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Government of India
Ministry of Railways

SCHEDULE OF TECHNICAL REQUIREMENTS FOR

INFRASTRUCTURE,MANUFACTURING,TESTING &QUALITY CONTROL
REQUIREMENTS

FOR

PAINTS BASED ON EPOXY AND POLYURETHANE RESIN

FOR PAINTING OF COACHES, DIESEL AND ELECTRIC
LOCOMOTIVES

STR No. - M&C/PCN/040/2011

(Revision1)

2011

Issued By

METALLURGICAL &CHEMICAL DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW-226 011
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TABLE OF CONTENTS

1. FOREWORD
2. SCOPE
3. APPLICABLE/REFERENCE DOCUMENTS
4. TERMINOLOGY/ABBREVIATIONS
5. GENERAL REQUIREMENTS
6. M&P REQUIREMENTS
7. TESTING FACILITIES
8. QUALITY CONTROL REQUIREMENTS & TRAINING FACILITIES
9. REPAIR/SERVICE CENTRE
10. MAJOR STEPS INVOLVED IN GETTING THE FIRMS
APPROVED/REGISTERED

11. LIST OF PAINTS TO BE APPROVED

12. ANNEXURE-I
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Schedule of Technical Requirements

of Epoxy & Polyurethane based Paints
in Two Packs for Painting of Coaches, Diesel & Electric locomotives

1. FOREWORD

1.1 This document has been prepared (Earlier reference STR

No.M&C/040/2009) to lay down the eligibility and capability of suppliers
seeking approval for manufacturing & supply Epoxy/Polyurethane based
Paints in Two Packs for Painting of Coaches, Diesel & Electric locomotives
as per the recommendation of design directorate.

2. SCOPE

2.1 This document covers the infrastructure facilities at works, procurement of

raw materials, manufacturing of paints, quality control etc. These paints will
be used for painting of Coaches, diesel and electric locomotives.

3. APPLICABLE/REFERENCE DOCUMENTS
(i) IS: 101
(ii) ASTM B117
(iii) ASTM D3359
(iv) ASTM G-154

4. TERMINOLOGY

STR – Schedule for Technical Requirements

NTH – National Test House
ISO – International Standards Organisation
M&P – Machinery & Plant
NABL –National Accredited Board of Laboratories
NSIC – National Small Industries Corporation Limited
 Page 04 of 13 Effective from JAN. 2011 M&C/PCN/040/2010 Rev.1

5. General Requirements

5.1 Any firm seeking approval of this organisation:

(i) shall possess valid ISO 9001 & ISO: 14000 Environmental
maintenance system installation certificate for the products for
which approval is sought
(ii) shall have minimum manufacturing experience of these paints for 3
years
(iii) shall procure these resins from reputed indigenous or international
sources.
(iv) shall have valid clearance from Pollution Control Board.
(v) Shall have the record of supplying the products to the reputed
national and international organisation like defence, heavy &
earthmover industries like BEML, BHEL, railway and major
automotive industries.
(vi) Shall have minimum turnover of 10 crores per annum for last three
years.
(vii) Shall have ERP/SAP supported multimodule application software
for managing the important parts of business
(viii) Firm should have R&D facilities approved by Govt. Agency and
copy of valid certificate should be available. Otherwise the firm
should have tie up with Govt. R&D Laboratory/University
(ix) The firm should have valid capacity certificate issued by NSIC
/Other approved agency for small scale industries.
(x) In case of medium & large scale industries, if capacity certification
is not possible by any approved agency, capacity shall be declared
by the firm itself detailing the points to arrive at the capacity and
subsequently assessing officer will verify the capacity during the
assessment of the firm.
The above information should be furnished by the firm in registration form.

5.2 Covered area with adequate space for storage of raw materials,
intermediate and finish products like pigments, extenders, resins,
hardeners, varnish, thinners, additives, paints etc. including bond room
facilities should be available, free from dampness and humidity in the
same campus of the factory. There should be one bond room with locking
arrangement for storage of finished products for purchase inspection.
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5.3 Approval of a firm will be given as per laid down procedure given in vendor
approval guideline of M&C Dte only after Inspection of the factory
premises to assess the capacity/capability of the firm and samples of
paints drawn during inspection (comprising of a system painting) meets
the norms and requirements of the relevant RDSO specifications on
testing at RDSO. The initial approval shall be given in Pt-II and further up
gradation to Pt-I will be given after meeting the requirement given in DOP/
M&C and supply of 20000 litres after last inspection.

