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Ref: CGW 0001 Page 2 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

INDEX

Cl. No. Contents Page

0 Foreword 3
Section-A
1 Scope 3
2 Materials 3
3 Sampling 4
4 Properties 4
5 Tests 5
6 Storage and shell life 5
Annexure - I Proforma 7
Appendix - 1 Fibre content and Fibre length 8
Appendix - 2 Resistance to boiling water 9
Section-B
1 The System 10
2 Plant, machinery and infrastructure requirements 10
3 Records 10
4 Approved manufacturers 10
 Ref: CGW 0001 Page 3 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

SCHEDULE OF TECHNICAL REQUIREMENTS FOR SHEET MOULDING

COMPOUND (SMC) TO BE USED FOR MANUFACTURE OF FRP PRODUCTS

0. FORWARD

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 Naval, ASTM, UIC and other
Indian Standard specifications. Unless otherwise specified, the latest version of the
relevant specifications shall be taken as reference.

0.3 For the purpose of deciding whether a particular requirement of this schedule is complied
with the final value observed or calculated, expressing the result 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.

0.4 In this schedule, due consideration has been given to the development in the field of
polymeric materials process technologies, serviceability requirements of the Indian
Railways as the practice followed in advanced countries in this field.

0.5 This schedule consists of two sections i. e- Section-A and Section-B. Section-A covers
the technical requirements, methods of sampling and tests for the Sheet Moulding
Compound proposed to be used for manufacture of FRP products for use on Indian
Railways and Section- B covers infrastructure requirements for manufacture, testing and
quality control at the works of the manufacturers.

SECTION - A

1. SCOPE:

1.1 This section covers the technical requirements, methods of sampling and tests for the
Sheet Moulding Compound to be used for manufacture of FRP products for use on Indian
Railways.

1.2 This Schedule shall be read along with the Schedule of Technical Requirements for
relevant products.

2. MATERIAL

2.1 Sheet Moulding Compound shall consist of resin, glass fibre reinforcements, fillers and
additives etc. processed in a continuous sheet form.
 Ref: CGW 0001 Page 4 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

2.2 Resin, glass fibre & other additives used in the manufacture of SMC shall be selected
such that the product conforms to the requirements as laid down in this Schedule and the
relevant product specifications.

3. SAMPLING:

3.1 Samples shall be selected at random from each lot of SMC stock from which the products
will be manufactured.

3.2 Five test laminates of 320 x 320mm size and 3 to 4mm mm thick shall be compression
moulded from samples drawn from each batch with the facilities available with the
manufactures/moulders. These test laminates shall be post cured in an oven at 80 ± 5ºC
for at least six hours or at 100 ± 5ºC for 4 hours and conditioned for 16 hrs. before test
are undertaken.

3.3 If schedule of requirements for the product stipulates that the same shall be fire retardant,
the test laminates as specified in product specification shall also be prepared by
compression moulding for testing of fire properties.

4. PROPERTIES

4.1 Workmanship and finish - The test laminates shall be free from crack, crazing, blister,
porosity, air-bubble, dry spot and other surface defects.

4.2 Physical properties - The test specimen prepared from the laminates when tested as per
the method of test indicated against each test shall conform to the requirements as laid
down in Table1.

TABLE-1

S. No. Property Specified Value Method of test

1 Specific gravity 1.75 - 2.0 ASTM D-792
2 Hardness, minimum
a) Barcol Hardness 48 ASTM 2583-67
OR
b) Rockwell R 115 ASTM D 785
3 Tensile strength (in any direction) (MPa) 70 ASTM D-3039
minimum.
4 Cross breaking strength (in both directions 150 ASTM D-790
at a testing speed of 25 mm per minute
with supports and loading nose of 1.5 mm
radius) Mpa. minimum.
5 Compressive strength 150 ASTM D-695
(Proof test) (Mpa) minimum.
6 Izod Impact strength (J/m) minimum. 450 ASTM D-256
 Ref: CGW 0001 Page 5 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

7 Water absorption at 0.5% ASTM D-570

27+2°C for 24+0 hrs., Maximum
8 Fibre content (%) minimum 35 Appendix 1
9 Fibre length 50% of the fibres Appendix 1
shall not be less
than 50 mm in
length
10 Resistance to boiling water Shall pass the Appendix-2
test

4.3 Fire worthiness Properties – Fire worthiness properties specified in table – 2 shall be
carried out as specified in relevant product specifications.

