CG-WI-4.2.1 -1 (Ver.3. 1) Page 1 of 2 Latest (Rev.lAmd.) issue: June'23 Spec. No.

RDSO/2017/CG-02
/ Rev.2 & Corr.No.1

INDIAN RAILWAYS

Document Techn ical Specification- I Yes

content Schedule of Technical Requirement I Yes
Description STANDARDIZED BRAKE DISC FOR LHB COACHES
of item
Remarks Nil

Reason for
S. No. MonthNear of Issue Revision/Amendment Page No.
Revision/Amendment

October, 2017 - - First issue

1.
To improve clarity with focus
All on functional requirements for
2. June, 2021 Rev.1
pages enhancing indigenous vendor
base
. Reduction in field trial period
Relevant as per Railway Board letter
3. April , 2023 Rev.2
pages no. 2021/RS(G)/779/7 dated
18.01 .2022

4. June, 2023 Corrigendum No.1 10 Corrigendum in Para 15.1

Issued By:
Carriage Directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow - 226011
.I ~.
Si nature
Name & Checked by: Vivek Anand
Desi nation SSE/Carria e
 CG-WI-4.2. 1-1 (Ver.3.1) Page 2 of 2 Latest (Rev.lAmd .) issue: June'23 Spec. No. RDSOl20171CG ·02
Rev.2 &Corr.No.1

Corrigendum No.1 to ROSe specification no. RDSe/2017/CG·02 (Rev.2l for Standardized Brake
Disc for LHB Coaches

The kilometres mentioned in Para 15.1 as '1,00,000 Km' may be read as '1,50,000 Km'.

~~------~~~~~~-=~~----~~--------~------~~~~~~ ~?
Signature
Name & Checked by: Vivek Anand
Desi nation SSE/Carria e I
t
•
 CG-F-4.2.1-4 (Rev.1) I Page 1 of 16 Latest (Rev.lAmd.) issue: April '23 Spec. No. RDSO/2017/CG·02 (Rev.2)

INDIAN RAILWAYS

Document Technical Specification- I Yes

content Schedule of Technical Requirement I Yes
Description STANDARDIZED BRAKE DISC FOR LHB COACHES
of item
Remarks Nil

Reason fo r
S. No. MonthN ear of Issue Revision/Amendment Page No.
Revision/Amendment

October, 2017 - - First issue

1.
To improve clarity with focus
All on functional requirements for
2. June, 2021 Rev.1
pages enhancing indigenous vendor
base
Reduction in field trial period
Relevant as per Railway Board letter
3. April, 2023 Rev.2
pages no. 2021/RS(G)/779/7 dated
18.01.2022

Issued By:
Carriage Directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow • 226011

. /
Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand Approved : SudHir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 2 of 16 Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

CONTENTS

CLAUSE DESCRIPTION PAGE NO.

NO.
1. FOREWORD 3
2. SCOPE 3
3. PARTICULAR REQUIREMENTS 3
4. FUNCTIONAL REQUIREMENTS 3
5. DESIGN REQUIREMENTS 4
6. PERFORMANCE REQUIREMENTS 5
7. GENERAL TECHNICAL REQUIREMENTS 5
8. SUBMISSION OF TECHNICAL DOCUMENTS 5
9. APPROVAL OF DRAWING 7
10. DIMENSIONS AND TOLERANCES 7
11. MANUFACTURE 8
12. PROTOTYPE INSPECTION 8
13. PURCHASE INSPECTION 8
14. TESTS 9
15. FIELD TRIAL 10
16. GURANTEE 10
17. AFTER SALES SERVICE 10
18. MARKING 11
19. PACKING 11
20. ANNEXURE -I 12
21 . ANNEXURE-II 14
22. ANNEXURE - III 15
23. ANNEXURE - IV 16

Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand Approved : Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4. 2.1-4 (Rev.1 ) I Page 3 of 16 Latest (Rev.lAmd .) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

