QUALITY ASSURANCE PLAN FOR ELASTOMERIC BEARINGS

1 Name of Manufacture : SAI RUBBER ENGINEERING PVT.LTD. 2 Drg. No. ;

3 Name of Project/Railway: 4 Authority (CA No./LOA No./Order No.) : ……. …………………………………
S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspecting Extent of
control
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW Physical Test As per Manufacturer test Verification of Authorized From batches Fabricato rs r IRC:83 (Part-II) Examination of Test
MATERIAL manufacturer certificate reference Inspector at & Certificates is required Test
1.1 Elastomer With values of certificate & &Challan document. appointed by Random IS:3400 (as Certificate shall be furnished by manufacturers
( Only virgin characteristics specified test required by zonal Railway and at per relevant test for following tests.
Polychloropr ene (CR) Authorized discretion procedure) (i) Composition
is permitted & inspector of zonal of Inspector (ii) Hardness
preferable grades are- Railway from Govt. (iii) Tensile strength
Neoprene WRT, / NABL approved (iv) Elongation at Break
Bayprene lab (v) Compression set
110, a) G Modulus 0.8 As Per Drg. (vi) Accelerated Ageing test
Skyprene B- (vii) Adhesion Strength
5 and Denka b) Hardness IRHD ( 60 ± 5 )
S-40V) IMPORTANT: Properties of Elastomer should
c) Min. Tensile strength ≥16 MPa be as per Table 1 of IRC:83
d) Min. Elong. at break 425% Part-II Polychloroprene
e) Max.Compression set ≤15% Content 60 %
f) Accelerated 100⁰c for Ash content
ageing test 72 Hours Note: (i) No reclaimed rubber, vulcanized
wastes or natural rubber shall be used.
I) Max. Change in ± 5 IRHD (ii) EPDM (Ethyle propylene
Hardness Dimonomer), IIR (Isobutane Isoprene
II) Max. Change in Tensile ±15% w.r.t. value of Copolymer), CIIR (Chloro-Isoprene
strength (b) Copolymer) are not permitted for manufacture
III) Max. Change in of bearings.
Elongation. ±125% w.r.t. value
of (c) Adhesion strength test to be conducted as
(f) Adhesion strength of per IS: 3400
Elastomer to Steel Plates Min. 7 KN/m Part XIV.

Note :- Large Lot means if Number of bearings are ≥ 24 & tests for acceptance level 1 to be conducted. Small lot means if number of bearings are < 24 Where Acceptancelevel 2 tests are done.Lot size to be approved by the
engineer. In large lot 2 extra bearings to be made whichh are consumed in destructive testing.

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspecting Extent of
control
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.1 Elastomer Chemical Test As per Manufacturer test Verification of Authorized From batches Fabricato rs r IRC:83 Examination of Test
Cont. i) Determination manufacturer certificate reference Inspector at (Part-II) Ash Certificates is required Test Certificate shall be
/ Identification of polymer certificate & &Challan document. appointed by Random content as per furnished by manufacturers for following
test required by zonal Railway IS:3400 part XXII tests.
Authorized ' and (i) Polymer Identification
inspector of zonal Polychloropr ene (ii) Polymer content
Railway content as per (iii) Ash content
from Govt./ ASTM-D297 (iv) Specific gravity
NABL Identification of (V) Ozone resistance
approved lab min polymer
ii) Polymer content 50% -do- as per Preferably test of polymer identification,
-do- ASTM D polymer content and Ash content should
iii) Ash content Max 5% 3677 (as per be either witnessed or sealed sample to be
-do- relevant test sent to NABL LAB for evaluation.
(iv) Specific gravity -do- procedure) Note:
-do- For acceptance testing level
(V) Ozone resistance -do- I,
-do- (a) Ash content on specimen
-do- from test bearing shall be compared with
those for specially moulded test pieces and
Max variation permitted is ± 0.5%
(b)Specific gravity on
specimen from test bearing shall be
compared with those for specially moulded
test pieces and Max variation permitted is
± 0.2%
(c) For other test max. and
min. limits to be adhered.
(d) Ozone resistance can be waived by test
engineer as per note 2 of Para
918.4.1.2 of IRC83 Part II.

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspecting Extent of Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Agency Inspection Records criteria
1 2 3 4 5 control
6 7 8 9 10 11
1.2 Mild Steel Mechanical Test As per Mill TC Mill TC and 1. Verification Authorized One test piece Fabricato rs IS: 2062-11, Manufacturer’s test certificate shall be
UTS, Yield Stress, & test required by Challan of reference Inspector per thickness record Co- E250 furnished. UST shall be conducted
Elongation%, Authorized document. appointed by per heat. related ,Quality BO for12mm
Bend test , Impact inspecting zonal Railway with Mill TC is generally &above thick plates per
test at 0 degree centigrade official of Zonal 2.Complete & test report. used. provision of relevant specification before
or -20 degree for sub- zero Railway from Govt. visual inspection. However processing the material for manufacturing.
zone Lab Quality C
./ NABL shall be
Chemical Test C, Mn, Si, P, approved lab. used for sub
S, CE. zero condition.
( As
specified in
Physical condition i.e. approved Drg.).
Pitting,rusting,rolli ng defect,
etc.

