Ref: CG-WI-4.2.

1-1 Page 1 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)

(Ver.–1.0) February - 2016

INDIAN RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS

FOR
COMPOSITE MOULDING FOR FLAT, ANGLE, BASE, CHANNEL USE IN
INDIAN RAILWAYS COACHES.

Month/Year of Revision / Reason for Revision/

S.N. Page No.
issue Amendment Amendment
1. July, 2015 - - First issue
Construction of material and Trial clause
added.
Shear strength test and its test equipment
added.
1,3,6,
2. February , 2016 Revision-1 The sample description for HRR included in
7,8,9,10 note below table 1 and test for HRR added.
Marking and Rejection of marking modified.

Issued By:

Carriage directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow - 226011.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 2 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

INDEX
Clause DESERIPTION Page No.
No.
0 Foreword 3
1 Scope 3
2 Requirements 3
3 Tests 6
4 Sampling and criteria for conformity 7
5 Packing 7
6 Marking 7
Annexure - A 8

SECTION - B
Clause Description Page No.
No.
1. Scope 9
2. Requirements 9
3. Plant, Machinery & Infrastructure 9
Requirements
4. Testing Facilities 9
5. Quality Control Requirements 10
6. Documentation 11
7. Training 11

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 3 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

SCHEDULE OF TECHNICAL REQUIREMENTS FOR COMPOSITE MOULDING FOR

FLAT, ANGLE, BASE, CHANNEL USE IN INDIAN RAILWAYS COACHES.

SECTION - A

0. Foreword:

0.1 This schedule is intended to cover the technical requirements/provisions relating to

materials, constructions and tests and does not include all the necessary provisions of the
contracts.

0.2 This schedule draws references to some of the relevant IS Specifications. Latest versions
of these specifications shall be taken as references.

0.3 For the purpose of deciding whether a particular requirement of the schedule is complied
with, the final value observed or calculated, expressing the result of a test or analysis,
shall be rounded off in accordance with the IS: 2. The number of significant places
retained in the rounded off value should be the same as that of the specified value in this
schedule.

1. SCOPE

1.1 This specification for Composite moulding for flat, angle, base, channel use in Indian
Railways coaches consists of two sections i.e. Section-A and Section-B. Section-A
covers the technical requirements, methods of sampling and tests of Composite moulding
for flat, angle, base, channel use in Indian Railways coaches and Section-B covers
infrastructure requirements of manufacture, testing and quality control.

2. REQUIREMENTS

2.1 Material

2.1.1 Composite Moulding be constructed using extrusion process and Polyvinyl Chloride
Resin (PVC Resin) suitably compounded as raw material so as to confirm to the
requirements of this schedule. The material shall have smooth surface. It should be free
from blisters, pinholes, porosity, blow holes and other visual defects.

2.2 Colour and surface finish

The colour and pattern of Composite moulding for flat, angle, base, channel shall be as
required by purchaser. The surface finish shall be smooth, injury free and no sharp edges
or sharp corners etc.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 4 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

2.3 Workmanship

2.3.1 The Composite moulding for flat, angle, base, channel shall be generally smooth, free
from surface defects, local deformation and other visual defects.

2.3.2 Machining test: - When operations are carried out for installation, the Composite
moulding for flat, angle, base, channel shall be capable of being sawn, drilled and tapped
without splitting or cracking.

2.3.3 Permissible defects as mentioned in clauses 5.4.1 to 5.4.5 of IS: 2046-95, shall be agreed.
However, the requirements given in clauses 5.4.6 to 5.4.8 shall be strictly complied with.

2.4 FUNCTIONAL REQUIREMENTS:

The composite moulding should have following functional requirements: -

1. Fire retardant properties as per existing RDSO standards or as per EN 45545.

2. Injury free and no sharp edges or sharp corners etc.
3. Ease in work and should not result skin itching etc. on body of workers while
drilling hole in it.
4. No painting to be required.
5. Normally it should not require replacement and should go alongwith panel life
minimum on which it is to be fitted.
6. It should properly press and fit on the panel joints so that there is no visible
unpleasant gap length.
7. It should have flexibility to take contour of panel where needed.
8. It should be aesthetically pleasant.

