(For official use)
SPECIFICATION NO. WD –U/FRAME – 86 – CS -2
FOR UNDERFRAME OF
PHOSHORIC ACID BOGIE TANK WAGON
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF TRANSPORT,
DEPARTMENT OF RAILWAYS
LUCKNOW – 226 011
PRICE Rs. 1,650.00
C O N T E N T S
3 Leading Particulars
4 Particular Requirements
5 Testing of Underframe
7 Painting and marking
9 Standard Specification
11 ‘As made’ Drawings
List of IRS, BS, IS and DGS&D Specifications superseded by ISI I
Specifications and corrigendum slips to IRS Specifications.
List of key Design Drawings. II (A)
List of part Drawings. II (B)
Method of determining tare weight of wagons. III
Tentative Specification for adhesive for joining hose pipes to swan IV
NO. WD –U/FRAME – 86 – CS –2
FOR THE SUPPLY OF UNDERFRAME FOR
PHOSHORIC ACID BROAD GAUGE BOGIE TANK WAGON
1.1 This specification covers the particular requirements of manufacture and supply
of underframe complete in all respects for Broad Gauge Bogie Phosphoric Acid
Tank wagons strictly to Drg. No. WD – 84064 – S – 01 alt.1 and other relevant
drawings as provided hereafter in this particular specification. These underframes
shall confirm to the requirements of this specification No. R6–59. (Read with all
1.2 Contractor will be responsible for the safe delivery of completed underframe at
the premises of barrel manufacturer. He should take such special precautions so as
to ensure that underframe do not develop any permanent set during transit.
1.3 Key design drawings and IRS Standard Components used are indicated in list A
and B respectively of Annexure – II. The Contractor shall prepare his own
working drawings based on the aforesaid key design drawings and submit them to
the ’Engineers’ for approval before undertaking construction.
1.4 The Contractor shall ensure that the working drawings submitted for the approval
of the Engineers are fully in accordance with the key design drawings and
deviation, if any, are specifically pointed out. Approval of the ’Engineers’ will
only pertain to the general design features, important controlling dimensions and
the deviations from the key design drawings specifically pointed out by the
Contractor. Engineers will not check correctness of the details in the drawings and
the responsibility for the same will be that of the Contractor.
2.1 ‘PURCHASER’ means the party placing the contract. 1.0 ‘Engineers’ means Research, Designs & Standards Organisation, Ministry of
Railways, Manak Nagar, Lucknow – 226 011.
2.3 ‘Inspection Officer’ means the officer and his deputies, nominated by or on behalf of the
Director General, RDSO, Manak Nagar, Lucknow – 226 011 to inspect the work on his
2.4 ‘Contractor’ means the person, firm or company on whom the order for manufacture
and supply of the underframe is placed and shall be deemed to include the Contractor’s
successors (approved by the Purchaser), representatives, heirs, executors and
administrators, as the case may be, unless excluded by the terms of the Contract.
2.5 ‘Sub–Contractor’ means the person, firms or company from whom the Contractor may
obtain any material or fittings to be used in the manufacture of the above said
3. LEADING PARTICULARS
3.1 Gauge 1,676 mm (5’–6“)
3.2 Length over headstocks 12,000 mm
3.3 Bogie Centres 8,000 mm
3.4 Length over coupling faces 12,929 mm
3.5 Maximum Axle Load 20.32 tonnes
4. PARTICULAR REQUIREMENTS
4.1.1 The general arrangement of the underframe shall be to Drg. no. WD-84064-S–03.
4.1.2 Cradle shall be fabricated as per Drg. No.. WD-84064-S–09. But holes for the bolts
meant for barrel mounting shall be left un-drilled.
4.1.3 The rivets shall be of steel to specification No. IS: 1148 and shall conform to the
specification No. IS: 1929 or IS : 2155 as the case may be.
4.2 Draft and Buffing Gear.
4.2.1 The wagon shall be equipped with automatic centre buffer coupler of knuckle type
(Non–transition) with draft gear as shown in drg. No. WD–84064–S–15 and as per
RDSO specification No. SL-BD-80 (with latest amendments).
