RDSO/Infra-II/B&S/RG/PG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD RAILWAY PLATE GIRDER

PART-A (TOP SHEET)

S.No. Item Details
1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/RG/PG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication.
13 Scope of fabrication in MT (Only Railway Plate Girders)
14. GAD Approved by
15 RDSO Drawing Nos. used.
16. Specifications

Note:- It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/RG/PG

PART B - MODEL QAP

Sl. Component / Characteristi Frequency & Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. Operations c to be type of Document Quality Inspecting Extent of record
checked check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Plates Identification As per Mill Challan, Mill Verification Zonal 100% Fabricator's 1) Steel Plates: IS 1. Grade and
and other and Co- Test T.C. of reference Railway/ Record 2062:2011 Quality of Steel
Structural relation with Certificate & documents Railway Grade E250 Quality Plates, structural
Steel Mill Test test required PSUs B0 as mentioned in the section to be
Sections Certificate by Zonal respective approved same as
from Supplier. Railway or drawing. mentioned in the
Source/Brand Railway PSU 2) Plates 12mm and respective
of steel to be from above thick are fully approved
decided as approved killed/normalized or drawings
per prevailing Laboratory/ control cooled. 2. For other
instructions Govt. 3) Rolled Sections or details of
issued from approved any other structural structural steel
Railway Laboratory/ steel member: IS plates and
Board. NABL/ 2062:2011 structural section
NABCB. Grade E250 Quality A&C no. 5 of IRS-
B0 as mentioned in the B1: 2001, IS
respective approved 2062-2011 and
drawing. codes referred in
these shall be
complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board.
 RDSO/Infra-II/B&S/RG/PG

Physical Visual -- Complete 100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Zonal Record 2000, IS 2062-2011
Pitting, inspection Railway/ and codes referred in
rusting, Railway these shall be
straightness PSU complied as applicable
,rolling
defects etc.

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per approved Report Railway/ notes below and other
IS-2062:2011 laboratory/ Railway relevant clauses of IS-
UTS,YS,%EL, Govt. PSUs 2062-2011 and codes
Bend Test approved referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.

Charpy Test Lab test at - Lab Test Zonal Heat / Cast -

at 0 ° C for approved Report Railway/ no. section
plates 12 mm laboratory/ Railway wise as per
thick and Govt. PSUs IS 2062-
above approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no. section notes below and other
per IS 2062- laboratory/ Railway wise as per relevant clauses of IS-
2011 Govt. PSUs IS 2062- 2062-2011 and codes
approved 2011 referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.
 RDSO/Infra-II/B&S/RG/PG

Ultra sonic By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM SA-
test for level- II Report Railway/ 435/435M and codes
12mm and operator Railway referred in it as per
above thick PSUs applicability
plates as per
IS-
4225/ASTM
SA-435/435M

Dimension Measurement Challan Measuremen 100% Fabricator's IS 2062: 2011 or other

t of Record & relevant codes
dimension Zonal referred in it as
Railway applicable
Record

1.2 HSFG Bolts Dimensions Visual / Challan and Verification Zonal As per BS- Fabricator's As per BS – 111 Procure from
with DTI Measurement Manufacture of reference Railway/ 111 (Latest Record (Latest revision) RDSO approved
washers r's Test Documents Railway revision) Vendor only.
Certificate PSUs

Mechanical & T.C. And Manufacture Verification Zonal

Chemical tests r Test of reference Railway/
properties required from Certificate Documents Railway
Govt./NABL/ PSUs
NABCB
approved lab
as per BS-
111 (Latest
revision)
 RDSO/Infra-II/B&S/RG/PG

1.3 Paints and Verification of Visual Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:5666, Test at the
Primers Manufacturer' Manufacture of Reference Railway/ er's Test IS:51, IS:104, IS:2339 approved
s Test 's Test Documents Railway Certificate and applicable codes laboratory
Certificate, Certificate PSUs referred in these codes suitable for the
Inspection purpose shall be
Certificate, done as per the
Challan instruction of the
Tests as per Lab test at Challan , Verification Random Lab Test Zonal Railway/
specification approved Manufacture of Reference Report Railway PSU
laboratory 's Test Documents
Govt. Certificate
approved
Laboratory/
NABL/
NABCB
1.4 Aluminium Properties of Review of Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:2590 Test at the
wire Aluminium reference Manufacture of Reference Railway/ e's Test and applicable codes approved
wire such as documents 's Test Documents Railway Certificate referred in these codes laboratory
Dia, class and with material Certificate PSUs suitable for the
purity as purpose shall be
mentioned in done as per the
appendix-VII instruction of the
of IRS B1- Zonal Railway/
2001 Railway PSU
Tests as per Lab test at Challan , Verification Random Lab Test
specification approved Manufacture of Reference Report
laboratory 's Test Documents
Govt. Certificate
approved
Laboratory/
NABL/
NABCB
1.5 Welding As Per Any Test as Challan & Verification Zonal As per Fabricator's IRS Welded Bridge As per
Consumables Specification required Manufacture of reference Railway/ requiremen record Code 2001, IRS M28, specification and
and r's Test Documents Railway t IRS M39, IRS M46 WPSS
approved Certificate PSUs and other applicable
WPSS codes referred in these
codes and
specifications
 RDSO/Infra-II/B&S/RG/PG

Sl. Component / Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked type of check Document Quality Inspecting Extent of record Criteria
Control agency Inspectio
n
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturing
Process
2.1 Layout Dimension Measurement Approved Measurement RDSO 100% Inspection Approved
with calibrated Drawings of Report of fabrication
steel Tape dimensions Inspection Drawings and
officials relevant IS/IRS
codes.

2.2 Master Plates Dimension, Measurement Approved Measurement RDSO 100% Record for Approved
intersection with calibrated Drawings of Master Plates fabrication
line,pitch, steel Tape & dimensions on proforma drawings, IRS
gauge, Dia. of gauges. same as of B1-2001 and
holes & No. of Appendix I(1) BS-110 (Latest
holes. proforma given revision)
in IRS B1-
2001
2.3 Preparatory Dimension , Visual / Inspection Visual & 100% Inspection Approved --
work such as freedom from Measurement Report of Measurement Report of fabrication
Cutting, defects with master Inspection of Inspection drawings, IRS
Straightening, plates and officials & dimensions officials & B1-2001, IS-
Edge templates fabricator's fabricator's 1852-85 and
Preparation, record record codes referred
Marking, Zonal Railway/ in these codes
Drilling, Fit up, Railway PSUs as applicable
Pre-assembly,
End finishing
 RDSO/Infra-II/B&S/RG/PG

Sl. Component Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. / checked & type of Document Quality Inspecting Extent of record Criteria
Operations check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.0 Welding
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to be
WPSS IRS B1-2001, Reference Record fabrication performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes B1-2001, IRS specification
referred in WBC-2001 and and
these codes codes referred parameters
as applicable in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), Only RDSO
established and NDT at Requirement of Reference Sheet to be IS 7310 (Part-1), certified
WPSS. 2. approved Documents recorded in IRS B1-2001, welders to be
Witnessing of laboratory presence of IRS WBC-2001 engaged in the
Welder Govt. RDSO and codes job
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB

3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Reference Railway/ Report of B1-2001, IRS
Chalk or Documents Railway Inspection WBC-2001 and
Infrared PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/PG

3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, moisture free of Electrodes Manufacture' of Reference Railway/ Report of and other
flux electrode and and heating s Documents Railway Inspection applicable
flux Recommend PSUs officials & codes.
ation fabricator's
record
3.5 Selection Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per WPSS
of Correct WPSS. Approved of Reference Railway/ Report of Bridge Code and other
Electrodes WPSS Documents Railway Inspection 2001, IRS M28, codes
& flux PSUs officials & IRS M39, IRS applicable.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Reference Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Documents Railway Inspection WBC-2001 and codes
PSUs officials & codes referred applicable.
fabricator's in these codes
record as applicable

3.8 Sequence Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
of Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable

3.9 Provision To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
of Run-on defects Approved Reference Railway/ Report of B1-2001, IRS
and Run- WPSS Documents Railway Inspection WBC-2001 and
off Plates PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/PG

