Page 1 of25 Date of issue Spec. No. C-9809 (Rev.

4)
Ma ,2009

INDIAN RAILWAYS

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SPECIFICATION FOR NON-ASBESTOS BASED 'K' Tyji"E--- ------)

HIGH FRICTION COMPOSITE BRAKE BLOCKS FOR COACHES
WITH BOGIE MOUNTED BRAKE SYSTEM ON INDIAN RAILWAYS

MonthlYear of Revision!
S. No. Page No. Reason for Amendment
Issue Amendment
1. November, 1998 First Issue - -
Friction band added. Test
2. November, 1998 Revision-1 7 to 9
scheme modified
All .Acceptance procedure
3. July-2003 Revision-2
modified
Upgraded as perUIC-541-4,
4. January-2009 Revision-3 All
May2007
5,6,8,9,15 to 21 Make test procedure more clear
5. May, 2009 Revision-4
&24 for inspection i

Issued By

Research Designs and Standards Organization

Manak Nagar, Lucknow-226 011
 Page 20f25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

INDEX

S. No. Description Page No.

1.0 Scope 3
2.0 Requirements 3
3.0 Acceptance procedure 6
4.0 Inspection 9
5.0 Testing facilities 10
6.0 Packing 10
7.0 Warranty 10
Appendix-I Features of Main Line Coaches 11
Appendix -II Instantaneous Coefficient of Friction 12
Appendix -III Test Scheme for Type Acceptance Test on Brake Blocks 13
Appendix -IV Shear Strength Test 15
Appendix -V Bending Strength Test 16
Appendix -VI Test Methods of:
A. Measurement of Density 19
B. Hardness Test 20
C. Acetone Extraction Method 21
D. Modulus of Elasticity (Compression) 22
E. Ash Content 23
F. Cross Breaking Strength 24
G. Location, form and dimensions of test specimens 25
 Page 3 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

SPECIFICATION FOR NON-ASBESTOS BASED 'K' TYPE

HIGH FRICTION COMPOSITE BRAKE BWCKS FOR COACHES
WITH BOGIE MOUNTED BRAKE SYSTEM ON INDIAN RAILWAYS

1.0 SCOPE

1. 1 High friction non-asbestos based 'K' type composite brake blocks are required for
application on mainline coaches with bogie mounted brake system of Indian Railways.

2.0 REQUIREMENTS:

2.1 General

This specification defines the necessary characteristics of brake blocks of composite

material, whose average coefficient of friction is 0.25.

2.1.1 This specification covers requirements of non-asbestos 'K' type composition brake blocks
for coaches equipped with bogie mounted brake system of Indian Railways.

2.1.2 The brief features of mainline coaches are given in Appendix-I

2.1.3 The wheel profile is as per RDSO drawing number SK-91 146 with latest alteration. For
bedding in the cross section profile of the brake block must correspond to the profile of
wheel given in RDSO drawing No. SK-91146 with latest alterations.

2.1.4 The composition of the material and the manufacturing process for series production of
'K' type composite brake blocks must always conform with that of the prototype brake
blocks for which approval has been given. '

2.1.5 The use of asbestos and other fibers harmful to health is prohibited .The use of lead and
zinc in the metal state or in the form of compounds is not advised. Use of other substances
of any composition, which could cause a risk to health and the environment in the form of
dust, fibres, particles or gas released during use of the composite brake block, is not
recommended.
PPM level of these compounds if present in traces should be below the OSHA guidelines.

2.1.6 The composition of the material constituting the brake blocks must be selected so as to
guarantee the best compromise between: ­
• Friction properties.
• Wear and service life of composite blocks.
• Wear on running surface of the wheels and aggressiveness against the wheel tread.
• The effect on adhesion values between the rail and wheel.
 Page 4 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

2.1.7 The characteristics laid down in this specification must be maintained for the complete
usable thickness of the braking material.

2.2 FRICTION REQUIREMENTS

2.2.1 As far as possible the co-efficient of friction must be independent of the initial braking
speed, the state of bedding-in of the brake block, the specific pressure as well as the
temperature and atmospheric conditions.

2.2.2 The tolerance bands of the mean coefficient of friction shall be as per Appendix-II. 80%
of the mean co-efficient of friction values must lie within the band. Not more than 5%
values should be above the band.

2.2.3 During bedding-in, the coefficients of friction must not vary by more than ±15% from the
values obtained under the same conditions when the bedding is complete.

2.2.4 Under the influence of water, i.e. under wet conditions the average coefficient of friction
must not vary by more than ± 15% in relation to the value obtained during braking when
dry with other conditions remaining the same.

2.2.5 After prolonged braking followed by braking to a stop, particularly high temperatures
occur. Even in the case of these temperatures (Max. 400°C on the opposing friction
surface) the average co-efficient of friction must not vary with the other conditions
remaining the same by more than ±15%, in relation to the value obtained during braking
in cold and dry state.

2.2.6 During tests on the friction test bench on the brake blocks, there must be no flame
formation, excessive smoke, bonding agent sweating, sustairied crushing, severe odour
formation, large area crumbling or detachment or other defects which reduces the
mechanical strength.

