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WD-20-MISC-95 (Rev - 4) Amendment 1 of July 2022
WD-20-MISC-95 (Rev - 4) Amendment 1 of July 2022
4)
(Supersedes Spec. No. WD-20-MISC-95 (Rev.3)
INDIAN RAILWAYS
SPECIFICATION
OF
ELASTOMERIC PAD
ISSUED BY
RESEARCH DESIGNS & STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
MANAK NAGAR, LUCKNOW – 226 011
January – 2022
Specification No. WD-20-MISC-95 (Rev.4)
1. All parameters for Design A (WD-95005-S-01) shall be followed as per Spec WD-20- Misc-95-
Rev-03 Amendment No. 6 of September-2016. The Field trial period for Design-A shall be 6
months.
2. Tolerance on Lowest value of Deflection in load deflection characteristics as per clause 3.4.3
& 3.4.4 to be read as 30% in lieu of 20%.
i
Specification No. WD-20-MISC-95 (Rev.4)
Contents
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Specification No. WD-20-MISC-95 (Rev.4)
List of Tables
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Specification No. WD-20-MISC-95 (Rev.4)
0.0 FOREWORD
0.1 This specification is intended to cover the technical provisions relating to material,
construction and tests and does not include all the necessary provisions of the
contract.
0.2 This specification draws reference to specifications and standards given below. The
firm shall have a copy of latest versions of these specifications:
Table 1: Reference to Specifications
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Specification No. WD-20-MISC-95 (Rev.4)
0.3 For the purpose of deciding whether a particular requirement of this standard 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. The number of significant
places retained in the rounded off value should be the same as that of the specified
value in this standard.
0.4 In the recent past, EM pad failures have been reported by Zonal Railways. The
matter has been examined in consultation with Premier Rubber Institutes and EM
pad Manufacturers. Based on their feedbacks, labs testing results and analysis,
suitable modifications in this specification have been envisaged. The improved
design of the EM pad is called as Design-B. Further, to improve the reliability and
life of Elastomeric Pad used on IR freight stocks, Premium Elastomeric Pad to RDSO
specification WD-37-Misc-2004 has also been prepared.
1.0 SCOPE
1.1 This Specification specifies the requirements and methods of tests for metal bonded
elastomeric pads to drawing no. WD-95005-S/1 latest alteration (called Design-A) or
drawing No. WD- 21109-S/02 (called Design-B) or any other approved Design
(Design-X) offered by firm to RDSO envelop Drawing no WD- 21109-S/01. This is
applicable to ‘Casnub 22W (modified adapter), 22W (M), 22NL, 22NLB, 22HS, LCCF
20 (C), IRF108HS and LWLH25 Bogies on freight stock of Indian Railways. Initially
EM Pad of Design-B will be used on BLC and BCN type wagons whenever
replacement of EM pads is warranted. After completion of trials of six months and
assessment of results, decision on further proliferation of design B in all other
wagons will be taken by RDSO. Continuation of EM pads of design A for new
fitments will be subject to the performance outcome of design B and other designs
being developed. However, the warrantee replacement of the EM pad design A will
continue as per the extant rules.
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Specification No. WD-20-MISC-95 (Rev.4)
1.2 The elastomeric pad placed between side frame and adapter is subjected to
compressive load and shear load developed in freight bogies fitted in Wagons of
upto 25 tons axle load on Indian Railways Track Conditions. It is primarily used to
reduce wheel wear and also acts as an anti-vibration member. The pad shall be
capable of withstanding wide climatic variation prevailing in India (temperature
range of -10 °C to +50 °C) including maximum permitted operating temperature (90
°C) of bearings on Indian Railway freight stock. The elastomeric pad shall operate
without adverse effect on reliability, physical deterioration and any marked change
of its characteristics, over service life.
2.0 DEFINITIONS
2.1 Purchaser - means Zonal Railways/Workshop/PU or any other agency procuring the
material on behalf of the President of India.
2.2 Engineers - means Wagon Directorate, Research Designs and Standards
Organisation, Ministry of Railways, Lucknow (India) – 226 011.
2.3 Inspecting Officer – means the person, firm or department nominated by the
purchaser to inspect the work on his behalf and the deputies of the Inspecting
Officer so nominated.
