RDSO 2008 CG 06 Rev-1

Ref:CG-WI-4.2.1-1, Ver.1.
0 Page 1 of 15 Date of issue: July, 2013 RDSO/2008/CG-06 (Rev-1)
INDIAN RAILWAYS
SCHEDULE OF TECHNICAL REQUIREMENTS

FOR
SELF- LUBRICATING POLYESTER RESIN COMPOSITE
BASED WEARING PIECE FOR SIDE BEARER,
FOR USE IN
ICF TYPE B.G. MAINLINE, EMU/DMU COACHES
(PROVISIONAL)
S.NO. Month/Year of Revision / Page Reason for Amendment

issue Amendment No.
1. July 2008 - - First issue
2. July 2013 Rev-1 To incorporate improvements
made during trial/extensive
trials.
Issued By:
Research Designs and standards organization

Manak Nagar, Lucknow – 226011.
Signature
Name & Prepared By:- Shyam Shankar Checked By:- Rakesh Kumar Approved By- Mahesh Kumar
Designation JE/SS/Carriage Dy. Dir/SS/Carriage Director/SS/Carriage

Ref:CG-WI-4.2.1-1, Ver.1.0 Page 2 of 15 Date of issue: July, 2013 RDSO/2008/CG-06 (Rev-1)
INDEX
SECTION-A
Clause No Description Page No.
0. Foreword 3
1. Scope 4
2. Requirements 4
3. Performance Requirements 5
4. Sampling Criteria for Conformity 6
5. Marking 7
6. Packing 7
7. Storage 8
SECTION-B
Clause Description Page No.
No.
1. Scope 9
2. Requirements 9
3. Plant, Machinery & Infrastructure 9
Requirements
4. Testing Facilities 10
5. Quality Control Requirements 11
6. Documentation 11
7. Training 12
8. Annexure-1, 13
Procedure for Compressive Load Test
9. Annexure-2, 15
Test Method for Endurance Testing
Signature

SCHEDULE OF TECHNICAL REQUIREMENTS FOR SELF- LUBRICATING

POLYESTER RESIN COMPOSITE BASED WEARING PIECE FOR SIDE
BEARER, FOR USE IN ICF TYPE B.G. MAINLINE, EMU/DMU COACHES.
(PROVISIONAL)
0. FOREWORD
0.1 This schedule consists of two parts viz. Section A and section B. Section A covers
the technical requirements/provision relating to material, manufacture and tests and
does not include all the necessary provisions of the contracts. Section B covers the
infrastructural, testing and quality control facilities required for manufacture of Self
Lubrication Polyester Resin Composite Based Wearing Piece for Side Bearer for
use in ICF type BG Mainline, EMU/DMU coaches.
0.2 These self lubricating polyester resin composite based wearing pieces for side
bearer are to be used in ICF type BG Mainline, EMU/DMU Coaches.
0.3 This schedule draws reference to some of the relevant IS/ISO specifications, which
shall be taken as reference unless mentioned otherwise.
0.4 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 IS:2 with latest revision. The
number of significant places retained in the rounded off value shall be the same as
that of the specified values in this schedule.
0.5 While preparing this specification, due consideration has been given to the latest
developments in the field of polymeric materials and process technologies, service
requirements of the Indian Railways and practices followed in advanced countries.
Signature