TABLE-2

S. No. Property Specified Value Method of test

1 Resistance to spread of flame Minimum Class ‘B’ Appendix-11 of
UIC-564-2 OR
2 Deterioration of visibility due to Minimum Class ‘B’ Appendix-15 of
smoke UIC-564-2 OR
3 Limiting Oxygen Index Minimum 28 IS: 13501
4 Toxicity Index Less than 1.5 NCD-1409

5. TESTS AND SAMPLING

5.1 The manufacturers shall furnish the Purchasing/Inspecting authorities the details of tests
and inspection records and other relevant records as required under the quality control
systems in force. These records & reports shall be maintained by the Competent
Technical Authority of the manufacturers and shall be open to examination by the
Purchasing/Inspecting Authorities at all reasonable a time.

5.2 The Purchasing/Inspecting Authorities at their discretion may draw samples of materials
at any stage of production for conformity tests either at the works of the manufacturers or
in an approved laboratory and the testing charges will borne by the manufacturers.

5.3 In case the samples do not conform to the requirements of the respective specifications,
double the number of samples from the same lot/batch shall be drawn for re-tests. Should
any of the re-test samples do not conform to the requirements, the entire lot/batch shall be
rejected.
 Ref: CGW 0001 Page 6 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

6. STORAGE AND SHELL LIFE:

6.1 The SMC stock shall be stored in a cool, dark and dry place, preferably at temperature
not beyond 30ºC. The stock shall be consumed within 45 days from the date of
manufacture.

6.2 In case the stock is not consumed within 45 days, tests as per clause 4 shall be conducted
again. If the SMC stock passes all the tests in re-testing, the same shall be consumed
immediately.

6.3 Stock of SMC shall be stored batch wise and in such a manner that it shall be possible to
easily identify the batch of each lot.

6.4 Details of stock of SMC stored by manufacturer shall be kept in a register maintained in
the format given in Annexure-I and shall be available for examination by the purchaser or
inspecting authority.
Ref: CGW 0001 Page 7 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

ANNEXURE - I

Fibre Date of
Batch Name of SMC Date of Date
Quantity Glass manufacture Initial
No. manufacturer Receipt Consumed
Content of batch
 Ref: CGW 0001 Page 8 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

APPENDIX - 1

FIBRE CONTENT AND FIBRE LENGTH

1. This test is to distinguish SMC with longer fibre from DMC and to ensure that SMC has
the stipulated fibre content. This method is not suitable for determining fibre content if
the filler is not removable by washing with hydrochloric acid in such a situation FRP
manufacturer shall indicate the test method.

2. At least two specimens cut out from two different laminates as per Clause 3.2 shall be
selected for checking of fibre content. All weighing shall be to the nearest 0.01 gm.

3. Specimen of size 75 x 75 mm shall be cut from the corners of the square laminates.

4. A silica dish of appropriate dimensions shall be heated in a muffle furnace at 575 +25ºC
for 15 min., cooled in a desicator and weighed (W1). The test specimen shall then be
placed in the dish and the whole unit heated at 105ºC for 2 hours, cooled in a desicator
and weighed (W2).

5. The sample with dish shall then be heated in a ventilated muffle furnace at a temperature
of 575 +25ºC for 30 minutes, cooled in a desicator and weighed (W3). This process is
repeated until the difference in weight in successive weighing is less than 0.01 gm.

6. The contents in the dish shall be treated with concentrated hydrochloric acid and the acid
shall be removed by washing. The contents remaining in the dish shall then be dried at
105ºC for 2 hours and weighed (W4). This process shall be repeated until the difference
in weight is less than 0.01 gm. The length of the fibre selected from the Centre of the
sample on the dish away from cut edges shall be measured and recorded. The contents
shall be examined to find whether filler particles still remain within the contents. If filler
particles are not present, the fibre content shall be calculated as follows: -

Firbre content (%) = 100 x (W4 - W1)

(W2 - W1)

The approximate filler content shall be as follows:

Filler content (%) 100 x (W3 - W4)

(W2 - W1)

7. REQUIREMENTS

7.1 Fibre length: - 50% of the fibres shall not be less than 50 mm in length and rest shall be
between 25 and 50 mm.

7.2 The fibre content shall be not less than the values specified in the relevant product
specifications.
 Ref: CGW 0001 Page 9 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

APPENDIX - 2

RESISTANCE TO BOILING WATER

1. This test is to assess the amount of water absorbed in boiling water and soluble matter
and to serve as an accelerated weathering test.