4.2.2 Coupler operating mechanism shall be positioned as shown in drg. No. WD–84064–S–
4.3 Air brake:
4.3.1 The wagon shall be equipped with twin pipe graduated release air brake equipment
generally in accordance with RDSO’s specification No. WD-02-ABR-84. The layout of
the complete air equipment shall conform to RDSO’s drg. No. WD–84064–S–13
incorporating automatic load sensing device for empty load change over. The
Contractor shall have to submit layout for fitment of his proposed Automatic Load
Sensing device, approved by his Principal, to UIC fabricated bogie (Box wagon bogie)
running over Indian Railways. Special consideration will be given to the Contractor who
will submit a layout involving minor / no modification to the existing UIC bogie. Such
layout will however require RDSO’s approval.
4.3.2 The pipes and joints consisting of brake pipe, feed pipe, branch pipe and pipe joints shall
be as specified in specification No. WD-04-ABR-84.
4.3.3 The complete air brake equipment including the pipe and joints shall be fitted with
pattern underframe as per RDSO’s layout drg. No. WD – 84064 – S – 13 and offered to
the Inspecting Officer for approval. The contractor shall carry out any modification in
the layout of the air brake equipment if found necessary by the Inspecting Officer.
4.3.4 The Contractor shall proceed with the bulk production of the pipes and joints only after
the final approval of the layout of complete air brake equipment is fitted on the
underframe correctly as per dimensions shown in the layout drawing. Special care must
be taken with regard to the clamping arrangement of the pipes to the underframe.
4.4 Brake Gear:
The wagon shall be equipped with the underframe brake gear in accordance with the
arrangement shown in drg. No. WD – 84064 – S – 11 incorporating auxiliary equipments
such as slack adjuster and automatic load sensing device meant for UIC type fabricated
bogie. The Contractor shall also ensure correct functioning of the brake gear components
in conjunction with air brake equipment.
4.5.1 For Bogie refer specification No. WD-01-UIC/Bogie-84.
4.6.1 General requirements and comprehensive guidance with regards to fit-up for welding,
welding procedure and inspection of welded joints are contained Technical pamphlet No.
G – 37, which can be had from DG / RDSO, Lucknow – 226 011. 4.6.2 Whenever welding is specified or adopted in the manufacture of the U/frame or in the
fabrication of such assemblies and components the manufacture shall submit his
proposed welding procedure and sequence to the Inspecting Officer for approval. This,
however, will not in any way, reduce the Contractors’ responsibility for satisfactory
execution of the Contract in all respects as stipulated in cause 4 of IRS Specn. No. A – 5
(Referred in IRS Specn. No. R 6 – 59, Clause 4).
5 TESTING OF UNDERFRAME
1.1 Before proceeding with regular production of the underframe, a pattern
underframe shall be manufactured and offered for inspection. The underframe
shall be inspected / tested in accordance with clause 26 of IRS Specn. No. R 6 –
59. Load test of the pattern underframe shall however, be done as per drg. No.
WD – 84064 – S – 19. Any modification, that may be called for as a result of
these tests, will have to be incorporated free of cost by the underframe
manufacturer in the bulk production.
1.2 The test of Air brake system fitted to the pattern underframe shall be carried out
as the procedure to be issued Engineers at a later stage.
The inspection of underframe complete with bogie and other components is to be
carried out by RDSO Wagon Inspection Directorate. The underframe
manufacturer will provide all the facilities to the Inspecting Officer as is at
present being given to them for the inspection of Railway Rolling Stock.
7 PAINTING AND MARKING
The underframe shall be painted in accordance with the clause 28 (a) of IRS Specn. No.
R 6 – 59. The underframe shall however, be cleaned and coated with priming paints only
by the manufacturer and finishing paint shall be done by the Barrel manufacturer. The
underframe shall be numbered serially as 1, 2, 3 and so on by the underframe
manufacturer as a despatch reference to the barrel manufacturer. The marking shall be in
accordance with the Clause 25 of IRS Specn. No. R 6 – 59 (read with corrigendum No.5).
All other marking shall be as indicated in drg. No. WD – 84064 – S – 18. However the
barrel manufacturer shall do these markings.