1.0 FOREWORD
1.1 LHB type coaches of Indian Railways have been provided with Axle Mounted Disc Brake
system wherein Brake Disc is that part of vehicle brake system that serves to convert kinetic
energy into heat by means of friction . Axle mounted brake discs are ring-shaped castings made
from cast steel or grey cast iron with crosswise cooling ribs.
1.2 This specification is intended to cover the provisions related to grey cast iron brake disc or
superior material to be pressed onto the Wheel set axle.
1.3 Following standards as applicable may be referred to in conjunction with this specification :
a. UIC541-3
b. EN 14535-1
c. EN 14535-3
d. DIN 27205-3
1.4 General:
1.4.1 Following shall be applicable when this item appears in RDSO's vendor directory:
"All the provisions contained in RDSO's ISO procedures laid down in Document No. 00-0-7. 1-
11 dated 19.07.2016 (titled "Vendor-Change in approved status") and subsequent
versions/amendments thereof, shall be binding and applicable on the successful
vendor/vendors in the contracts floated by Railways to maintain quality of products supplied to
Railways.
1.4.2 The Govt. of India policy on 'Make in India' shall apply.
1.4.3 Manufacturer will ensure the usage of environment friendly material and energy efficient in-
stru ments/eq uipments.
2.0 SCOPE
2.1 This specification is intended to provide technical specification for Standardized Brake Disc for
LHB Coaches with interchangeability & ease in maintenance and does not include all the
necessary provisions of the contracts.
3.0 PARTICULAR REQUIREMENTS
3. 1 The firm seeking registration for Brake Disc of LHB Coaches shall register with RDSO as per
extant ISO procedures pertaining to vendor approval guidelines, ISO:9001 certifications etc.
3.2 The firm shaJI have adequate infrastructure for manufacturing, testing and quality control
requ irements of Brake Disc as detailed later in this document. This will be verified by the RD SO
at the time of registration of the firm .
3.3 The firm shall submit their design of brake disc for approval of RDSO .
4.0 FUNCTIONAL REQUIREMENTS
4.1 The Brake Disc of Axle Mounted Disc Brake system shall fulfil the following requireme nts under
Indian Railway service conditions without crack, damage [except as permitted under
DIN27205-3], damage or degradation other than normal wear of the friction face beyond
permissible limits:
4.1 .1 Brake Disc shall permit a braking moment or torque to be generated, supported and
transmitted to the rail vehicle axle .
4.1 .2 Brake Disc shall permit, by frictional engagement of a brake pad or pads, the conversion into
heat of the kinetic energy involved in retarding the vehicles which is attributed to the use of the
disc brake.
4.1 .3 Brake disc shall absorb part o ~ all of the ki fc energy arising from the braking ' co
Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand
Desi nation JE/Carria e SSE/Carria e
CG-F-4.2.1-4 (Rev.1) I Page 4 of 16 Latest (Rev'/Amd.) issue: April '23 Spec. No. RDSO/2017/CG·02 (Rev.2)

4.1.4 Brake disc shall dissipate the absorbed energy by radiation, convection and conduction .
5.0 DESIGN REQUIREMENTS
5.1 The axle mounted brake disc shall consist of a friction ring with cooling ribs and hub. The
friction ring of Brake Disc shall be cast as a single piece or two piece (split brake disc) fo llowed
by its machining on required surfaces as per EN 14535-1. The thickness of the friction ri ng and
the size of the cooling ribs are related to prevent overheating during brake application.
5.2 The brake disc (including friction ring and spokes) shall have adequate mechanical and thermal
capacity for service on and off the Indian Railways, under the environmental and operating
conditions identified in Annexure-III.
5.3 Brake Disc shall be of 12 bolt design.
5.4 Friction ring & hub shall be assembled by using M12 bolts conforming to IS:1 364-2002 Part-I
and IS:1367 -2002 Part-III or equivalent, with suitable mating nuts.
5.5 All parts of the brake disc shall be designed for fatigue strength.
5.6 In the design of axle mounted discs, the fatigue life of the connection between the hub and
friction ring must take into account cyclic loading from thermal and shock environments that are
separately considered and are encountered in normal service.
5'? The fatigue life at the most stressed location in the connection between the hub and spoke, due
to combined stress! strains from thermal load and shock load, shall be equal to or greater than
the projected service life of the friction ring or 20,00,000 km, whichever is greater.
5.8 Brake disc shall be designed and constructed in such a way that in case of hitting of flying
stones raised from ballast track, it does not affect the functional efficiency or cause failure of
the brake disc.
5.9 The connections between brake discs and wheel set axle must satisfy the fo llowing
requirements:
5.9.1 Transmission of brake power.
5.9.2 Largely unrestricted thermal expansion of friction faces and friction segments.
5.10 A minimum true specific weight.
5.1 1 The friction ring shall be designed additionally with a view to minimizing overall weight.
5.12 The friction ring of the brake disc shall have a groove around outside circumference to indicate
the condemning limit and when it has to be replaced .
5.13 The crosswise cooling ribs carry off the heat and serve simultaneously to maintain a thermal
balance within the friction rings.
5.14 Cooling fins that are arranged radially between the friction surfaces provide for sufficient
cooling at the friction ring , and convey a stream of cooling air from the hub through the interior
of the friction ring to the outside, using a centrifugal force that is controlled by speed .
5.15 Low-noise behaviour by the brake disc under all operational conditions.
5.16 Ventilation grids of tbe brake disc to be so designed as to avoid entrapping of debris like paper,
polythenes etc. which may otherwise get trapped in service and cause choking. The design of
the ventilation grids of the brake disc shall achieve proper self-cleaning .
5.17 Brake Disc should be easy to replace . Damaged single piece friction ring if provided can be
dismounted after cutting and it shall be possible to replace with split disc friction ring .
5.18 Supplier should also offer split disc design so that replacement for damaged or worn out friction
rings can be achieved with ease without the necessity of dismounting of wheels from the axles
and also the same can be mounted on hub of standard interface having 12 bol s design.

