metal anvil. The weight of the metal anvil
block shall not be less than 12 t and the area of the base not less than 4.2 sq.m. The

21
 IRS-T-I2-2009

metal anvil block shall be supported direct on a concrete or masonry foundation weighing
not less than 25 metric tons and having an area of not less than 9.3 sq.m. No timber or
spring shall be permitted between the rail supports and the anvil or between the anvil
and the foundation. Block guides shall be provided which shall permit free fall of the
weight. The upper surface of the supports shall be curved to a radius of not more than
75mm.

One blow shall be delivered midway between the supports, by means of a freely
falling iron weight or ‘TUP’, the striking face of which shall be rounded to a radius of not
more than 125mm. the weight of the “TUP”, the distance between the centre of the
bearings , the height between the surface of the rail and the bottom of the “TUP”, before
the latter is released shall be as specified in table-4.

Table-4
Rail Section Weight of Distance between Height of drop (m)
Tup (kg) centers of
bearers (m)
52 kg 1270 0.85 6.4
60kg 1270 0.85 7.4
ZU-1-60 1270 0.85 7.4
68 kg 1270 0.85 8.4

20.2 Extent of Tests

One Test per cast shall be carried out. Sample for 20% (minimum) of the fresh casts
rolled per day shall be selected at random from straightened rails and the remaining
samples shall be hot sawn. No retest shall be permitted on account of sample from
straightened rails failed in Falling weight test. However, present provision of retests
shall be applicable to rest 80% of samples taken from un-straightened rails. Choice
of the test sample location within cast and strand shall normally lie with the
manufacturer. The test sample position within bloom/ rail shall be selected at the
discretion of the inspecting agency.

20.3 Results to be Obtained

20.3.1 The blow shall be sustained without fracture, and the permanent set resulting
from the blow shall be measured after every test, over the specified distance
between the centers of the bearer and recorded and advised to the purchaser.

20.3.2 The Inspecting Agency shall be entitled to test to destruction any rail piece
subjected to the falling weight test or carry out any other
test/examination/analysis in order to confirm that the rails are sound.

20.4Retest
Test sample shall be selected at random from the finished rails at the discretion of
the Inspecting Agency.

22
 IRS-T-I2-2009

If a falling weight test piece gives unsatisfactory result, three retests shall be made
on two rails from the same strand and one from any other strand. If all the three tests are
satisfactory, all the rails of the cast shall be accepted.

If either of the two tests from original strand gives unsatisfactory result and the
third test from the other strand gives satisfactory results, all the rails of the original strand
shall be rejected and other rails of the cast shall be accepted.

If the third test from the other strand gives unsatisfactory result, further retest
shall be conducted strand by strand. For sequential continuous cast, if rails are rejected or
withdrawn from one or more stands of a cast, the rails rolled from the changeover bloom
at the end of the same strands of the previous and next cast in the sequence shall either be
withdrawn or subjected to two retests, failure of either of retest shall result in rejection of
the rails rolled form the changeover blooms of the same strand.

21 DETERMINATION OF HYDROGEN CONTENT

Vacuum degassing of liquid steel shall be done to reduce the hydrogen content.
For this purpose RH degasser shall be used. The vacuum level and the duration for which
liquid steel shall be kept under this vacuum level shall be decided mutually by the
purchaser and the manufacturer. All measurement of hydrogen shall be done for the
liquid steel in tundish or mould. Any other method of sampling or determination of
hydrogen will require prior approval of the purchaser.

21.1 The measurement of hydrogen shall be done by following method:

21.1 (a) On-Line/Instantaneous Method-

HYDRIS is approved as method of on-line instantaneous measurement. The

method of measurement as prescribed by the manufacturer of HYDRIS system shall be
adopted with approval of the purchaser. Any other alternate method of determination of
hydrogen will require prior approval of the purchaser.

(b) Pin Sample Method-

In case, the manufacturer has not installed the facility for on-line/instantaneous
facility for measurement of hydrogen as described in Para (a) above, this method may be
adopted with prior approval of the purchaser.
In this method, sample of liquid steel shall be taken by plunging the sampler 300
mm below the molten slag-metal interface. The sample should be held for 2 to 3 seconds
and then quenched in cold water so that sample temperature falls to below 1500C within 5
seconds.
The sample should be removed from cold water and packed in dry ice if analysis
is carried out within 48 hours of sampling or placed in liquid nitrogen if analysis is to be
carried out beyond 48 hours after sampling. Sampling should be done by 6 mm dia
vacuum tube of Pyrex glass with wall of thickness of 1.0mm and approximately 0.5 mm
thick in the fill-end. The tube should have desired vacuum of 10-3 mm of Hg.
The hydrogen sample can be analysed by inert gas fusion technique in which
sample is to be fused at approximately 19000 C in an induction heating graphite crucible.
A nitrogen carrier gas transports the released hydrogen to thermal conductivity cell. The
amplified and integrated output of the cell is to be calibrated for hydrogen in ppm.
23
 IRS-T-I2-2009

LECO – RH –2 Hydrogen Analyser may be used for Hydrogen determination.

Any other size and material of tube and method of hydrogen determination will
require prior approval of the purchaser.

21.2 The level of hydrogen measured by the method described under Para 21.1 above
shall be as under for acceptance of a heat for production of rail:
i) When measured by the method described under Para 21.1 (a) = 1.6 ppm max.
ii) When measured by the method described under Para 21.1 (b) = 2.0 ppm max.

22 QUALIFYING CRITERIA TESTS

22.1 Residual Stress Measurement

22.1.1 Residual stresses are measured by attaching electrical strain gauge at various
locations on the rail surface. The surfaces to which the strain gauges are attached are
progressively isolated from the rail and the relaxed strain are then used to estimate the
stresses which have been relieved whilst the original residual stresses are taken to be
these values but with a change of sign.

22.1.2 Procedure of Measurement of Residual Stresses

A test piece of 1.0 m length shall be cut from the sample rail. A 150 mm long
area in the centre of the test piece shall be ground by hand using fine stones. During
grinding it shall be ensured that the surface does not get overstressed. Final finishing
shall be done using emery-paper. Strain gauges shall be fixed on minimum 7 & 12
locations on the rail as shown in figure 9.

C/L OF RAIL
H1 H2 H1
H3 H2 H3

H4 H5

H1,H2,H3,H4,H5,W1,W2,
H1,H2,H3,W1, F1,F2,F3,F4,F5
F1,F2,F3 ARE STRAIN W2 W1 C/LOF
W1 C/LOF
ARE STRAIN GAUGE LOCATION WEB
WEB
GAUGE LOCATION
F5

F2 F1 F3 F4
F1 F2 F3

Fig 9-A Fig 9-B

Figure 9 : Location of strain Gauges to measure
surface longitudinal residual stresses

The strain gauge location shall be accurately marked and these locations shall be
cleaned with the help of Acetone and cotton. Rust shall be cleaned by acid and the acid
cleaned locations shall be treated by basic solutions. Strain gauges shall be fixed using
24
 IRS-T-I2-2009

proper adhesive and then connecting wires and terminals are soldered. Null balancing of
strain shall be done and reading of each strain gauge brought to zero using balancing
bridge and strain indicator. The wires shall be disconnected from the balancing bridge
and 60 to 80 mm length of samples shall be cut containing all the strain gauges. Wires
shall be connected to the balancing bridge and reading of strain gauge taken using same
setting of balancing bridge as was before cutting the samples. The reading of strain at the
corresponding locations shall be converted to stress by multiplying with Young’s
modulus of elasticity for steel (2.05 x 106 Kg/cm2). Residual stress will have same value
as relieved stress with opposite sign.

22.1.3 Results to be obtained

Residual tensile stress anywhere in the rail section shall not exceed 190 MPa,
anywhere in the section.

22.2 Fracture Toughness K1c

22.2.1 Test pieces and test methods

Tests shall be performed in accordance with APPENDIX-XI

22.2.2 Qualifying Criteria:

The values of K1c shall comply with table given below:

Steel grade Minimum single value Minimum Mean

K1c( MPa m ½) K1c( MPa m ½)
880 26 29
1080 Cr 24 26
1080 HH 30 32

Note: In some circumstances KQ values can be used for the purpose of

qualification – see B.6 of appendix XI.

22.3 Fatigue Test

22.3.1 The constant amplitude fatigue test shall be carried out in accordance with
ASTM E606.

22.3.2 Test Pieces

The test pieces shall be machined from the sample rail at a location at least 2m
from the rail ends.

22.3.3 Number of Tests and Test Conditions

A minimum of three tests shall be performed under the following conditions:-

Test temperature = Ambient

Control variable shall be axial strain amplitude.

25
 IRS-T-I2-2009

Note:- Load control during the test is acceptable provided the requirements of
ASTM E606, clause 10.2.1 are complied with.

The strain cycle shall be symmetrical about the initial zero load strain level.

22.3.4 Each sample should endure 10 million cycles at strain of 0.00135. For rails of
Grade 1080 HH the each sample should endure 10 million cycles at strain of 0.00166.

23 INSPECTION

23.1 The purchaser/Inspecting Agency shall have free access to the works of the
manufacturer at all reasonable times. The Inspecting Agency shall be at liberty to inspect
at every stage the process of steel manufacture and rail production and cross check the
results of the stipulated tests when so desired by it.