These moulding should work satisfactorily under the following operating conditions and
properties of composite moulding for IR coaches:

2.4.1 COACH DYNAMICS:

Composite moulding for Flat, Angle, Base, Channel used in IR coaches should provide
adequate strength during the vibrations and shocks normally encountered in service as
indicated below:
i) Maximum vertical acceleration 1.0g
ii) Maximum longitudinal acceleration 3.0g
iii) Maximum transverse acceleration 2.0g
The vibrations are of sine wave form and the frequency vibration is between 1 Hz to 50
Hz.
The amplitude ‘a’ expressed in millimeters is given as a function of f, by equations
a = 25/f for values of f from 1 Hz to 10 Hz.
a = 250/f2 for values of f exceeding 10Hz and up to 50 Hz.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 5 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

2.4.2 In the direction corresponding to the longitudinal movement of the vehicle, the composite
moulding is subjected for 2 min. to 50 Hz Vibrations of such a value that the maximum
acceleration is equal to 3g.

2.4.3 COACH-BODY DISPLACEMENT ENCOUNTERED UNDER DYNAMIC

CONDITIONS.

i) Vertically- ±100 mm
ii) laterally - ±55 mm
iii) longitudinally- ±10 mm
iv) bogie rotation about center pivot- ±40

2.4.4 Ambient Conditions

(i) Ambient temperature : -4 C to 50 C
Altitude : Sea level to 2500m
Max. temperature under Sun : 70 C
Relative humidity : 40 to 95
(ii) The rainfall is fairly heavy.
(iii) During dry weather, the atmosphere is likely to be dusty.
(iv) Temperature variations can be quite high in the same journey or short period of
time.
(v) Coaches operate in coastal areas with continued exposure to salt laden air.

2.4.5 Coach Inside Condition:

Inside condition of the coach may consider as under:
The ambient conditions may be similar as mentioned under para 2.4.4 above for Non-air-
conditioned coaches. However in summer day the value of upper range of the temperature
may go up. For AC coaches temperature may be maintained.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 6 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

3 Tests: The Composite moulding for flat, angle, base, channel shall be tested for the
following requirements as per test method given against them .
TABLE-1
S. N Properties Required Test Method
value
1 Sp. Gravity (gm/cm3) 1.5 ( ± 0.2) Appendix A of
IS:6307/1985
2 Hardness (Shore D) 65-95 ASTM D2240
3 Flexural Modulus (Kg/cm2) Minimum. 20000 ASTM D790
4 Tensile strength (Kg/cm2) Minimum. 150 Appendix D of
The shape and size of sample as per IS:13411 IS:6307/1985
Annexure F, Clause F-3.1.2
5 Elongation at break (%) Minimum. 15% Appendix D of
The shape and size of sample as per IS:13411 IS:6307/1985
Annexure F, Clause F-3.1.2
6 Drop impact test To Pass Appendix A
of this Specification
7 Flexibility To Pass Appendix A of IS:3462
8 Water absorption (%) Maximum. (by Weight) 0.5 ASTM D570
9 Ash content (%) Maximum 35% ASTM D5630,
Procedure B
10 Dimensional stability at 20C (Sample made to be in such manner
so product can be tested in supply condition.) IS: 2046 - 95
Machine Direction Curve 4 of Annexure- G
Right angle to machine direction Annexure A

11 Resistance to staining Not worse IS:2046-95Annexure-M

than 5
12 Resistance to colour change (Blue wool standard No.)
In xenon arc light (Minimum) 6
or or IS:2046-95Annexure-N
In enclosed carbon arc light (Minimum) 5 or
IS:2046-95Annexure-O
13 Surface finish (by 60o Specular gloss meter) 15-40 ASTM D523
Gloss value
15 *Resistance to spread of flame (Minimum) Class A Appendix 11 of
UIC546-2 OR
16 **Deterioration of visibility due to smoke Class A Appendix 15 of UIC
(Minimum) 546-2OR
17 Limiting Oxygen Index – Minimum 35 IS: 13360 Part-6,
Section-19
18 Toxicity Less than1.0 NCD 1409
19 ***Heat Release Rate (MARHE i.e. Maximum
Average Rate of Heat Emission in KW/m2) as ISO:5660-1
specified in EN 45545-2:2013 R1 HL3 50 Kw/m2
20 Shear strength (Kg/cm2) Minimum 100 ASTM D 732-02

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 7 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

* , ** and *** The test will be conducted on specially manufactured sample but before
conducting the test Sp. Gravity and Ash Content to be carried out on product for supply and
sample. The Sp gravity with slight variation +0.1 and Ash Content with slight variation +1% to
be considered.

4. SAMPLING AND CRITERIA FOR CONFORMITY:-

The sampling and criteria for conformity shall be as given in clauses 8, 9 and 10 of IS:
2046 - 95. Any sample Composite moulding failing in one or more requirements of the
specification shall be termed as defective. No defective Composite moulding shall be
found in the sample lot to be considered as conforming to the specification.