5.4 The firm should submit the Brand Names of the applied products.

5.5 The approval to the firm will be given for full paint system and not for
individual paint items. The list of paint items from which a system is
formed is furnished at Clause.11.0

6. Manufacturing Machines & Plants

6.1 Firm should possess the following minimum machines and plants for
manufacture paints based on Epoxy & Polyurethane resins.

Table-I

Sl. Equipments Quantity

No. (min.)
1. High Speed Disburser/Pug mixer, min. 3 Nos.
capacity 500 kgs(in case of higher capacity
of the mill ,total capacity shall be 1500
kgs/day irrespective of no.of machines).
2. Sand Mill/LMZ Sand mill,(min.chamber 2 Nos.
capacity10 lts.) (in case of higher capacity of
the mill ,total capacity shall be 2000 ltrs./day
irrespective of no.of machines)
3. Bead Mill/ Dyno mill/ LMZ Sand mill,(min. 3 Nos.
capacity1000 lts./day), (total capacity of the
mill shall be 3000 ltrs./day irrespective of
no.of machines)
4. Paint Mixer, min. capacity 2 K ltr.( in case of 5 Nos.
higher capacity of the mill ,total capacity
shall be 10000 ltrs./day irrespective of no.of
machines)
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5. Thinning Pump 6 Nos.

6. Automatic Filling Machine 3 Nos.

7. Weighing Machine, 300 Kg., Least count 2 Nos.

0.100 Kg.
Weighing Machine, 60 Kg., Least count 2 Nos.
0.050 Kg.
Weighing Machine, 10 Kg., Least count 2 Nos.
25.00 gm
8. Electronic Balance, 1.00 Kg., Least count 3 Nos.
10.00 gm.
9. Industrial Vibrator or agitator 3 Nos.
10. Solvent Pump 3 Nos.
11. Unloading Pump 5 Nos.
12. Slow Speed Premixer and High Speed 3 Nos.
Premixer / variable speed premixer with gear each
design
13. Resin Transfer Pump 2 Nos.
14. Diesel Generator of adequate capacity 1 Nos.
15. Hoist 2 ton 2 Nos.
16. Filter press with variable mesh size filter 2 Nos.

7. Testing facilities

Quality Control Facilities

7.1 The firm should have proper air conditioned laboratory to maintain lab test
conditions at 27 ± 20C and 65 ± 5% relative humidity, for which suitable
indicating/measuring instruments will be available in the lab.

7.2 There should be full testing facilities with equipments which are covered as
per requirements of IS: 101 latest version or as per ASTM. Other
equipments not covered in IS /ASTM shall be of reputed make and these
should have valid calibration certificate. It is mandatory for a firm seeking
approval of RDSO to have equipments listed in table –II at their end.
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Table-II
Sl Name of the Equipment Quantity (min.)
No.
1. Humidity Chamber as per IS : 101 1 No.
2. Salt Fog Test Cabinet as per ASTM B117 1 No.
3. Gas chromatograph 1 No.
4. Cross cut adhesion tester as per ASTM 1 No.
5. Sagging index as per IS : 101 1 No.
6. Gloss-O-Meter of 600 angle of incidence as per IS : 101
1 No.
7. Abel’s Flash Point Apparatus as per IS : 101 1 No.
8. Cryptometer or Black & White Charts as per IS : 101 1 No. or Black and
White Charts in
adequate quantity
9. Flexibility & Adhesion Apparatus as per IS : 101 1 No.
10. Scratch Hardness Tester as per IS : 101 1 No.
11. Flow Cup (Ford Cup No. 4) as per IS : 101 1 No.
12. Stormer/Brooke Field Viscometer as per IS : 101 1 No.
13. Weight/10 Litre Cup as per IS : 101 1 No.
14. Hegman Gauge as per IS : 101 1 No.
15. Centrifuge as per IS : 101 1 No.
16. Dry Film Thickness Measuring Equipment as per IS : 1 No.
101t
17. Dean & Stark Apparatus as per IS : 101/Carl Fischer 1 No.
apparatus
18. Lovibond Tintometer as per IS : 101 1 No.
19. Accelerated Weathering Tester viz QUV to ASTM G-53 1 No.
20. Taber abrasion tester as per ASTM 1 No.
21. Color spectrophotomrter 1 No.
22. Chemical Balance upto 4 decimal places (in gms.) 1 No.
23. Physical Balance upto 2 decimal places (in gms.) 1 No.
24. Hot Air Electric Oven 1 No.
25. Distillation Plant 1 No.
26. Hydrometer of different ranges 1No.of each range
27. Hygrometer 1 No.
28. Drying time recorder as per ASTM 1 No
29. Air & Air less spray gun 1 No each
30. Hot Plates 3 Nos.
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31. Set of Sieves, Thermometers, Glass Wares, Crucibles, In adequate