3.0 REQUIREMENTS
3.1 Material of Compound
3.1.1 Natural or synthetic rubber or a blend of elastomers suitably compounded shall
be used for the manufacture of elastomeric pads to conform to the requirements
stipulated in this specification. The Pad shall be manufactured from virgin base
material only and Reclaimed / re-refined/recycled/ regenerated rubber / elastomer
shall not be used.
3.1.2 Firm may offer its own design of EM Pad conforming to RDSO boundary envelop
drawing No WD-21109-S/01 and/or any other compound with prior approval of
DG (Wagon), RDSO, Lucknow to conform to the requirements stipulated in this
specification. In Case the Firm is offering its own design and/or any material
other than Natural Rubber, the firm shall submit the detailed test report as
specified in this specification, documentary evidences, physical and functional
properties of the material, Dynamic Mechanical Analysis (DMA-Glass transition
temperature (Tg), modulus, viscoelasticity (storage modulus, loss modulus, tan
delta) as per relevant ASTM/ISO standards, FTIR as per ISO-4650, TGA as per
ASTM E1131/Relevant ISO Standards, working temperature range of the product,
etc. to Wagon Directorate/RDSO, Lucknow for obtaining approval before use. The
details of the Design of EM Pad and the material specification shall be submitted
by the firm in the drawings and QAP.
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Specification No. WD-20-MISC-95 (Rev.4)
ii) Design-B: RDSO Design to drawing no WD- 21109-S/02 latest alteration. The
dimensions and tolerances shall be as per the drawing. Untoleranced rubber
dimensions shall have tolerances as per ISO 3302-1 (Class M4 of Table 1). Un-
tolerance dimensions of steel plate shall have tolerances as per standard IS:
2102 (medium).
iii) Design-X: Any other Design offered by firm conform to RDSO boundary
envelop Drawing No WD- 21109-S/01 and approved by DG (Wagon), RDSO,
Lucknow. The dimensions and tolerances shall be as per the drawing.
Untoleranced rubber dimensions shall have tolerances as per ISO 3302-1
(Class M4 of Table 1). Un-tolerance dimensions of steel plate shall have
tolerances as per standard IS: 2102 (medium).
3.3 Construction and Finish
3.3.1 The metal plates shall be degreased, shot/grit blasted to Sa 2.5 and chemically
cleaned with any suitable degreasing agent before bonding with rubber. The
shots/grits shall be as per IS 4606 Grade G12. The metal plates must be degreased
before mechanical cleaning. After mechanical cleaning and before application of
primer adhesive the metal plates should be cleaned with dry air. It has to be
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Specification No. WD-20-MISC-95 (Rev.4)
ensured before bonding that the metal surface is free from dust, rust, moisture,
metal oxide, oily contaminants and other foreign matter. In case there exist
standard guidelines/recommendations/instructions from OEM of the bonding
agent for the surface preparation, the same can be used for the best performance
of the Bonding agent. However, Firms shall obtain approval from the Wagon
Directorate/RDSO for the process before use. Chemlok primer shall be applied on
dry plates within one hour of last chemical cleaning or as suggested by the OEM
of the bonding agent. The process adopted for bonding of rubber to metal plate
shall be a proven one using Chemlok-205 for primer & Chemlok-6411 for Cover
Coat or superior grade bonding agent to achieve the required durable bond
strength under the operating condition & temperature range mentioned in this
specification. Any other bonding agent superior to mentioned additive can also
be used with prior approval of Director General (Wagon), RDSO, Lucknow.
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Specification No. WD-20-MISC-95 (Rev.4)
3.3.9 Manufacturer shall maintain records for the raw-rubber, metal plate and adhesive
& primer (Applied thickness on metal plates of EM Pads). It shall be
ensured/verified during inspection/quality audit/fresh registrations.
3.3.10 Manufacturer shall maintain records of injection molding (EM Pad Molded per
day/shift). It shall be ensured/verified during inspection/quality audit/fresh
registrations.