23.2 Rails rolled from passed heats only shall be inspected by the Inspecting Agency or
as mutually agreed by purchaser and Inspecting Agency . The acceptance procedure
should not interfere with the normal manufacturing process. When a cast is rolled in
several batches, tests carried out on the first part of the cast may be considered valid for
the remaining parts of the cast in agreement with the Inspecting Agency.

23.3 Before the rails are submitted to the Inspecting Agency, these rails shall be
properly examined by the manufacturer’s inspectors and all defective rails shall be
conspicuously marked and segregated. Rails passed in internal inspection should only be
offered for examination by the Inspecting Agency.

23.4 The analysis of all casts rolled together with a report on the manufacturer’s
rejections shall be submitted in proforma as appendix IX and X to the Inspecting Agency.

23.5 After inspection, every accepted rail shall be clearly stamped with the Inspecting
Agency’s stamp at one end in the presence of the Inspecting Agency and painted as per
colour code specified in clause 8.4. Cast numbers shall be cold stamped on the faces of
the rails at one end.

23.6 Passed rails should be properly stacked on leveled and well drained stacking area.
Rails shall be stacked in head up position with 100 x 25mm mild steel flats as spacers at a
distance of 3.0 meters between successive layers.

23.7 For lifting rails, single point slinging is not permitted. For 13m long rails, there
should be two lifting point spaced at 6 to 7.5 m apart and the maximum rail end overhang
beyond the lifting point should not be more than half of the distance between the lifting
point. For lifting longer rails the spacing between lifting points shall not be more than 7.5
m. Lifting of rails using magnetic chucks shall be preferred.

23.8 Sudden impact on rails during loading, unloading, stacking or transferring from
one point to the other shall be avoided.

26
 IRS-T-I2-2009

24 METHOD OF PAYMENT

24.1 The calculated weights of rails given in appendix I , II , II-A and III of this
specification shall be regarded as actual weights and payment shall be made on these
weights unless otherwise agreed to.

25 SHIPMENT
25.1 No rail shall be loaded or dispatched until notification has been received from the
Inspecting Agency that it has been inspected and has satisfactorily passed all specified
tests.

25.2 Industrial Use (IU) rails should be loaded in one wagon and should not be mixed
with other rails for dispatch.

25.3 Import Shipment

The rails shall be loaded in bundles of three rails each bundle containing one
rail upside down placed in between two rails snugly fitting and suitable tied by M.S.
straps at four or more places along the length of rails so that they will not get loosened
during their transportation from manufacturer’s place to site of work.

25.4 Rail Transport

Transportation within the country
Rails shall be loaded in wagons in layers with wooden/steel spacer flats
between them so that the rails do not get damaged during transportation. Any
missing bolster in BFRs/BRHs/BRNs shall be replaced by the manufacturer at his
expense. The rails shall be tied as per the extant instructions.

27
 IRS-T-I2-2009

IRS- 52 kg/m APPENDIX-I

67
18

R80
R305 R13

51
R2
R2
1 7 ,5
2 .7 5
R8 1 IN

R2 2.5
R3 81

R381

STRAIGHT

156
19

15.5
R381
TO CENTRE OF 381 mm RAD

R381

60
R1
3
R20

2 .7 5
1 IN
29

R5 1 IN 6
13

13

R2
24 44 44 24

136

C A L C U L A T E D W E IG H T 5 1 .8 9 kg p er m etre
C R O S S S E C T IO N A R E A 6 6.15 sq cm

28
 IRS-T-I2-2009

APPENDIX-II

UIC 60 kg/m
74.3
72
70.6
52
21

14.3

300R.

300R.

80R.
80R
.
13R. 13R
1:20

1:20

13.5
C/L

51
. 3R
3R .
1:2.7 . 75
5 33 1:2

28.75
.
7R

.
35R
28.2
19.5

120R.
16.5

STRAIGHT
8.25 8.25

89.5
32

172
28.75
16.5
19.5

120R.
28.2

40R.
35R.
7R.

40R. 33
1:2.7
5
31.5

1:14
16.9

4R.
11.5

2R.
150
CALCULATED WEIGHT 60.34 KG PER METRE
CROSS SECTION AREA 76.86 sqcm

29
 IRS-T-I2-2009

APPENDIXX II-A

ZU 1-60 PROFILE

Y.
74.5
72
49
52
21
14.3

R13
R13

39.5
1:20
1:20

R80
R300

R300
R80

53
R3
R3
1:2.7 5
5 1:2.7

R19
R19
X. X.

134
28 16
R1
9 44 R19

1: 4 1 : 17
33.7

R4
R4
25
20

R3

R3

Y Y
55 85
140
WEIGHT PER METER 73 kg/m
AREA OF SECTION 93 cm³

30
 IRS-T-I2-2009

136 RE 14 (68 kg/m) APPENDIX -III

74.61
35.56

R 31.75
R 355.60
R 14.29

1:20
49.21
R 7.94
R 7.94
1:4

7.14

R19.05
17.46
CL R508 & R203.2

185.74
106.36 NEUTRAL AXIS

R508.00
98.43
85.29
R19.05

1:4
30.16
R1.59 R3.18

152.40
CALCULATED WEIGHT; 67.364 kg/m
SEC. AREA :86.131 sqcm
ALL DIMENSION ARE IN MILLIMETRES
FOR INDIAN RAILWAYS, HEAD SLOPE HAS
BEEN KEPT 1:20 IN PLACE OF 1:40 AS
AREMA PROFILE

31
 IRS-T-I2-2009

COLOUR CODE FOR RAILS APPENDIX – IV

S. Grade Colour Code 13m, 26m, 130m, 12m, 25m, 11m, 24m 10m
No. 260m 129m, 259m
1 GR. 880 Only common length wise colour code and no paint on web surface

2 GR.1080 H.H. In addition to common length wise colour code, Blue paint on both sides of web
surface for a distance of 500 mm from each end.

3 Gr 1080 Cr In addition to common length wise colour code, Green paint on both sides of web
surface for a distance of 500 mm from each end.

4 CLASS’A’ RAIL In addition to common length wise colour code, grade code as 1, 2 & 3 and Green
paint on gauge/non gauge face for a distance of 500 mm from each end.

5 In addition to common length wise colour code, Purple paint on both sides of web
NIOBIUM surface for a distance of 500 mm from each end.
880 NB

6 In addition to common length wise colour code, Yellow paint on both sides of web
VANADIUM surface for a distance of 500 mm from each end.
880 VN

7 Copper- In addition to common length wise colour code, White paint on both sides of web
Molybdenum surface for a distance of 500 mm from each end.
880 CM
8 Nickel Chromium In addition to common length wise colour code, Brown paint on both sides of web
Copper surface for a distance of 500 mm from each end.
880 NC
9 IU In addition to common length wise colour code, Blue paint on end face of flange and
both sides of flange for a distance of 500mm from each end.
Common lengthwise colour code
1. No paint on gauge/non-gauge face indicates class ‘B’ rails. 2. Yellow paint on each end face on web region indicates 13m, 26m, 130m, and 260m length.
3. Blue paint on each end face on web region indicates 12m, 25m, 129m, and 259m length.
4. White paint on each end face on web region indicates 11m, 24m length. 5. Green paint on each end face on web region indicates 10m length.
Note: - This colour code is for new rails, for second hand rails Para 321 of IRPWM-1986 may be referred to.

32
 IRS-T-I2-2009

APPENDIX-V
GAUGE FOR CHECKING THE ASYMMETRY
c
H = Height of the rail.
L = Width of the railfoot.
C = nominal width of the railhead.
a = Distance between the orthogonal projections,
measured on the base of the foot , of the end
of the foot and the bottom edge of the extreme
rounding all of the running surface:
a = L2- C

x = Depends on the section, according of the

H
general table of tolerance.

H-b
b = Height ,relative to top of rail, of the bottom
of the extreme rounding all of the running
surface (for the construction of the gauge,
H - b may be rounded off to the nearest mm)

a-x mm
a+x mm

2L/3

12 12
2L/6

L
The ( -) gauge, applied against the base of the railfoot ,
The ( + ) gauge, applied against the base of the railfoot ,
is pushed sideways towards the rail.
is pushed sideways towards the rail.
The (-) stop must not come into contact with the railhead.
The ( + ) stop must not come into contact with the railhead.

33
 IRS-T-I2-2009

APPENDIX-V

X=18.0 mm FOR 60 Kg/M. RAIL

X
1 2 3 4 5 6 7 8 9 10 11 12 X=23.0 mm FOR 52 Kg/M. RAIL

A B B C C D D D E E F F

X
SECTION - G.G.
LENGTH 12.5 (REFERENCE SECTION- F.F.)
INCLINED NOTCH 20°
WITH VERTICAL
A B B C C D D D E E F F 12.5 mm LONG
1.0 mm WITH
HEAD

MINIMUM DEPTH
CLOF RAIL 0.25 mm AT 20° ANGLE
CLOF RAIL CLOF RAIL CLOF RAIL CLOF RAIL CLOF RAIL
Ø 1.5 DRILL
CL OF HEAD

19 MIN.
19 MIN.
Ø 1.5 &
Ø 2.0 FBH BRAND SIDE
(2 PLACES) Ø 1.5 & Ø 2.0 FBH CL OF WEB
CL OF WEB BRAND SIDE CL OF WEB THROUGH HOLES CL OF WEB CL OF CL OF WEB
(2 PLACES)(MIN. 20 mm
Ø 2.0 FBH WEB Ø 2.0 FBH MAX: 15 mm
LONG AT CENTRE) G. X
G. 1. ALL DIMENSIONS ARE IN MILLIMETRES.
AT 3 PLACES AT 2 PLACES BASE WEB JUNCTION
2. FBH DENOTES FLAT BOTTOMHOLE.
3. DIMENSIONS ARE NOT TO SCALE.
SECTION - A.A. SECTION - B.B. SECTION - C.C. SECTION - D.D. SECTION - E.E. SECTION - F.F. 4. HOLES AT LOCATIONS 1, 3, 4, 10 ARE KEPT
FOR ALIGNMENT/ SETTING PURPOSE ONLY.
FOR SYMMETRICAL RAIL SECTION 5. SENSITIVITY LEVEL SHALL BE WITH REFERENCE HOLES/
NOTCHES AT LOCATIONS 2, 5, 6, 7, 8, 9, 11, 12
HEAD

i.e. TOP HEAD Ø 1.5 THROUGH HOLE ------------------- 1 NO.