The underframe shall be guaranteed against defects of materials and fabrication for a
period of 24 months from the date of despatch or for a period of 18 months from the date
of putting them in service.
9 STANDARD SPECIFICATION
Those IRS, BS and DGS&D specifications, called for in clause 6 (g) of IRS
specifications R 6 – 59 which have been superseded by IS specifications & corrigendum
slips issued to the IRS specifications are Listed in Annexure – I. All materials required by
the manufacturer of the underframe shall conform to the latest issue of relevant
specification, adopted by RDSO, unless otherwise specified therein.
10.1 The relevant drawings are Listed in Annexure – II. List A indicates key design
drawings and List B indicates standard component drawings.
10.2 The alternation number indicated against each drawing in Particular Specification,
are however, subject to advancement in the course of manufacture of these
underframes and the Contractor shall comply with these amendments in
manufacturing components. Copies of such amended drawings will be supplied to
the Contractor free of cost. The drawings Listed in Annexure – II (List A & List B)
are complete in all respects and any detailing necessary will be done by the
11 ‘AS MADE’ DRAWINGS
11.1 The Contractor shall supply a complete set of ‘AS MADE’ Polyester Film
Tracing (50 Micron Thick Matte) of complete set of drawings followed in the
manufacture of the underframe alongwith an index and diagram to the Purchaser
and Engineers for their record. The diagram shall indicate the leading particulars,
overall dimension and salient feature of the wagon. These tracings shall conform
to the requirements as detailed in Clause 32 IRS Specification no. R6 – 59. The
Contractor shall incorporate in the above set of tracings, any deviations,
modifications and relaxations granted in the course of manufacture of wagons, as
called for in Clause 31 IRS Specification no. R6 – 59.
11.2 The ‘AS MADE’ drawings detailed above shall contain full details of each
components / sub – assembly / assembly inclusive of the material specification,
actual average weight and reference drawings. The general order of the drawings,
title block etc. shall be strictly as indicated in drawing No. SK 67521, with space
for IRS Drg. No. left blank. The size of the sheet shall be A1 (841 mm x 594 mm)
and the code of practice for drawing shall conform to IS Specification No. 696.
The hard wood strips for binding the tracing shall conform to drawing No. 67520,
alongwith 6mm size brass set screw for binding strips drawing No.67522.
ANNEXURE – 1
The following IRS, IS, DGS&D Specifications called for in Clause 6 (g) of IRS
Specifications. IRS Specification no. R6 – 59 (upto corrigendum slip no. 7) have been
superseded by corresponding Specification corrigendum shown against each of them and
therefore the latter shall be followed wherever applicable.
IRS/ IS Specn. IS Specification
H3 - 53 i For non – calibrated (Electric butt welded)chain
Grade – 30 IS : 2429 – 70 (Part I)
Grade – 40 IS : 3109 – 82 (Part I)
Grade – 63 IS : 6217 – 82
Grade – 80 IS : 6215 – 82
ii For calibrated (Electric butt welded) chain.
Grade – 30 IS : 2429 – 70 (Part II)
Grade – 40 IS : 3109 – 82 (Part II)
Grade – 63 IS : 6296 – 71
Grade – 80 IS : 6216 – 82
H5 - 51 i IS: 1929 – 1982 Rivets for general purpose (12 to 48 mm
diameter with amendment Nos. 1, 2 & 3).
ii IS: 2155 – 82 Rivets for general purpose (below 12 mm
diameter) (Amendment 1 & 2).
H6 - 59 i IS: 2393–1980 Cylindrical & Tapper pins (Amendment No.1).
ii IS: 6688 – 81 Tapper pins
iii IS: 6689 – 72 Cylindrical pins (Hardened). H7 - 51 i IS: 2638 – 74 Flat Split Cotter.
H19 - 59 i IS: 1364 – 1967 & IS: 1364 – 83 (Pt. II) Precision and semi –
precision hexagon bolts, screws, nuts and look nuts (dia, range
M – 3 to M – 36) Amendment No.1
ii IS: 2016 – 1967 Plain washer (with Amendment No.1 to 3 ).
iii IS: 2232 – 1967 Slotted and castle nuts (with Amendment
No.1 to 3).