SECTION-A
TECHNICAL REQUIREMENTS/PROVISION RELATING TO MATERIAL,

MANUFACTURE AND TESTS FOR SELF- LUBRICATING POLYESTER
RESIN COMPOSITE BASED WEARING PIECE FOR SIDE BEARER, FOR
USE IN ICF TYPE B.G. MAINLINE, EMU/DMU COACHES.
1. SCOPE
This schedule covers the requirements, sampling and methods of tests for self
lubricating polyester resin composite based wearing piece for side bearer to be used
in ICF type BG Mainline, EMU/DMU Coaches. The detailed dimension will be
same as given in the drawing of wearing piece i.e. CG – K8152 with latest
alteration.
2. REQUIREMENTS
2.1 Material
2.1.1 The raw material used for manufacture of Wearing Piece for side Bearer shall be
“Self Lubricating Polyester Resin Composite” conforming to the properties
specified in this schedule. Use of regenerated/reconstituted material is not
permitted. A guarantee shall be given by the manufacturer that no reconstituted and
recovered material has been used for the manufacture of Wearing Piece for the side
bearers.
2.1.2 The manufacturer shall have a valid tie up in the form of a written Memorandum of
Understanding (MOU)/contract with M/s TENMAT Ltd of UK or with
manufacturer of any other equivalent “Self Lubricating Polyester Resin
Composite” material, covering raw material supplies and technical support
including quality control.
2.1.3 The wearing piece for side bearer shall be supplied in dark grey/ black color and
use of any external coloring agent is not permitted.
2.1.4 The raw material used for the manufacture of wearing piece shall conform to the
requirements prescribed in table-1.
2.1.5 The material shall be graphite filled and should have self-lubricating properties.
2.1.6 In case alternative equivalent material other than proved material for an existing
design is offered for manufacture of wearing piece for side bearer, the same will be
first subjected to limited field trials on 100 coaches for a period of at least one POH
in minimum two Railways. Final approval will be given only after satisfactory
performance of wearing piece for side bearers in field trials and capacity
assessment of the firm.
2.1.7 Manufacturers shall maintain records of raw materials received from suppliers and
references of supplies made to Indian Railways and shall be presented whenever
required by RDSO.
Signature

2.2 Construction, Workmanship and Finish

2.2.1 The surface of the product shall be smooth, sound and free from moulding defects
such as bubbles, surface sinking, crazing, blistering, cracks etc. All edges shall be
neatly finished and free from flash.
2.2.2 Self-lubricating polyester resin composite based wearing piece for side bearer
should be manufactured by compression moulding process. If required, the product
may be machined after moulding to achieve the desired dimensions.
2.3 Dimensions & Tolerances
Dimensions and Tolerances shall be as per the drawing no CG – K8152 with latest
alteration.
3. PERFORMANCE REQUIREMENTS
3.1 Unless otherwise specified, all tests shall be carried out under the following
atmospheric conditions:
a) Temperature : 27 ± 2°C.
b) Relative humidity : 65 ± 5%.
The temperature and humidity shall be substantially constant during a series of
measurements carried out as part of one test on one lot.
3.2 Visual Inspection test:
The product shall be visually inspected for compliance with the requirements of
clause 2.2 of this specification.
3.3 Checking of dimensions:
The dimensions shall be checked for conformity with the drawing approved by the
purchaser
3.4 Type test: The following shall constitute type tests.
Table-1
S. Properties Values Specimen Test Number of Test
No. size Direction Samples Method
1. Compressive 160 MPa 12mmX12mm Into 5 ISO 604
Strength (min) X12mm right Moulded
Prism Face
2. Rockwell 75 (min) Min 6 mm -do- 3 ISO 2039-2
hardness M thick Sheet
3. Impact 75 kJ/ 12.7mm X -do- 3 ISO 180
Strength sq.mt 12.7mm X
Izod Un (min) 64mm
notched
4. Residual ash 22 to 27% Nominal 3 gm NA 3 ISO 3451-1
at 950 °C
5. Density 1.60-1.68 Gm/cc NA 3 ISO 1183
6. Endurance Test - - - 1 Annexure-2
Signature