Sl. Componen Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. t/ to be checked & type of Document Quality Inspecting Extent of record Criteria
Operation check Control agency Inspection
s
1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection For Fillet Visual, Approved Visual RDSO 100% Fabricator's Approved It is to be
of Welded Welds - Visual, Gauge and fabrication Inspection & Record fabrication ensured during
componen D.P. Test, Fillet Macro Drawings & Verification Drawings, IRS fabrication
ts Size, etching WPSS of Dimension B1-2001, IRS process that
Penetration, Leg by Gauge WBC-2001 and fabrication has
length, Throat codes referred been done as
thickness etc. in these codes per the WPSS
. as applicable approved by
RDSO and
Welders
approved by
RDSO. This is
to be ensured
by Zonal
Railway/
Railway PSUs
and certificate to
this effect (By
Minimum JAG
officer) shall be
given in the form
of four point
certification
along with
inspection call
raised to RDSO
 RDSO/Infra-II/B&S/RG/PG

5.0 Inspection a) Overall length Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. RDSO
of first b) Bearing Dimensiona Drawings Dimensional Report of IRS WBC-2001 inspection call to
span in centres l Check of Inspection and applicable be raised by
assembled c) Height Assembly officials & codes referred Zonal Railway/
condition d) Girder fabricator's in these codes. Railway PSUs
Centres record in the form of 4
e) Squareness point
f) Verticality certification
g) Camber on after
Jack (if provided
satisfactory
in drawing.)
h) Dead Load quality checks.
deflection 2. Assembly
(Camber without shall be done in
Jack if provided Workshop of
in drawing ) fabricator only.
i) Dimension Fabricator shall
j) Fairness of ensure that
Holes sufficient space
k) Temporary is available in
fasteners workshop for
l) Any assembly before
Infringement finalizing the
m) Butting of order of
compression fabrication for a
members particular span.
 RDSO/Infra-II/B&S/RG/PG

6.0 Inspection i) Overall Visual, Stage clearance Verification RDSO 100% Inspection IRS B1-2001, 1. All spans are
of length ii) Dimensiona Record of Stage Report of IRS WBC-2001 to be checked in
Componen Bearing l& clearance Inspection and applicable leaf assembled
ts of centres Structural Record officials & codes referred condition
nd
2 span fabricator's in these codes. 2.RDSO
iii) Height
onwards record inspection call to
iv) Girder be raised by
Centres Zonal Railway/
v) Squareness Railway PSUs
vi) Verticality in the form of 4
vii) Camber if point
provided in certification
drawing after
viii) Dimension satisfactory
ix) Fairness of quality checks.
Holes
x) Butting of
compression
flanges
 RDSO/Infra-II/B&S/RG/PG

7.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001 1. Clearance
Preparatio condition after checking Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII shall be given
n by blasting with Drawing & IRS - clearance Random by IS: 6586, by Zonal
Blasting & reference B1-2001 and Record Zonal IS:5905 , Railway/
Metalizing to surface codes referred Railway/ IS:2590 and Railway PSUs
preparation in these Railway codes referred
PSUs in these codes
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's
after metalizing checking Fabrication of Stage Railway PSUs fabricator & Record
Drawing & IRS - clearance Random by
B1-2001 and Record Zonal
codes referred Railway/
in these Railway
PSUs
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of Stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and Record
codes referred
in these
 RDSO/Infra-II/B&S/RG/PG

8.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking Fabrication of stage Railway PSUs fabricator & Record and appendix
painting with Drawing & IRS - clearance Random by VII of IRS B1-
reference B1-2001 and records Zonal 2001, IS: 5666,
to surface codes referred Railway IS:51, IS:104,
preparation in these IS: 2339 and
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's applicable
after painting checking Fabrication of stage Railway PSUs fabricator & Record codes referred
Drawing & IRS - clearance Random by in these codes
B1-2001 and records Zonal
codes referred Railway
in these
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and records
codes referred
in these
9.0 Final 1. Shipping Visual Fabricator's Zonal Railway/ Random Approved Approved Site Painting is
Dispatch Mark on all Record Railway PSUs Fabrication Fabrication to be done after
including Components as Drawing & Drawing & assembly and
packing, per Approved Fabricator's Clause 42, 43 erection of
Shipping Fabrication record and 44 of IRS - girder on site as
mark and drawings B1-2001 and per IRS B1-
loading 2. Fixing of codes referred 2001
etc. Inscription Plate in these
3. Packing
4. Loading
Note: During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per approved
WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to RDSO for
Assembly or components inspection etc.
 RDSO/Infra-II/B&S/RG/CG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD RAILWAY COMPOSITE GIRDER

PART-A (TOP SHEET)

S.No. Item Details
1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU.)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/RG/CG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication.
13 Scope of fabrication in MT (Only Railway composite Girders)
14. GAD Approved by
15 RDSO Drawing Nos. used.
16 Specifications

Note:- It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/RG/CG

PART B - MODEL QAP

Sl. Component Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. / Operations to be checked type of Document Quality Inspecting Extent of record
check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Plates Identification As per Mill Challan, Mill Verification Zonal Fabricator's 1) Steel Plates: IS 1. Grade and
and other and Co- Test T.C. of reference Railway/ 100% Record 2062:2011 Quality of Steel
Structural relation with Certificate & documents Railway Grade E250 Quality Plates, structural
Steel Mill Test test required PSUs B0 as mentioned in the section to be
Sections Certificate from by Zonal respective approved same as
Supplier. Railway or drawing. mentioned in the
Source/Brand Railway PSU 2) Plates 12mm and respective
of steel to be from above thick are fully approved
decided as per approved killed/normalized or drawings
prevailing Laboratory/ control cooled. 2. For other
instructions Govt. 3) Rolled Sections or details of
issued from approved any other structural structural steel
Railway Board. Laboratory/ steel member: IS plates and
NABL/ 2062:2011 structural section
NABCB. Grade E250 Quality A&C no. 5 of IRS-
B0 as mentioned in the B1: 2000, IS
respective approved 2062-2011 and
drawing. codes referred in
these shall be
complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board.
 RDSO/Infra-II/B&S/RG/CG

Physical Visual -- Complete 100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Record 2000, IS 2062-2011
Pitting, rusting, inspection Zonal and codes referred in
straightness, Railway/ these shall be
rolling defects Railway complied as applicable
etc. PSUs

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per IS- approved Report Railway/ notes below and other
2062:2011 laboratory/ Railway relevant clauses of IS-
UTS,YS,%EL,B Govt. PSUs 2062-2011 and codes
end Test approved referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.

Charpy Test at Lab test at - Lab Test Zonal Heat / Cast -

0 ° C for plates approved Report Railway/ no. section
12 mm thick laboratory Railway wise as per
and above Govt. PSUs IS 2062-
approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no. section notes below and other
per IS 2062- laboratory Railway wise as per relevant clauses of IS-
2011 Govt. PSUs IS 2062- 2062-2011 and codes
approved 2011 referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.
 RDSO/Infra-II/B&S/RG/CG

Ultra sonic By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM SA-
test for level- II Report Railway/ 435/435M and codes
12mm and operator Railway referred in it as per
above thick PSUs applicability
plates as per
IS-
4225/ASTM
SA-435/435M

Dimension Measurement Challan Measurem 100% Fabricator's IS 2062: 2011 or other

ent of Record & relevant codes
dimension Zonal referred in it as
Railway applicable
Record

1.2 HSFG Bolts Dimensions Visual / Challan and Verification Zonal As per BS- Fabricator's As per BS – 111 Procure from
with DTI Measurement Manufacturer's of Railway/ 111(Latest Record (Latest revision) RDSO approved
washers Test Certificate reference Railway revision) Vendor only.
Documents PSUs

Mechanical & T.C. And Manufacturer Verification Zonal

Chemical tests Test Certificate of Railway/
properties required from reference Railway
Govt./NABL/ Documents PSUs
NABCB
approved lab
As per BS –
111 (Latest
revision)
 RDSO/Infra-II/B&S/RG/CG