SIDE HEAD Ø 1.5 FBH ------------------------------ 1 NO.
CLOF RAIL WEB Ø 2.0 FBH ----------------------------------- 3 NO.
CLOF RAIL CLOF RAIL CLOF RAIL
CLOF RAIL CLOF RAIL FOOT WEB JUNCTION: Ø 2.0 THROUGH HOLE ------------ 1 NO.
Ø 1.5 DRILL
19 MIN.
19 MIN.

CLOF HEAD LEFT FOOT-12.5mm LONG , 1.0mm WIDE

Ø 1.5 & BRAND SIDE
RECTANGULAR NOTCH INCLINED 20° WITH VERTICAL
Ø 2.0 FBH AXIS ( SHORT EDGE 0.5 mm). ------------------ 1No.
Ø 1.5 & Ø 2.0 FBH C OF CLOF WEB
CL OF WEB (2 PLACES) CLOF WEB WEB CL OF WEB
THROUGH HOLES L CL OF RIGHT FOOT - 12.5mm LONG, 1.0mm WIDE RECTANGULAR
BRAND SIDE Ø 2.0 FBH WEB Ø 2.0 FBH NOTCH INCLINED 2O° WITH VERTICAL AXIS
(2 PLACES)(MIN. 20 mm MAX: 15 mm
G. X
G.
AT 3 PLACES AT 2 PLACES
LONG AT CENTRE)
BASE WEB JUNCTION
SECTION - A.A. SECTION - B.B. SECTION - C.C. SECTION - D.D. SECTION - E.E. SECTION - F.F.
FOR ASYMMETRICAL RAIL SECTION

34
 IRS-T-I2-2009

APPENDIX- VII

LADLE ANALYSIS OF RAIL STEEL

Date HEAT PERCENTAGE H2 O2

NO PPM PPM
C Mn Si S P Mo Cr V Ni Cu Al

35
 IRS-T-I2-2009

APPENDIX- VIII

ALBUM
OF
MACROGRAPHIC PRINTS

36
IRS-T-I2-2009

37
IRS-T-I2-2009

38
IRS-T-I2-2009

39
IRS-T-I2-2009

40
IRS-T-I2-2009

41
IRS-T-I2-2009

42
 IRS-T-I2-2009

APPENDIX- IX

MECHANICAL PROPERTIES

DATE HEAT SPECIMEN BEFORE AFTER % BREAKING YS UTS HARDNESS FALLING WEIGHT TEST
NO FRACTURE FRACTURE ELONGATION LOAD MPa MPa (BHN)
kg
DIA AREA INITIAL FINAL BROKEN/ DEFLECTION
mm mm2 GAUGE GAUGE NOT mm
LENGTH LENGTH BROKEN
mm mm
1 2 3 4 5 6 7 8 9 10 11 12 13

43
 IRS-T-I2-2009

APPENDIX- X

DETAILS OF RAILS OFFERED FOR INSPECTION

Date Heat No of Wt. Of No of rails of length No of rails found o.k. after internal No of rails rejected during internal
no blooms blooms inspection inspection
produced produced
from the from the heat
heat
1 2 3 4 5 6 7

11&10 M

11&10 M

11 &10M
260 M
259 M
130 M
129 M

260 M
259 M
130 M
129 M

260 M
259 M
130 M
129 M
26 M
25 M
24 M
13 M
12 M

26 M
25 M
24 M
13 M
12 M

26 M
25 M
24 M
13 M
12 M
44
 IRS-T-I2-2009

APPENDIX -XI

Standard test method for the determination of the plane strain fracture toughness
(K1c) of rails

B.1 Test methods

This test shall be performed in accordance with the requirements of ASTM E399
except where superseded by the requirements specified in this part of IRS T 12. The
requirements specified in this part of the IRS T 12 apply only to the determination of
plane strain fracture toughness of railway rail steels covered by the definitions and
requirements of this standard.

B.2 Test pieces

B.2.1 The location of the test piece in the rail’s transverse section is shown in Figure
B.1.

B.2.2. The thickness “B” of all test pieces shall be 25 mm. For any rail head transverse
profile the test piece width “W” shall be the maximum achievable of the following
dimensions:

40 mm;
45 mm;
50 mm.

B.3 Number of tests

A minimum of 5 tests from each sample shall be performed.

B.4 Test conditions

B.4.1 Fatigue pre-cracking shall be carried out in the temperature range + 15o C to + 25o
C using a stress ratio in the range > 0 <+0.1. Fatigue pre-cracking shall be carried out at a
cyclic frequency in the range 15 Hz to 120 Hz. The final crack length to test piece width
ratio shall be in the range 0.45 to 0.55.

B.4.2 The single edge notched bend test piece shall be loaded under displacement
control using three point bending with a loading span (S) equal to four times the test
piece width (W)

B.4.3 Tests shall be performed at a test temperature of -20o C + 2o C. Test piece

temperature shall be measured using a beadless thermocouple spot welded to the test
piece at the location shown in figure B.2.
_____________________________________________________________________
1)
It is recommended that the chevron notch in ASTM E399 is used to avoid crack
front curvature problems.

45
 IRS-T-I2-2009

B.5 Analysis of test data

B.5.1The calculation of KQ shall be in accordance with ASTM E399. The checks made
to establish whether this value is a valid K1c shall be in accordance with ASTM E399
except for the requirements of B.5.2 to B.5.6.

B.5.2 Pmax / PQ shall be less than 1.10 for force-crack mouth opening curves where pop-
in does not occur before the intersection of the curve with the 95 % secant. There shall
be no Pmax / PQ .criterion for other types of curve.

B.5.3 The linearity of force-crack mouth opening curves la. lb. lla and lll (see figure
B.3) shall be checked in the following manner.

Measure the distance (υ1) between the tangent OA and the force-crack mouth opening
curve at a constant force of 0.8 PQ Measure the distance (υ) between the tangent OA and
the force-crack mouth opening curve at a constant force of PQ .for a test result to be
valid… υ1≤ 0.25υ

B.5.4 The linearity of force – crack mouth opening curves llb and llc (see Figure B.3)
shall be checked in the following manner.

Measure the distance between the tangent OA and the force-crack mouth opening curve
at constant forces of 0.8 PQ.and PQ.recording these values as υ1 *and υ*..respectively.

Measure the crack mouth opening values arising from all “pop-ins” that occur up to
PQ.this is done by measuring the horizontal distance travelled along the crack mouth
opening axis between the start and finish of each “pop-in”. Sum the values for “pon-ins”
occurring below 0.8 PQ.and for those occurring between 0.8 PQ.and PQ.recording them as
∑υ1p1 and ∑ υp1.respectively.

For a test result to be valid …[. υ1 - ∑υ1p1 ] ≤ 0.25[υ –(∑υp1 + ∑υ1p1 )]

B.5.5 The linearity criterion cannot be applied to force-crack mouth opening curve IV.

B.5.6 For all force-crack mouth opening curves the KQ value shall be subjected to the
validity check that the test piece thickness (B) and crack length (a) are equal to, or greater
than, the value of 2.5(KQ / Rp0.2 )2, where Rp0.2 ..is the 0.2% proof stress at the fracture test
temperature of – 20oC.

B.6 Reporting of results

All measurements required to calculate the test result and to show that the test
conditions were as specified in the test procedure shall be recorded.

All results shall be reported as either K1c values KQ*.values or KQ.values; where
KQ*.values are those KQ values which failed the validity criteria due only to one or more
of the following:

i) PMAX / PQ >1.1;
ii) Exceedence of the 2.5(KQ / Rp0.2 )2 criterion;
iii) Crack mouth opening displacement-force relationship.

46
 IRS-T-I2-2009

The mean and standard deviation of both K1cand KQ*results shall be recorded. For each
grade of rail tested these results shall be included in a table giving the following
information.

Steel 0.2% proof Mean K1c Number Samples Mean (KQ) Number Sample
Grade stress at (MPa of K1c standard (MPa m1/2) of KQ.. standard
–20oCMPa m1/2) results deviation Results deviation
(MPa m1/2) (MPa m1/2)

The value to be used for the acceptance criteria is that of the mean K1c and shall
be based on a minimum of five K1c values.

When five K1c values have not been obtained any KQ *.values shall be included
with any K1c values in the mean value to be used for the acceptance criteria. In this event
the number of test results shall be at least ten.

All values of K1c And KQ* shall be above the minimum value specified in Table 2.