3.4 Technical Requirements
3.4.1 Physical Properties of Rubber
Physical properties of rubber compound carried out from the finished product
shall be as given in Table 2:-
Table 2: Physical Properties of Rubber
S. N. Properties Permissible Limit Method/Standard
i Tensile strength (Kg/cm ),
2 225 min. IS:3400 (Part-1)
ii Elongation at break (%) 400 min. IS:3400 (Part-1)
iii Compression set at Constant 20 max. IS:3400 (Part-X)
Strain at 85±1 °C for 24+0/-2
hours, (%)
iv Hardness (Shore ‘A’) 70 ±10 IS:3400 (Part-23)
v Ash content not to exceed 7% IS:3400 (Part-22)
vi Specific gravity not to exceed 1.3 IS:3400 (Part-9)
vii Resistance toi Ozone Test 85 min. ASTM D1171
(Quality retention rating) (%)
Note 1: Deviations from above specified values, if any, required for achieving
deflection characteristics [compressive, & shear (lateral & longitudinal)]
and other functional requirements as specified in the specifications
mentioned may be permitted with prior approval of DG (Wagon), RDSO,
Lucknow.
Note 2: Variation of hardness on entire surface of pad and at core shall not be
more than 2° shore “A”.
Note 3: For Tensile Strength, Elongation at Break, Compression Set, Resistance to
Ozone use Test Slab & buttons prepared from same compound of
Premium Elastomeric Pad and for other tests rubber compound shall be
taken out from finished product.
Note 4: Resistance to Ozone Test as per ASTM D1171 should be carried out at
manufacturer premises on their own machines, if facility does not exist at
firm’s premises to conduct this test as per ASTM D1171 then it may be
carried out from NABL accredited lab/Government agency.
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Specification No. WD-20-MISC-95 (Rev.4)
For compound other than rubber, firm shall provide in QAP the variation in
properties after aging with respect to properties of unaged final product. Ageing
tests as described above shall be carried out accordingly.
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Specification No. WD-20-MISC-95 (Rev.4)
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Specification No. WD-20-MISC-95 (Rev.4)
The test is similar to lateral (shear) - deflection test and the same assembly is to be
used. The only difference is that the shear load application is in longitudinal
mode.
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Specification No. WD-20-MISC-95 (Rev.4)
Note: In case one Elastomeric Pad is used, the applied lateral load shall be half as
specified in the table 7, rest all other parameters shall remain same.
3.4.8.1 Observations/evaluation of Critical Functionality Test
The observations/evaluation of critical functionality test shall be same as
given in para 3.4.7.2.
3400-3799 16
3800-4199 18 and so on
(v) Shear Bond : No. of samples shall be one sample every calendar
strength month, during the period of manufacture of
elastomeric pads.
(vi) Shear Fatigue test : For the purpose of shear fatigue test, lot size shall
consist of maximum 5000 no. , One sample shall be
picked up on random basis from the lot offered for
inspection. If the sample fails, then 4 samples will
be taken from the same lot and if any sample fails
out of these, the entire lot will be mandatorily
rejected and destroyed.
Inspection shall not be recommenced until the firm
has investigated and come up with satisfactory
reasons for the failure, taken remedial action to
improve the quality of material and improved
process control and has also implemented the
same.
(vii) Critical : For the purpose of Critical Functionality Test, lot
Functionality Test size shall consist of maximum 5000 no. , two
sample shall be picked up on random basis from
the lot offered for inspection. If the sample fails,
then 8 samples will be taken from the same lot and
if any sample fails out of these, the entire lot will be
mandatorily rejected and destroyed. Inspection
shall not be recommenced until the firm has
investigated and come up with satisfactory reasons
for the failure, taken remedial action to improve
the quality of material and improved process
control and has also implemented the same.
Note: In case the testing is done on a single pad,
one sample shall be picked up on random basis
from the lot.
(viii) Mechanical : Metal plate shall be taken from any pad, which is
Properties of metal used for above destructive testing. Number of
plates samples shall be one from the lot offered for
inspection of Metal Plates.
(ix) Physical properties : Lot Size No. of Samples
of the rubber for 1500-2000 2
metal plate 2000-2500 3
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Specification No. WD-20-MISC-95 (Rev.4)
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Specification No. WD-20-MISC-95 (Rev.4)
4.6 In the event of rejection, the entire lot offered for inspection shall be made unusable
for Railway application in the presence of the inspecting /purchasing authority.