I
Si nature
Name & Prepared by: Ma singh Meena Checked by: Vivek Anand Approv y: Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 5 of 16 Latest (Rev.lAmd.) issue: April '23 Spec. No. RDSO/2017/CG·02 (Rev.2)

5.19 Unless the purchaser requests otherwise, a suitable hole and groove feature shall be
incorporated to facilitate pressurized liquid assisted assembly and/or disassembly of hub and
axle. The threaded hole connection is to be closed with a locking bolt G1/4A to DIN 90S/DIN
910 and sealing ring A14 x 20 x 1.5 to DIN 7603.
5.20 Where a disc consists of more than one constructional element designed for in-service
replacement of the brake ring or part of it, the associated parts of that disc shall be
interchangeable while the hub or carrier remains installed on the axle or shaft within the
vehicle.
5.21 The design shall be such as to prevent the detachment of any part of the disc at any braking
conditions and at any rotational speed up to the maximum permissible rotational speed in all
degraded conditions (e .g. wear, cracking) up to the limits specified by the supplier.
6.0 PERFORMANCE REQUIREMENTS
6.1 The brake disc is to be so designed that it provides faultless operation under the conditions of
use mentioned at Annexure-III for a period of at least 6 years from the date of commissioning.
6.2 Brake disc should be so designed that it has minimum wear and tear and maintenance
possibility. The wear limit on friction faces and friction segments shall be 2 million kilometres.
6.3 Design of the brake disc shall be such that the performance is not adversely affected under
extreme positions of wheel and suspension movements under maximum wear conditions.
6.4 Brake Disc shall be able to expand during the braking process to avoid crack formation on the
disc. The expansion shall be such that vibrations are minimised.
6.5 Brake Disc shall have a high strength against external dynamic loads (shocks upto 100g).
6.6 The maximum thermal temperature of the brake disc shall in no case exceed the permissible
value beyond which the mechanical properties of the material degrade beyond the design
value .
6.7 The brake disc offered shall be suitable to work with any UIC/RDSO approved Organic Brake
Pads suitable for operational speed upto 160kmph and must qualify frictional and thermal
characteristics as stipulated in UIC 541-3.
7.0 GENERAL TECHNICAL REQUIREMENTS
7.1 The general technical requirements for manufacture of Standardized Brake Disc are
mentioned in Annexure-I .
7.2 The general design and drawing of the brake disc shall be got approved from RDSO.
7.3 QAP for the manufacture and inspection of the brake discs should be prepared by the fi rm
and submitted to RDSO for approval.
7.4 Routine and Type tests on the brake disc shall be done as indicated in Clause 14.
7.5 The prototype testing of any new design brake disc (which is being used by IR for the first time)
shall be witnessed by the RDSO at the firm premises. In case type testing facilities are not
available in firm's premises, the test may be conducted at UIC approved friction test benches or
labs meeting accreditation criteria as detailed in RDSO ISO procedure and firm may have to
submit the Brake Disc Classification Certificate as per Annexure-A of EN 14535-3.
8.0 SUBMISSION OF TECHNICAL DOCUMENTS
S.1 The following technical documents/details shall be submitted by the firm along with application:
S.1.1 The clause by clause comments on this specification, confirming compliance with all the
clauses and elaborating , wherever necessary.