2.3 GEOMETRICAL CHARACTERISTICS

2.3.1 The controlling dimension of the brake block shall conform to the requirements given in
RDSO drawing number SK-98066 with latest alteration.

2.3.2 The constructional features of the brake block must enable them to wear down to a
thickness of 10mm, including the back plate, without parts of the reinforcement or back
plate coming into contact with the running surface ofthe wheel tread.

2.3.3 The composition brake blocks must have permanently legible wear limit marks in red
colour in the area of the brake block side facing away from the flange, where marks have
a distance of 10mm from the rear of the backing plate.
 Page 5 of25 Date of issue Spec. No. C-9809 (Rev.4) .
Ma ,2009

2.4 MECHANICAL, PHYSICAL AND CHEMICAL FEATURES

2.4.1 Proof obligations of manufacturer:

The manufacturer of eBB must present a product specification giving sufficient detail of
the mechanical, physical and chemical features in their QAP. The values of density,
hardness, compression modulus, cross breaking strength, acetone extract & ash content
must be given for acceptance purposes. The test procedure of these properties shall be as
per Appendix-VI of the specification.

2.4.2 The various elements making up the brake blocks must be spread uniformly in the body of
the block. There must be no pitting, flakes or other defects. The material must not attack
the opposing friction surface or give rise to the formation of metallic inclusions.

2.4.3 No method is laid down for fixing the composition material to the back plate. The back
plate must be designed to withstand the forces likely to occur during service.

2.4.4 The blocks must not reduce the adhesion between the wheel and rail to an unacceptable
degree compared with that normally obtained from vehicles fitted with cast iron brake
blocks.

2.5 Mechanical requirements

2.5.1 Shear Strength:

The backs of the brake blocks and method of connection between the backing plate and
friction material must be designed so that any stresses occurring can be safely resisted.
The connection shall be tested using the test device shown in Appendix-IV with a test load
of minimum 15 KN. After the end of the test, there should be.~o damage to the friction
material/backing plate connection.

2.5.2 Bending Strength:

The bending strength is tested in the method shown in Appendix-V. .

After the end of test there must be no visible surface or through cracks and no detachment
from the backing plate.

2.6 Thermal Requirement:

2.6.1 The friction material must not cause heat damage to the wheel treads in service. Also it
must not damage the friction surface or have a tendency to form metallic inclusions.
 Page 60f25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

2.6.2 Composite brake blocks must resist the maximum heat stresses occurring within the
limits without burning, melting, forming and sewer deposits on the wheel treads or
wearing to an unusually great extent during service.

2.6.3 The brake blocks in service should give least/controlled smoke emission and should
not give away unpleasant burning odour.

2.6.4 The frictional material should be able to withstand a temperature of 400°C, without
worsening of its performance properties, measured on the rubbing surface of the
brake block.

2.7 MARKING

2.7.1 The composite brake blocks must bear the following marking on the backing plate:
a) Manufacturer's name I short name.
b) Month & Year of manufacture
c) Type designation of brake block i.e. "KNAC"- to indicate 'K' type non-asbestos
composite material for coaching stock.

The above marking should be embossed or punched and must be applied so that
each composite brake block can be identified even after complete wear.

d) Condemning limit
e) The manufacturer's name/short name, Batch and Lot Number shall be marked
on the side of brake block in black on the condemning limit mark, so that it should
be visible throughout the service life of brake blocks.

3 ACCEPTANCE PROCEDURE
3.1 For new SupplierlManufacturer

3.1.1 A Supplier I manufacturer seeking to supply brake blocks to Indian Railways must have a
technical collaboration with a foreign manufacturer who has experience in manufacturing
rail road brake blocks. The foreign collaborator must have existing manufacturing and
test facilities including full-scale dynamometer for manufacturing and testing of brake
blocks. The foreign company collaborator will have to give detailed information including
type acceptance test data run as per Clause No. 2.2 and other details in accordance with
Clause No. 2.4.1. The tests on the dynamometer will be carried out by the collaborator as
per Test Scheme given in Appendix-III.

3.1.2 The condition of foreign collaboration is strictly applicable for those companies, which
are not in the business of manufacturing friction composition materials. However, the
companies, which are in the business of friction composition material and have
established all the requisite manufacturing and testing facilities including full scale rail
 Page 7 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

dynamometer for indigenous manufacture of the Railway brake block and are following a
quality assurance plan to the satisfaction of RDSO may be exempted by RDSO from the
requirement of foreign collaboration. Such firm's should submit dynamometer test results
after testing of samples on their own dynamometer.

3.1.3 The collaborator presenting a new composition brake block would have to ascertain it's
performance and particularly it's possible deleterious effects on wheels by means of trials
carried out in service. The tests must be continuous for at least six months.

3.1.4 The supplier shall submit a copy of approval certificate issued to their collaborator by any
rail road for composite brake blocks.