4.7 Each pad which has been passed by the Inspector shall be stamped as per RDSO
extent norms.
The quality audit of the firm shall be carried out to ensure the adherence to its
quality assurance plan and its general quality consciousness as per extant RDSO
ISO procedures. This quality audit may also be carried out on the need basis in
case of reports of severe premature failures of the product are received from
Railways. For establishing this, the samples shall be collected from Railways and
sent to RDSO, Lucknow as and when required for carrying out the tests mentioned
in this Specification including Dynamic Mechanical Analysis (DMA), TGA,
Damping Tests and Tear properties test etc.
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Specification No. WD-20-MISC-95 (Rev.4)
6.3 There should be a system to ensure use of correct raw material and traceability of the
product from raw material stage to finished product stage. This system should also
facilitate to identity the raw material composition from the finished product stage.
6.4 Ensure that there is a system to identify defective components at various stages of
manufacture, the reasons for occurrence of defects and also a system for disposal of
those defective rejected components.
6.4.1 Ensure that proper analysis is being done on monthly basis to study the
rejection/defect at various in internal stages, and to take corrective action
thereafter.
6.4.2 Ensure that a proper documentation of all the above steps is there, which is to be
presented on demand by the engineer.
6.5 Ensure the proper record of complaints received from customers of Railway and
corrective action take thereof, is maintained.
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Specification No. WD-20-MISC-95 (Rev.4)
8.2.2 The firm shall have trained manpower to produce quality product as given in
para 6.0.
8.2.3 RDSO document ‘Vendor application processing’ ISO QO-D-8.1-6 shall be
followed for the registration and approval of the firm.
8.2.4 RDSO will scrutinize the documents submitted by the firm and if found in order,
nominated team shall visit the firm for infrastructure verification and capability
assessment. In case of inappropriate/incomplete information during scrutiny, firm
shall be informed accordingly for necessary compliance.
8.2.5 After satisfactory compliance of all the infrastructural requirements and
capability assessment, the firm shall be conditionally approved as a
developmental source for limited quantity for manufacturing and supply of EM
pads for field performance monitoring.
8.2.6 On ascertaining the compliance of QMS/STR and QAP of the product prototype
testing shall be undertaken. The firm shall be required to submit in house test
results of their product to Director General QA/Mech., RDSO which shall include
all required tests mentioned in Para-3 (except 3.4.8) to this specification.
8.2.7 After successful completion of above, confirmatory testing as mentioned in Para-3
(except 3.4.8) to this specification shall be undertaken at firms’ premises in
presence of RDSO officials. Ozone resistance may be carried out at Firm
Premises/Government Agencies/NABL accredited labs for which the firm shall
bear the test charges. If needed, the confirmatory testing of few tests or all tests as
mentioned in Para-3 (except 3.4.8) may be carried out at RDSO for which firms
shall submit samples to Director General QA/Mech., RDSO, and necessary
charges shall be paid by firm in advance.
8.2.8 The firm shall submit all copies of the purchase order (issued by the purchaser) to
RDSO. The wagon depots(s) where the pads shall be supplied and fitted will be
nominated by RDSO (Wagon Directorate) in order to monitor their field
performance. Wagon directorate shall monitor all elastomeric pads manufactured
by the firm for field performance on CC rakes. Firm shall be permitted to supply
maximum 10,000 nos. pads for the trials duly inspected by QA (Mech) for a
period of six months ascertaining performance & reliability evaluation.
The Vendor shall also ensure that they do not secure total order quantity more
than the limited quantity mentioned in the Vendor Directory.
Failure criteria shall be as follows:-
(i) During field performance monitoring, Railways shall maintain and provide
Quarterly performance details of EM to Wagon Directorate. The performance
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Specification No. WD-20-MISC-95 (Rev.4)
Apart from this, four pads shall be subjected to load deflection tests as
mentioned in para 3.4.3, 3.4.4 and 3.4.5. The measured value shall be within
the 20% variation from the initially measured values of these provided by the
firm. None of the EM pad shall exceed the maximum allowed variation. In
case any EM pad exceeds the limit then, then eight pads shall be randomly
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Specification No. WD-20-MISC-95 (Rev.4)
selected out of the remaining EM pads. These eight EM pads shall subjected
to load deflection tests as mentioned in para 3.4.3, 3.4.4 and 3.4.5. The
measured value shall be within the 20% variation from the initially measured
values of these provided by the firm. None of the EM pad shall exceed the
maximum allowed variation.