Ultrasonic
Testing of plates
IS:4225 or
(100% for12mm ASTM A435
& above thick plates)
100%

2.0 Manufacturing Dimensional inspection Visual & MeasuremeAs per approved Measureme nt Manufacturer At Fabricato rs reIRC 83 Part- II & Internal report will be furnished which will
process Specified tolerances drawing of Inspecting Discretion as per be
-0,+6mm dimension Agency drawing verified by Zonal Railway
Inspector. However random check may be
done by Zonal
Railway inspector during
a) Over all plan -2 MM, +4 MM Manufacturing.
dimension (length & Note: During manufacturing
Breadth) test pieces will also be moulded with identical
b) Thickness of ±12% compound and under identical vulcanizing
Individual internal layer conditions and suitably marked for
of elastomer identification at the time of tests. This process
c) Thickness of -0mm, +2MM shall be open to inspection by Railway
individual inspecting official.
outer layer d)Plan -
dimension of
laminates(length & +2mm,+1mm
Bresdth)

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspecting Extent of
control
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
2.0 &Breadth)
Cont.
e) Thickness of +0.8mm, -0.4mm
laminate
f) Parallelism of 1 in 100
laminate with respect to
bearing base as datum Manufacturer
Visual & As per approved Measurement of Fabricators IRC 83 Part - II &
Inspecting At Discretion -do-
Measurment Drawing Dimension Record as per drawing
(g) Hardness during Agency
manufacturi ng IRHD 60 ±5

3.0 Final Inspection All bearings to be visually inspected for

3.1 Visual examination and Dimensions of bearing as absence of any defects in surface finish,
dimensional per specified tolerances as shape or any other discernible superficial
check under : defect. Also after load testing, during
a) Over all plan
-2mm, +4 mm visual examination of bearing no defects
dimension(I ength &
Breadth) Authorized should be noticed in surface finish, shape
b) Over all ±2mm Inspector or other noticeable superficial defects.
Thickness Fabricators
Visual & As per approved Measurement of As per table 2 of
c) Parallelismof top 1 in 300 Measurment Drawing Dimension
appointed 100% Record &
IRC 83 Part - II
surface of bearing with by zonal Test Report Authorised inspector has to carry out
respect to the bottom Railway 100% dimensional check for item a) & b)
surface as datum and random check for item c)& d) to be
d) Parallelism of one
side surface with
done till full satisfaction.
respect to the other as 1 in 100
datum

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspecting Extent of
control
Agency Inspection
1 2 3 4 5 6 8 9 10 11
3.2 Chemical & Chemical Test As per Manufacturer Test Verification of Authorized From batches Fabricato rs IRC:83 Test certificate shall be furnished by
Physical i) Determination/ manufacturer Certificate reference Inspector at Random record. (Part-II) Ash manufacturers. For level I acceptance
Test Identification of polymer. certificate & test &Challan document. appointed by content as per sample from randomly selected bearing of
3.2.1 required by zonal Railway IS:3400 part XXII each lot of Elastomer bearing as prescribed in
Authorized and Polychloropr procedure in IS3400 and IRC83 (Part-II) shall
inspector from ene content as be drawn by authorize inspector and tested in
Govt./ NABL per house lab. or in Govt./ NABL approved
approved lab min -do- ASTM-D297 laboratory for all the
-do- Identification of 5 tests. These test are in addition to tests
ii) Polymer content 50% polymer conducted on specially moulded test pieces
iii) Ash content max 5% as per prepared at the time of manufacture of
(iv) Specific gravity -do- ASTM D bearing.
v) Ozone -do- 3677 (as per For Level II acceptance
resistance relevant test tests on specially moulded test pieces to be
procedure) done.
Tests to be done for
(i) Polymer Identification
(ii) Polymer content
(iii) Ash content
(iv) Specific gravity
(v) Ozone resistance Preferably test of
polymer identification, polymer
content and Ash content should be either
witnessed or sealed sample to be sent to
Govt./NABL LAB for evaluation.
For Level-I Acceptance additional test
will be,
(a) Ash content on specimen
from test bearing shall be compared with
these for specially moulded test pieces and
Max variation permitted is ± 0.5%

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspecting Extent of
control
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
(b)Specific gravity on
specimen from test bearing shall be
compared with these for specially molded test
pieces and Max variation permitted is
± 0.2%
(c) For other test max. and
min. limits to be adhered.
(d) Ozone resistance can be
waived by test engineer as per note 2 of
Para
918.4.1.2 of IRC83 Part II. Polychloroprene
Content 60
%
Ash content
Note: (i) No reclaimed rubber, vulcanized
wastes or natural rubber shall be used.
(ii) EPDM (Ethyle propylene Dimonomer), IIR
(Isobutane Isoprene
Copolymer), CIIR (Chloro-Isoprene
Copolymer) are not permitted
for
manufacture of bearings.