Si nature
,
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand Approved . Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 6 of 16 Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

8.1 .2 Detailed drawing in A1/A2 size of Brake Disc which shall contain details regarding broad
material specification , dimensions, estimated weight, marking particulars, reference to
manufacturing / original collaborator's drawing etc.
8.1.3 Material data sheet for all components i.e. friction ring, hub, bolts etc. shall be made available
for verification to the visiting inspection agency.
8.1.4 In case of new supplier/entrant or any critical design changes in brake disc by existing supplier
which may affect any physical/chemical/functional property of the brake diSc, ' FEA report of
brake disc must be offered to Indian Railways. The maximum stress from the FEA at the
specified load, with a factor of safety of at least 1.50, shall be less than the allowable fatig ue
limit. The FEA report must include an analysis for fatigue life showing the damage factor due to
loads imposed by vertical and lateral axle box acceleration and thermal loads resulting from
friction between disc and brake pads. The FEA report shall include but not be limited to, the
following:
a) Introduction
b) Table of contents
c) Summary
d) Physical properties of each material used for the disc. This table shall include but not be
limited to :
• Yield strength
• Ultimate strength
• Elongation
• Tension modulus
• Compression modulus
• Shear modulus
Minimum values shall be used and shall be selected from material specification
e) Views of key structural areas (spoke, hub-friction ring connections, etc.) showing member
locations and geometry and indicating the material and thickness of each. Other FEA views
may be required where critical stresses are identified .
D A tabulation or fatigue curve justifying the contractor's selection of allowable fatigue
stresses for the disc material for each transition or joint and the fatigue-critical stress
ranges . The FEA report shall include a description of how this process is carried out.
g) The complete test report must be submitted including procedure, raw and inferred data,
and summary of results, including:
• Structural sketches and/or layouts of the critically stressed locations showing locations
and shapes depicted in scale, thickness, section properties and material.
• Diagrams displaying externally applied loads and boundary conditions.
• Colour plots of stress under each load and boundary conditions.
• Natural frequencies of the disc.
8.1.5 In the FEA analysis following braking conditions must be considered with emergency braking
(with maximum deceleration value as 1.3 m/sec 2):
8.1.5.1 Simulation of one emergency braking with new disc.
8.1.5.2 Simulation of two consecutive emergency braking with new disc.
8.1.5.3 Simulation of three consecutive braking (1 emergency braking + 1 service braking + 1
emergency braking) with new disc.

Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand Approved by: Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4,2,1-4 (Rev,1) I Page 7 of 16 Latest (Rev.lAmd,) issue: April'23 Spec, No, RDSO/2017/CG·02 (Rev.2)

8,1,5.4 Simulation of one emergency braking with worn out disc (7mm taken out per side) .
8, 1,5,5 Simulation of two consecutive emergency braking with worn out disc (7mm taken but per side).
,
8,1,5.6 Simulation of three consecutive braking (1 emergency braking + 1 service .braking + 1
emergency braking) with worn out disc (7mm taken out per side),
8,1,5.7 Bolt calculation in the worst of the above configurations,
8,1,5,8 Maximum/Allowable temperature for the Brake Disc and its associated components,
8,1,5.9 Stress & Displacement values under dynamic condition.
8.1 ,6 Hub & Friction ring connecting Bolt calculation report.
8.1,7 The corresponding wear calculations and/or tests at the testing bench .
8,1,8 Details of testing facilities available at manufacturers.
8,1,9 For a new entrant or in case of any design changes of the registered suppliers, the type and
routine test specification and test reports shall be submitted. RDSO or authorized Railway
representative have their discretion to pick up sample for conducting type and routine test.
8,1,10 Operation & maintenance manual and service instructions.
8.2 In addition to the above, further information, if required by the RDSO / Indian Rai lways, shall
be promptly provided by the firm ,
9.0 APPROVAL OF DRAWING
9,1 The design/drawing of the Brake disc shall be developed based on the technical and
performance requirements given in this specification and sound engineering practice . The
entire drawing shall be submitted by the firm with technical data and calculations to RDSO for
approval.
9,2 The drawing shall be developed in SI units.
9.3 Broad material grade/specifications for main components shall be indicated on th e re levant
drawings of the firm and the firm shall supply copies of translation in English of such
specifications/drawings other than Indian Standard specifications to RDSO.
9,4 Approval of the design means the approval of the general design features. Notwithstanding the
approval , the contractor will be wholly responsible for the performance of the Brake disc
offered,
10.0 DIMENSIONS AND TOLERANCES
10,1 Brake discs are intended to be mounted on the axle to RCF Drg. NO.LW02100 with latest
alteration. It shall be ensured by the firm that disc/discs offered are suitable to be fitted on to
the axle as per this drawing,
10,2 Broad specification of the brake disc shall be as under:
a) Dimensions 640 x 110 mm
b) Outer Diameter of friction ring 640-+D/-1 mm
c) Inner Diameter of friction ring 350+1/-1 mm
d) Width of friction ring 110-+D/-03 mm

