Flat Bottom Railway Rail RDSO Spec.
Flat Bottom Railway Rail RDSO Spec.
Flat Bottom Railway Rail RDSO Spec.
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
INDIAN RAILWAY
STANDARD SPECIFICATION
FOR
ISSUED BY
LUCKNOW-11.
IRST-12-96
INDEX
2. Rail Section 1
4. Definition 2
5. Manufacture 3
Properties
8. Marking 6
11. Finishing 12
23. Inspection 34
25. Shipment 36
Appendix
ultrasonic testing
SEAL
(GOVERNMENT OF INDIA)
INDIAN RAILWAYS
STANDARD SPECIFICATION
FOR
FLAT BOTTOM RAILWAY RAILS
1988.
tensile strength (UTS) of 880 MPa, 1000 MPa and 1080 MPa.
1. SCOPE
2. RAIL SECTION
drawings. Also, two sets of plus and minus limit gauges made of
checking purpose.
may direct.
4. DEFINITIONS
strands .The pouring of the next cast from ladle into the
Blooms that may contain steel from more than one cast
i.e. material arising during the changeover from one cast to the
5. MANUFACTURE
5.2 The cross sectional area of the bloom shall not be less
i) Basic oxygen - O
ii) Electric - E
8.2 Hot Stamping
iii) For rails from change over bloom, cast number should be
clause.
short pieces of rails, not less than 300mm each in length, shall
fall within 0.5 percent below and 1.5 percent above the
section.
7
Thickness of web : + 1.0mm This will be
minimum thickness.
Verticality/Asymmetry : + 1.2mm
0.40mm shall be
permissible.
- 10.0mm
9.4 Straightness
Table –2
Straightness Tolerances
Class ‘A’ rails Class ‘B’
rails
9
10 FREEDOM FROM DEFECTSD
10.4.3 Seams
Rails with seams greater than 0.2mm in depth are not
acceptable and shall be ground. On the running surface of the
rail, dressing shall be limited to 0.3mm deep and in other
places, it shall be limited to 0.5 mm deep.
10.4.4 Protrusions
All protrusions in the head or foot of the rail shall
be ground to match the parent contour. Protrusions on web
greater than 1.5mm high and 20mm square shall be ground. All
protrusions affecting the fitment of the fishplate shall be
ground.
11.2 The rails must be cut to length when cold. Burrs shall
be removed without any perceptible bevelling of the section.
12 TESTING FACILITIES
13 QUALIFYING CRITERIA
13
calculation which contribute to the final results.
14 NATURE OF TESTS
a) Chemical analysis
b) Tensile test
c) Sulphur Print
f) Hydrogen content.
a) Chemical analysis
b) Tensile test
c) Sulphur Print
f) Hydrogen content.
C. Grade 1080 (Head Hardened Rails)
a) Tensile test
b) Hardness test
c) Macroscopic test
14
14.2 The choice of the test sample location within the cast
and strand shall normally lie with the manufacturer. The test
sample position within the bloom/rail shall be selected at the
discretion of the Inspecting Agency.
14.3 The initial test pieces and also the samples intended for
retest must not be taken from the change over or intermediate
blooms. Tests will only be carried out on these blooms when part
or the whole of the adjacent cast has been withdrawn as not
conforming to specification, or for supplying supplementary
information, if required by the purchaser.
14.4 The test methods and the conditions, under which the
tests are carried out, shall conform to the standard in force in
the country of manufacture, in so far as they are not defined in
the present specification.
15 TEST SAMPLE
15.1 The samples drawn for preparation of the test pieces
shall be marked and stamped under the supervision of the
Inspecting Agency.
15.2 If during the preparation of test pieces, any marks
have been removed, they shall be replaced on the actual test
pieces in the presence of the Inspecting Agency.
16 CHEMICAL ANALYSIS
For casts > 150t, two tests per cast, one sample taken
from first half of the cast and the other
from the second half and different strand.
16.4 Retest
Two additional chemical analyses shall be made. If
both analysis pass, the casts shall be considered as complying
with clause 7. If one or both of the analyses fail, the cast
shall be rejected.
16
17.1.3 Results to be obtained
18.1.4 Retests
22
and for any corrective action as required. The hardness values
should preferably be as under:
24
metal anvil. The weight of the metal anvil block shall not be
less than 121t and the area of the base not less than 4.2 sq.m.
The metal anvil block shall be supported direct on a concrete or
masonry foundation weighing not less than 25 metric tonnes and
having an area of not less than 9.3 sq.m. No timber or spring
shall be permitted between the rail supports and the anvil or
between the anvil and the foundation. Block guides shall be
provided which shall permit free fall of the weight. The upper
surface of the supports shall be curved to a radius of not more
than 75mm.
26
20.4 Retests
Test sample shall be selected at random from the
finished rails at the discretion of the Inspecting Agency.
27
28
Hydrogen determination.
29
length of samples shall be cut containing all the strain gauges.
Wires shall be connected to the balancing bridge and reading of
strain gauge taken using same setting of balancing bridge as was
before cutting the samples. The reading of strain at the
corresponding locations shall be converted to stress by
multiplying with Young’s modulus of elasticity for steel (2.05 x
106 Kg/cm2). Residual stress will have same value as relieved
stress with opposite sign.