Dimension in millimetre

1 2 .5 1 2 .5
2 1
2
H
W

= =

Figure
Key

1. Notch machined in this face

2. Section through rail heat
3. Letter ‘H’ to be stamped on end face of test piece as shown
B = 25
W = see B.2.2
For all other test piece proportions See ASTM E399

Figure B.1-Location and section of fracture toughness test pieces

47
 IRS-T-I2-2009

Dimension in millimetres

R5
3

R1
0

Key
1. Notch
2. Thermocouple to be placed in the shaded zone
3. Fatigue crack tip

Figure B.2-Location
Location of thermocouple on fracture toughness specimens

Key
1. Force, P
2. Crack mouth opening displacement (v)
 IRS-T-I2-2009

Key
1. Force, P
2. Crack mouth opening displacement (v)

Figure B.3 – Force-Crack mouth opening curves

I

~~- ~{~At - ~i7{ :qSf-~-~1'4 Government ()flndia-?i!inisrry ofRaiiways

~~~ ~f'4q;04 i,7; ~n~'~,~1~';tO~ Re-search Designs &. Standards Organisasion
::rer~7? - 2:::6 o1[ Lucknow -2.26 OJ J
"Z'0' ~-;.t~ ,~_~_~:~"¥"f~~":1'i;. U t '"-.,t.,,
EPBX (0522) 245,200 oso (0522) 245>],,5
Fax (0522l2458500 DID (0522) 246531;)

No. CT/SpecificationfT-12 Dated: 29.09.2011.

As per list enclosed.

Sub: Addendum and Corrigendum Slip to Specification for Flat Bottom

Rails -IRS T-12:2009.
~: ~ 3lmR ~ c5 f4 fM&:: - ~~O 3ffi0 ~O iTo 12 : 2009 1f W'CFf I

Ref: (i) Railway Board's letter no. Track/21/201 0/0513/7 dated 14.09.2011.
(ii) This office letter of even no. dated 22.07.2011.

~: (i) ~~ ~ c5 ~ ~ ~q)/21/2010/0513/7 ~ 14/9/20111

(ii) ~ cpI41(,>j~ c5 "ffll ~ ~ ~ 22/07/2011 I

*******

Please find enclosed herewith Addendum and Corrigendum Slip No.1 to

Indian Railway Specification for Flat Bottom Rails, IRS T-12:2009.
This has the approval of competent authority.

DA: 05 Pages

~"\ (
~tm-)
(CfJI4CfJIi) ~wq) /~ -1)
~ SH::IP1~~lcp/ ~~
 ADDENDUM & CORRIGENDUM SLIP NO. 1
TO
INDIAN RAILWAYS STANDARD SPECIFICATION FOR FLAT BOTTOM RAILS
IRS T-12:2009

I. In Table No. 1 of chemical composition and mechanical properties

corresponding to Clause 7 for corrosion resistant rail is replaced as per table
enclosed herewith as Annexure-A.

II. Following note below table of Para 9.1.2 is deleted.

“All other requirements as regards variation in dimensions, length and falling
weight tests shall be as per prime quality rail 9.1.1”

III. Appendix V (wrongly written) at Page no. 34 is replaced with Appendix VI

and VI-A for test rail for USFD testing of rails referred in Clause10.3. Details
of test rail for symmetrical rail section is shown in Appendix VI and details of
test rail for asymmetrical rail section is shown in Appendix VI-A.

IV. Clause 23.6 at is to be replaced as under: -

“23.6 Passed rails should be properly stacked on leveled and well drained
stacking area. Rails shall be stacked in head up position with 100 x 25 mm
mild steel flats as spacers at a distance of 4.0 m between successive layers.
Recommended arrangement for stacking of rails shall be as per RDSO
drawing no. RDSO/T-6219, as Appendix XII.”

   
 TABLE 1 – Contd...

CORROSION RESISTANT RAIL STEEL

Grade
Chemical Composition (percentage) Mechanical Properties

Running surface
Elongation % on

hardness (BHN)
max by mass O

content in liquid

gauge length –
Yield Strength

5.65√So (min)
10-4% ( ppm)

(MPa)(Min.)
steel (max.)

UTS (MPa)
Hydrogen
Mo (max)
Al (max)
S (max)

P (max)

(Min)

min
Mn

Cu
Cr

Ni
Si
C

Copper-
0.60- 0.80- 0.10- 0.2- 0.25- 1.6
Molybdenum 0.030* 0.030* 0.015 - - - 880 460 10.0 260
0.80 1.30 0.50 0.3 0.35 ppm
(CM)
Nickel Chromium
0.60- 0.80- 0.10- 0.50- 0.3- 0.25- 1.6
Copper 0.030* 0.030* 0.015 0.25 - 880 550 10.0 260
0.80 1.30 0.50 0.65 0.4 0.40 ppm
(NC)

So = Cross sectional area of tensile test piece in mm2

* 0.035 maximum for finished rail
The chemical compositions specified as above are applicable to Ladle analysis and Product Analysis. Manufacture shall ensure that chemical composition at
ladle analysis should be such that product analysis also satisfies the requirement of chemical composition as above.
** Desirable Value.
 APPENDIX-VI
11000

1 2 3 4 5 6 7 8 9 10 11 12

X
X=18.0 mm FOR 60 Kg/M. RAIL
3000 5250 X=23.0 mm FOR 52 Kg/M. RAIL
A B B C C D D D E E F F

Ø 1.5 Ø2
Ø2 Ø1.5
LENGTH 12.5

X
SECTION - G.G.
(REFERENCE SECTION- F.F.)
INCLINED NOTCH 20°
A B B C C D D D E E F F WITH VERTICAL
12.5 mm LONG
1.0 mm WIDTH

HEAD
MINIMUM DEPTH
25 MM. 0.25 mm AT 20° ANGLE
CL OF RAIL CL OF RAIL CL OF RAIL
Ø1.5 DRILL
45mm.DEEP.
Ø 1.5 &
Ø 2.0 FBH
(2 PLACES) Ø 1.5 & Ø 2.0
CL OF WEB CL OF WEB CL OF WEB THROUGH HOLES
(ON BOTH
(2 PLACES)
THE SIDES)

1. ALL DIMENSIONS ARE IN MILLIMETRES.

SECTION - A.A. 2. FBH DENOTES FLAT BOTTOM HOLE.
SECTION - B.B. SECTION - C.C. 3. DIMENSIONS ARE NOT TO SCALE.
4. HOLES AT LOCATIONS 1, 3, 4, 10 ARE KEPT
CL OF RAIL FOR ALIGNMENT/ SETTING PURPOSE ONLY.
CL OF RAIL CL OF RAIL 5. SENSITIVITY LEVEL SHALL BE WITH REFERENCE HOLES/
NOTCHES AT LOCATIONS 2, 5, 6, 7, 8, 9, 11, 12
19 MIN.
19 MIN.

i.e. TOP HEAD Ø 1.5 THROUGH HOLE ------------------- 1 NO.

BRAND SIDE SIDE HEAD Ø 1.5 FBH ------------------------------ 1 NO.
CL OF WEB Ø 2.0 FBH ----------------------------------- 3 NO.
C
L OF CL OF WEB WEB 1.0 FOOT WEB JUNCTION: Ø 2.0 THROUGH HOLE ------------ 1 NO.
Ø 2.0 FBH WEB MAX: 15 mm LEFT FOOT-12.5mm LONG , 1.0mm WIDE

0.5
Ø 2.0 THROUGH HOLE
AT 3 PLACES G. X G. RECTANGULAR NOTCH INCLINED 20° WITH VERTICAL
AT 2 PLACES BASE WEB
JUNCTION AXIS ( SHORT EDGE 0.5 mm). ------------------ 1No.
RIGHT FOOT - 12.5mm LONG, 1.0mm WIDE RECTANGULAR
20

SECTION - D.D. SECTION - E.E. SECTION - F.F.

°

NOTCH INCLINED 2O° WITH VERTICAL AXIS

FOR SYMMETRICAL RAIL SECTION

 

APPENDIX-VI-A

11000
3000 250X11=2750 500 250X9=2250
A A1 B B1 B2 B3 B4 B5 B6 B7 C C1 D D1 D2 D3 E E1 F F1 F2 F3
1.5 5 1.5 2 1.5 2 1.5 2 1.5 2 2 1.5 2 2 2 2 2 2 2 2

F2 & F3 , 2MM WIDE

Ø 2 FLATE BOTTOM
25 MM LONG
HOLES MARKED
LONGITUDINAL
D,D1 & D2 DRILL
RECTANGULAR
FROM BRANDED
Ø 1.5X32 DEEP FBH NOTCH,10MM DEEP

23

20
SIDE OF RAIL C.B. F& F1
23

CL OF RAIL MARKED- B Ø 2 MM FROM BOTTOM (AT

15 C1 5MM DIA FBH
Ø 1.5x45 DEEP FBH Ø 2X32 DEEP FBH THROUGH ANY POINT FROM
90° MARKED- B-1 90° CENTER OF WEB TO

25
AT C.L. OF RAIL 15 Ø 1.5 HOLE MARKED HOLES
WEB C DRILL THROUGH D2 FOOT END)

10
Ø 1.5X32 DEEP FBH E&E1-THROUGH
Ø 5 FBH CB C HEAD. D1 F2 F3
MARKED- B2 20

10
Ø 5 FBH CB D HOLE DIA-2MM

77
Ø 2.0 HOLE MARKED

67
(COUNTER BORE)

57
(COUNTER BORE) Ø 2X32 DEEP FBH

37
C1 DRILL THROUGH
MARKED- B3 F F1
HEAD. CL OF WEB CL OF FOOT
SECTION - EE SECTION - FF
SECTION - AA SECTION - BB SECTION - B2 B2 SECTION - C C SECTION - DD SECTION - E1E1
SECTION - D1D1 SECTION - F1F1
SECTION - B1B1 SECTION - B3 B3 SECTION - C1C1
SECTION - D2D2 1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. FBH DENOTES FLAT BOTTOM HOLE.
Ø5 X 45 DEEP 3. DIMENSIONS ARE NOT TO SCALE.
Ø 1.5 X 32 DEEP FBH 4. HOLES AT LOCATIONS A, A1, B1, B3, B4, B5 ,B6, B7, C1, D3 & E1 ARE
MARKED- B4 KEPT FOR ALIGNMENT/ SETTING PURPOSE ONLY.
CL OF RAIL HEAD
Ø 2 X 32 DEEP FBH 15 5. SENSITIVITY LEVEL SHALL BE WITH REFERENCE HOLES/
15
MARKED- B5 NOTCHES AT LOCATIONS B, B2, C, D, D1, D2, E, F, F1
30

90°
30

2 i.e. TOP HEAD Ø 1.5 THROUGH HOLE ----------- 1 NO.

90° SIDE HEAD Ø 1.5 FBH ------------------------------- 1 NO.EACH SIDE
Ø 1.5X32 DEEP FBH
WEB Ø 2.0 FBH ---------------------------------------- 3 NO.

42 40
Ø 5 FBH CB Ø 5 FBH CB MARKED- B-6
(COUNTER BORE) (COUNTER BORE)
D3 FOOT WEB JUNCTION: Ø 2.0 THROUGH HOLE ------------ 1 NO.
Ø 2X32 DEEP FBH 8
MARKED- B-7 6. LEFT FOOT-Ø2.0 THROUGH HOLE (LENGTH MIN 20MM)
AT THE CENTRE OF SIDE OF FOOT (AT ONE SIDE)-------1 NO.
SECTION - A1A1 SECTION - B4B4 SECTION - B6B6 RECTANGULAR RIGHT FOOT-Ø2.0 THROUGH HOLE (LENGTH MIN 20MM)
AT THE CENTRE OF SIDE OF FOOT
SECTION - B5B5 SECTION - B7B7 SLOT AT WEB (AT OPP NOT IN SAME LINE ALONG THE LENGTHSIDE) SIDE)-----1 NO.
MARKED D3 7. IT IS ESSENTIAL THAT THE BOTTOM OF ALL BLIND HOLES ARE
DRILLED FLAT FOR FB HOLES.
8. SPECIFIED HOLE TOLERANCE
1.5 MM HOLE : 1.5 TO 1.55 MM
2.0 MM HOLE : 2.0 TO 2.06 MM
FOR ASYMMETRICAL RAIL SECTION 5.0 MM HOLE : 5.0 TO 5.08 MM
( ALL OTHER TOLERENCES OF THE ABOVE HOLES SHALL BE IN
ACCORDANCE WITH ASTM E 428).
9. NOT TO SCALE
 A P PE N D I X - X I I
500 4000 4000 4000 500

RAILS / PANELS

MILD STEEL FLAT SECTION

100 X 25@ 4000mm C/C.

GROUND
500 500
GROUND LEVEL. LEVEL.
75 200

15
. . . .. . . . .. . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500 500 4000 4000 4000 500 500

50
10 mm DIA BARS @ 150 mm c/c CONCRETE BED OF M 20 10 mm DIA BARS @ 150 mm C/C EMBEDDED RAIL 52 Kg / 90 R