1.3 Paints and Verification Visual Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS: 5666 Test at the
Primers of Manufacture's of Railway/ er's Test IS: 51, IS: 104, IS: approved
Manufactur Test Certificate Reference Railway Certificate 2339 and applicable laboratory
er's Test Documents PSUs codes referred in these suitable for the
Certificate, codes therein. purpose shall be
Inspection done as per the
Certificate, instruction of the
Challan Zonal Railway/
Tests as Lab test at Challan , Verification Random Lab Test Railway PSU.
per approved Manufacture's of Report
specificatio laboratory Test Certificate Reference
n Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.4 Aluminium Properties Review of Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:2590 Test at the
wire of reference Manufacture's of Railway/ e's Test and applicable codes approved
Aluminium documents Test Certificate Reference Railway Certificate referred in these codes laboratory
wire such with material Documents PSUs suitable for the
as Dia, purpose shall be
class and done as per the
purity as instruction of the
mentioned Zonal Railway/
in Railway PSU.
appendix-
VII of IRS
B1-2001
Tests as Lab test at Challan , Verification Random Lab Test
per approved Manufacture's of Report
specificatio laboratory Test Certificate Reference
n Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.5 Welding As Per Any Test as Challan & Verification Zonal As per Fabricator's IRS Welded Bridge As per
Consumables Specificatio required Manufacturer's of Railway/ requiremen record Code 2001, IRS M28, specification and
n and Test Certificate reference Railway t IRS M39, IRS M46 WPSS.
approved Documents PSUs and other applicable
WPSS codes referred in these
 RDSO/Infra-II/B&S/RG/CG

codes and
specifications

1.6 Stud Visual Test as Approved 100 % Zonal 100% Test Approved Fabrication
Inspection , mentioned in Fabrication Visual Railway/ Reports & Drawing, IS 9595-96,
dimensions BS 115 Drawings and inspection Railway Fabricator IRSB1-2001 and
inspection (Latest WPSS & PSUs report codes as applicable
Revision) verification instructions issued by
of Railway Board also to
dimension be followed.
by gauge
and test
record
2.0 Manufacturing
Process

2.1 Layout Dimension Measurement Approved Measurem RDSO 100% Inspection Approved fabrication
with Drawings ent of Report of Drawings and relevant
calibrated dimensions Inspection IS/IRS codes.
steel Tape officials
2.2 Master Plates Dimension, Measurement Approved Measurem RDSO 100% Record for Approved fabrication
intersection with Drawings ent of Master drawings, IRS B1-
line, pitch, calibrated dimensions Plates on 2001 and BS-110
gauge, Dia. steel Tape & proforma (Latest Revision)
of holes & gauges. same as of
No. of Appendix
holes. I(1)
proforma
given in
IRS B1-
2001
 RDSO/Infra-II/B&S/RG/CG

2.3 Preparatory Dimension Visual / Inspection Visual & 100% Inspection Approved fabrication --
work such as , freedom Measurement Report of Measurem Report of drawings, IRS B1-
Cutting, from with master Inspection ent of Inspection 2001, IS- 1852-85 and
Straightening,
defects plates and officials & dimensions officials & codes referred in these
EdgePreparatio Zonal
n,Marking,Drillin
templates fabricator's fabricator's codes as applicable
record Railway/ record
g, Fit up,Pre- Railway
assembly, End
PSUs
finishing

Welding
3.0
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to
WPSS IRS B1-2001, Reference Record fabrication be performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes B1-2001, IRS specification
referred in WBC-2001 and and
these codes codes referred parameters
as applicable in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), Only RDSO
established and NDT at Requirement of Reference Sheet to be IS 7310 (Part-1), certified
WPSS. 2. approved Documents recorded in IRS B1-2001, welders to be
Witnessing of laboratory/ presence of IRS WBC-2001 engaged in
Welder Govt. RDSO. and codes the job
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB
 RDSO/Infra-II/B&S/RG/CG

3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Reference Railway/ Report of B1-2001, IRS
Chalk or Documents Railway Inspection WBC-2001 and
Infrared PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable

3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, flux moisture free of Electrodes Manufacture' of Reference Railway/ Report of and other
electrode and and heating s Documents Railway Inspection applicable
flux Recommend PSUs officials & codes.
ation fabricator's
record
3.5 Selection of Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per WPSS
Correct WPSS. Approved of Reference Railway/ Report of Bridge Code and other
Electrodes & WPSS Documents Railway Inspection 2001, IRS M28, codes
flux PSUs officials & IRS M39, IRS applicable.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Reference Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Documents Railway Inspection WBC-2001 and codes
PSUs officials & codes referred applicable.
fabricator's in these codes
record as applicable

3.8 Sequence of Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/CG

3.9 Provision of To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
Run-on and defects Approved Reference Railway/ Report of B1-2001, IRS
Run-off Plates WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/CG

Sl. Componen Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. t/ to be checked & type of Document Quality Inspecting Extent of record Criteria
Operation check Control agency Inspection
s
1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection For Fillet Visual, Approved Visual RDSO 100% Fabricator's Approved It is to be
of Welded Welds - Visual, Gauge and fabrication Inspection & Record fabrication ensured
componen D.P. Test, Fillet Macro Drawings & Verification Drawings, IRS during
ts Size, etching WPSS of Dimension B1-2001, IRS fabrication
Penetration, Leg by Gauge WBC-2001 and process that
length, Throat codes referred fabrication
thickness etc. in these codes has been
as applicable done as per
the WPSS
approved by
RDSO and
Welders
approved by
RDSO. This is
to be ensured
n by Zonal
Railway/
Railway PSUs
and certificate
to this effect
(By Minimum
JAG officer)
shall be given
in the form of
four point
certification
along with
inspection call
raised to
RDSO.
 RDSO/Infra-II/B&S/RG/CG

4.1 Stud Visual Test as Approved 100 % Visual Zonal Railway/ 100% Test Reports Approved
Welding Inspection, mentioned Fabrication inspection & Railway PSUs & Fabricator Fabrication
dimensions in BS 115 Drawings and verification of report Drawings 9595-
inspection, ring (Latest WPSS dimension by 96, IRSB1-2001
test and bend revision) gauge and and codes as
test etc. As test record applicable
applicable, for instructions
good issued by
penetration & Railway Board
crack free weld. also to be
followed.
5.0 Inspection a) Overall length Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. RDSO
of first b) Bearing Dimensiona Drawings Dimensional Report of IRS WBC-2001 inspection call
span in centres l Check of Inspection and applicable to be raised
assembled c) Height Assembly officials & codes referred by Zonal
condition d) Girder fabricator's in these codes. Railway/
Centres record Railway PSUs
e) Squareness in the form
f) Verticality of 4 point
g) Camber on certification
Jack after
h) Dead Load
satisfactory
deflection
(Camber without quality
Jack) checks. 2.
i) Dimension Assembly
j) Fairness of shall be done
Holes in Workshop
k) Temporary of fabricator
fasteners only.
l) Any Fabricator
Infringement shall ensure
m) Butting of that sufficient
compression space is
members available in
workshop for
assembly
before
finalizing the
order of
fabrication for
a particular
 RDSO/Infra-II/B&S/RG/CG

span.
6.0 Inspection i) Overall Visual, Stage clearance Verification RDSO 100% Inspection IRS B1-2001, 1. All spans are
of length ii) Dimensiona Record of Stage Report of IRS WBC-2001 to be checked in
Componen Bearing l& clearance Inspection and applicable leaf assembled
nd
ts of 2 centres Structural Record officials & codes referred condition.
span fabricator's in these codes. 2. RDSO
iii) Height
onwards record inspection call to
iv) Girder be raised by
Centres Zonal Railway/
v) Squareness Railway PSUs
vi) Verticality in the form of 4
vii) Camber point
viii) Dimension certification
ix) Fairness of after
Holes satisfactory
x) Butting of quality checks.
compression
flanges
 RDSO/Infra-II/B&S/RG/CG