2. Three test specimens used for measuring cross-breaking strength as per ASTM -D - 790
shall be prepared. The specimens shall be dried in an oven at 50+3ºC for 24 hrs., cooled
in a desicator and weighed (W1). These shall then be immersed in boiling distilled water
for 4 hours. The specimens shall then be cooled for 15 minutes in water at room
temperature and dried with a clean cloth or filler paper and weighed (W2)

3. The specimen shall then be redried in an oven at 50±3ºC for 24 hours, cooled in a
desicator and weighed (W3). The percentage of water absorption.

= 100 x (W2 - W3)

W1

The percentage water soluble matter = 100 x (W1 - W3)

W1
4. The specimens shall then be tested for cross-breaking strength as per ASTM D-790(say
CBS-2) and percentage reduction computed against the value obtained with the original
sample (cross breaking strength, CBS-1)

Percentage reduction = (CBS-1 - CBS-2)

CBS-1
5. Requirements

5.1 The test specimens shall not show any warping, cracking or change in appearance.

5.2 The percentage of water absorbed (average of three measurements) shall be less than 2%.

5.3 Percentage of water soluble matter shall not exceed 0.1%.

5.4 The percentage reduction in CBS (Cross-breaking strength) after boiling in water for 4
hours shall not be more than 20%.
 Ref: CGW 0001 Page 10 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

SECTION – B

CODE OF PRACTICE FOR QUALITY CONTROL AND INSPECTION

1 THE SYSTEM

1.1 The manufacturers shall furnish to the purchasing/Inspecting Authorities information in

respect of quality control systems in force at their works on various materials used in the
manufacture of components.

2 PLANT, MACHINERY AND INFRASTRUCTURE REQUIREMENTS

2.1 The manufacturers shall have adequate space and covered area with cemented floor to
accommodate the following:

a) Damp free place for storage of powder chemicals and other raw materials
including bought out items.
b) Independent manufacturing areas for various FRP components and SMC
separately.
c) Storing of SMC rolls & components and dispatch of finished products.
d) Finishing and inspection area.

2.2 SMC manufacturing plant owned by any manufacturer should be capable of producing
500mm width (Min.) SMC sheet and shall be equipped with speed controller. The firm
shall also have stainless steel container with high-speed motorised stirrer for resin
mixing.

3 RECORDS

3.1 The manufacturers shall furnish the Purchasing/Inspecting authorities the details of tests
and inspection records and other relevant records as required under the quality control
systems in force. These records & reports shall be maintained by the Competent
Technical Authority of the manufacturers and shall be open to examination by the
Purchasing/Inspecting Authorities at all reasonable a time.

4 APPROVED MANUFACTURERS

4.1 For reasonable quality assurance, it is desirable that the components are procured form
manufacturers approved by Research, Designs & Standards Organisation (RDSO),
Lucknow or by any other agency as assigned by the Purchasing Authority, based on
evaluation of the components as per the specification, manufacturing & quality control
facilities and quality/assurance programme. However, such approval does not guarantee
the supply of consistent quality of material/components; & therefore, every lot/batch
offered shall be subjected to inspection and testing as per the specification.
 Ref: CGW 0001 Page 11 of 11 Date of issue: Spec. No. RDSO/2007/CG-01
(Rev. – 3) April, 2007

4.2 The approved manufacturers shall be subjected to periodical re-apprisal (periodicity for
each components shall be assigned by the approving authority). In case of withdrawal of
any manufacturing & quality control facilities provided at the time of approval or the
components produced at the time of reapprisal are not conforming to the specification,
the manufacturers are liable to be withdrawn from the approved list. The approving
authority reserves the right to withdraw the manufacturers from the approved list without
assigning any reason.

4.3 The consignee may also periodically arrange testing if so desired, in an approved
laboratory for conformatory tests within six months from the date of receipt of the
supplies, in their original packings. In case of samples do not conform to the
specification, the consignees may at their discretion suspend the manufacturer for further
supply and the fact brought to the notice of approving/inspecting authorities for
appropriate action.