e) Inner bore 199 mm (H6)

o Width of hub 150 mm
g) Pitch Circle dia of hub/friction ring 276-+D 5/-03 mm
connecting bolt
h) No, of connecting bolts 12 nos.
i) Size of connecting bolts M12
Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand Approved , dhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 8 of 16 Latest (Rev.!Amd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

The reference sketch for general arrangement & interface dimension of hub and friction ring are
provided in Annexure-IV (RDSO Sketch NO.CG-15066 AIt.1). Firm's drawing shall comprise of
the wear limit of 7mm (each side) of friction ring as detailed in Para 5.3.5 of EN 14535-1 . '
10.3 The imbalance of new discs shall be equal to or less than 16g.m.
11.0 MANUFACTURE
11.1 Brake Disc shall be manufactured as per drawing approved by RDSO .
11 .2 Brake Disc shall be free from casting defects.
11.3 No sharp corners or edges shall be present.
11.4 The surface roughness on friction faces shall be Rz~16~m, except where otherwise specified
by the IR or purchaser.
11.5 The surface roughness on hub bore shall be between Ra=0.8~m to 3.2~m, except where
otherwise specified by IR or purchaser.
11.6 The distance of edges from the center of M12 holes should be minimum 20 mm from all sides
in both friction ring & hub.
11.7 Hub connection to the friction ring shall be made properly. The connecting bolts shall be
tightened with the specified torque wrench .
11.8 The brake disc shall be carefully protected against corrosion .
11 .9 The friction faces, friction segments and surfaces which are exposed to high temperature shall
not be provided with surface protection.
11.10 The remaining surfaces shall be provided with either an appropriate lacquer structure or
galvanic coating or phosphating. Other suitable coating for corrosion protection can also be
provided with prior approval of RDSO.
11 .11 Surface protection shall be indicated on the drawing .
12.0 PROTOTYPE INSPECTION
12.1 The manufacturer shall offer at least 3 Nos. Prototype discs of a new or modified brake disc.
Necessary testing according to Para 14 of this specification shall be carried out on test pieces.
12.2 The Prototype inspection of brake disc shall be carried out by RDSO at manufacturer's
premises. The manufacturer shall provide, without extra charges, material, tools and any other
assistance, which may be considered necessary for any test / examination and dimensional
checking.
12.3 After prototype clearance, the brake disc shall be subjected to field trial as per Para 15.0 of this
specification .
12.4 The manufacturer shall preserve three prototype Brake Disc samples for a period of 18 months
from the date of start of field trial.
13.0 PURCHASE INSPECTION
13.1 The purchase inspection shall be carried out at the premises of the manufacturer. The following
procedure shall be followed :
13.2 The Inspecting Authority shall make audit checks of the manufacturing procedure 'Internal
Quality Assurance System' to ensure that the Brake Disc offered for inspection is man ufactured
strictly as per 'Internal Quality Assurance System' and the manufacturer has carried out all the
tests/inspections during manufacturing stage to ensure that the Brake Disc as well as their
components are manufactured strictly to the specification/drawing and quality standard of the
collaborator. During audit checks the inspection Authority shall see from the records of 'Internal
Quality Assurance' that the Raw material used for the manufacture of Brake Disc is as per
specification laid down.
Si nature
Name & Prepared by: Mansingh Meena y: Vivek Anand Approved : Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 9 of 16 Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