7.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001 1. Clearance
Preparatio condition after checking Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII shall be given
n by blasting with Drawing & IRS - clearance Random by IS: 6586, by Zonal
Blasting & reference B1-2001 and Record Zonal IS:5905 , Railway/
Metalizing to surface codes referred Railway/ IS:2590 and Railway PSUs
preparation in these Railway codes referred
PSUs in these codes
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's
after metalizing checking Fabrication of Stage Railway PSUs fabricator & Record
Drawing & IRS - clearance Random by
B1-2001 and Record Zonal
codes referred Railway/
in these Railway
PSUs
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of Stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and Record
codes referred
in these
 RDSO/Infra-II/B&S/RG/CG

8.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking Fabrication of stage Railway PSUs fabricator & Record and appendix
painting with Drawing & IRS - clearance Random by VII of IRS B1-
reference B1-2001 and records Zonal 2001, IS: 5666,
to surface codes referred Railway IS:51, IS:104,
preparation in these IS: 2339 and
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's applicable
after painting checking Fabrication of stage Railway PSUs fabricator & Record codes referred
Drawing & IRS - clearance Random by in these codes
B1-2001 and records Zonal
codes referred Railway
in these
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and records
codes referred
in these
9.0 Final 1. Shipping Visual Fabricator's Zonal Railway/ Random Approved Approved Site Painting is
Dispatch Mark on all Record Railway PSUs Fabrication Fabrication to be done after
including Components as Drawing& Drawing & assembly and
packing, per Approved Fabricator's Clause 42, 43 erection of
Shipping Fabrication record and 44 of IRS - girder on site as
mark and drawings B1-2001 and per IRS B1-
loading 2. Fixing of codes referred 2001
etc. Inscription Plate in these
3. Packing
4. Loading

Note: During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per
approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to
RDSO for Assembly or components inspection etc.
 RDSO/Infra-II/B&S/RG/OWG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD RAILWAY OPEN WEB GIRDER

PART-A (TOP SHEET)

S.No. Item Details
1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU.)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/RG/OWG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication.
13 Scope of fabrication in MT (Only Railway Open Web Girder)

14. GAD Approved by

15 RDSO Drawing Nos. used.
16 Specifications

Note:- It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/RG/OWG

PART B - MODEL QAP

Sl. Component Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. / Operations to be checked type of Document Quality Inspecting Extent of record
check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Plates Identification As per Mill Challan, Mill Verification Zonal Fabricator's 1) Steel Plates: IS 1. Grade and
and other and Co- Test T.C. of reference Railway/ 100% Record 2062:2011 Quality of Steel
Structural relation with Certificate & documents Railway Grade E250 Quality Plates, structural
Steel Mill Test test required PSUs B0 as mentioned in section to be
Sections Certificate from by Zonal the respective same as
Supplier. Railway or approved drawing. mentioned in the
Source/Brand Railway PSU 2) Plates 12mm and respective
of steel to be from above thick are fully approved
decided as per approved killed/normalized or drawings
prevailing Laboratory/ control cooled. 2. For other
instructions Govt. 3) Rolled Sections or details of
issued from approved any other structural structural steel
Railway Board. Laboratory/ steel member: IS plates and
NABL/ 2062:2011 structural section
NABCB. Grade E250 Quality A&C no. 5 of IRS-
B0 as mentioned in B1: 2001, IS
the respective 2062-2011 and
approved drawing. codes referred in
these shall be
complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board
 RDSO/Infra-II/B&S/RG/OWG

Physical Visual -- Complete Zonal 100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Railway/ Record 2000, IS 2062-2011
Pitting, rusting, inspection Railway and codes referred in
straightness, PSUs these shall be
rolling defects complied as
etc. applicable

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per IS- approved Report Railway/ notes below and
2062:2011 laboratory/ Railway other relevant
UTS,YS,%EL Govt. PSUs clauses of IS- 2062-
,Bend Test approved 2011 and codes
Laboratory/ referred in it, for
NABL/ quality and grade of
NABCB steel as mentioned in
respective drawings
as applicable.

Charpy Test at Lab test at - Lab Test Zonal Heat / Cast -

0 ° C for plates approved Report Railway/ no. section
12 mm thick laboratory Railway wise as per
and above Govt. PSUs IS 2062-
approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no. section notes below and
per IS 2062- laboratory Railway wise as per other relevant
2011 Govt. PSUs IS 2062- clauses of IS- 2062-
approved 2011 2011 and codes
Laboratory/ referred in it, for
NABL/ quality and grade of
NABCB steel as mentioned in
respective drawings
as applicable.
 RDSO/Infra-II/B&S/RG/OWG

Ultra sonic test By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM
for 12mm and level- II Report Railway/ SA-435/435M and
above thick operator Railway codes referred in it
plates as per PSUs as per applicability
IS-4225/ASTM
SA-435/435M

Dimension Measurement Challan Measureme 100% Fabricator's IS 2062: 2011 or

nt of Record & other relevant codes
dimension Zonal referred in it as
Railway applicable
Record

1.2 HSFG Bolts Dimensions Visual / Challan and Verification Zonal As per BS- Fabricator's As per BS – 111 Procure from
with DTI Measurement Manufacturer's of reference Railway/ 111(Latest Record (Latest revision) RDSO approved
washers Test Documents Railway revision) Vendor only.
Certificate PSUs

Mechanical & T.C. And Manufacturer Verification Zonal

Chemical tests Test of reference Railway/
properties required from Certificate Documents Railway
Govt./NABL/ PSUs
NABCB
approved lab
as per BS-
111 (latest
revision)
 RDSO/Infra-II/B&S/RG/OWG

1.3 Paints and Verification of Visual Challan , Verification Zonal Each Batch Manufacturer's IRS B1-2001, Test at the
Primers Manufacturer's Manufacture's of Railway/ Test IS:5666, IS:51, approved
Test Certificate, Test Reference Railway Certificate IS:104, IS:2339 and laboratory
Inspection Certificate Documents PSUs applicable codes suitable for the
Certificate, referred in these purpose shall be
Challan codes therein. done as per the
Tests as per Lab test at Challan , Verification Random Lab Test instruction of the
specification approved Manufacture's of Report Zonal Railway/
laboratory Test Reference Railway PSUs.
Govt. Certificate Documents
approved
Laboratory/
NABL/
NABCB
1.4 Aluminium Properties of Review of Challan , Verification Zonal Each Batch Manufacture's IRS B1-2001, Test at the
wire Aluminium wire reference Manufacture's of Railway/ Test IS:2590 and approved
such as Dia, documents Test Reference Railway Certificate applicable codes laboratory
class and purity with material Certificate Documents PSUs referred in these suitable for the
as mentioned codes purpose shall be
in appendix-VII done as per the
of IRS B1-2001 instruction of the
Tests as per Lab test at Challan , Verification Random Lab Test Zonal Railway/
specification approved Manufacture's of Report Railway PSUs.
laboratory Test Reference
Govt. Certificate Documents
approved
Laboratory/
NABL/
NABCB
1.5 Welding As Per Any Test as Challan , Verification Zonal As per Fabricator's IRS Welded Bridge As per
Consumables Specification required Manufacture's of reference Railway/ require- record Code 2001, IRS specification and
and approved Test Documents Railway ment M28, IRS M39, IRS WPSS.
WPSS. Certificate PSUs M46 and other
applicable codes
referred in these
codes and
specifications
 RDSO/Infra-II/B&S/RG/OWG

Sl. Component / Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked type of check Document Quality Inspecting Extent of record Criteria
Control agency Inspectio
n
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturing
Process
2.1 Layout Dimension Measurement Approved Measurement RDSO 100% Inspection Approved
with calibrated Drawings of Report of fabrication
steel Tape dimensions Inspection Drawings and
officials relevant IS/IRS
codes.