4.1 No. of Test: -

All the tests given in Table – 1 except Dimensional stability at 20 0C and Resistance to
colour change (Blue wool standard) in xenon arc light shall be carried out on each
lot. The test for Dimensional stability at 20 0C and Resistance to colour change (Blue
wool standard) in xenon arc light are type tests and shall be done once in a year.
However, manufacturers shall carry out these tests for each lot and maintain the records
of test results. Records of test results should be furnished by the manufacturer to
inspecting agency at the time of inspection.
4.2 RDSO may draw the sample for quality checks at its discretion and firm shall arrange the
testing of the samples in a reputed outside laboratory as decided by RDSO. Testing
charges shall be borne by the manufacturer.
4.3 The test for Heat Release Rate (HRR) is type test. Heat Release Rate (HRR) test is to be
done at every six months till 31.03.2016. Thereafter it will be the part of acceptance test.
4.4 Trial of the Composite moulding should be done in limited coaches before approval of
the vendors.

5. MARKING AND PACKING

5.1 Marking- The following shall be marked by printing on the back side of the all
Composite mouldings at distance of 50 cm as under;
5.1.1 Manufacturers name and recognized trademark if any.
5.1.2 Month & Year of manufacture.
5.1.3 Lot or batch number.

5.2 Rejection Marking :

Any lot rejected by inspecting authority during inspection shall be permanently stamped
by “REJECTED” so it cannot be re-offered and used anywhere for Railway Purpose.

5.3 Packing: -
After inspection and approval, Composite mouldings shall be suitably packed to prevent
damage in transit. The method of packing used shall be as agreed to between the
purchaser/inspector and the supplier.
.
Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 8 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

ANNEXURE - A

DROP IMPACT TEST: - The drop impact test shall be carried out with a falling weight
type of impact tester, which shall essentially consist of the following,

i) A rigid metallic base preferably with leveling screws. The base shall have a hole
or a ring of 25mm. inside diameter attached to it for supporting the test specimen
on it. The ring/hole should be so situated that its axis coincides with the line of fall
of the striker. A device for clamping the test specimen to hold it in position while
under impact shall also be provided.

ii) A striker consisting of a 19mm diameter hardened steel ball ended plummet
capable of being clamped released and falling freely in the guides. The spherical
striking surface of the plummet shall be free from faults or any other
imperfections. The entire striker assembly shall weigh 900 gm. The line of fall of
the plummet shall be perpendicular to the specimen surface and shall be
concentric to the axis of the ring.

iii) Superstructure shall consist of rigid frame with guides to adjust the height of the
striker. The height of the frame shall be such that the maximum height of fall of
the striker is not less than 300 mm. and the frame shall be calibrated from 0 to
the maximum of the fall.
iv) The test specimen supported on the ring shall be subjected to drop impact. The
material shall not fracture in drop impact test with a drop height of 200 mm. Minor
cracks on the reverse side, if any should confine to the point of indentation only
and shall not propagate beyond an area with 20 mm diameter.
v) Sample Size: Five test Sample made to be in such manner so product can be
tested in supply condition shall be subjected to test and each of the test
specimens shall confirm to the requirements.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 9 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

SECTION-B
1. SCOPE

1.1 This section covers the infrastructural requirements for manufacture of Composite
moulding for flat, angle, base, channel use in Indian Railways coaches

2. REQUIREMENTS

2.1 All vendor seeking registration with RDSO shall comply all the requirements mentioned
below.

3. PLANT, MACHINERY AND INFRASTUCTURE REQUIREMENTS

3.1 The manufacturers shall have adequate space and a covered area with cemented floor to
accommodate the following.
a) Damp free place for storage of raw materials.
b) Independent manufacturing area for Composite moulding for flat, angle, base,
channel use in Indian Railways coaches.
c) Inspection area.
3.2 The firm should have at least one number Extrusion plant of 65 mm or 75 mm extruder
Dia..
3.3 The firm should have at least one number Chiller plant.
3.4 The firm should have at least one number Grinder.
3.5 The firm should have at least one number Hi speed Batch mixture.
3.6 The firm should have at least one number cut-off Machine.
3.7 The firm should have facility for producing “specially manufactured sample” for FST
properties including HRR.