3.1.5 The supplier shall submit a copy of memorandum of understanding (MOD) jointly signed
by the supplier and collaborator.

3.1.6 The supplier shall submit the list of past supplies made by their collaborator to different
rail road along with specifications followed for manufacture and supply of brake blocks.

3.1.7 The supplier shall submit the list of plant and equipment available along with capacity, no.
of such equipments, manufacturer name etc. available with collaborator.

3.1.8 The report on the tests mentioned in clause 3.1.1, 3.1.2 and 3.1.3 as applicable should be
presented together with a request for type acceptance.

3.1.9 The supplier shall submit detailed drawings of the brake block and back plate for approval
of RDSO. The dimensions mentioned in the RDSO drawing No.SK-98066 (Latest
Alteration) must be complied for the fitment aspects and design changes (Except fitment
aspect) can be suggested by manufacturer.

3.1. 10 The supplier will submit six numbers of brake blocks for test on RDSO's own brake
dynamometer and four samples will be tested as per Test Scheme given in Appendix-III.
The test charges will be paid by the supplier.

3.1.11 The wear should be uniformly distributed over the entire depth of the block. It should be
as low as possible and be largely independent of the type of brake load application. The
wear value found by weighing should not exceed 5 cel kwh / block.

3.1.12 The average wear rate recorded during dynamometer testing at RDSO on prototype brake
blocks for which approval has been given will form the basis for further quality checks.
The wear rate in subsequent dynamometer testing should not be more than 20% higher
than the wear rate of prototype brake block for which approval has been given. The
manufacturers will specify the wear rate in their QAP. This will be only part of quality
checks not the acceptance test.
 Page 80f25 Spec. No. C-9809 (Rev.4)

3.1.13 The brake blocks tested on the dynamometer must meet the requirements concerning
friction and temperature given in clause 2.2 of this specification.

3.1.14 On successful completion of the dynamometer testing at RDSO the brake blocks shall
undergo extended field trials. The field trial shall be carried out in two phases. The first
phase shall consist of field trials of 1000 imported brake blocks for six months or 1,00,000
km whichever is earlier. On successful completion of these field trials 1000 indigenously
manufactured brake blocks shall undergo the field trials for six or 1,00,000 km whichever
is earlier. The field trials shall be monitored by DGIRDSO or his authorized
representative. Imported trials may be dispensed with at discretion of RDSO subject to
firm having all facilities for indigenous production and testing including dynamometer.
Wherever such dispensation is granted either for imported or indigenous suppliers the
field trial scheme will be suitably modified to have more assurance of the brake block and
will be nine months or 1,50,000 whichever is earlier.

3.1.15 Based on the technical evaluation further action will be taken for manufacture of
composition brake blocks.

3.2 For supplier/manufacturers already cleared for imported/indigenous supply

3.2.1 The supplier shall get his Quality Assurance Plan approved by RDSO before undertaking
manufacture of the brake block. The Quality Assurance plan must contain the details of
process of manufacture, process controls, quality records maintained, specific wear rate
and values of following parameters.

a) Density Variation should be within. ± 0.10 units

b) Ash content (in %) Variation should be with~n ± 3
c) Acetone extract Should be less than 3% .
d) Hardness To be within ± 10 Units.
Also, out of all nine individual hardness reading, at
least 7 values should be within the specified range of
± 10 Units and remaining two readings may be
within the range of ± 15 units.
e) Minimum Cross-breaking strength value.
t) Maximum Compression modulus value.

The base values of above parameter shall be taken as per the actual test results
obtained on prototype brake blocks for which type approval was given.

The location for taking test specimen from brake block is given in Appendix-VI.

3.2.2 The supplier shall undertake full-scale dynamometer test on the brake blocks under supply
to Indian Railways as per test scheme given at Appendix-III. For this purpose requisite
 Page 9 of25 Spec. No. C-9809 (Rev.4)

samples shall be picked up by RDSO/Inspecting Authority and the supplier shall arrange
testing of the blocks. To audit the quality control, RDSO at their discretion may pick up
samples for dynamometer testing at RDSOlLucknow.

The frequency of testing samples on dynamometer should be after manufacture of every

50,000 numbers of brake blocks.

3.2.3 In case dynamometer is under break down due to any of the reasons, the dynamometer
testing shall be conducted at the collaborator plant or at RDSO. The manufacturer shall
bear the testing charges in case blocks are tested at RDSO.

4 INSPECTION

4.1 The inspection of the brake block shall be carried out by Director General/RDSO or his
authorised representative at the premises of the supplier.