2.2 Master Plates Dimension, Measurement Approved Measurement RDSO 100% Record for Approved
intersection with calibrated Drawings of Master Plates fabrication
line,pitch, steel Tape & dimensions on proforma drawings, IRS
gauge, Dia. of gauges. same as of B1-2001 and
holes & No. of Appendix I(1) BS-110 (Latest
holes. proforma given revision)
in IRS B1-
2001
2.3 Preparatory Dimension , Visual / Inspection Visual & 100% Inspection Approved --
work such as freedom from Measurement Report of Measurement Report of fabrication
Cutting, defects with master Inspection of Inspection drawings, IRS
Straightening, plates and officials & dimensions officials & B1-2001, IS-
Edge templates fabricator's fabricator's 1852-85 and
Preparation, record record codes referredin
Marking, Zonal Railway/ these codes as
Drilling, Fit up, Railway PSUs applicable
Pre-assembly,
End finishing
 RDSO/Infra-II/B&S/RG/OWG

Sl. Component Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. / checked & type of Document Quality Inspecting Extent of record Criteria
Operations check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.0 Welding
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to be
WPSS IRS B1-2001, Reference Record fabrication performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes B1-2001, IRS specification
referred in WBC-2001 and and
these codes codes referred parameters
as applicable in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), Only RDSO
established and NDT at Requirement of Reference Sheet to be IS 7310 (Part-1), certified
WPSS. 2. approved Documents recorded in IRS B1-2001, welders to be
Witnessing of laboratory presence of IRS WBC-2001 engaged in the
Welder Govt. RDSO. and codes job
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB

3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Reference Railway/ Report of B1-2001, IRS
Chalk or Documents Railway Inspection WBC-2001 and
Infrared PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable

3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, moisture free of Electrodes Manufacture' of Reference Railway/ Report of and other
flux electrode and and heating s Documents Railway Inspection applicable
flux Recommend PSUs officials & codes.
ation fabricator's
record
 RDSO/Infra-II/B&S/RG/OWG

3.5 Selection Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per WPSS
of Correct WPSS. Approved of Reference Railway/ Report of Bridge Code and other
Electrodes WPSS Documents Railway Inspection 2001, IRS M28, codes
& flux PSUs officials & IRS M39, IRS applicable.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Reference Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Documents Railway Inspection WBC-2001 and codes
PSUs officials & codes referred applicable
fabricator's in these codes
record as applicable

3.8 Sequence Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
of Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable

3.9 Provision To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
of Run-on defects Approved Reference Railway/ Report of B1-2001, IRS
and Run- WPSS Documents Railway Inspection WBC-2001 and
off Plates PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/OWG

Sl. Component / Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked & type of Document Quality record Criteria
Inspecting Extent of
check Control agency Inspection

1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection of For Fillet Visual, Approved Visual RDSO 100% Fabricator's Approved It is to be
Welded Welds - Visual, Gauge and fabrication Inspection & Record fabrication ensured during
components D.P. Test, Fillet Macro Drawings & Verification Drawings, IRS fabrication
Size, etching WPSS of Dimension B1-2001, IRS process that
Penetration, by Gauge WBC-2001 and fabrication has
Leg length, codes referred been done as
Throat in these codes per the WPSS
thickness etc. as applicable approved by
RDSO and
Welders
approved by
RDSO. This is
to be ensured
by Zonal
Railway/
Railway PSUs
and certificate to
this effect (By
Minimum JAG
officer) shall be
given in the form
of four point
certification
along with
inspection call
raised to RDSO
 RDSO/Infra-II/B&S/RG/OWG

5.0 Inspection a) Overall Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. RDSO
of trial length Dimensiona Drawings Dimensional Report of IRS WBC-2001 inspection call to
assembly b) Bearing l Check of Inspection and applicable be raised by
of first centres Assembly officials & codes referred Zonal Railway/
span. c) Height fabricator's in these codes. Railway PSUs
d) Girder record in the form of 4
Centres point
e) Squareness certification
f) Verticality after
g) Camber on
satisfactory
Jack
h) Dead Load quality checks.
deflection 2. Assembly
(Camber shall be done in
without Jack) Workshop of
i) Dimension fabricator only.
j) Fairness of Fabricator shall
Holes ensure that
k) Temporary sufficient space
fasteners is available in
l) Any workshop for
Infringement assembly before
m) Butting of finalizing the
compression order of
members fabrication for a
particular span.
 RDSO/Infra-II/B&S/RG/OWG

6.0 Inspection Dimensional Visual and Stage clearance Verification RDSO 100% Inspection IRS B1-2001, . RDSO
of check. Dimensiona Record of Stage Report of IRS WBC-2001 inspection call to
dismantled l clearance Inspection and applicable be raised by
Component Record officials & codes referred Zonal Railway/
st
s of 1 fabricator's in these codes. Railway PSUs
span and record in the form of 4
nd
2 span point
onwards certification
after
satisfactory
quality checks.

7.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001 1. Clerance
Preparation condition after checking Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII shall be given
by blasting with Drawing & IRS - clearance Random by IS: 6586, by Zonal
Blasting & reference B1-2001 and Record Zonal IS:5905 , Railway/
Metalizing to surface codes referred Railway/ IS:2590 and Railway PSUs
preparation in these Railway codes referred
PSUs in these codes
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's
after checking Fabrication of Stage Railway PSUs fabricator & Record
metalizing Drawing & IRS - clearance Random by
B1-2001 and Record Zonal
codes referred Railway/
in these Railway
PSUs
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of Stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and Record
codes referred
in these
 RDSO/Infra-II/B&S/RG/OWG

8.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking Fabrication of stage Railway PSUs fabricator & Record and appendix
painting with Drawing & IRS - clearance Random by VII of IRS B1-
reference B1-2001 and records Zonal 2001, IS: 5666,
to surface codes referred Railway IS:51, IS: 104
preparation in these IS: 2339 and
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's applicable
after painting checking Fabrication of stage Railway PSUs fabricator & Record codes referred
Drawing & IRS - clearance Random by in these codes
B1-2001 and records Zonal
codes referred Railway
in these
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and records
codes referred
in these
9.0 Final 1. Shipping Visual Fabricator's Zonal Railway/ Random Approved Approved Site Painting is
Dispatch Mark on all Record Railway PSUs Fabrication Fabrication to be done after
including Components as Drawing& Drawing & assembly and
packing, per Approved Fabricator's Clause 42, 43 erection of
Shipping Fabrication record and 44 of IRS - girder on site as
mark and drawings B1-2001 and per IRS B1-
loading 2. Fixing of codes referred 2001
etc. Inscription Plate in these
3. Packing
4. Loading
Note: During fabrication, internal inspection areto be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per
approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to
RDSO for Assembly or components inspection etc.
 RDSO/Infra-II/B&S/ROB/TTG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD TRUSS TYPE ROB GIRDER

PART-A (TOP SHEET)

S.No. Item Details
1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU /NHAI or any other government agency.)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/ROB/TTG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication.
13 Scope of fabrication in MT (Only ROB Truss Type Girder)

14. GAD Approved by

15 RDSO Drawing Nos. used.
16 Specifications

Note:- It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/ROB/TTG

PART B - MODEL QAP

Sl. Component Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. / Operations to be checked & type of Document Quality record
Inspecting Extent of
check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Identification As per Mill Challan, Mill Verification Zonal Fabricator's 1) Steel Plates: IS 1. Grade and
Plates and and Co- Test T.C. of reference Railway/ 100% Record 2062:2011 Quality of Steel
other relation with Certificate documents Railway Grade E250 Quality Plates, structural
Structural Mill Test & test PSUs B0 as mentioned in the section to be
Steel Certificate from required by respective approved same as
Sections Supplier. Zonal drawing. mentioned in the
Source/Brand Railway or 2) Plates 12mm and respective
of steel to be Railway above thick are fully approved
decided as per PSU from killed/normalized or drawings
prevailing approved control cooled. 2. For other
instructions Laboratory/ 3) Rolled Sections or details of
issued from Govt. any other structural structural steel
Railway Board. approved steel member: IS plates and
Laboratory/ 2062:2011 structural section
NABL/ Grade E250 Quality A&C no. 5 of IRS-
NABCB. B0 as mentioned in the B1: 2001, IS
respective approved 2062-2011 and
drawing. codes referred in
these shall be
complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board
 RDSO/Infra-II/B&S/ROB/TTG

Physical Visual -- Complete Zonal 100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Railway/ Record 2000, IS 2062-2011
Pitting, rusting, inspection Railway and codes referred in
straightness, PSUs these shall be
rolling defects complied as applicable
etc.