4. TESTING FACILITIES:
4.1. The firm should have at least one number Electronic/Chemical Balance.
4.2. The firm should have at least one number Tensile strength testing machine.
4.3. The firm should have at least one number water vessel (With specimen holder).
4.4. The firms should have at least one number Impact testing machine (Falling weight
method).
4.5. The firms should have at least one number Dimensional stability machine (Two No.
Conditioning chamber).
4.6. The firms should have at least one number Shor hardness tester for Durometer ‘D’ scale.
4.7. The firms should have at least one number Muffle furness of suitable capacity for
determination of Ash content.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 10 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

4.8. The firms should have the testing facility for resistance to colour change in xenon arc
light or enclosed carbon arc light. In case, in-house testing facility is not available firm
should arrange testing at reputed laboratory as decided between IR/Inspecting authority
and manufacturers. The cost of testing shall be borne by manufacturers.

4.9. The firms should have at least one No. Gloss meter (60 o specular gloss meter)
4.10. The firm should have in-house testing facilities for conducting test for Resistance to
spread of flame, Limiting Oxygen Index, Deterioration of visibility due to smoke and
toxicity.

4.11 The firm should have in-house testing facilities as per ISO 5660-1 for conducting test for
Heat release rate (HRR) w.e.f. 01.01.2016. Till such time, firm should arrange testing at
reputed laboratory as decided between IR/Inspecting Authority and manufacturer. The
cost of testing will be borne by the manufacturer.

4.12` The firm should have the following instruments.

a) Vernier calipers with Digital display
b) Micro meters with Digital display
c) Measuring scale
d) Measuring tape
e) 900 Angles
f) Flatness table
g) Thermometer
h) Hydrometer
4.13 The firm should have arrangement for periodical calibration of all the gauges &
instruments.
4.14 The firms should have at least one number shear strength testing machine.

5. QUALITY CONTROL REQUIREMENTS

5.1 The firm should have acquired ISO: 9001certification from the agency accredited by an
accreditation body which is a part of International Accreditation Forum (IAF), and the
same/ similar product for which the approval is sought should be broadly covered in the
scope of the certification for manufacture and supply.

5.2 The Quality manual of the firm for ISO: 9001- 2000 should clearly indicate at any stage
the control over manufacturing and testing of the said railway product.

5.3 There should be a system to ensure the traceability of the product from raw material stage
to finished product stage. The system should also facilitate to identify the raw material
composition from the finish product stage.

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage
 Ref: CG-WI-4.2.1-1 Page 11 of 11 Date of issue: RDSO/2015/CG-02(Rev-1)
(Ver.–1.0) February - 2016

5.4 It should be ensured that there is a Quality Assurance Plan for the product detailing the
following various aspects
• Organisation chart
• Process flow chart
• Stage inspection details from raw materials stage to finish product stage
• Various parameters to be checked and level of acceptance of such parameters
indicated and method to ensure control over them.
• Disposal system of rejected raw material and components.

5.5 There should be at least one full time technologist having a minimum bachelor’s degree
in relevant field with experience of at least 5 years or a person with diploma in relevant
field with 12 years experience. He should be free from day-to-day production, testing
and quality control responsibilities. He should be mainly responsible for development of
a product, analysis of products, control over raw material, and corrective action in case of
difficulties in achieving the parameters.

5.6 Ensure that the incharge of the Quality Control Section is having a qualification of
minimum bachelor’s degree in the relevant field and has a minimum of 5 years
experience. Alternatively he should be a diploma holder with minimum of 12 years
experience. He should be actively involved in day-to-day activities of quality control /
stage inspection / compliance of QAP etc.

5.7 The firm must ensure that proper analysis is being done on monthly basis to study the
rejections at various internal stages and it is documented.
5.8 The firm should ensure that latest version all the relevant specifications, IS standards are
available with the firm.

6. DOCUMENTATION: Firm shall maintain following documents/records:

6.1 A well documented Quality Plan.

6.1 Incoming raw material register with Test Certificates references of suppliers and internal
test results.
6.2 Stage inspection results including finished products results.
6.3 Records of internal rejection and its analysis vis-a-vis action plan.
6.4 Records of final products inspection by external agencies (like RDSO), Non –Conformity
Reports and case analysis as well as action taken thereof.
6.5 Records for maintenance of dies/moulds.
6.6 Ensure that proper systems are available for dealing with customer complaint.

7. TRAINING
7.1 Training needs should be identified for all concerned officials and regular training shall
be organised and imparted on maintenance of machines, quality assurance, safety
parameters etc.
************************

Signature

Name & Prepared By: C.M. Prasad Checked By: - P.K.Srivastava Approved By: - M.K.Pandey
Designation JE/Design/Carriage JD/ SS/Carriage Dir./SS/Carrage