Reagents & Chemicals for Testing of Raw Materials, Qty./Nos.
Intermediate and Finished Products as per relevant
specifications
32. Heating Mantles 3 Nos.
33. Water Bath 2Nos.
34. Muffle Furnace 1 No.
35. Mild Steel, Tinned and Glass Panels and Test Racks In adequate
number

8. Quality Control Requirements

8.1 There should be a well designed system for traceability and identification
of the materials from raw material, intermediate and finished product
stages.
8.2 The quality manual of the firm for ISO should clearly indicate at any stage
the quality control over procurements of raw materials, manufacturing of
intermediate and finished products by computerized process control
technique.
8.3 The technical supervisors/managers responsible for production & quality
control activities related to manufacturing of subject paint item should have
the minimum qualification of B.E. / B.Tech (Paint /Polymer
Technology/Chemical Engg.) with a minimum of 3 years experience or
M.Sc. (Chemistry) with a minimum of 7 years experience in relevant
fields to look after the production, quality control and testing activities and
should have knowledge of paint manufacturing, testing of raw materials
etc. They should be able to take corrective steps in case of difficulties in
maintaining quality control.
8.4 The firm should ensure that proper analysis is being done on monthly
basis to study the rejection at various levels and it is documented.
Process capability should also be studied.
8.5 The firms should ensure that all the relevant RDSO/BIS/ASTM and other
specifications, standards, manuals etc. are available with them.
8.6 If the firm intends to obtain approval for paints based on epoxy as well as
polyurethane resins they should possess test certificates for both.
The firm should have test certificates issued by approved test house viz
NTH, RTC, HBTI, Shri Ram Test House, NABL accredited National
Laboratories under CSIR for one primer and finishing paint based on
epoxy and polyurethane resins.
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8.7 A frequent Quality Audit check may be carried out regularly at consignee
end to check the quality of paint and other infrastructure and testing
facilities mentioned in the STR.

8.8 The firm should prepare and submit Quality Assurance Plan for products,
which they intend to supply to Indian Railway and Production Units as per
format QMF 0024, detailing various aspects:
- Organisation chart
- Write up on manufacturing process of paints
- Process flow chart for paints
- Recipe of various products
- Trace ability of various products.
- Inspection and testing plan for all the products starting from
raw materials, in process and final product.
- Details of non-conformity and
- Covering other clauses of ISO manual

9. Repair / Service Centre

The firm should have 24X7 customer complaint registration & redressal
mechanism through website.

10. Major steps involved in getting the firms approved/registered:

10.1 Firm shall obtain fresh application form, vendor approval guidelines,
specifications, STR and other relevant documents after depositing
Rs.15000/- vendor registration fee from M&C Dte/Online.
10.2 Firm shall submit the application form duly filled along with copies of all
relevant documents to M&C Dte.
10.3 The application form and other relevant documents shall be scrutinized at
M&C Dte and if any deficiencies are found, the firm shall be asked to
comply the deficiencies.
10.4 After all deficiencies are complied by the firm, the capability of the firm
shall be assessed by nominated official. Samples shall also be drawn from
the firms premises and shall be tested at RDSO/Outside approved lab, as
applicable.
10.5 If all the test results are satisfactory and all other requirements are fulfilled,
the firm shall be approved for a period of 2 years in Part-II only.
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11. The list of paints based on epoxy and polyurethane resins which may be
used for painting, coaches, diesel and electric locomotives as per RDSO
Specn. M&C/PCN/100/2009 etc. in Indian Railways and Production Units is
furnished below:

(i) Epoxy Zinc Phosphate Primer to M&C/PCN/100/2009. (Chapter II)