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per IS- approved Report Railway/ notes below and other
2062: laboratory/ Railway relevant clauses of IS-
2011 Govt. PSUs 2062-2011 and codes
UTS,YS,%EL, approved referred in it, for quality
Bend Test Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.

Charpy Test at Lab test at - Lab Test Zonal Heat / Cast -

0 ° C for plates approved Report Railway/ no. section
12 mm thick laboratory Railway wise as per
and above Govt. PSUs IS 2062-
approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no. section notes below and other
per IS 2062- laboratory Railway wise as per relevant clauses of IS-
2011 Govt. PSUs IS 2062- 2062-2011 and codes
approved 2011 referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.
 RDSO/Infra-II/B&S/ROB/TTG

Ultra sonic test By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM SA-
for 12mm and level- II Report Railway/ 435/435M and codes
above thick operator Railway referred in it as per
plates as per PSUs applicability
IS-4225/ASTM
SA-435/435M

Dimension Measure- Challan Measurement 100% Fabricator's IS 2062: 2011 or other

ment of dimension Record & relevant codes
Zonal referred in it as
Railway applicable
Record

1.2 HSFG Dimensions Visual / Challan and Verification Zonal As per BS- Fabricator's As per BS – 111 Procure from
Bolts with Measurem Manufacturer's of reference Railway/ 111(Latest Record (Latest revision) RDSO approved
DTI ent Test Certificate Documents Railway revision) Vendor only.
washers PSUs

Mechanical & T.C. And Manufacturer Verification Zonal

Chemical tests Test Certificate of reference Railway/
properties required Documents Railway
from PSUs
Govt./NAB
L/ NABCB
approved
lab as per
BS-111
(latest
revision)
 RDSO/Infra-II/B&S/ROB/TTG

1.3 Paints and Verification of Visual Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:5666, Test at the
Primers Manufacturer's Manufacture's of Railway/ er's Test IS:51, IS:104, IS:2339 approved
Test Certificate, Test Certificate Reference Railway Certificate and applicable codes laboratory
Inspection Documents PSUs referred in these codes suitable for the
Certificate, therein. purpose shall be
Challan done as per the
Tests as per Lab test at Challan , Verification Random Lab Test instruction of the
specification approved Manufacture's of Report Zonal Railway/
laboratory Test Certificate Reference Railway PSUs.
Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.4 Aluminium Properties of Review of Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:2590 Test at the
wire Aluminium wire reference Manufacture's of Railway/ e's Test and applicable codes approved
such as Dia, documents Test Certificate Reference Railway Certificate referred in these codes laboratory
class and purity with Documents PSUs suitable for the
as mentioned material purpose shall be
in appendix-VII done as per the
of IRS B1-2001 instruction of the
Tests as per Lab test at Challan , Verification Random Lab Test Zonal Railway/
specification approved Manufacture's of Report Railway PSUs.
laboratory Test Certificate Reference
Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.5 Welding As Per Any Test Challan , Verification Zonal As per Fabricator's IRS Welded Bridge As per
Consumab Specification as required Manufacture's of reference Railway/ requiremen record Code 2001, IRS M28, specification and
les and approved Test Certificate Documents Railway t IRS M39, IRS M46 WPSS.
WPSS. PSUs and other applicable
codes referred in these
codes and
specifications
Test as Approved 100 % Zonal 100% Test Approved Fabrication
1.6 Stud mentioned Fabrication Visual Railway/ Reports & Drawing, IS 9595-96,
Visual
in BS 115 Drawings and inspection & Railway Fabricator IRSB1-2001 and
Inspection,
(latest WPSS verification PSUs report codes as applicable
dimensions
revision) of Instructions issued by
inspection
dimension Railway Board also to
by gauge be followed.
 RDSO/Infra-II/B&S/ROB/TTG

and test
record

Sl. Component / Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked type of check Document Quality Inspecting Extent of record Criteria
Control agency Inspectio
n
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturing
Process
2.1 Layout Dimension Measurement Approved Measurement RDSO 100% Inspection Approved
with calibrated Drawings of Report of fabrication
steel Tape dimensions Inspection Drawings and
officials relevant
IS/IRS/IRC
codes.

2.2 Master Plates Dimension, Measurement Approved Measurement RDSO 100% Record for Approved
intersection with calibrated Drawings of Master Plates fabrication
line,pitch, steel Tape & dimensions on proforma drawings, IRS
gauge, Dia. of gauges. same as of B1-2001 and
holes & No. of Appendix I(1) BS-110 (Latest
holes. proforma given revision)
in IRS B1-
2001
2.3 Preparatory Dimension , Visual / Inspection Visual & 100% Inspection Approved --
work such as freedom from Measurement Report of Measurement Report of fabrication
Cutting, defects with master Inspection of Inspection drawings, IRS
Straightening, plates and officials & dimensions officials & B1-2001, IS-
Zonal Railway/
Edge templates fabricator's fabricator's 1852-85 and
Railway PSUs
Preparation, record record codes referredin
Marking, these codes as
Drilling, Fit up, applicable
 RDSO/Infra-II/B&S/ROB/TTG
Component /
Sl. Pre-assembly, Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No.EndOperations
finishing checked & type of Document Quality Inspecting Extent of record Criteria
check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.0 Welding
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to be
WPSS IRS B1-2001, Reference Record fabrication performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes B1-2001, IRS specification
referred in WBC-2001 and and
these codes codes referred parameters
as applicable in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), Only RDSO
established and NDT at Requirement of Reference Sheet to be IS 7310 (Part-1), certified
WPSS. 2. approved Documents recorded in IRS B1-2001, welders to be
Witnessing of laboratory presence of IRS WBC-2001 engaged in the
Welder Govt. RDSO. and codes job
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB

3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Reference Railway/ Report of B1-2001, IRS
Chalk or Documents Railway Inspection WBC-2001 and
Infrared PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable

3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, moisture free of Electrodes Manufacture's of Reference Railway/ Report of and other
flux electrode and and heating Recommendat Documents Railway Inspection applicable
flux ion PSUs officials & codes.
fabricator's
record
 RDSO/Infra-II/B&S/ROB/TTG

3.5 Selection Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per WPSS
of Correct WPSS. Approved of Reference Railway/ Report of Bridge Code and other
Electrodes WPSS Documents Railway Inspection 2001, IRS M28, applicable
& flux PSUs officials & IRS M39, IRS codes.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Reference Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Documents Railway Inspection WBC-2001 and applicable
PSUs officials & codes referred codes.
fabricator's in these codes
record as applicable

3.8 Sequence Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
of Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable

3.9 Provision To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
of Run-on defects Approved Reference Railway/ Report of B1-2001, IRS
and Run- WPSS Documents Railway Inspection WBC-2001 and
off Plates PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/ROB/TTG

Sl. Component / Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked & type of Document Quality record Criteria
Inspecting Extent of
check Control agency Inspection

1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection of For Fillet Visual, Approved Visual RDSO 100% Fabricator's Approved It is to be
Welded Welds - Visual, Gauge and fabrication Inspection & Record fabrication ensured during
components D.P. Test, Fillet Macro Drawings & Verification Drawings, IRS fabrication
Size, etching WPSS of Dimension B1-2001, IRS process that
Penetration, by Gauge WBC-2001 and fabrication has
Leg length, codes referred been done as
Throat in these codes per the WPSS
thickness etc. as applicable approved by
RDSO and
Welders
approved by
RDSO. This is
to be ensured
by Zonal
Railway/
Railway PSUs
and certificate to
this effect (By
Minimum JAG
officer) shall be
given in the form
of four point
certification
along with
inspection call
raised to RDSO
 RDSO/Infra-II/B&S/ROB/TTG

4.1 Stud Visual Test as Approved 100 % Visual Zonal Railway/ 100% Test Reports Approved 1. Welding to be
Welding Inspection, mentioned Fabrication inspection & Railway PSUs & Fabricator Fabrication performed
dimensions in BS 115 Drawings and verification of report Drawing IS following the
inspection, ring (latest WPSS dimension by 9595-96, different
test and bend revision) gauge and IRSB1-2001 and specification
test etc. As test record codes as and parameters
applicable, for applicable and mentioned in
good instructions WPSS approved
penetration & issued by by RDSO 2: For
crack free Railway Board details of Stud
weld. are also to be welding refer BS
followed. 115 (latest
revision)
 RDSO/Infra-II/B&S/ROB/TTG