8.2.9 Supply beyond the field trial quantity shall commence only after successful
completion of the field trial.
8.2.10 After successful field trial, firm shall be registered as ‘RDSO Vendor for
Developmental Orders’. Final approval shall be accorded as per existing
procedure prevailing at that time.
8.2.11 Vendor-Changes in Approved status: All the provisions contained in RDSO's ISO
procedures laid down in Document No. QO-D-8.1-11 version No:1.7 date effective
22.01.2021 (titled “Vendor-Changes in Approved status”) and subsequent
versions/amendments thereof, shall be binding and applicable on the successful
vendor/vendors in the contracts floated by Railways to maintain quality of
products supplied to Railways.
8.2.12 All terms and conditions for vendor registration/approval of foreign firms shall
be applicable as stipulated in RDSO ISO document QO-D-8.1-5 (latest version)
title “Application for registration of vendor”. In case of any contradiction between
the clauses of this specification and ISO document QO-D-8.1-5 regarding the
vendor registration/approval of foreign firms, the clauses of ISO document shall
prevail.
(b) For Design – B and Design-X
8.3 All vendors fulfilling the requirements of Design-B and/or Design-X and willing to
register shall follow the following procedure:-
8.3.1 Firm shall apply to Director General QA/Mech., RDSO, Lucknow along with list
of M&P, drawing, applicable MOUs if any and quality assurance program
(QAP). Firm shall submit QAP in latest ISO format for the product from
purchase of raw material to finished product determining and controlling each
critical stages in the process. QAP should clearly specify critical stages with their
control parameters and system of their measurements.
8.3.2 Firm shall have all the facilities including steel fabrication, shot/grit blasting
facilities, cleaning facilities, adhesive application facilities, injection molding
facilities, rubber-testing facilities, and fatigue testing facilities in-house as per
QMS 05:2000 (latest).
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Specification No. WD-20-MISC-95 (Rev.4)
8.3.5 RDSO will scrutinize the documents submitted by the firm and if found in order,
nominated team shall visit the firm for infrastructure verification and capability
assessment. In case of inappropriate/incomplete information during scrutiny, firm
shall be informed accordingly for necessary compliance.
8.3.6 After satisfactory compliance of all the infrastructural requirements and
capability assessment, the firm shall be conditionally approved as a
developmental source for limited quantity for manufacturing and supply of EM
pads for field performance monitoring.
8.3.7 On ascertaining the compliance of QMS/STR and QAP of the product prototype
testing shall be undertaken. The firm shall be required to submit in house test
results of their product to Director General QA/Mech., RDSO which shall include
all required tests mentioned in Para-3 to this specification.
8.3.8 After successful completion of above, confirmatory testing as mentioned in Para-3
to this specification shall be undertaken at firms’ premises in presence of RDSO
officials. Ozone resistance may be carried out at Firm Premises/Government
Agencies/NABL accredited labs for which the firm shall bear the test charges. If
needed, the confirmatory testing of few tests or all tests as mentioned in Para-3
may be carried out at RDSO for which firms shall submit samples to Director
General QA/Mech., RDSO, and necessary charges shall be paid by firm in
advance.
8.3.9 The firm shall submit all copies of the purchase order (issued by the purchaser)
to RDSO. The wagon depots(s) where the pads shall be supplied and fitted will
be nominated by RDSO (Wagon Directorate) in order to monitor their field
performance. Wagon directorate shall monitor all elastomeric pads
manufactured by the firm for field performance on CC rakes. Firm shall be
permitted to supply maximum 10,000 nos. pads for the trials duly inspected by
QA (Mech) for a period of six months ascertaining performance & reliability
evaluation.
The Vendor shall also ensure that they do not secure total order quantity more
than the limited quantity mentioned in the Vendor Directory.
Failure criteria shall be as follows:-
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Specification No. WD-20-MISC-95 (Rev.4)
These Pads shall be checked for cracking, perishing and bond failure, if
observed, during the field trials shall be recorded. The pad shall be
considered as “failed” if any one of the following limits is exceeded:
(a) If a crack in a rubber exceeds 10 mm in length and 3 mm in depth
in any layer.