4.2 The inspection will be carried out as per the following procedure.

i) Supplier to submit pre-inspection report for the lots offered for inspection as per the
approved QAP of the firm.
ii) Supplier to ensure traceability of each block to it's parent mix batch number.
iii) The Inspecting Authority shall inspect the quality records maintained by the supplier
for the entire lot.
iv) Each lot offered for inspection shall consist of 2000 brake blocks or part thereof and
shall represent the mix batch numbers out of which these brake blocks have been
manufactured. The brake block of the lot shall be kept batch wise in such fashion that
random sampling from all batches of the offered lot is made possible. The brake
blocks manufactured from same mix shall constitute one batch.
v) Minimum 20 numbers of every offered lot of 2000 numbers brake blocks are part
thereof will be selected at random and checked fOf dimensional accuracy.
Dimensions are to be checked as per approved drawing of manufacturer. However it
is to be ensured that blocks from different mix batches will be taken up for inspection.
vi) One brake block selected at random will be subjected to shear strength test as per
Appendix-IV.
vii) At least five brake blocks shall be tested for bending strength test for each condition
given in Appendix-V.
viii) One brake block selected at random from the above lot shall be tested as per
Appendix-VI for the following which should confirm to the values approved in the
QAP of the supplier. In case, two brake blocks are selected for the test, then test
specimen for density, ash content, hardness, acetone extract and compression modulus
shall be taken from the one brake block and only the test specimen for cross breaking
strength shall be taken from other brake block.
 Page 10 of25 Spec. No. C-9809 (Rev.4)

a) Density
b) Ash contents
c) Hardness
d) Acetone extract
e) Cross breaking strength
f) Compression modulus
g) Any other test specified by RDSO

The block shall be accepted based on acceptable readings given in the approved
QAP of the supplier. The test methods are given in Appendix-VI.

ix) One brake block selected at random from the lot shall be subjected to any other
test as decided by the manufacturer and RDSO.

4.3 The brake blocks shall conform to the requirements mentioned in clause 4.2. Should
any of the samples selected as per clause 4.2 fail to meet the requirements of any of
the requirements, double the quantity of samples stipulated in clause-4.2 shall be
selected for tests. Should any of the brake blocks fail to meet the requirements of any
of the tests on retesting, the entire quantity of brake blocks offered for inspection shall
be rejected and brake blocks shall be rendered unserviceable.

5 TESTING FACILITIES

i) Supplier shall have adequate facilities for checking of brake blocks according to
dimensional tolerances shown on drawing.
ii) The supplier shall have adequate facilities for determini~g the characteristics laid
down in clause 4.2. '
iii) The supplier shall have in house full scale dynamometer facilities to test the brake
block as per test scheme laid down in Appendix-ill. The brake block tests on full­
scale dynamometer shall meet the requirements given in clause 3.1.11 to 3.1.13.

6 PACKING

The brake blocks shall be securely packed in cardboard crates with enough cushions so
that there is no damage to brake blocks during transit.

7 WARRANTY

The composite brake block will have warranty against any manufacturing defect noticed
during the service before the condemning limit is reached or 18 months from the date of
supply whichever is earlier. Manufacturer shall replace the defective brake blocks within a
month's time from the receipt of information from user railways without any cost.
 Page 11 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

Appendix-I

FEATURES OF MAIN LINE COACHES

Sl.No. Item Mainline coaches

1 Max. axle load (t) 16.25

2 No. of axles per coach 4

New
915+3/-0
3 Wheel dia
(mm) Condemning 813

4 No. of wheels/coach 8

5 No. of brake blocks/wheel 2

6 Brake force on block (kg) Max. 1500

7 Maximum speed (kmph) 140

8 Type of brake system Clasp

9 Type of brake head RDSO Sk-98033

10 Type of brake block required Non-asbestos 'K' type

Ref: COW 0001 Page 12 of25 Date of issue Spec. No. C-9809 (RevA)
(Rev. - 4) Ma ,2009

Appendix-II
,------------------------------------_._-----­
----------_._-----------------------,

INSTANTANEOUS COEFFICIENT OF FRICTION J.1a FOR K-BLOCKS

Jla
0.50 r------,-----,-----,----,-­
048

o. 40 ~r--"_A~,_____-+----+-----t---__+_--_+_--_+_-___I

0.325
o 3 0 hL-/--/-7"74+r'r---+--r-7--.l4--+r--'-7Z7'"7-G-~___y__,__+_,_____,______+_r_r_r_r__+_,________I 0 .3 0 0

022
0.20 r--_--=j'='-~~L..L....Lj-L---+.L..L....L..L...---t-.L..L....L..L...__+_...L..L..L..L..._+_.L..L....L..L..._+_'--L....___I
0 200
o 175

o 10 f - - - - - + - - - + - + - - - - + - - - + - - - + - - - - + - - - - + - - _ _ _ I

o 20 40 50 60 80 100 120 140 160

V[km/h]

MEAN COEFFICIENT OF FRICTION J.1m FOR K-BLOCKS

__ _ __- , - - , -_ _- , -_ _,--.L..L..._,---_----,

040
04

03

0.2

o1

o
o 20 40 50 60 80 100 120 140 160
V[km/h]
 Page 13 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