M2 - 65 IS: 1030 – 82 Carbon steel Casting for general Engg. Purpose. M 3 – 49 i IS: 1875 – 78 Carbon steel Billets, blooms, slabs and bars for
forgings (with Amendment No.1 to 3).
ii IS: 2004 – 1978 Carbon steel forgings for general Engg.
M4 - 65 i IS: 1875 – 1978 (Forging Quality)adopted type C – 45 to IS:
7283 – 74 (steel black bars for Production of machine parts
Non – forging Quality adopted (Amendment No.1) M8 - 61 i IS: 1148 – 1982 Hot rolled steel viet bars (upto 40 mm
diameters) for structural purposes.
M9 i IS: 7283 – 74 Carbon steel Black bars for production of
machined parts for general Engg. Purpose. (with Amendment
M10 – 71 i IS: 3885 Steel for the manufacture of laminated springs
and (Railway Rolling Stock).
M11 - 71 i Part – I – 1977 flat section (with Amendment No.1 & 2)
ii Part – II – 1982 Rio and groove sections
iii IS: 7377 – 1974 Intensity of shot peening of helical &
laminated springs (Railway Rolling Stock). M16 - 49 i IS: 1079 – 73 Hot rolled carbon steel and springs (with
M23 - 38 i IS: 961 – 1975 Structural steel (high tensile) (Amendment
No.1 to 4)
M24–62 i IS: 3195– 82 steel for the manufacture of volute and helical
and M25 - 62 springs (Railway Rolling Stock).
M27 - 54 i IS: 1149 – 1982 High steel rivet for structural purposes. M30 - 61 i IS: 3747 – 1982 steel flanging & pressing quality. N2 - 62 i IS: 319 – 1974 Free cutting brass bars rods and sections.
ii IS: 320 – 1980 high tensile brass bars rod and sections (other
than forging stock).
N6 – 49 rods for i IS:1458 – 1965 Railway Bronze ingots and casting (with
Amendment No.1 to 4)
N10 – 54 i IS: 25 – 1979 – Antifriction bearing alloys adopted. N18 – 48 i) IS:292-1983 leaded Brass Ingots and casting. IS: 84-50 i) IS:1745-1978 (Second Revision) Petroleum hydro carbon
IS:127-62 i) IS:167-1950 Ready mixed paint, thick white for lettering (with
amendment Nos. 1 to 3).
IS:226, Gr.’A’i i) IS:226-75 Structural steel (Standard Quality) (with amendment
Nos.1 to 3)
IS:226-Gr.’ASW’ i) IS:2062-1969 Structural Steel (Fusion Welding Quality) (with
amendment Nos. 1 to 4).
G/0-307-244 i) IS: 340-1978, Varnish, Mixing
G/0-101-46 i) IS:1628-1971, Axle Oil
B.S.84 IS:4218-ISO Matric Screw Threads
i) Part-I-1976, Basic and Design Profiles (with amendment No.1)
ii) Part-II-1976, Diameter Pitch Combinations (with amendment
iii) Part-III-1976, Basic Dimensions for Design Profiles.
iv) Part-IV-1976, Tolerancing System (with amendment No.1)
v) Part-V-1979, Tolerances.
vi) Part-IV-1978, Limits of sizes for commercial bolts and nits
(diameter Range 1 to 52mm)
BS:309 i) IS:2107-1977, White Heart Malleable Iron Castings. BS:310 i) IS:2108-1977, Black Heart Malleable Iron Castings BS:916 i) IS:1363-1967, Black Hexagon Bolts Nut and lock nuts (Dia 6
to 39 mm) and Black Hexagon (Dia 6 to 24 mm) (with
BS:1916 (Part-I) i) IS:919-77, Recommendations for limits and fits for Engg.
ii) IS:2101-62, Recommendation for limits and fits for sizes
above 500 mm upto 3150 mm (Amendment Nos 1 and 2). BS:2799 i) IS: 1865-1974, Iron Castings with Spheroidal and Modular