3.2.2 Elastomer Physical Test As per Manufacturer test Verification of Authorized From batches Fabricato rs r IRC:83 (Part-II) Test certificate shall be furnished by
(Only virgin With values of manufacturer certificate reference Inspector at & manufacturers.
Polychloropr ene (CR) characteristics specificed certificate & test &Challan document. appointed by Random IS:3400 (as per (For level I acceptance sample from each lot
is permitted & required by zonal Railway relevant test of Elastomer as prescribed in specification
preferable grades are- Authorized procedure) shall be drawn
Neoprene WRT, inspector from by authorize inspector and tested in either In-
Bayprene Govt./ NABL house Lab. or in NABL/ Govt. Approved
110, Skyprene B- approved lab laboratory. For level 2 acceptance, tests on
5 and Denka specially
S-40V) molded test pieces to be done.
a) Hardness IRHD
( 60 ± 5 ) Tests to be done are
b) Min. Tensile strength 16 MPa (i) Composition
c) Min. Elong. at break 425% (ii) Hardness

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Inspecting Extent of Records criteria
control Agency Inspection
1 2 3 4 5 6 8 9 10 11
3.2.2 d) Max. ≤15% (iii) Tensile strength
Cont. Compression set (iv) Elongation at Break
e) Accelerated 100 ± 1o c for (v) Compression set
ageing test 72 Hours (vi) Accelerated Ageing test
i) Max. Change in Hardness ±5% w.r.t. value of (vii) Adhesion Strength
ii) Max. Change (a)
in Tensile strength ±15% w.r.t. IMPORTANT:
iii) Max. Change in value of (b) Properties of Elastomer should be as per
Elongation. ±25% w.r.t. value of Table 1 of IRC:83 Part-II
(c)
(f) Adhesion
strength of Min. 7 KN/m
Elastomer to Adhesion strength test to be conducted as per
Steel Plates IS: 3400
Part XIV.

3.3 Load Test Upto 15MPa All bearing of the lot As per relevant Fabricators Authorized 100% Fabricato rs IRC 83 Part- II For both Acceptance Level 1
on complete bearings shall be tested. drg. and record. Inspector record. & Acceptance Level 2, all
a) Axial load test specification appointed by 100% bearings to be
zonal Railway Checked for axial load tests as per Para
918.4.1.1(3),
check for misalignment of
plates, poor bonding of elastomer and
laminated
steel plate, surface defect, low stiffness etc.
Variation in
stiffness of any one bearing shall not be
larger than 20%
Load testing on of mean of measured values.
Test to be conducted as per Two test In case of Note:-
b) Elastic Annexure 2 of IRC: 83 (Part- bearings. large lot For acceptance level l sample from randomly
Modulus test II) acceptance value of selected bearing of each lot (for destructive
Ea=±20% testing) of elastomeric bearing as prescribed
1÷(0.2/S2+0.0005) in procedure of IS:
MPa where “S “is 3400 & IRS:83 (Part –II) shall be drawn by
shape factor authorized inspector and all test mention from
(b) to (e) are to be got done either in house lab
or in

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 S. Component Characteristic Frequency & Reference Fabriactor’ Inspection details Type of Acceptance Remarks
No. Operation Checks & Tolerances Type of check Document s quality Records criteria
Inspection Extent of
control
Agency Inspection
1 2 3 4 5 6 8 9 10 11
3.3 (c) Shear Modulus test Test to be conducted as per Load testing on Govt./NABL approved lab.
Cont. Annexure 2 of IRC: 83 (Part- Two test bearings. (A) These tests are in addition to tests
II) conducted on specially moulded test
value of G for acceptance pieces prepared at the time of manufacture of
from bearings. Note that the bearing selected for
0.8MPa to 1.2 test
MPa will not be reused and destructive test will be
(d) Stripping strength Load testing on done on sample prepared from them.
test / Adhesive strength Test to be conducted as per Two test
test Annexure 2 of IRC: 83 (Part- bearings. (B) For acceptance level 2 shear modulus
II) examination for evidence tests is mustwhich will be done on randomly
of cracking/ peeling both in selected bearings and which after test can be
strained (Strain value 2.0) used in the bridge.
and unstrained state.

60MPa Ultimate Compressive

(e)Ultimate Strength test.
compressive strength There should be no failure of steel laminate or
test Load testing on irreversible squeezing out of elastomer upto
Two test load of 60MPa.
bearings for
Destructive Test.

Note :- Large Lot means if Number of bearings are ≥ 24 & tests for acceptance level 1 to be conducted. Small lot means if number of bearings are < 24 Where Acceptancelevel 2 tests are done.Lot size to be
approved by the engineer. In large lot 2 extra bearings to be made whichh are consumed in destructive testing.

Manufactured by Contractor Consultant Client