(ii) Unsaturated Polyester Putty to M&C/PCN/100/2009 (Chapter III)
for coaches only.
(iii) PU Surfacer to M&C/PCN/100/2009 (Chapter IV) for coaches .
(iv) Polyurethane finishing paint to M&C/PCN/100/2009 (Chapter V)
for coaches.
 Page 11 of 13 Effective from Jan.11 M&C/PCN/040/2010 Rev.1

ANNEXURE –I

SN Description of Capacity Total No.of Operation to Capacity of Year & Present

Machine/Equipment/Manp requirement/ requirem Machine be performed available Make of Status—
ower Qualification ent s by Machine machine Working/
available Machine/Equi Underco
pment mmencin
g/Not
working
1 2 3 4 5 6 7 8 9
1 Highspeed Disburser/ 500 kg. 3 Nos.
Pug Mixer
2 Sand Mill/LMZ Sand 2000 lit. 2Nos.
Mill(chambercap.10lit.) /day
3 Bead/Dyno Mill/LMZ Sand 3000 lit. 3 Nos.
Mill /day
4 Paint Mixer 2K lit.each 5 Nos.
5 Thinning Pump 6 Nos.
6 Automatic Filling Machine 3No.
7 WeighingMachine,LC=0.1 300 kg 2 Nos.
00 kg
8 WeighingMachine 60 kg 2 Nos.
LC=0.050 kg
9 WeighingMachine 10 kg 2 Nos.
LC=25.0 gm
10 Electronic Balance 1.0 kg 3 Nos.
LC=10.0 gm
11 Industrial Vibrator or 3 Nos.
Agitator
12 Solvent Pump 3 Nos.
13 Unloading Pump 5 Nos.
14 Slow /High/Variable speed 3 Nos.
premixer each
Resin Transfer Pump 2 Nos.
15

16 Hoist 2 ton 2 Nos.

17 Diesel Generator Adequate 1 Nos.
18 Filter Press 2 Nos.
19 Humidity Chamber 2 Nos.
20 Gas Chromatograph 1No.
21 Salt Fog Test Cabinet as 1No.
per ASTMB117
22 Cross cut adhesion as per 1No.
ASTMD3359
23 Sagging Index 1No.
24 Glossometer 60° Angle 1No.
25 Abel’s Flash point 1No.
Apparatus
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26 Cryptometer/Black & White 1No.

Charts
27 Flexibility & Adhesion 1No.
Apparatus
28 Scratch Hardness Tester 1 No.
29 Ford Cup no.4 1No.
30 Stromer/ Brookefield 1No.
Viscometer
31 Weight/10 lit Cup 1No.
32 Hegman Gauge 1No.
33 Centrifuge 1No.
34 Dry FilmThickness 1No.
MeasuringApparatus
35 Dean & Stark Apparatus 1 No.
36 Lovibond Tintometer 1 No.
37 Accelerated Weathering 1 No.
Tester
38 Taber Abraser 1 No.
39 Colour Spectrometer 1 No.
40 Chemical Balance,upto 4 1 No.
decimal place
41 Physical Balance,upto 2 1 No.
decimal place
42 Hot Air Oven 1 No.
43 Muffle Furnace 1 No.
44 Distillation Plant 1 No.
45 Hydrometer 1 No.
each
46 Hygrometer 1 No.
47 Drying time Recorder 1 No.
48 Air & Airless Spray Gun 1 No.
each
49 Set of Sieves, Adequat
Thermometers, Glassware, e qty.
Crucible, Reagents &
Chemicals for testing of Raw
materials, Intermediate &
finished products as per
relevant specifications.
50 Hot Plates 3 No.
51 Heating Mantles 3 No.
52 Water Bath 2 No.
53 Mild Steel, Tinned & Glass Adequat
panels & test Racks e
 Page 13 of 13 Effective from Jan.11 M&C/PCN/040/2010 Rev.1

1 2 3 4 5 6 7 8 9
52 Manpower— The 1 No.
technical supervisors/ each
managers responsible for
for production & quality Product
control activities related ion &
to manufacturing of Quality
subject paint item Control
should have the respect
minimum qualification ively.
of B.E. / B.Tech (Paint
/Polymer
Technology/Chemical
Engg.) with a minimum
of 3 years experience
or M.Sc. (Chemistry)
with a minimum of 7
years experience in
relevant fields to look
after the production,
quality control and
testing activities and
should have knowledge
of paint manufacturing,
testing of raw materials
etc.
Note: Information in column 1 to 4 shall be indicated by RDSO whereas information in column 5 to 9 shall
be furnished by vendor.