13.3 Manufacturer shall have to maintain the internal tests record and present to the Inspection
Authority.
13.4 a
The Inspection Authority shall conduct the following checks/tests of the Brake Disc from lot of
250 Nos. or part thereof.
13.4.1 2% or minimum three number Brake Discs picked up at random shall be checked for
dimensions and tolerances, general workmanship and surface finish as per RDSO approved
drawings .
13.4.2 1% or minimum two disc picked up at random shall be verified for tests mentioned in clause
14.2.1 (a) , (b) , (c) & (d) of specification during inspection. The supplier shall produce relevant
test reports of the test done on the test bars/samples used for the manufacture of particular
batch/loUheat of disc for the tests mentioned in clause 14.2.1 (a), (b), (c) & (d) during purchase
inspection. Manufacturer will also keep the test bar samples with appropriate marking of each
heat code received from casting/forging supplier and shall keep the record of other sub-items
which have gone for manufacturing of brake disc. The test results must be conform ing to
specified values in approved OAP.
The manufacturer shall preserve the test bar samples for the period of 18 months from the date
of supply.
13.4.3 Test reports for 2% or minimum three numbers Disc picked up at random shall be verified for
tests mentioned in clause 14.2.1 (e) & (0 of specification.
13.5 In case the samples picked up fail in any of the tests/checks indicated at clause 13.4. 1 to
13.4.3, the entire lot of the Brake Disc shall be rejected by the Inspecting Authority.
13.6 Inspecting authority shall have access to all detailed manufacturing/orig'inal collaborator's
drawings for all items of equipment. The firm shall be obliged to show these drawings as and.
when called for.
13.7 The inspecting authority may deviate from the agreed procedure if and when found necessary
to re-assure that the material is being furnished in accordance with this specification. In this
regard the manufacturer shall not be entitled to object on any ground whatsoever on the nature
and procedure of testing that'may be followed by the inspecting authority.
14.0 TESTS
14.1 Type Test
14.1 .1 The following tests shall constitute type tests and shall be carried out in accordance to EN
14535-3 at the time of Product approval of new entrant or at the time of design change or
localization of-existing design:
a) Performance and Endurance Test
b) Centrifugal Test
c) Ventilation Test
d) Heat dissipation test
14.2 Routine Test
14.2.1 The following tests shall constitute routine tests and shall be verified against value specified in
manufacturer's specification/OAP:
a) Chemical characteristics
b) Hardness
c) Tensile Testing
d) Micro-structure

Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand
Desi nation JE/Carria e SSE/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 10 of 16 I Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2) I

e) Magnetic Particle' Testing

D Residual imbalance
15.0 FIELD TRIAL
15.1 Brake Disc Shall be subjected to field trials on minimum 18 coaches (Preferably 1 rake) for a
period of minimum 09 months or 1,00,000 Km whichever is earlier. The following parameters
will be monitored during field trial:
• Mechanical integrity.
• Wear characteristics including wear rate .
• Fastening system performance (loosening/breakage of bolts etc.).
• Breakage of cooling fins.
• Any other cracks, breakage or adverse effect on other system components .
15.2 After the satisfactory performance of the brake disc in field trials, the disc offered may be
considered for regular service on Indian Railways.
16.0 GUARANTEE
16.1 The firm shall at their cost replace the Brake Disc failing prematurely or proving unsatisfactory
in service for reasons attributed to defective/faulty design, defective material or poor
workmanship within a period of 72 months from the date of delivery or 66 months fro m the date
of fitment, whichever is later. This warranty shall survive, notwithstanding the fact that the
brake disc may have been inspected, accepted and payment thereof made to the firm.
16.2 Brake Disc shall be subjected to detailed trials as discussed in Clause 15 of the specification.
Any modifications found necessary as a result of these tests or furthe r service trials shall be
carried out by the contractor at his own cost in the coaches in a manner approved by the
purchaser. All schematic layouts and installation drawings incorporating the modifications shall
be submitted to RDSO for final approval.
17.0 AFTER SALES SERVICE
17.1 Firm may be required to send their technical expert during the installation and commission ing
of their brake disc on coach/coaches. The charges for this service shall be quoted separately.
17.2 Firm shall also depute its technical expert on request by the Purchaser/RDSO to investigate
and attend to specific problems that may come up during actual operation of Brake Disc.
17.3 Firm shall supply at least 3 copies (soft & hard copy both) of the Operation & Maintenance
Manuals and ·Servicing Instructions to each coaching depot where LHB coach maintenance is
done, detailing :
17.3.1 Brief details of brake disc.
17.3.2 Details of attention to be given during IOH/POH or any other schedule examination.
17.3. 3 Details of tools & machinery for maintenance of brake disc.
17.3. 4 Typical defects and their remedial measures.
17.3.5 Maintenance standards including clearances and tolerances at various locations and
permissible limits of wear for good service performance of equipments.
17.3.6 Firm shall submit the frequency and detailed work content of various inspection / maintenance
schedules necessary for maintenance of brake disc offered by them. Whether these
requirements are time based or distance travelled based shall be indicated fo r each schedu le.