3.4.1 Product sample should be tested in accordance with method given in Table-1, and
comply with the requirements mentioned there in.
4. SAMPLING CRITERIA FOR CONFORMITY
4.1 Tests
4.1.1 The tests in table-1 shall constitute Type Test performed on the raw material
specimen (S. No. 1-5) whereas S. No. 6 shall be performed on finished product.
4.1.2 The type test, for all the requirements laid down in this schedule is mandatory for
product approval. The entire type test will be repeated at an interval of six months.
However Approving Authority reserves the right to repeat the test at any time on
their discretion. Record of type test results shall be maintained by the manufacturer
& will show to inspecting authority whenever required.
4.1.3 RDSO may draw the sample for quality check at its discretion and firm shall
arrange the testing of these samples in a reputed out side laboratory as decided by
RDSO. The testing charges should be borne by the manufacturer.
4.1.4 In any consignment, all the wearing pieces for side bearers of the same type
manufactured by the same factory during the same period shall be grouped together
to constitute a lot.
4.1.5 From each lot a certain number (as specified under para 4.2.3) of wearing pieces
for side bearers shall be selected at random and subjected to Acceptance Test as
given in Clause 4.2. Any wearing piece for side bearers failing to satisfy the
requirements of the specification shall be considered defective.
4.2 Acceptance Test
4.2.1 The Acceptance Test shall consist of the following:

i. Visual inspection test. (Refer to clause 3.2)
ii. Checking of dimensions. (Refer to clause 3.3)
iii. Density test. (Refer to table 1)
iv. Rockwell Hardness Test (Refer to table 1)
v. Residual ash at 950 degree C. (Refer to table 1)
vi. Compressive Load Test (Refer Annexure-1)
4.2.2 The lot shall consist of 1000 pieces or part thereof.
Signature

4.2.3 The number of pieces to be selected from the lot for acceptance tests shall be as
under:
i. Visual Inspection 5% of the lot shall be checked as per

clause No. 3.2.
ii. Dimensional Check 10 samples selected at random from
each lot shall be checked as per clause
No. 2.3
iii. Hardness 10 samples shall be drawn at random
iv. Ash Content from each lot. Out of these samples
v. Density selected, 3 nos. shall be tested as per
vi. Compression Load test clause No. 2.2.1 and 2, 4 & 5 of table-1,
after they pass Compression Load test as
per Annexure-1
4.2.4 Each sample selected for Acceptance Test shall conform to the requirements as laid
down in the specification. Should any one of the test samples fail to meet the
requirements of Acceptance Test, double the number of samples from the same lot
shall be drawn for re-testing. Should any of these samples fail, the entire lot shall
be rejected.
4.2.5 In case of non-compliance in regard to dimensional check, the manufacturer may

be given one chance to segregate the lot for dimensional conformity.
4.2.6 In the event of rejection of the lot, all self lubricating polyester resin composite
based wearing piece for side bearer constituting the lot shall be made unusable in
the presence of the Inspecting Authority.
4.2.7 During inspection, Purchasing/Inspecting Authority, at their discretion may

conduct Type Test and the samples shall conform to the values specified in Table 1
of this schedule.
5. MARKING
Each self lubricating polyester resin composite based wearing piece for side bearer
shall be suitably marked as per size and location indicated in the drawing.
i. Manufacturer’s name/initial/trade mark.
ii. The month and year of manufacture.
iii. Drawing Number.
6. PACKING
The wearing pieces for side bearers shall be supplied so as to permit convenient
handling and to protect against loss or damage during transit and storage.
Signature

7. STORAGE
7.1 The self-lubricating polyester resin composite based wearing piece for side bearer
shall be stored in a cool and dry place.
7.2 The self lubricating polyester resin composite based wearing piece for side bearer
shall be kept covered and free from exposure to bright light, particularly sunlight.
7.3 The self lubricating polyester resin composite based wearing piece for side bearer
shall be stocked and arranged in such order so as to ensure use of old stock first.
Signature