Appendix-III
TEST SCHEME FOR TYPE ACCEPTANCE TEST ON 'K' TYPE COMPOSITE
BRAKE BLOCKS FOR PASSENGER STOCK

I. Diameter of wheel- 915mm (ICF B.G. Main Line wheel)

2. No. of brake blocks per wheel- 2
3. Axle load - 16.25t.

Brake Blower Force per Initial temp. of

Speed
application speed brake wheel tread Remarks.
(km/h)
No. (rpm) block (kg) (0C)
1 2 3 4 5 6
Braking to stop lDltil running in conditions of
3-n 60 750 1000 20-100 80% is obtained.
Weigh
Braking to stop under dry conditions after
1-3 50 750 500 20-60
coolin~ the wheel if necessary.
4-6 80 750 500 60-80 -do­
7-9 120 750 500 80-90 -do­
10-12 140 750 500 80-90 -do-
Braking to stop under wet conditions after
13-15 50 750 500 20-60
cooling the wheel ifnecessary.
16-18 80 750 500 60-80 -do­
19-21 120 750 500 60-80 -do­
22-24 140 750 500 60-80 -do-
Braking to stop lDlder <by conditions after
25-27 50 750 1000 20-60
cooling the wheel if necessary.
28-30 80 750 1000 60-80 -do­
31-33 120 750 1000 80-90 -do­
34-36 140 750 1000 80-90 -do-
Braking' to stop under wet conditions after
37-39 50 750 1000 20-60
cooling the wheel if necessary.
40-42 80 750 1000 60-80 -do­
43-45 120 750 1000 60-80 -do­
46-48 140 750 1000 60-80 -do-
Braking to stop under <by conditions after
49-51 50 750 1500 20-60
cooling the wheel if necessary.
52-54 80 750 1500 60-80 -do­
55-57 120 750 1500 80-90 -do­
58-60 140 750 1500 80-90 -do-
Braking to stop under wet conditions after
61-63 50 750 1500 20-60
cooling the wheel if n
64-66 80 750 1500 60-80 -do­
67-69 120 750 1500 60-80 '-do­
-do-
70-72 140 750 1500 60-80 Weigh at the end of the last stop.
 Page 14 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

Drag braking with 45 H.P. for 20 minutes

immediately by braking to stop with brake
block force of 1500 kg. Under warm
73 60 750 20-40 condition. Measure temperature of wheel and
brake block after drag braking and
immediately after drag braking to a stop.
Weigh

Note:­

1. The average wear values shall be measured by weighing by taking weights at the
beginning of stop 1 and at the end of stop 72. The value calculated shall not exceed 5
cc/kwh. Wear value shall be also measured during drag braking conditions and results
shall be evaluated.
2. The following parameters shall be measured / recorded during the above test:
• Wheel tread diameter before and after test.
• Brake block diameter before and after test.
• Surface condition of brake block after the test specially in respect of grooving
metallic inclusions, burning, uniform wear, over-heating etc. and the wheel tyre in
respect of polishing, pitting, flaking, cracking and other defects after the test is
over.
• Max. temperature reached on brake block and wheel tread after the test.
• General observations regarding smoke, smell, sparks and noise.
3. Before beginning the test on a tyre turned wheel, the running tread of the wheel shall be
polished by direct brake applications with composite brake blocks.
4. Friction characteristics shall be measured and evaluated as under:
• The value of instantaneous co-efficient of friction should be plotted and presented
for generating data.
• The mean co-efficient of friction should be as per chart given in Appendix-II.
5. Analysis of data shall be done as per methods given in OlC leaflet 541- 4 OR and ORE
Report B-64 / RP 10.
 Ref: COW 0001 Page 15 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. - 4) May, 2009

Appendix-IV
TEST FORCE
F
- METAL "LULK--~ ...

BRAKE BLOCI<-~I-r-"-""'J'l

I :
_,_ ...J

I :
.i :,
, I '

H~
,-0
, . ,
: I :
I, , I
,
)

Lt~

FRICTION MATERIAL

SCHEMATIC DIAGRAM

DEVICE FOR TESTING THE SHEAR STRENGTH

Test conditions:

Test load, F = Minimum 15 KN

Test Specimen: Brake block having a groove of minimum 3mmwidth in centre upto back plate
as shown above.
ApparatuslEguipment:
• Universal testing machine, capable ofloading minimum 15KN within the four seconds and
maintaining the load for minimum two minutes.
• Testing device as shown above.

Procedure:
• The test is to be carried out on UTM with testing device as shown above.
• A new block is to be used for the test.
• Test load 'F' is to be applied evenly in the direction of the circumferential load when braking
and increased to the load of minimum 15KN within 4 seconds and maintained constantly for
minimum two minutes.
• After end of the test, brake block should meet the requirements specified under clause-2.5.1.
Brake block shall be tested at both ends.