(b) If de-bonding of rubber from metal plate exceeds 10 mm long on
any one rubber/metal interface.
(c) If crack is observed in any of the metal plate.
(d) Permanent set of more than 1.5 mm.
(e) Any other defects
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Specification No. WD-20-MISC-95 (Rev.4)
Apart from this, four pads shall be subjected to load deflection tests as
mentioned in para 3.4.3, 3.4.4 and 3.4.5. The measured value shall be within
the 20% variation from the initially measured values of these provided by the
firm. None of the EM pad shall exceed the maximum allowed variation. In
case any EM pad exceeds the limit then, then eight pads shall be randomly
selected out of the remaining EM pads. These eight EM pads shall subjected
to load deflection tests as mentioned in para 3.4.3, 3.4.4 and 3.4.5. The
measured value shall be within the 20% variation from the initially measured
values of these provided by the firm. None of the EM pad shall exceed the
maximum allowed variation.
8.3.10 Supply beyond the field trial quantity shall commence only after successful
completion of the field trial.
8.3.11 After successful field trial, firm shall be registered as ‘RDSO Vendor for
Developmental Orders’. Final approval shall be accorded as per existing
procedure prevailing at that time.
8.3.12 Procedure for approval of Vendors who are registered for Design-A to Rev.-3
and willing to register theme-self for Design-B also shall take place from Para-
8.3.6 onward.
8.3.13 Vendor-Changes in Approved status: All the provisions contained in RDSO's ISO
procedures laid down in Document No. QO-D-8.1-11 version No:1.7 date
effective 22.01.2021 (titled “Vendor-Changes in Approved status”) and
subsequent versions/amendments thereof, shall be binding and applicable on the
successful vendor/vendors in the contracts floated by Railways to maintain
quality of products supplied to Railways.
8.3.14 All terms and conditions for vendor registration/approval of foreign firms shall
be applicable as stipulated in RDSO ISO document QO-D-8.1-5 (latest version)
title “Application for registration of vendor”. In case of any contradiction
between the clauses of this specification and ISO document QO-D-8.1-5
regarding the vendor registration/approval of foreign firms, the clauses of ISO
document shall prevail.
9.0 MARKING
9.1 Top plate & flange of the Elastomeric Pad shall be legibly marked/ punched in the
following sequence: -
i) Manufacturer’s name (initials or trademark or/and serial number) XYZ
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Specification No. WD-20-MISC-95 (Rev.4)
ii) Month & Year of manufacturer (e.g. 06 21 for June- 2021), month code in two
digit & last two digits of the year. The month will be shown from 1 to 12
covering January through December, while the last two numbers of the year
of manufacture are sufficient.
iii) ‘‘GA-30’ (for Design-A) or ‘GB-30’ (for Design-B) or ‘GX-30’ (for Design-X)
Where ‘G’ stands for Guarantee and ‘30’ stands for period in months.
iv) There must be at least one blank space or dash between each items. There
must also be a dash, asterisk, or blank space between the month and year of
manufacture. Example: XYZ - 06 21-GA/GB/GX 30 (as applicable). Character
must be at least 6 mm high and depth 0.13 mm. The marking location to be
ensured as shown RDSO drawing or drawing approved by RDSO. The
marking shall be such that it shall withstand and readable till the life of
Elastomeric pads.
10.0 PAINTING
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Specification No. WD-20-MISC-95 (Rev.4)
11.0 GUARANTEE
11.1 The vendor shall guarantee elastomeric pad for a period of 30 (thirty) months from
the month and year of manufacturing. In case of premature service failure of
elastomeric pads, Wagon Depot In-charge in Zonal Railways will report the failure
to vendor, with copy to DG (Wagon) & DG QA (Mech.), RDSO. Vendor will make
free replacement of failed elastomeric pad to the depot, where failure has been
reported. The replacement should be made within reasonable time.
Whenever repeated failures of elastomeric pads are reported, vendor shall
investigate and come up with satisfactory reason(s) for failure and take remedial
action to improve the quality of elastomeric pads.