Section-B
REQUIREMENTS OF INFRASTUCTURE & TESTING FACILITIES TO

MANUFACTURE SELF LUBRICATING POLYESTER RESIN COMPOSITE BASED
WEARING PIECE FOR SIDE BEARER, FOR USE IN ICF TYPE B.G. MAINLINE,
EMU/DMU COACHES.
1. SCOPE
1.1 This section covers the Infrastructural requirements for manufacture of Self-
lubricating Polyester resin based composite wearing pieces for side bearers for
ICF/RCF/BEML BG Mainline, EMU/DMU Coaches.
2. REQUIREMENTS
2.1 All vendors seeking registration with RDSO must fulfill the requirement of this
schedule.
3. PLANT, MACHINERY & INFRASTRUCTURE REQUIRMENTS.
3.1 The Manufacturer shall have adequate space and covered area with cemented floor
to accommodate the following & for smooth logistics:
a) Damp-free place for storage of raw materials.
b) Adequate manufacturing area.
c) Finishing, Assembly and Inspection area.
d) Storing and dispatch of finished products.
3.2 In case where the firm is manufacturing its own raw material, it must have all items
of plant and machinery required for the manufacture of the same.
3.3 In case where the firm is moulding the wearing pieces for side bearer made out of
raw material manufactured by itself or purchased from approved source, it must be
in possession of the following additional items of plants and machinery.
a) Hydraulic press of at least 100MT capacity with digital controls of temperature.

b) Mould for the product.
c) Lathe machine.
3.4 The Manufacturer shall have suitable tools, cutters, polishing files, and suitable
equipment for de-flashing of moulded products.
Signature

3.5 The manufacturer shall have a system to ensure that moulds are checked at regular
intervals and adequate mould handling facilities like Chain Pulleys or Electric
Hoists or other suitable equipment for moving heavy moulds.
3.6 Prior to release of dies/moulds for production, these are to be checked

dimensionally and records containing details of such inspection and date
maintained.
3.7 Two Electronic Weighing Machines of reputed make, one of maximum 3 Kg
capacity with an accuracy of 0.2% and the other of 100 Kg. capacity with an
accuracy of 2% shall be provided. Weighing machines shall be calibrated regularly
and the frequency of calibration specified.
3.8 In-house availability of minimum infrastructure for maintenance and polishing of
dies and moulds shall be ensured.
4. TESTING FACILITIES
4.1 The Manufacturer must have the following testing and other equipment installed in
a laboratory set up with controlled temperature and humidity
a. Digital Vernier caliper (0-200 mm range)

b. Compression testing machine
c. Weighing balance (Capable to measure up to 0.0001gm)
d. Izod Impact Tester.
e. Muffle furnace for temperature up to 1000 degree C with temperature
control and indication.
f. Rockwell hardness tester.
g. The firm must also be in possession of the following equipments:
 Hydraulic press for compression moulding of test specimens
 Moulds for type test specimens.
h. 50 MT compression testing machine capable to travel at the speed of 10+/-

5 mm/minute.
i. 15 MT Capacity fatigue testing machine capable of applying sinusoidal
vertical load at a frequency of 2 Hz for 5,00, 000 cycles.
4.2 The manufacturer shall have dies/moulds for preparation of various test specimens
for the relevant tests.
4.3 All gauges required to ensure that the dimensions of Self lubricating Polyester resin
based composite wearing pieces for side bearers are as per drawings shall be
available.
4.4 Jigs & fixtures for conducting load test, compression, flexural test etc. shall be
available.
Signature

4.5 The Manufacturer shall have arrangements like vice, cutter, polishing files etc. for
preparation of various samples for tests such as tensile strength, hardness, specific
gravity etc.
5. QUALITY CONTROL REQUIREMENTS
5.1 The manufacturer shall have valid ISO: 9000 series certification for the product for
which the approval is sought.
5.2 There should be the system to ensure the traceability of the product beginning with
raw material stage to finish product stage. The firm shall have a system for
traceability of the raw materials used, especially the liquid resins.
5.3 There should be the system to ensure ‘first-in first-out’ for all raw materials and
intermediate stages to finish products.
5.4 It should be ensured that there is a Quality Assurance Plan for the product
detailing the following various aspects:
 Organization 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 The quality manual of the firm for ISO: 9000 should clearly indicate the control
over manufacturing at every stage and testing of the said Railway product.
5.6 There shall be at least one graduate degree holder person in relevant technology
with field experience of at least 5 years or a diploma holder with experience of 10
years on thermo setting polymers for regular production and quality control.
5.7 It should be ensured that proper analysis is being done on monthly basis to study
the rejection at various stages of production and is documented.
5.8 Latest version of all the relevant specification IS, ISO and RDSO standards and
drawings with latest alterations should be available with the firm.
6. DOCUMENTATION
Firm shall maintain following documents/records:
6.1 A well documented quality Plan.
Signature