Si natu re
Name & Prepared by: Mansingh Meena Approved . Sudhir Singh
Desi nation JE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 11 of 16 I Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017lCG·02 (Rev.2)

18:0 MARKING
18.1 The detailed form of the marking shall be indicated on the drawing. The following shall be
marked in the part in a clearly recognizable way: '
a) Manufacturer's data (manufacturer's name / trade mark), month & year of manufacture and
serial number.
b) Residual imbalance in g.m (Data regarding residual brake disc imbalance shall be located
directly in the place where the imbalance occurs) .
The above data shall be stamped/engraved and be clearly legible at an appropriate location.
19.0 PACKING
19.1 Supplier shall ensure that Brake Discs in assembled condition are adequately packed before
dispatch to prevent damage in transporting, handling and storage . Packing for safe
transportation shall be the responsibility of the manufacturer.

Note: The date of enforcement of the specification is with immediate effect i.e. date of issue of
specification.

Si nature
Name & Prepared by: Mansi gh Meena Checked by: Vivek Anand Approved : Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4(Rev.1) I Page12of16I Latest (Rev.lAmd .) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

AN NEXURE·I
INFRASTRUCTURE &TESTING FACILITIES REQUIRED FOR MANUFACTURE OF
STANDARDIZED BRAKE DISC USED IN LHB COACHES OF INDIAN RAILWAYS
1.0 SCOPE
1.1. This section covers the infrastructural requirements for manufacture of standardized brake disc
used in LHB Coaches of Indian Railways.
2.0. REQUIREMENTS
2.1 All vendors seeking registration must fulfill the requirements of this schedule.
2.2 The firm should have adequate plant, machinery and manufacturing capacity for manufacture
and supply the brake disc within the delivery schedule.
2.3 The firm should have a well-established quality control system and testing facility to ensure
adequate quality at all stages of manufacture.
3.0 PLANT, MACHINERY AND INFRASTRUCTURE REQUIREMENTS
3.1 The Manufacturer shall have adequate space and covered area with cemented floor to
accommodate the following and for smooth logistics:
a) Damp-free place for storage of raw materials.
b) Adequate manufacturing area.
c) Finishing , Assembly and Inspection area.
d) Storing and dispatch of finished products.
3.2 The Manufacturer shall have following machines/facility:
3.2 .1 *For Friction Ring
Vertical Turret Lathe/Special Purpose Machine (SPM):
Capacity: Minimum turning diameter 700 mm
Minimum turning thickness 200 mm
3.2.2 *For Hub
a) Turret Lathe/Special Purpose Machine (SPM): For machining, facing, drilling, internal
boring & finishing operation etc.
Capacity:. Minimum turning diameter 400 mm
Minimum turning length 200 mm
Minimum turning internal bore size 199mm (H6)
b) Grinding machine of suitable capacity for grinding of inner bore size.
Note:(*) It shall be acceptable if requirements at Para 3.2.1, Para 3.2.2 (a) & (b) are fulfilled by
one or more machines.
3.2.3 For Brake Disc
a) Hub & Friction Ring assembly stand having suitable jigs & fixtures with auto
torqueing tool having screw tightening sequencing program.
b) Auto balancing machine for Brake Disc (with material removal provision).
4.0 TESTING FACILITIES
The manufacturer shall have the following testing equipments to test the product as per the
requirements of the specification , installed in a workstation with controlled emperature and
humidity.
Si nature (

Name & Prepared by: Manslngh Meena Checked by: Vivek Anand Approve y: Sudhir Singh
Desi nation JE/Carria e SSE/Carria e Jt. Director/Carria e
 CG-F-4.2. 1-4 (Rev.1) I Page 13 of 16 I Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG·02 (Rev.2)

a) Magnetic particle testing facility.