CEMENT CONCRETE 1:4.8 OR LIME CONCRETE (No:OF RAILS SHALL BE AS
SIDE ELEVATION OR WELL RAMMED MOORUM OR BRICK FRONT ELEVATION INDICATED IN THE TABLE
BALLAST 75 mm THICK. GIVEN BELOW)
SCHEDULE OF DIMENSIONS
RAIL LENGTH / WELDED NUMBER OF EMBEDDED
PANEL (METRES) RAILS
12 / 13 4@ 4000 mm C/C THIS DRAWING IS THE PROPERTY OF
RESEARCH DESIGNS & STANDARDS ORGANISATION
26 7@ 4000 mm C/C (MINISTRY OF RAILWAYS)
39 10@ 4000 mm C/C LUCKNOW-226011, INDIA
130 33@ 4000 mm C/C AND SHALL NOT BE USED, COPIED,REPRODUCED IN
8 . THE DRAWING SUPERSEDES THE DRG:No.RDSO/T- 4962. 260 66@ 4000 mm C/C PART OR WHOLE WITHOUT PRIOR CONSENT IN WRITING.
7 . ONE RAIL/PANEL MAY BE REDUCED AFTER EVERY THIRD LAYER TO ACHIVE PROPER STACKING
FROM BOTH SIDES.
6 . BETWEEN TWO LAYERS OF RAILS M.S.FLAT OF SIZE 100X25 mm SHOULD BE PROVIDED AT 4000 mm
R. D. S. O.
C/C AND IT SHALL BE ENSURED THAT RAIL ENDS DO NOT OVERHANG BY MORE THAN 1500 mm.
5 . ONLY ONE TYPE OF FREE RAILS/ WELDED PANELS SHALL BE STACKED IN ONE STACK. ARRANGEMENT FOR STACKING
4 . MAX. NUMBER OF LAYERS IN WHICH FREE RAILS AS WELL AS WELDED PANELS CAN BE STACKED,
SHALL BE LIMITED TO 10. FREE RAILS AND WELDED PANELS
3 . 52 Kg.per m. / 90 R RAIL SHALL BE EMBEDDED IN THE CONCRETE BED OF M-20 GRADE CONCRETE (I) M. S. FLAT TO
(TO IS:456-1978) AS SHOWN IN THE DRG: ABOVE. IS: 226-1975. STAND.------------------------ ADVANCE
2 . A SLOPE OF 1:400 MAY BE GIVEN IN CONCRETE BED ACROSS THE LENGTH OF RAIL.
1 . ALL DIMENSIONS ARE IN MILLIMETRES EXCEPT WHERE OTHER WISE SHOWN.
(II) IS:456-1978 FOR CANCLD.--------------------- 15.5.2002 (T)
CONCRETE BED. REVSD.------------------------
NOTE SPECIFICATION SCALE ALT: DESCRIPTION DATE R. D. S. O. /T- 6219
I
'at-mi t1(=tH - ~.~ :G13Ua4
Govemmenlof Iadia-Ministry'of Rail,\-ays
~ai~tfFi ~-~k4 .am 'J~'V «~i,&~ Researeh Designs &. Standards Organisation
7t!i;;"t~, - :n6 (HI Lccknow - 2260H
EPBX(0522'} 2451200 DID {0522) 2450115
Fax (0522) 2458500 DlD {0522) 246S31(}

No. CT/SpecificationfT-12 Dated: 03.02.2012.

As per list enclosed.

Sub: Addendum and Corrigendum Slip to Specification for Flat Bottom

Rails - IRS T-12:2009.
~: ~ 311'CfR
~ ~ FclRI~ - ~03lR0 ~O iTo 12 : 2009 ~
x=rm-tFf I

Ref: Railway Board's letter no. Trackl21/201 010513/7 dated 01.02.2012.

~: ~ ~ ~ 'f5f ~ 0P/21/2010/0513/7 ~ 01/02/20112

*******

Please find enclosed herewith Addendum and Corrigendum Slip NO.2 to

Indian Railway Specification for Flat Bottom Rails, IRS T-12:2009.

This has the approval of competent authority.

=~)
DA: 01 Page ~

(CbI4CbI~ . /~~ -1)

~ j!H51f.1~~ICb
/ Tc1q~
 ADDENDUM & CORRIGENDUM SLIP NO. 2

TO

INDIAN RAILWAYS STANDARD SPECIFICATION FOR FLAT BOTTOM RAIL

IRS T-12:2009

26.0 WARRANTY

As a warranty for supply of rails free from manufacturing defects by rail suppliers,
after initial USFD testing of new rails in rail manufacturing plants, a USFD test free period
of 25% of service life of rails in terms of GMT as given below (Para 302 (i) (d) of IRPWM-
2004 as amended from time to time) shall be applicable. This clause of test free period of
25% of service life of rails shall also be applicable for all types of 90 UTS (grade 880) and
higher grade of rails of this specification.

Rail Section Assessed GMT service life for 90 UTS rails

60 Kg 800
52 Kg 525
90 R 375
 
 'qJT<1ffi<f.I( - m~ Government of India-Minisrry of Railways
'~ifR ~ ~ 'Wf<j; ~ Research Designs & Standards Organisation
~@f~ - 2260ll Lucknow - 226 011
EPBX (0522) 2451200 DID (0622) 2450115
Fax (0522) 2458500 OlD (0522) 2465310

No. CT/SpecificationlT-12 Dated: 27.06.2012.

As per mailing list enclosed.

Sub: Addendum and Corrigendum Slip to Specification for Flat Bottom Rails
-IRS T-12:2009.
~: 'l'I ct1C1crt 3ITUR Ttwit c5 Pcifi~ - ~ 0 3JR'0 1Rf 0 t)- 0 12 : 2 00 9 cil
-R~I

Ref: Railway Board's letter no, Trackl21/2008/0801/7 dated 22.06.2012.

~af: ~ ant c5 'Q'5I' ~ ~/21/2008/0801!7 ~

22/0612012

*******

Please find enclosed herewith Addendum and Corrigendum Slip NO.3 to

Indian Railway Specification for Flat Bottom Rails, IRS T-12:2009.

This has the approval of competent authority.

DA: As above
 ADDENDUM & CORRIGENDUM SLIP NO.3

TO

INDIAN RAILWAYS STANDARD SPECIFICATION FOR FLAT BOTTOM RAIL

IRS T-12:2009 DATED 27.6.2012

The Rails in regard to their quality, manufacturing process, chemical

composition, testing/ retesting, qualifying criteria, etc., shall be complying
Indian Railway Specification IRS-T-12-2009 for Flat Bottom Rail with following
amended clauses.

1. Clause 5.4: Head Hardening Process

For head hardening, rails shall be suitably heat treated to meet the
requirements of the specification. The method of heat treatment adopted by
the manufacturer should be made available to the purchaser. In-line
established deep Head Hardening methods using air quenching process would
be acceptable with the prior approval of the Purchaser. Any other process of
Head Hardening would also be acceptable with the prior approval of the
Purchaser.
2. Clause 7: Grade, Chemical Composition and Mechanical Properties
The steel for the rails shall be of fully killed quality and shall confirm to
chemical composition and mechanical properties given in Table -1. Micro
alloying elements of Cr(0.3% max.) & V (0.01% max.) may also be acceptable,
as it helps in improving mechanical properties. The limits for chemical
composition are applicable both for tests on ladle samples and for check
analysis of finished rails. Ladle and check analysis of steel, will be carried out
by the method specified in the relevant part of IS: 228 or by any other
established instrumental/chemical method of testing with the approval of the
purchaser. In case of any dispute, the procedure given in the relevant part of
IS:228 shall be referred.
3. Clause 8.1: Brand Marks
With the prior approval of purchasers, brand marks of suitable size clearly
legible, shall be rolled in relief on one side of web at 3.0 to 4.0 meters interval.
The brand mark shall include:

a) The rail section.

b) The grade of steel, i.e.
Grade 880 880

'--------- .
 Grade 1080 HH 1080 HH
Grade 1080 Cr 1080 CR
Grade 880 Cu-MO 880 CM
Grade 880 Ni Cr Cu - 880 NC
Grade 880 Vanadium- 880 VN
Grade 880 Niobium - 880 NB

c) Identification mark of the manufacturer

d) Month (using roman numbers) and last two digits of year of manufacture.
e) Process of steel making: -
i) Basic oxygen - 0
ii) Electric E

4. Clause 8.2: Hot Stamping

Each rail shall be identified by a numerical, alphabetical or combined alphabetical
and numerical code which will be distinctly hot stamped at least once every
5.0m on the web in figures and letters of suitable size from which following
information can be obtained:

i) The number of the cast from which the rails has been rolled with
letter 'C'

ii) Number of the strand.

iii) For rails from change over bloom, cast number should be the preceding
cast number with prefix letter'B'.

5. Clause 8.3: Cold Punching

8.3.1 Following should be cold punched on one of end face of each rail

a) Inspecting Agency ID and Group ID

b) Shift No in which product inspected
c) Date of Inspection
To avoid damage to the HH rails, instead of cold punching, any other method of
marking can be adopted, with the prior approval of the Purchaser.
6. Clause 8.4:Colour code
Rails shall be painted as per colour code given in Appendix-IV to distinguish grade,
class, length and other special requirements. Paint of good quality should be used
with the prior approval of the Inspecting Agency. Alternatively, different colour
code may also be decided by the supplier with the prior approval of purchaser.
7. Clause 9.2: Length of Rails
The standard length of rail shall be 13 meters or 25 meters or 26 meters. The
manufacturer shall be entitled to supply in pairs of short lengths up to 10% by
weight of the quantity contracted for or ordered. Shorter lengths shall not be
less than 10.0m in length for 13.0M and shall not be less than 23M in lengths
for 25M and 24 M in lengths of rail for 26M. Short lengths shall be in multiples
of 1.0M. In case of ZU 1-60, 1080 HH grade Rails, length shall be suitable for
turnout design offered/proposed.
Type of Rail Tolerance in length
Prime Quality Rail +20mm -lOmm
IU Grade +30mm -30mm

8. Clause 18.3: Macro-Structure Test (For 1080 HH Grade Rails)

One macro-structure test of hardened layer per 1000 meters of heat treated
rails shall be performed. Macro structure of heat affected zone shall confirm to
figure 7.

a,c >
-
IOmm
-
~~~