6.2 Incoming raw material register with Test Certificates references of suppliers and
internal test results.
6.3 Stage inspection results including finished products results.
6.4 Records of internal rejection and its analysis vis-à-vis action plan.
6.5 Records of final products inspection by external agencies (like RDSO). Non
Conformity Reports and case analysis as well as action taken thereof.
6.6 Records for maintenance of dies/moulds.
6.7 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 organized and imparted on maintenance of machines, quality assurance,
safety parameters etc.
Signature

ANNEXURE-I
Compression Fixture for Load Testing:
A compression fixture as per sketch below will be used for load testing. The compression
fixture shall be place on the bottom platen and the wearing piece shall be placed on it with
flat portion facing up. The load shall be applied at the rate of 100 ± 10 KN/min. The test
shall be continued till the applied load reaches 48 MT. Thereafter the load shall be
released. After the test, wearing piece should not show any cracks/fissures.
Signature

Signature

Annexure-2
Test Method for Endurance Testing

The Wearing Piece shall be subjected to Endurance test in vertical directions continuously
to determine the endurance life at the time of approval.
The load to be applied for this purpose on the Wearing Piece shall be 5 MT to 14 MT at a
frequency of 2 Hz for 5, 00, 000 cycles.
Endurance testing machine should satisfy following parameters:
i) It should be possible to read load applied as well as number of
cycles/counts directly in the machine.
ii) The loading cycle shall be sinusoidal.
A fixture as per sketch below will be used for Endurance Testing. The Wearing Piece shall
be located on the bottom platen of Endurance Testing Machine and the Fixture shall be
placed on it with flat portion facing up.
The Wearing Piece shall not show any sign of cracking / fissures / delamination or any
other defect during and after completion of Endurance test.
Signature

RDSO 2008 CG 06 Rev-1

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Ref:CG-WI-4.2.1-1, Ver.1.

0 Page 1 of 15 Date of issue: July, 2013 RDSO/2008/CG-06 (Rev-1)

SCHEDULE OF TECHNICAL REQUIREMENTS

S.NO. Month/Year of Revision / Page Reason for Amendment

Research Designs and standards organization

SCHEDULE OF TECHNICAL REQUIREMENTS FOR SELF- LUBRICATING

TECHNICAL REQUIREMENTS/PROVISION RELATING TO MATERIAL,

2.2 Construction, Workmanship and Finish

4. SAMPLING CRITERIA FOR CONFORMITY

4.2 Acceptance Test

4.2.1 The Acceptance Test shall consist of the following:

4.2.2 The lot shall consist of 1000 pieces or part thereof.

i. Visual Inspection 5% of the lot shall be checked as per

4.2.5 In case of non-compliance in regard to dimensional check, the manufacturer may

4.2.7 During inspection, Purchasing/Inspecting Authority, at their discretion may

REQUIREMENTS OF INFRASTUCTURE & TESTING FACILITIES TO

3. PLANT, MACHINERY & INFRASTRUCTURE REQUIRMENTS.

a) Hydraulic press of at least 100MT capacity with digital controls of temperature.

3.6 Prior to release of dies/moulds for production, these are to be checked

a. Digital Vernier caliper (0-200 mm range)

h. 50 MT compression testing machine capable to travel at the speed of 10+/-

5. QUALITY CONTROL REQUIREMENTS

Firm shall maintain following documents/records:

6.1 A well documented quality Plan.

6.3 Stage inspection results including finished products results.

6.6 Records for maintenance of dies/moulds.

Test Method for Endurance Testing

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