This test is based on UIC code 541-4 OR, May 2007

 Ref: COW 0001 Page 16 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. - 4) May, 2009

Appendix-V

BENIHNG STRENGTH: - Test procedure)s based on UIC code 541-4 OR, May 2007

Fb

r ,
11------11
II II
II II

,
II II

TEST 1

TEST 2
N
s:

//. 7 7 / / 7 / / / / / / / / /

FIG.-1 TEST OF BENDING STRENGTH

Test Conditions:
For Test-I: ­
Test Force, Fb = Minimum 19 KN
Support width, LsI = 220 mm
Deflection, D. hI = Minimum 2 mm

For Test-2: ­
Test Force, Fi/2 = Minimum 9.5 KN
Support width, Ls2 = 85mm
Deflection, D. h2= Minimum 1 mm
Test Specimen: Brake block
ApparatuslEguipment:
• Universal testing machine (UTM) should be capable to apply test force at speed of 30mm/min.
and should be able to maintain the test force constantly for minimum two minutes. Machine
should also have the facility to display/record the load & deflection with accuracy of minimum
two decimal places.
• Fixtures shown in fig. 2 & fig.4.
• Support bracket shown in fig. 3 & fig. 5.
 Ref: COW 0001 Page 17 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. -4) May, 2009

Test-I: ­
NOT TO SCALE

94
1.:---=----t--'2~S
T T . ..--::3d-­
I

SCHEMATIC DIAGRAM
FIXTURE FOR LOAD APPLICATION
FOR BENDING STRENGTH TEST -FULL BLOCK
FIG.-2

LSI - 220 +6
-

204 Cj

I' '1
'0"1
Q:­

,
1'--"
I-I--­
I
,
1'--"
uf
I" I
I,
<:~
Lf) Lf)
o 0
o sl,o I

~II
Lf) 8 8
,I 1

~ :
I 1 1

I. Min.78 .1
SCHEMATIC DIAGRAM

SUPPORTING BRACKET FOR BENDING STRENGTH TEST -FULL BLOCK

FIG.-3

Note: 1. The height 'H' to be kept as that the back plate of brake bloek become horizontal.
2. The dimension, 62 +01-2, support length LsI, 220 +51-0 and support radius R5±0.1 must be
maintained. .
3. All dimensions are in mm.
Test procedure:
• Mark the support locations on brake block.
• Place the support bracket shown in Fig.-3 on UTM.
• Place the brake block on support bracket as shown in Fig.l.
• Place the fixture (Fig.-2) on brake block for load application.
• To ensure the positive contact between the fixture and brake block, apply a load of
minimum lOON and set the deflection at zero.
• Increase the load of minimum 19KN or for deflection of minimum 2mm at the speed of
30mmlmin., hold constant for minimum two minutes and then release the load.
• Brake block should meet the requirements specified under c1ause-2.5.2.
Five tests must be performed.
 Ref: CGW 0001 Page 18 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. - 4) May, 2009

Test-2: ­

ffi
78
I

I I !
o
~,
~ 7~ I
I en
0

<J.. t- I

!
I
I

I
I
I
f--------5~
I
~L-L-_------!--,-----+_~ I
I
I

Lfll-l
I 16 110
----~~----
SCHEt.4ATIC DIAGRAt.4

FIXTURE fOR LOAD APPLICATION

fOR BINDING STRENGTH TEST -HALf BLOCK
FlG.-4

Min 7 .

SCHEt.4ATlC DIAGRAt.4

SUPPORTING BRACKET fOR BENDING STRENGTH TEST -HALf BLO.CK

FlG.-5

Note: 1. The height 'H' to be kept as that the back plate of brake block become horizontal.
2. The support length LS2 , 85 +5/-0 and support radius R5±O.I must be maintained.
3. All dimensions are in mm.

Test procedure:
• Mark the support locations on brake block.
• Place the fixture shown in Fig.-4 for load application on UTM.
• Place the support bracket (Fig.-5) on fixture for load application.
• Place the brake block on support bracket as shown in Fig.I.
• To ensure the positive contact between the fixture and brake block, apply a load of
minimum lOON and set the deflection at zero.
• Increase the load of minimum 9.5KN or for deflection of minimum 1mm at the speed of
30mm!min., hold constant for minimum two minutes and then release the load.
• Brake block should meet the requirements specified under clause-2.5.2.
Five tests must be performed.
 Page 19 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

Appendix -VI

TEST METHODS: - The test methods given in this appendix are based on DIC code 541-4 OR,
1990 and ORE Report B-64 / RP 10.

Preparation of Specimens
The specimens are obtained from the brake blocks as described in this appendix.
The diagram shows their location, form and dimensions.

A MEASUREMENT OF DENSITY

Preparation of Specimens:
Cut sample of40 x 40 x lOmm mm from the block as shown in sub clause-G of Appendix-VI.
The specimen intended for the hardness test may be used for measuring the density, before the
hardness test is carried out. The specimen should be dried suitably to carry out the hardness test
on the same specimen.