b
> I5mm
~a", I -
-

I
- -t
Figure -7

Due to specific process of heat treatment being adopted by the manufacturer

e.g. inline air quenching method, Macro-structure of heat affected zone may not
 show distinct zones, as shown above in figure-7, supplier should advise about
the same to the purchaser in advance.
9. Clause 19.2.3: Hardness Distribution Test
The hardness distribution test shall be conducted on transversely cut rail
section as shown in figure-8 . Hardness value at any point shall not exceed
390BHN. The cross sectional hardness distribution of heat treated rails shall
slope towards the inside. No sharp drop in hardness should be present. The
hardness at 10mm below, the rail head shall be 340BHN minimum. The
hardness at 15 mm below the rail head table at centre shall be minimum
315BHN.
10.Clause 21: Determination of Hydrogen Content
Vacuum degassing of liquid steel shall be done to reduce the hydrogen content.
For this purpose, RH degasser or REDA (Revolutional Degassing Activator)
shall be used. In case, any other method of vacuum degassing is adopted, then
the same will require prior approval of the Purchaser. The vacuum levels and
the duration for which liquid steel shall be kept under this level shall be
decided mutually by the purchaser and manufacturer. All measurement of
hydrogen shall be done for the liquid steel in tundish or mould. Any other
method of sampling or determination of hydrogen will require prior approval
of the purchaser.

Clause 21.1 The measurement of hydrogen shall be done by following method:

Clause 21.1 (a) On-Line/Instantaneous Method-

HYDRIS is approved as method of on-line instantaneous measurement. The

method of measurement as prescribed by the manufacturer of HYDRIS system
shall be adopted with approval of the purchaser. Any other alternate method of
determination of hydrogen will require prior approval of the purchaser.

(b) Pin Sample Method-

In case, the manufacturer has not installed the facility for on-line/instantaneous
facility for measurement of hydrogen as described in Para (a) above, this method
may be adopted with prior approval of the purchaser.
•
i,

In this method, sample of liquid steel shall be taken by plunging the sampler
200mm - 300 mm below the molten metal surface in mould and molten slag-metal
interface in tundish. The sample should be held for 2 to 3 seconds and then
quenched in cold water so that sample temperature falls to below 150°C within
5 seconds.

The sample should be removed from cold water and packed in dry ice if
analysis is carried out within 48 hours of sampling or placed in liquid nitrogen if
analysis is to be carried out beyond 48 hours after sampling. Sampling should be
done by 6 mm dia vacuum tube of Pyrex glass with wall of thickness of 1.0mm and
approximately 0.5 mm thick in the fill-end. The tube should have desired vacuum
3
of 10- mm of Hg.

The hydrogen sample can be analysed by inert gas fusion technique in which
sample is to be fused at approximately 1900° C in an induction heating graphite
\ crucible. A nitrogen carrier gas transports the released hydrogen to thermal
conductivity cell. The amplified and integrated output of the cell is to be
calibrated for hydrogen in ppm.

LECO- RH -2 Hydrogen Analyser may be used for Hydrogen determination.

Any other size and material of tube and method of hydrogen determination will
require prior approval of the purchaser.

21.2 The level of hydrogen measured by the method described under Para 21.1 above
shall be 1.6 ppm maximum for acceptance of a heat for production of rail.

11. Clause 26: WARRANTY

As a warranty for supply of rails free from manufacturing defects by rail suppliers,
after initial USFD testing of new rails in rail manufacturing plants , a USFD test
free period of 25% of service life of rails in terms of GMT as given below (Para 302
(1) (d) of IRPWM-2004 as amended from time to time) shall be applicable. This
clause of test free period of 25%of service life of rails shall also be applicable for
all types of 90 UTS (grade 880) and higher grade of rails of this specification. If
any rail fracture due to suspected manufacturing defect is detected within a period
of 25% service life of rail in terms of Gross Million Tonne, then investigation will
be conducted jointly by purchaser and supplier to ascertain the cause of failure".
Rail Section Assessed GMT service life for 90 UTS rails
60 Kg 800
52 Kg 525
90R 375
 qi(c cov6m.m of hdi..lrinistt of lLilstvs
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EPBX {0522)
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Flr 0522) 2458500 DrD 10522) 2,165310

No. CT/Specif ication/T-1 2 Dated: 04.034)19

As per list enclosed

Sub:Addendum and Corrigendum Slip to Specification fol FH Bolbm

Rails - IRS T-12:2009.

Ref: (i) Railway Board's letter no. Tacv21l201v0513fltm W

06.07.2018
(ii) This ofiice letter of even no. dated 18.05.2018

Please find enclosed herewith Addendum and Corrigendum Slip No- 4 to

Indian Railway Specification for Flat Bottom Rails, IRS T-'12:2009.