5.0 Inspection a) Overall Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. RDSO
of trial length Dimensional Drawings Dimensional Report of IRS WBC-2001 inspection call to
assembly b) Bearing Check of Inspection and applicable be raised by
of first centres Assembly officials & codes referred Zonal Railway/
span. c) Height fabricator's in these codes. Railway PSUs in
d) Girder record the form of 4
Centres
point
e) Squareness
f) Verticality certification
g) Camber on after
Jack satisfactory
h) Dead Load quality checks.
deflection 2. Assembly
(Camber shall be done in
without Jack) Workshop of
i) Dimension fabricator only.
j) Fairness of Fabricator shall
Holes ensure that
k) Temporary sufficient space
fasteners is available in
l) Any workshop for
Infringement assembly before
m) Butting of finalizing the
compression order of
members fabrication for a
particular span.
 RDSO/Infra-II/B&S/ROB/TTG

6.0 Inspection of Dimensional Visual and Stage clearance Verification RDSO 100% Inspection IRS B1-2001, . RDSO
dismantled check. Dimensional Record of Stage Report of IRS WBC-2001 inspection call to
Components clearance Inspection and applicable be raised by
st
of 1 span Record officials & codes referred Zonal Railway/
nd
and 2 span
onwards
fabricator's in these codes. Railway PSUs in
record the form of 4
point
certification
after
satisfactory
quality checks.

7.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001 1. Clerance
Preparation condition after checking Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII shall be given
by blasting with Drawing & IRS - clearance Random by IS: 6586, by Zonal
Blasting & reference B1-2001 and Record Zonal IS:5905 , Railway/
Metalizing to surface codes referred Railway/ IS:2590 and Railway PSUs
preparation in these Railway codes referred
PSUs in these codes
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's
after metalizing checking Fabrication of Stage Railway PSUs fabricator & Record
Drawing & IRS - clearance Random by
B1-2001 and Record Zonal
codes referred Railway/
in these Railway
PSUs
DFT checking Measure- Approved Verification Zonal Railway/ Minimum one Measuremen
ment Fabrication of Stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and Record
codes referred
in these
 RDSO/Infra-II/B&S/ROB/TTG

8.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking Fabrication of stage Railway PSUs fabricator & Record and appendix
painting with Drawing & IRS - clearance Random by VII of IRS B1-
reference B1-2001 and records Zonal 2001, IS: 5666,
to surface codes referred Railway IS:51, IS: 104
preparation in these IS: 2339 and
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's applicable
after painting checking Fabrication of stage Railway PSUs fabricator & Record codes referred
Drawing & IRS - clearance Random by in these codes.
B1-2001 and records Zonal
codes referred Railway
in these
DFT checking Measure- Approved Verification Zonal Railway/ Minimum one Measuremen
ment Fabrication of stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and records
codes referred
in these
9.0 Final 1. Shipping Visual Fabricator's Zonal Railway/ Random Approved Approved Site Painting is
Dispatch Mark on all Record Railway PSUs Fabrication Fabrication to be done after
including Components as Drawing& Drawing & assembly and
packing, per Approved Fabricator's Clause 42, 43 erection of
Shipping Fabrication record and 44 of IRS - girder on site as
mark and drawings B1-2001 and per IRS B1-
loading 2. Fixing of codes referred 2001
etc. Inscription Plate in these
3. Packing
4. Loading
Note: During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per
approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to
RDSO for Assembly or components inspection etc.
 RDSO/Infra-II/B&S/ROB/BSG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD WELDED BOW STRING TYPE ROB GIRDER

PART-A (TOP SHEET)

S.No. Item Details

1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU/NHAI or any other government agency)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/ROB/BSG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication
13 Scope of fabrication in MT (Only Bow String Girder(s))

14. GAD Approved by

15 RDSO Drawing Nos. used
RDSO Drawing no. for ISMB Intermediate Cross Girders RDSO/B-10413
16 Specifications

Note: It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/ROB/BSG

PART B - MODEL QAP

Sl. Component / Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. Operations to be checked type of Document Quality Inspecti Extent of record
check Control ng Inspection
agency
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Plates Identification As per Mill Challan, Mill Verification Zonal 100% Fabricator's 1) Steel Plates: IS 1. Grade and
and other and Co- Test T.C.,Test of reference Railway/ Record 2062:2011 Quality of Steel
Structural relation with Certificate & Report documents Railway Grade E250 or E350, Plates, structural
Steel Sections Mill Test test required PSUs Quality B0 as section to be
Certificate from by Zonal mentioned in the same as
Supplier. Railway/ respective approved mentioned in the
Source/Brand Railway drawing. respective
of steel to be PSUs or 2) Plates 12mm and approved
decided as per RDSO from above thick, Plates are drawings
prevailing Govt. fully killed/normalized 2. For other
instructions approved or control cooled. details of
issued from Laboratory/ 3) Rolled Sections or structural steel
Railway Board. NABL/ any other structural plates and
NABCB steel member: IS structural section
2062:2011 A&C no. 5 of IRS-
Grade E250 or E350, B1: 2000, IS
Quality B0 as 2062-2011 and
mentioned in the codes referred in
respective approved these shall be
drawing. complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board.
 RDSO/Infra-II/B&S/ROB/BSG

Physical Visual -- Complete Zonal Zonal100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Railway/ Record 2000, IS 2062-2011
Pitting, rusting, inspection Railway and codes referred in
straightness, PSU. these shall be
rolling defects complied as applicable
etc.

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per IS- approved Report Railway/ notes below and other
2062:2011 laboratory Railway relevant clauses of IS-
UTS,YS,%EL,B Govt. PSUs 2062-2011 and codes
end Test approved referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
Charpy Test at Lab test at - Lab Test Zonal Heat / Cast - applicable.
0 ° C for plates approved Report Railway/ no section
12 mm thick laboratory Railway wise as per
and above Govt. PSUs IS 2062-
approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no section notes below and other
per IS 2062- laboratory Railway wise as per relevant clauses of IS-
2011 Govt. PSUs IS 2062- 2062-2011 and codes
approved 2011 referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.

Ultra sonic test By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM SA-
for 12mm and level- II Report Railway/ 435/435M and codes
above thick operator Railway referred in it as per
plates as per PSUs applicability
 RDSO/Infra-II/B&S/ROB/BSG

IS-4225/ASTM
SA-435/435M

Dimension Measurement Challan Measuremen 100% Fabricator's IS 2062: 2011 or other

t of Record & relevant codes
dimension Zonal referred in it as
Railway applicable
Record
1.2 Paints and Verification of Visual Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:5666 Test at the
Primers Manufacturer's Manufacture's of Reference Railway/ er Test IS:51, IS:104, IS:2339, approved
Test Certificate, Test Certificate Documents Railway Certificate and applicable codes laboratory
Inspection PSUs referred in these codes suitable for the
Certificate, purpose shall be
Challan done as per the
Tests as per Lab test at Challan, Verification Random Lab Test instruction of the
specification approved Manufacture's of Reference Report inspecting agency
laboratory Test Certificate Documents which is
Govt. responsible for
approved passing of the
Laboratory/ material
NABL/
NABCB
1.3 Aluminium Properties of Review of Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:2590 Test at the
wire Aluminium wire reference Manufacture's of Reference Railway/ e's Test and applicable codes approved
such as Dia, documents Test Certificate Documents Railway Certificate referred in these codes laboratory
class and purity with material PSUs suitable for the
as mentioned purpose shall be
in appendix-VII done as per the
of IRS B1-2001 instruction of
 RDSO/Infra-II/B&S/ROB/BSG