40mm
45mm
50mm
22.2.3. The crack length to test piece width ration (a/w) shall
be between 0.45 and 0.55.
31
22.2.4 Number of Tests
23. INSPECTION
23.1 The purchaser/Inspecting Agency shall have free access
to the works of the manufacturer at all reasonable times. The
Inspecting Agency shall be at liberty to inspect at every stage
the process of steel manufacture and rail production and cross
check the results of the stipulated tests when so desired by it.
34
23.2 Rails rolled from passed heats only shall be inspected
by the Inspecting Agency. The acceptance procedure should not
interfere with the normal manufacturing process. When a cast is
rolled in several batches, tests carried out on the first part of
the cast may be considered valid for the remaining parts of the
cast in agreement with the Inspecting Agency.
35
36
37
38
TABLE-1
Note: Any other micro alloying element can be added in grade 1000 rails with the approval of
the purchaser.
5
APPENDIX – VII
Mechanical Properties
Date Heat Specimen before fracture Final % Breaking UTS Hardness Falling weight test
No. gauge elongation load (Kg/mm2) (BHN)
length (Kg)
Dia Area Initial gauge (mm) Result Deflection
(mm2) length Broken/Not (mm)
(mm) (mm) broken
48
APPENDIX – IX
Date Heat No. of Weight No. of rails rolled No. of rails found No. of rails
No. blooms of of length OK after internal rejected during
produced blooms inspection internal inspection
from the produced
13m
12m
11m
10m
13m
12m
11m
10m
13m
12m
11m
10m
heat from the
9m
8m
9m
8m
9m
8m
heat
49
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AMENDMENT NO. 5
TO
INDIAN RAILWAY STANDARD SPECIFICATION
FOR
FLAT BOTTOM RAILWAY RAILS
a) Tensile Test
b) Hardness Test
c) Macroscopic Test
III. 2. Para 17.2.1 shall be reworded as under:
The manufacturer shall determine the tensile properties of the steel in accordance
with the requirements of IS: 1608. Such test shall be made on standard test pieces taken
from position as shown in fig.6 given below.”
Contd…2/-
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-2-
The diameter of the test piece shall be 6 mm with gauge length 3.54D or 21 mm.
4. Para 19.2 For Grade 1080 Head Hardened Rails shall be reworded as under:
The hardness test on the rail head surface shall be carried out for 10% of
rails, at one end of the rail (after removing the decarburised surface), at regular
interval of heat treatment and the hardness should be in the range of 340-390
BHN for 1080 HH Grade Rails. In case of non-conformance of any rail, 9
consecutive rails on either side of the rails having non- conformed value shall be
checked for hardness in the sequence. Rails not meeting the hardness stipulations
maybe retreated only once at the option of the manufacturer and such rails may be
retested as above.”
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Figure -8
Contd…3/-
-3-
Hardness Distribution
19.2.3 Hardness Distribution Test
The hardness distribution test shall be conducted on transversely
cut rail sections as shown in figure 8. Hardness value at any point shall not exceed
390BHN. The cross sectional hardness distribution of heat treated rails shall
slope towards the inside. No sharp drop in hardness should be present. The
hardness at 10 mm below, the rail head table at centre shall be 340 BHN
minimum.
The hardness at 15 mm below, the rail head table at centre shall be
between 315-325 BHN.
One hardness distribution test per 1000 m length of heat treated Rail shall
be performed.
19.2.5 Microstructure :
Test piece for microstructure should be taken from the top of rail head.
Test piece should be polished, etched and viewed under microscope X100 and
X500 magnification. The microstructure shall be fine pearlite without formation
of any martensite and Bainite. One test per 1000m of heat treated rail from one
heat to be carried out.
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Contd…4/-
-4-
7. Para 22.3.3 should be reworded as under:
Each sample should endure 10 million cycles at strain of 0.00135. For
rails of Grade 1080 HH the each sample should endure 10 million cycles at strain
of 0.00166.
8. Table 1 for Rail chemistry shall be replaced with the revised Table 1 enclosed.
“A cold punching of “II-Q” at the middle of the web on the center length of rail
on non branding side should be done for clear identification of such rails. Size of
these letters should be 15 mm high. “
-----------
Contd…5/-
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-5-
TABLE-1
Grade
Chemical Composition (percentage) Mechanical Properties
Elongation % on gauge
length – 5.65√So (min)
10-4% ( ppm) max by
Hydrogen content in
liquid steel (max.)
Running surface
hardness (BHN)
Mo (max)
Al (max)
S (max)
P (max)
V (max)
N (max)
mass O
Mn
Cr
Si
C
880 0.60-0.80 0.80-1.30 0.10-0.50 0.030* 0.030* 0.015 - - - - - 1.6 ppm 880 10.0
Min 260**
1000 0.60-0.80 0.80-1.30 0.10-0.50 0.030* 0.030* 0.015 0.25 - - - - 1.6 ppm 1000 10.0
300-350
1080 Cr 0.60-0.80 0.80-1.20 0.50-1.10 0.008-0.025 0.020 0.004 - 0.80-1.20 0.18 0.009 20 1.6 ppm 1080 9.0
320-360
1080 HH 0.60-0.80 0.80-1.30 0.10-0.50 0.030* 0.030* 0.015 - - - - - 1.6 ppm 1080 10.0
340-390
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