DA: 28 Pages

(Nilmani)

For Director GenerauTrack

 ADDENDUM & CORRIGENDUM SLIP NO. 4

TO

INDIAN MILWAYS STANDARD SPECIFICATION FOR FLAT BOTTOi'I RAIL

IRS T-12:2009 DATED 0/ry03/2019

The following clauses of lndian Railway Specification IRS-T-12-2009 for Flat Bottom Rail
are amended as under:

Sr. Clauses and ltems

no.
2 Rail section
The Section of the flat bottom rails shall be in accordance with the section
profiles shown in Appendixl, ll(Revised), llA and lll, unless otherwise specified
by the purchaser.

2. 4.4 Classification of rails

52 kg/m, 60E1, 68 kg/m & ZUI -60 rails shall be classified as class 'A' ano class
'B' based on tolerance in end straightness as specified in Clause 9.4.2.

3. 6 TNFORMATION TO BE SUPPLIED BY THE PURCHASER

The purchaser shall provide the following information to the supplief when
inviting tender for supply of rails according to this specification:
i) Rail steel grade (Table 1)
ii) Rail Section profile (Appendix I, ll(Revised), llA and lll)
iii) Class of rail
iv) Length of rail. .
v) Undrilled or drilled rails ends.
vi) Colour code requirements (Appendix lV)

4. 8.1 Brand Marks

With the prior approval of purchasers, brand marks of suitable size clearly
legible, shall be rolled in relief on one side of web atleast at every 4.0 meter
interval. The brand mark shall include.
a) The rail section.
b) The grade of steel, i.e.
880
Grade 880
GradeloSoHH 1080HH
GradeloSocr 1080 CR

Page 1of 28
 GradeSS0Cu-MO 880 CM
GradeS8oNi Cr Cu 880 NC
GradeSSovanadium 880VN
Grade 880 Niobium 880 NB
c) ldentification mark of the manufacturer
d) Month (using roman numbers) and last two digits of year of manufacture.
e) Process of Steel making
i) Basic Orygen - O
ii) Electric - E

5. 8.2 Hot Stamping

Each rail shall be identified by a numerical, alphabetical or combined alphabetical

and numerical code which will be distinctly hot stamped at least onc€ every 5.0m
on the web in figures and letters of suitable size from which following information
can be obtained:
i) The number of the cast from which the rails has been rolled with letter'C'
ii) Number of the strand
iii) For rails from change over bloom, cast number should be the preceding
cast number with Drefix letter'8.
Alternatively, the identification system employed shall be such as to enable the
hot stamped marking to be collated with the:
a) number of the heat from which the rail has been rolled;
b) number of the strand and position of bloom within the strand;
c) Position of the rail in the bloom (A, B ... Y).
Further, in the event of identification marks having been removed, omitted or
requiring alteration, re-identification of such marks shall be made by rotary bun.

b- 8.3 Cold Punching

8.3.1 Following should be cold punched on one of end face of each rail;
a) Inspecting Agency lD and Group lD
b) Shift No in which product inspected
c) Date of Inspection
Alternatively, any other method of marking/identification of rail can be adopted
containing above information on one of end face of each rail.
To avoid damage to the HH rails, instead of cold punching, any other method of
marking/identification on one of end face of each rail containing above
information can be adoDted.

7. 9.1 Permissible Variations in Dimensions

The tolerances in sectional dimensions shown here under shall be allowed,

provided,
For Prime quality rail the actual weight computed by weighing short pieces of
rails, not less than 300mm each in length, shall fall within 0.5 percent below and
'1.spercent above the calculated weight shgwn,ln Appendix l, ll(Revised), llA and

Page 2 ot 28
lll for each rail section.
For lU Rail the actual weight computed by weighing short pieces of rails not less
than 300 mm each in length is not less than the calculated weight shown in
Appendix l, ll(Revised), llA and lll of this specification for each section of rail by
moIe than 1.5%.
The weight test shall be conducted for each rail section, grade and class atleast
once per 5000 MT quantity.

9.1.1 Tolerances in sectional dimensions (For Prime Quality rails)

For profile as per Appendix l, ll-A, lll

Overall Height +0.8 mm

of Rails -0.4 mm

This will be measured 14mm below the rails

top.

Width of flange For section less than 60Kg/m

For sections 60kg and above

This will be measured at the ooint of

minimum thickness

Measured by gauge shown in App. V)

The base of the rail shall be kue and flat, but a slight
cbncavity not exceeding 0.40mm shall be permissible.

Fishing surface The standard template for rail fishing surface shall not
stand away from the contour of web by more than 1.20mm
and the clearance at the fishing surfaces shall not exceed
0.2mm at any point.

For profile as per Appendix ll(Revised) (Prime Quality rails)

*Reference Points(see Proiile Gauge/figure
(tolerance numoer(see
in mm) Annex A)

Heiqht of Raila

Page 3 of 28
 Width of railhead

Height of fishing

Width of Rail foot

Foot toe thickness

total height variation over any rail length shall not be greater than 1.2
mm for rails > 165 mm.
Measurement will be done as per inspection gauges at Annexure-A

9.1.2 Tolerancea in sectional dimensions (for lU rails)

For profile as per Appendix l, l|-A, lll

Dimension Tolerance Remarks
Overall Height of +2.0 mm
Rails -1-0 mm
Width of Head +2.0mm " This will be measured 14mm below the
rails top
-2.0mm
Thickness of +2.0 mm This will be measured at the Doint of
* weo -1.0 mm minimum thickness
Width of flanoe +1.5 mm
-2.0mm
Flange The base of the rail shall be true and flat, but a slight
concavity not exceedinq 0.40mm shall be permissible.
Fishing surface The standard template for rail fishing surface shall not
stand away from the contour of web by more than
'l.20mm and the clearance at the fishing surfaces shall
not exceed 0.2mm at any point.

Page 4 of 28
 For profile aa per Appendix ll(Revised) (lU rails)
Sr. *Refsrence Points(see Profile Gauge/ figure number
No lioure A1) (tolerance In (see Annex A)
Location/ Symbol mm)
oroDeny
1 Height of +0.6 A3
Raila
2 Crown 10.6
Profile

width of +0.6 A5
railhead -0.5
*As A6,A7
4 Rail
Asymmetry
Height of -HF +0.6 A8
fishing
o Web +1.0 A9
thickness -0.5
7 Wdth of +1.5 410
Rail foot -1.0

8 Foot toe *TF +0.75 All

thickness -0.5

o Foot base 0.3 max.

c,oncavity

"The total height variation over any rail length shall not be greater than 1.2
mm for rails > 165 mm.
Measurement will be done as per inspection gauges at Annexure'A

10.
10.3 The manufacturer in his offer shall furnish the detailed method of on-line
ultrasonic testing of rails to be followed by him. The limits of permissible defects
for ultrasonic testing of rails shall be as follows and the standard test piece shall
be as shown in drawing of Appendix-Vu1 and Appendix-Vl/2 for symmetric rail
Head: 1.5 mm dia FBH at two locations
'l.smm dia and 2.omm dia through holes
Web: 2.0 mm dia FBH at four locations
Web & foot junction: 2.0 mm dia drilled hole
Foot: 2.0 mm dia horizontal hole (both side)
The limits of permissible defects for ultrasonic testing and standard test piece of
asymmetric rails shall be as shown in drawing ofAppendix-Vl A.

A-
All Flash Butt Welds executed bv the manufaclurer for welding of rails in to lonq

Page 5 of 28
panels shall be subjected to ultrasonic testing along with other acceptance
criteria as per provisions of Manual for Flash Butt Welding of Rails, 2012 with
latesl amendment.

10.4 Eddy Current Tosting

The manufiacturer should have eddy current testing covering bottom area of the
rail as also the lop surfiace and sides of surface head. The ECT Drobes should
cover complete area of rail bottom and at least 80% area of top surface and
sides of the head.
The equipment used shall be able to detect artificial imperfections on the
underside of the rail foot with sizes as shown in below table. For artificial
imperfections, a tolerance ofl0.1 mm shall apply:

13 QUALIFYING CRITERIA

The following test shall be done for each railrsection, grade and class after any
change in the process of manufacture which may affect the results or annually for
first three years for each contract. The first set of tests would be conducted Drior
lo commencement of production for supply of rail under the contract and will be
witnessed by purchaser or his nominated inspecting agency. lf results of these
three years are consecutively found satisfac{ory, this frequency may be relaxed
to three years by Purchaser. The test shall be undertaken by the supplier to
demonstrate compliance with the qualii/ing criteria. lf so desired, the purchaser
/lnspecting Agency should be provided all facilities to check the sample and
witness the test.
a) Residual stress measurement.
b) Fracture toughness measurement
c) Fatigue test
The samples for these (ests shall be collected from finished rails. These samotes
shall not be subjected to any further mechanical or thermal treatment. The resrs
shall be carried out by an accredited/recognized laboratory approved by the
purchaser and the test results shall be reported to the purchaser. The purchaser
shall have access to alltest records, calibrations and calculation which contribute
to the final results.
In case any sample fails to meet the rcquirement laid in the qualifying criteria the
manufacturer shall review its process of manufacturing within six months to
eliminate any shortcomings and fresh qualirying criteria test shalt be undenaKen
under intimation to the Purchaser.