Two methods are available for use:

1 The specimen is weighed to an accuracy of 1mg and measured to an accuracy of

50 Ilm.
The density is obtained by the following formula:

Mass of specimen (g)

Density (g/cm3)
Volume of specimen (cm 3)

2 The specimen is suspended by a thin thread from the hook to a weighing scale and
its weight in air is measured to an accuracy of 1mg. The specimen is then freely
suspended in water at a temperature between 18°C and 24°C and then weighed
again. Before weighing, any air bubbles adhering to the specimen must be
removed, which can be facilitated by adding a trace of detergent to the water. The
density is then obtained by the following formula:

Weight in air
------------------------------------ = Specific gravity
Weight in air- weight in water

Density = Specific Gravity x Density of water i.e. 19/cm3

3 Test specimen shall be taken from the location of brake block shown in sub clause­
G of Appendix-VI.
 Ref: CGW 0001 Page 20 of25 Date of issue I Spec. No. C-9809 (Re~.4) I
I (Rev. - 4) May, 2009

B HARDNESS TEST

Preparation of Specimens
Cut sample of 40 x 40 x 10mm mm from the block as shown in sub cIause-G of
Appendix-VI and machining the back until the whole holding plate has been removed and
a smooth surface parallel to the top side (braking side) obtained.

The specimen intended for the hardness test may be used for measuring the density, before
the hardness test is carried out. The specimen should be dried suitably to carry out the
hardness test on the same specimen.

After recording the hardness measurements on the upper surface (To preparation refer to
paragraph 2) this surface is ground down 5mm parallel to the lower surface. A new series
of hardness measurements is then obtained.

2 Test method
The test is carried out in accordance with method A of standard ASTM D 785
For soft materials «100HRX) a non-standard 19 mm ball is used in order to
prevent wide scatter. The minimum (initial) load is 10kgf (98.0665N), the
maximum (total) load is 60 kgf (588.399N).
The test scale is called "X"
For hardness values greater than 100HRX standard scale "R" is recommended.

2.1 Method A (scales "X" and "R")

After putting the specimen into position, the minimum load of 10 kg is applied and
the small pointer is set to zero within 10 seconds.
The large pointer is set to (B) 30 on the red scale. Within 10 seconds, after the
application of the minimum load and immediately after setting the dial, the
minimum load of lOkgf (98.0665 N) is increased to maximum load of 60kgf
(588.399N). The maximum load is then reduced to the minimum load after 15
seconds.
The Rockwell hardness HRX is read off on the red scale 15 seconds after the
reduction of the maximum load.

The HRX hardness value is obtained as follows:

HRX value=130-penetration depth (scale divisions)

Note: If the depth of penetration exceeds 130 scale divisions (0.26mm), negative
values are obtained
Ref: CGW 0001 Page 21 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. -4 Ma ,2009

3 Number of measurements and calculation of hardness

Nine measurements are to be obtained on the two surfaces. Five measurements are
to be obtained from upper surface and four measurements are to be obtained 5mm
below the original upper surface. The minimum distance between two penetrations
or between one penetration and the edge of the specimen shall be 10mm. The
arithmetical mean of these values is the surface hardness.

C ACETONE EXTRACTION TEST

The following materials and equipment are required:

a) Pure acetone
b) Apparatus for crushing the specimen into powder
c) A sieve with a nominal mesh of 425 JIm in accordance with ISO standard 565 (1)
d) A sieve with a nominal mesh of 250 JIm in accordance with ISO standard 565 (1)
e) An analytical scale with an accuracy ofO.001g.
f) A Soxhlet extraction apparatus, or other apparatus, which has been shown to produce
similar results.
g) A drying oven with air circulation adjustable to 50±2 °C.

Specimen Preparation:

A specimen representative of the friction material is reduced to powder form by filing,

milling, turning or boring, without excessively heating the material. The powder is then
sieved, using the sieves described under c) and d) above, preserving for extraction only the
matter having passed through sieve c) and retained by sieve d). Suitable precaution must
also be taken to prevent the powdered specimen from absorbing moisture.

Test Procedure:

Two portions of the sieved material must be tested. One specimen of approx 3g is
weighed to an accuracy ofO.001g on calibrated filter papei with large pore size or in a thin
extraction crucible. The use of whatman filter paper is considered acceptable for this
purpose. After covering the crucible, or the filter paper containing the specimen, so that
none of the powder can escape, the specimen is placed into the siphon of the extraction
apparatus. The condenser, siphon and flask, into which 50 to 200 ml of pure acetone has
been filled, are then assembled. Heating is regulated so that siphoning occurs 20 to 30
times per hour and extraction is continued for at least 6 hours. At the end of this period
the flask is withdrawn and the content is transferred to the smaller flask or a bowl having
previously been weighed to an accuracy of 0.001 g. The empty flask is rinsed with
approximately 20 ml acetone, which is then added to the extract.

The acetone is then evaporated by a suitable method, taking care that the temperature does
not exceed 50 °C. The receptacle holding the residue is then placed into the oven, where it
 Page 22 of25 Date of issue Spec. No. C-9809 (Rev.4)
Ma ,2009

remains for 30 minutes at a temperature of 50±2 0c. The receptacle is then removed from
the oven, cooled in a drier to room temperature and weighed heating, cooling and
weighing is repeated until a consistent mass is obtained, i. e. until the difference between
two successive weightings does not exceed 0.003g.

The specimen content of matter soluble in acetone is obtained in the form of a mass
percentage by applying the following formula:

m1
---- x 100
mO

where:
mO- Mass ofthe test specimen in g,
m1- Mass of dry extract in g.