Tests as per Lab test at Challan , Verification Random Lab Test Zonal
specification approved Manufacture's of Reference Report Railway/PSUs
laboratory Test Certificate Documents
Govt.
approved
Laboratory/
NABL/
NABCB
1.4 Welding As Per Any Test as Challan & Verification Zonal As per Fabricator's IRS Welded Bridge As Per
Consumables Specification required Manufacturer's of reference Railway/ requiremen record Code 2001, IRS M28, Specification
/WPSS Test Certificate Documents Railway t IRS M39, IRS M46 /WPSS
PSUs and other applicable
codes referred in these
codes and
specifications
1.5 Stud Visual Test as Approved 100 % Visual Zonal 100% Test Approved Fabrication
Inspection , mentioned in Fabrication inspection & Railway/ Reports & Drawing, IS 9595-96,
dimensions BS 115 (latest Drawings and verification of Railway Fabricator IRSB1-2001 and
inspection revision) WPSS dimension by PSUs report codes as applicable
gauge and Instructions issued by
test record Railway Board also to
be followed.
 RDSO/Infra-II/B&S/ROB/BSG

Sl. Component / Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations to be checked type of check Document Quality record Criteria
Control Inspecting Extent
agency of
Inspecti
on
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturing
Process
2.1 Layout as Dimension Measurement Approved Measurement Zonal Railway/ 100% Inspection Approved
applicable with calibrated Drawings of Railway PSUs as Report of fabrication
steel Tape dimensions delegated vide Inspection Drawings and
RDSO letter no. officials relevant
CBS/Insp./ROB IS/IRS/IRC
dated 24.02.2020 codes.

2.2 Preparatory Dimension , Visual / Inspection Visual & Zonal Railway/ 100% Inspection Approved --
work such as freedom from Measurement Report of Measurement Railway PSUs Report of fabrication
Cutting, defects with master Inspection of Inspection drawings, IRS
Straightening, plates and officials & dimensions officials & B1-2001, IS-
Edge templates fabricator's fabricator's 1852-85 and
Preparation, record record codes referred
Marking, in these codes
Drilling, Fit up, as applicable
Pre-assembly,
End finishing
 RDSO/Infra-II/B&S/ROB/BSG
Sl. Component Characteristic Frequency Reference Fabricator Inspection Details Type of Acceptance Remarks
No. / checked & type of Document s Quality Inspecting Extent of record Criteria
Operations check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
3.0 Welding
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to be
WPSS IRS B1-2001, Reference Record fabrication performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes referred B1-2001, IRS specification
in these codes WBC-2001 and and
as applicable codes referred parameters
in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of 1. Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), RDSO certified
established and NDT at Requirement of Sheet to be IS 7310 (Part-1), welders to be
WPSS. 2. approved Reference recorded in IRS B1-2001, engaged in the
Witnessing of laboratory Documents presence of IRS WBC-2001 job
Welder Govt. RDSO and codes
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB
2. If butt weld
then RT/UT
test required.
3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Railway/ Report of B1-2001, IRS
Chalk or Reference Railway Inspection WBC-2001 and
Infrared Documents PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable
3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, moisture free of Electrodes Manufacture's of Railway/ Report of and other
flux electrode and and heating Recommendat Reference Railway Inspection applicable
flux -ion Documents PSUs officials & codes.
fabricator's
record
 RDSO/Infra-II/B&S/ROB/BSG

3.5 Selection Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per wpss
of Correct WPSS Approved of Railway/ Report of Bridge Code and other
Electrodes WPSS Reference Railway Inspection 2001, IRS M28, applicable
& flux Documents PSUs officials & IRS M39, IRS codes.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Reference Railway Inspection WBC-2001 and applicable
Documents PSUs officials & codes referred codes
fabricator's in these codes
record as applicable
3.8 Sequence Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
of Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable
3.9 Provision To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
of Run-on defects Approved Reference Railway/ Report of B1-2001, IRS
and Run- WPSS Documents Railway Inspection WBC-2001 and
off Plates PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/ROB/BSG

Sl. Component / Characterist Frequency & Reference Fabricators Inspection Details Type of Acceptance Remarks
No. Operations ic to be type of check Document Quality Inspecting Extent of record Criteria
checked Control agency Inspection

1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection 1. For Fillet Visual, Gauge Approved Visual RDSO 100% Fabricator's Approved It is to be
of Welded Welds - and Macro fabrication Inspection & Record fabrication ensured during
components Visual, D.P. etching Drawings & Verification Drawings, IRS fabrication
at workshop Test, Fillet WPSS of Dimension B1-2001, IRS process that
Size, by Gauge WBC-2001 and fabrication has
Penetration, codes referred been done as
Leg length, in these codes per the WPSS
Throat as applicable approved by
thickness RDSO and
etc. Welders
2. For butt approved by
welds – RDSO. This is
RT/UT test to be ensured
from by Zonal
approved Railway/
lab. Railway PSUs
and certificate to
this effect (By
Minimum JAG
officer) shall be
incorporated in
the form of four
point
certification
while raising
inspection call to
RDSO.
 RDSO/Infra-II/B&S/ROB/BSG

4.1 Stud Visual Test as Approved 100 % Visual Zonal Railway/ 100% Test Reports Approved 1. Welding to be
Welding Inspection , mentioned in Fabrication inspection & Railway PSUs & Fabricator Fabrication performed
dimensions BS 115 (latest Drawings verification of report Drawing IS following the
inspection , revision) and WPSS dimension by 9595-96, different
ring test and gauge and IRSB1-2001 and specification
bend test etc. test record codes as and parameters
As applicable and mentioned in
applicable, instructions WPSS approved
for good issued by by RDSO 2: For
penetration & Railway Board details of Stud
crack free are also to be welding refer BS
weld. followed. 115 (latest
revision)
5.0 Components a) Overall Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. Half laydown
Inspection length Dimensional Drawings Dimensional Report of IRS WBC-2001 assembly of first
of first span b) Cross – Check of Inspection and applicable span to be
nd
and 2 span section etc. Assembly officials & codes referred checked by
onward fabricator's in these codes. RDSO.
record 2. There after
only
components of
first and
subsequent
spans to be
checked by
RDSO.
3. RDSO
inspection call to
be raised by
Zonal Railway/
Railway PSUs
in the form of 4
point
certification
after
satisfactory
quality checks.
 RDSO/Infra-II/B&S/ROB/BSG

Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's

finish after checking Fabrication of Stage Railway PSUs fabricator & Record
metalizing Drawing & clearance Random by
Zonal
IRS- B1- Record
Railway
2001 and
codes
referred in
these

DFT Measurement Approved Verification Zonal Railway/ Minimum one Measuremen

checking Fabrication of Stage Railway PSUs reading per t Record
Drawing & clearance square meter
IRS- B1- Record
2001 and
codes
referred in
these

6.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001
Preparation condition checking with Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII
by Blasting after blasting reference to Drawing & clearance Random by IS: 6586,
& Metalizing surface IRS - B1- Record Zonal IS:5905 ,
preparation 2001 and Railway IS:2590 and
codes codes referred
referred in in these codes
these
 RDSO/Infra-II/B&S/ROB/BSG

7.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking with Fabrication of stage Railway PSUs fabricator & Record and appendix
painting reference to Drawing & clearance Random by VII of IRS B1-
surface IRS - B1- records Zonal 2001, IS: 5666
preparation 2001 and Railway IS:51, IS:104
codes IS:2339 and
referred in applicable
these codes referred
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's in these codes
after painting checking Fabrication of stage Railway PSUs fabricator & Record
Drawing & clearance Random by
IRS - B1- records Zonal
2001 and Railway
codes
referred in
these
DFT checking Measurement Approved Verification Zonal Railway/ Minimum one Measurement
Fabrication of stage Railway PSUs reading per Record
Drawing & clearance square meter
IRS - B1- records
2001 and
codes
referred in
these
8.0 Final Complete Visual & Fabricator's RDSO 100% Approved Approved RDSO
inspection Assembly Measurement Record Fabrication Fabrication inspection call to
in Drawing & Drawing & be raised by
assembled Fabricator's Clause 42, 43 Zonal Railway/
condition record and 44 of IRS Railway PSUs
before - B1-2001 and in the form of 4
launching codes referred point
at site. in these certification
(Including after
Site
satisfactory
welding)
quality checks.

Note: During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per RDSO
approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to
RDSO for Assembly or components inspection etc.