Page 5 of
t3 20 FALLING WEIGHT TEST
20.1 Nature of Test
20.1.1 The single guided falling weight test shall be carried out, the minimum
height of the drop (in m) varying in relation of the mass per unit length of the
profile Mr (in Kg) and the mass ofthe falling weight selected M. (in Kg) according
to the formula-
. H=150![r
M.
Falling weight test piece minimum 1.3 melers long shall be cut from a location as
per choice of the Inspecting Agency. For heat treated rails, the sample shall be
taken after heat treatment. The test piece shall be placed in horizontal position
with the head up on two iron or steel supports resting on a solid metal anvil. The
weight of the meial anvil block shall not be less than 10,000 kg and its supporling
base would be sufficiently rigid. No timber or spring shall be permitted between
the rail supports and the anvil or between the anvil and the foundation. Block
guides shall be provlded which shall permit free fall of the weight. The upper
surface of the supports shall be curved to a radius of not more than 125 mm.
One blow shall be delivered midway between the supports, by means of a freely
falling iron weight or 'TUP', the striking face of which shall be rounded to a radius
of not more than 125mm. The weight of the "TUP', the distance between the
centre of the bearings, the height between the surface of the rail and the bottom
of the 'TUP", before the latter is released shall be as specified in table4.
Table - 4
Rail .Weight of *'Distance beiween Height ofdrop (m)
section TUP (Kg) centers of bearers(m)
52ko '1000 1.00 Measured from the top of
60ks 1000 1.00 the rail head and variable
60El 1000 1.00 accoding to the above
zu-1-60 '1000 1.00 formula.
68kq 1000 1.00
'100OKg in principle but it may be vary according to the formula above
**1.00 m in principle but may vary between 1.00 m and 0.85 m
Note- The value of the height should be rounded to the nearest first digit of
decimal.

20.3 Resulb to be Obtained

20.3.1 The blow shall be sustained without fracture or crack. and the permanent
set resulting from the blow shall be measured after every test, over the specified
distance between the centres of the bearer and recorded and advised to the
DUrcnaser.

14. 21: Determination of Hydrogen Content

Vacuum degassing of liquid steel shall be done to reduce the hydrogen content.
For this purpose, RH degasser or REDA (Revolutional Degassing Activator) shall
be used. All measuremenl of hydrogen shall be done for the liquid sleel in
tundish or mould.

Page 7 of 28
 2'1.1 The measurement of hydrogen shall be done by following method:
On-Line/lnstantaneous Method-
HYDRIS is approved as method of oniine instantaneous measurement. The
method of measurement as prescribed by the manufacturer of HYDRIS system
shall be adopted.

21.2 The level of hydrogen measured by the method described under Para 21.1
above shall be 1.6 Dpm maximum for acceotance of a heat for Droduction of rail.
't5 22.1 Rgsidual stress in rail foot

22.1.1 Test method

The residual stresses in the rail foot shall be determined in accordance with
APPENDIX.XIII-
22.1.2 Test oieces
For residual stress tests, there shall be 6 sample rails and the test pieces shall
be taken at least 3m from each lail end. Each of the 6 test pieces from the rail
section shall be 1 m in length.
NOTE- Only a small part of the test piece will be destroyed for the purpose of
measuring residual stress; the remainder can be used for other qualifying
approvaltests.
22.1.3 Measurements
Longitudinal residual slress determinations shall be made on the rail foot of each
of the 6 test pieces described in 22.1.2. fhe location of the measurements is
shown in Figure 9(A) & 9(B).

.F'
IS STRAIN GAUGE LOCATION

Page 8 of 28
 S'IS STRAIN
GAUGE
tOCATION.

F
Fig.98

Dimensions in millimeters
a

gauge, 4 rail foot

69]f 1 centre line, 2 saw cut, 3 strain
Fig. 9C- Slice removed from the rail
22.'1.4 Qualirying criteria
The maximum longitudinal residual stress in the foot shall be 250 MPa for all
steelqrades.
,16. 22.3 Fatigue test

22.3.4 Each sample should endure 10 million cycles at strain of 0.00135 for
880grade rails. For rails of grade 1080 the each sample should endure lomilion
cycles at strain of 0.00166. Testing shall be done in such a way that peak strain
shall be 0.00135 in tension and 0.00135 in compression for 880grade rails. For
rails of grade 1080 the peak strain shall be 0.00166 in tension and 0.00166 in
comDression.
,t7. 25.3 lmport Shipment
The rails shall be loaded in bundles of three rails each bundle containing one rail
upside down placed in between two rails snugly fitting and suitable tied by M.S.
straps at four or more places along the length of rails so that they will not get
loosened during their lransportation from manufactureis place to site of work.
Altematively, manutaciurer may supply loose rails i.e. single rail without bundling.
'The manufacturer shall supply rail handling equipmenb free of charge in
sufficient numbers to the satisfaction of purchaser so that unloading/ loading of
rails is not delayed on this account.

,
|
d,.' '/'-' Page 9 of 28
 Appendix ll (Revised)

60El (as per EN 1367+1:2011+41t2O17(E l

Ey
1 ..rcrrlirrofbodi4
ctrols-taatoal arar 1 7d|,70 .!2
Ee IEAE|,Ea I f,.PL fab
|!6tni dirad.:-! ci: : 303&3 cia4
iatt6 &addli - Saad : :}'36 rDt
racfiod DoiHlr - Sara : :rr55 lr!3
. E@rd ef irdn yt|ris : $ag 64
Lati|EDr|!l[sryrri! : 6&3 .s3
ir.lidiirr diErrEkr!5r it = 20,.t56 uD
I = 52J53 Ee

Page l0 of 28
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 Appendix- Xlll

Method for the determination of rail foot surface longitudinal residual stresses
1. Procedure
Residual stresses shall be estimated by first attaching an electrical strain gauge on the rail
foot surface. The surface to which the gauge is attached shall be progressively isolated
from the rail and the relaxed strains shall then be used to estimate the stresses which have
been relieved whilst the original residual stresses are taken to be lhose values but with a
change of sign.
2. Strain gauges and their location

Electrical strain gauges of the encapsulated type shall be used, 3 mm in length with gauge
factor accuncy of better than * 1 %.
The strain gauge shall be attached to the surface of the rail fool in order to measure
longitudinal strain at the positions as shown in Figure Fig. 9A & Fig. 98. The surface of the rail
foot shall be prepared and the stEin gauge shall be attached, in accordance with the
recommendations of the strain gauge manufacturer.
Any surface preparation shall not result in a change of the residual stresses in the rail foot.

NOTE- The strain gauge should be located at the centre of the 1 m lenglh of the sample rail
set aside for this work.
Readings shall be taken from the strain gauges. While cooling the rail to maintain a constant
temDerature. two saw cuts shall be made to remove a 20 mm thick slice from the centre of the
rail length (Fig. 9C). A second set of measurements shall be taken.
The residual stresses shall be calculated from the differences between the first and second
sets of measurements of relieved strains by multiplying with Young's modulus of elasticity for
steel i.e. 2.05X106 kg/cm2.

(-,--.-'
t.y'
t,/
//-

Page 13 of 28
 Annexure-A

l$

Tatb A- Rail transition leferences {see Figurg A)

Rail Dimension ih mm
p|ofile h1 h2 h3 t2 L3 u1 !2 U3

60E1 52.O5 72.N 14.30 12.00 118.57 101.50 87.06 36.61 4.25 3.20 26.83 4.25 3.20

Figure A- Principal rail tlansition references

v
v
Page t4 ol28
 Gauges for inspection

The gauges for manufacture as specified in clause 9.1.1 and 9.1.2 for 60El profile as per
appendix ll (Revised) are summarised In Table 41

Table Al Summary of figures

-
Datum references for tolerances

Datum references for decision

Width or rail head

Fioure AO and A7

Fioure Al l Foot toe thickness

Figure A12 and 413 Drilling gauges

I
t' .t"

Page 15 of 28
)Fiqure Al- Datum refercnces for tolerances (Soe Para 9.1.1. 9"1.2. Fiourc-A and Table-Al

Page 16 of28
Datum Reforcnce Fiqure No,
0 height - must not A3
+ must pass
0 crown orotile - must A4
+ must not Dass the wedoe
1 width of rail head - must not A5
+ must touch
2 rail asymmetry - must not 46, A7
+ must touch
4,5 height offishplating - must A8
+ must not touch
web thickness - must not A9
+ mu$ Dass
3,6 -
foot toe thickness must be All
within * limits
6 width of rail foot - must not A10
+ must Dass

Fiqure A2 Datum refercnces for decision

-

Page 17 of 28
Fiqure A3- Heioht of Rail

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LI
Page 18 of 28
 ( 3 20 20
t-
I I
I

.,.,;-T-
K€Y-

1 Maximum width of rail head tolerance

2 Theoretical Droflle
3 Step gauge to check the table shape, 1omm thickness

Fioure A4- Crown Profile

Page 19 of 28
Fiqure A5- Width of Rail Head

Page 20 ol2A
 Escle A6i-BeilAg@trt

! PaEe 2l ot 28
 \v
)

Page 22 ot 28
c{
N

I :'
Nt
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1 HF= Fishing heoht (see Figure Al) and

2 h 3= Theoretical
Fiourc A8- Flshino Heloht

Page Zl of 28
Floure A9- Web Thickness

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Page 24 of 28
Page 25 of2E
a=+Tolerancexn
b--Talerancexn

Pate 25 of 28
 +
I

Kgy- WT- web thickness

Fiqure Al2- Gauoe for checkinq distance between holea and rail end and hole
diameter

Page 27 oJ 8
 t-

(c]C Wf= width of foot, WT= web thickness, Z= distance b€tween cenler of the hole and
base of the rail

Page 28 of 28