The arithmetical mean of the values obtained from the two portions of the test specimens
is considered to be the specimen content of matter soluble in acetone.

The test report should present the following details:

a) Reference to this method.
b) Complete description of the specimen.
c) Method used to reduce the block material into powder form.
d) Content of matter soluble in acetone of each portion of the test specimen.
e) Arithmetical mean of the results obtained from the two portions.
£) Date of test.

Test specimen shall be taken from the location of brake blqck shown in sub c1ause-G of
Appendix-VI.

D MODULUS OF ELASTICITY (COMPRESSION)

The diameter and the height of the 6 specimens are measured to an accuracy of 10 Ilm.

The specimens are submitted to a test on a Rockwell hardness tester, on which the ball has
been replaced by a cylindrical mandrel of 13.3mm diameter.

The minimum (initial) load is 10kgf(98.0665N) and the maximum (total) load is 35 kgf
(343.233N).

Before the test is started, the deflection of the test apparatus between minimum and
maximum loads is measured without the test specimen.
Ref: CGW 0001 Page 23 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. - 4) Ma ,2009

The following test sequence is applied to each specimen as shown in sub c1ause-G of
Appendix-VI.

The specimen is placed centrally underneath the mandrel, the minimum load is applied
and the dial is again set to zero (black scale). The maximum load is then applied for 45
seconds, followed by an application of the minimum load for a further 10 seconds. The
dial is again set to zero and the maximum load is applied again. The reading is taken,
when after approximately 10 seconds the movement of the pointer suddenly slows down.

The deflection of the apparatus is then subtracted from this reading and the net deflection
expressed in scale graduations is multiplied by two in order to obtain the depression ~h of
the specimen in Ilm.

The modulus of elasticity E (mean value of the results obtained with the 6 specimens) is
then calculated by the formula:

3. 122 x 105 x h
2
E = ------------------- N/mm
D2x~h

H height of specimen (mm)

=
D = diameter of specimen (mm)
~h = depression of specimen (~m )

Test specimen shall be taken from the location of brake block shown in sub c1ause-G of
Appendix-VI.

E ASH CONTENT

Preparation of test specimen:

A specimen of fine particles of the brake block is prepared by drilling out with 10mm dia.
Drill bit without overheating. The drilling is done perpendicular to the working surface
and the depth of the drilled holes shall not be more than 50% of the total block thickness.
Specimen is to be prepared from the area shown in the Appendix-VI.

Apparatus:
1. Analytical Balance with an accuracy of 1mg.
2. Muffie furnace with pyrometric control to ±50 °c with temperature to 10000 C
3. Crucible
4. Tongs
5. Desiccator

No. oftests: One

Ref: CGW 0001 Page 24 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. - 4 Ma ,2009

Procedure:
Weigh previously ignited and cooled empty crucible (without lid) and the record the
weight WI. Load the drilled particles of Igm in the pre-weighed crucible and weigh to an
accuracy of ± O.Igm (W2). The crucible containing the sample is placed in the muffle
furnace at 825 ± 15°C and left for 2 hours. After ignition, the crucible shall be removed,
cooled in a desiccators and weigh (W3). The ash content shall be calculated as follows,
W3-WI
Ash Content in % = ------------ x 100
W2-WI
WI = Weight of the crucible in gms
W2 = Weight of the crucible and sample in gms
W3 = Weight of the crucible and sample (after ignition) in gms

Test specimen for this test may be taken from the location of brake block shown in sub
clause-G of Appendix-VI.

F CROSS BREAKING STRENGTH

Test specimen: Size of the test specimen is I20mm x I5mm x lOmm. Test specimen is to
be prepared from the area shown in the clause-G of Appendix-VI.
Apparatus:
1. Universal Testing machine (UTM)
2. Suitable Jig & fixture having supporting span of IOOmm

No. of tests: One

Procedure:
The test shall be carried out at room temperature. The top portion of the jig shall be placed
in the adjustable crosshead of the Universal testing machine and lock in with the key.
Place the bottom portion of the jig in the centre position of the UTM table and adjust the
jig so that the top portion of the jig is aligned to the middle of the bottom portion of the
jig. Place the specimen on the jig. Select load range of the UTM for testing the sample.
Apply the load until the sample breaks. Read the load in kgf. Calculate the cross breaking
strength ofthe specimen using the following equation,
WxL .
Cross breaking Strength = 1.5 x -------­
bxd2
Where, W= Load in Kgf
L = Distance between jaws of cross break jig
b = width of the specimen (cm)
d = Thickness of the specimen (cm)
Test specimen shall be taken from the location of brake block shown in sub clause-G of
Appendix-VI.
Ref: COW 0001 Page 25 of25 Date of issue Spec. No. C-9809 (Rev.4)
(Rev. -4) Ma ,2009

G LOCATION, FORM AND DIMENSIONS OF TEST SPECIMENS:

AREA FOR ACETONE ExTRACT AND ASH CONTHJT

FOR HARDNESS AND DENSITY TESTS

68

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