b) 3-D CMM for checking geometrical dimensions.
Other required testing facilities to conduct routine tests should also be available .
5.0 QUALITY CONTROL REQUIREMENTS
5.1 The firm should possess ISO:9001 certificate issued by International Accreditation Forum (IAF)
under Multilateral Recognition Arrangement (MLA) for his works address, covering the item for
which he seeks registration with ROSO.
5.2 Quality manual of the firm for ISO:9000 should clearly indicate provisions for control over
manufacturing and testing of the railway product.
5.3 The firm should submit the Quality Assurance Plan (QAP) as per ROSO's relevant ISO
document.
5.4 The firm must ensure that proper analysis is being done on regular basis to study the
rejections at various internal stages and this analysis is well documented.
5.5 The firm should ensure that latest versions all the relevant specifications & referred standards
are available with the firm.
5.6 Records for traceability of product / parts thereof from raw material upto finished stage should
be available.
5.7 There should exist a quality manual of the firm indicating the extent of control for production
and testing.
5.8 Documented System for calibration of testing & measuring equipment and records thereof.
6.0 DOCUMENTATION
Firm shall maintain the following documents/ records:
6.1 A well-documented Quality Plan.
6.2 Incoming raw material register with Test Certificates, references of suppliers and internal test
results.
6.3 Stage inspection results including finished products results .
6.4 Records of internal rejection and its analysis vis-a-vis action plan .
6.5 Records of final products inspection by external agencies (like ROSO/Railways), Non-
Conformity Reports and case analysis as well as action taken thereof.
6.6 There should exist a system of documentation in respect of rejection at customer end, warranty
replacement and in service performance.
6.7 Records of raw material received and supplies made to Railways against the raw material.
Incoming raw material with TC reference of supplier as well as internal test/audit checking from
outside agency.
6.8 The details regarding stage inspection and test results thereof.

Si nature
Name & Prepared by: Mansingh Meena Approved by: dhir Singh
Desi nation JE/Carria e Jt. Director/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 14 of 16 I Latest (Rev.lAmd.) issue: April'23 Spec. No. RDSO/2017/CG-02 (Rev.2)

ANNEXURE-II

DESIGN DATA AND LOAD CASES FOR BRAKE DISC

a) THERMAL LOAD AND BRAKING SCENARIO

S. Description Unit Emergency Service

No. Braking Braking
1. Mean Braking Radius meter 0.247 0.247
2. Wheel diameter (New) meter 0.915 0.915
3. Wheel diameter (Worn) meter 0.845 0.845
4. Mean Co-efficient of friction of Brake Pads - 0.35 0.35
5. Surface Area of Brake Pads cm 2 400 400
6. Braked Mass kg 8000 8000
7. Starting velocity kmph 160 160
8. Final velocity kmph 0 0
9. Brake application time sec 4 4
10. Deceleration rate m/sec 2 1.2 0.80
11. Clamping force per disc kN 42 25
12. Kinetic energy MJ 7.9 7.9
13. Load cycles - 6000 62500

b) IMPACT LOAD

S.No. Description Vertical Axial

1. Standard Impact 25g 3g
2. Extraordinary Impact 100g 100g
Note: 19 = 9.8 m/s2

Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand
Desi nation JE/Carria e SSE/Carria e
 CG-F-4.2.1-4 (Rev.1) I Page 15 of 16 I Latest (Rev'/Amd.) issue: April '23 Spec. No. RDSO/2017/CG·02 (Rev.2)

An nexure·1II
OPERATING CONDITIONS FOR BRAKE DISC

1. Coach Type LHB Type BG Passenger

Coaches
2. Axle Load 16.25t (max.)
3. Gross Load (Coach) 65t (max.)
4. Gross Load (Train) 1700t (max. without loco)
5. Operating speed (max) 160 kmph
6. Maximum deceleration 1.3 m/sec2
7. Emergency Braking distance (min) 1200 meter
8. Wheel diameter 915 (New)
845 (Worn)
9. Wheelbase 2560mm
10. Minimum clearance above rail level 91 mm under loaded and worn
condition
11 . Maximum bogie rotation and swing 3.50, 82mm
12. Track Parameters

a) Steepest Gradient 1 in 37
b) Sharpest curvature 145.83 m radius
c) Super elevation (max) 185 mm
13. Environmental conditions
a) Maximum temperature under sun 70 °C
b) Maximum temperature under shade 45 °C
c) Minimum temperature at Night -10 °C
d) Altitude Sea level to 1776 meters
e) Humidity 100% saturation during rainy season
D Rain falls Fairly heavy
g) Atmosphere during hot weather Dusty
Note: Coaches shall be working in coastal area with saline and corrosive atmosphere.
14. The vibrations and shocks normally to be encountered in service.
a) Maximum vertical acceleration = 3.0 g
b) Maximum longitudinal acceleration = 5.0 g
c) Maximum transverse acceleration = 2.0 g

Si nature
Name & Prepared by: Mansingh Meena Checked by: Vivek Anand
Desi nation JE/Carria e SSE/Carria e
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