11.2 The Zonal Railways will send the information in the following format while
claiming guarantee replacement. Following shall be treated as failures for warrantee
replacement:-
i) If a crack in a rubber exceeds 20 mm in length and 6 mm in depth in any layer
or if the accumulated crack in any layer exceed 50 mm.
ii) Any crack/failure in metal plate/s, crushing/perishing of rubber or other
compound.
iii) De-bonding of rubber from metal plate exceeds 50 mm long on any one
rubber/metal at any surface of the rubber/other compound.
iv) Permanent set of elastomeric pad of more than 4 mm from the nominal value
of elastomeric pad.
Table 7: Format
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Specification No. WD-20-MISC-95 (Rev.4)
Permanent set of
elastomeric pad of more
than 4mm from the
nominal value of
elastomeric pad.
De-bonding of rubber
from metal plate exceeds
50 mm (any layer of
rubber between the
metal plates) long on
any one rubber metal at
any surface of the
rubber/other compound
Crack in any of the
metal plate
12.0 PACKING
12.1 The rubber pads shall be dusted with French Chalk and suitably protected against
damage during transit and storage.
12.2 In the event of sublet orders from bogie manufacturers, packing shall be as agreed to
between purchaser and the supplier.
The supplier shall regularly collect data and samples of previous supply from field
to access the actual life obtained nature of defects occurring in the service and
should take necessary corrective action to improve quality. Half-yearly report
should be submitted to Director General (Wagon) RDSO/ LKO on data, samples
collected and corrective action taken.
14.0 STORAGE
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STR No. WD-20-Misc-95(Rev.3)
INDIAN RAILWAYS
SPECIFICAITON
OF
ELASTOMERIC PAD
NO. WD-20-MISC-95 (REVISION –3)
ISSUED BY
0.4. All the provisions contained in RDSO’s ISO procedures laid down in
document No. QO-D-7.1-11 dated 19/07/2016 (titled “Vendor-Changes in
approved status”) and subsequent versions/amendments thereof, shall
be binding and applicable on the successful vendor/vendors in the
contracts floated by Railways to maintain quality of products supplied to
Railways.
******************
STR No. WD-20-Misc-95(Rev.3)
1. This elastomeric pad is also suitable for IRF 108 HS Bogie. Hence IRF 108 HS
Bogie is added in all respective places in the Specification.
DRAFT
elastomeric pads. The firm shall submit The firm shall submit a copy of the first
a copy of the first purchase order purchase order (issued by purchaser) to
(issued by purchaser) to wagon RDSO. First 1500 Nos. (one thousand
directorate of RDSO. First 1500 (one and five hundred numbers) of
thousand and five hundred) numbers elastomeric pads manufactured by the
of elastomeric pads manufactured by firm duly inspected by QA/Mech shall be
the firm shall be inspected by wagon monitored for field performance on CC
directorate of R.D.S.O. Lucknow and rakes by R.D.S.O. Lucknow. The wagon
supplied for performance monitoring. depot(s) where these elastomeric pads
The wagon depot(s) where these shall be supplied and fitted will be
elastomeric pads will be supplied and nominated by RDSO (Wagon dte) in
fitted will be nominated by RDSO in order to monitor their field performance
order to monitor their field performance for a period of 12 (twelve) months from
for a period of 12 (twelve) months from the date of fitment. The firm shall be
the date of fitment. The firm shall be generally permitted to supply a total of
generally permitted to supply a total of 10000(Ten thousand only) nos. of
10000(Ten thousand only) Elastomeric elastomeric pads duly inspected by
pads until the field performance is QA/Mech. until the field performance is
certified by RDSO. Balance quantity certified by RDSO.
supply shall be inspected by I&L
directorate of RDSO
STR No. WD-20-Misc-95(Rev.3)
***
STR No. WD-20-Misc-95(Rev.3)
The vendor shall guarantee elastomeric pad for a period of 30 (thirty) months
from the month and year of manufacturing. In case of premature service failure of
elastomeric pads, wagon depot incharge in zonal railways will report the failure to
vendor, with copy to DG ( wagon) & DG(I&L), R.D.S.O. Vendor will make free
replacement of failed elastomeric pad to the depot, where failure has been reported.
The replacement should be made within reasonable time.
The zonal railways will send the information in the following format while
claiming guarantee replacement:
S.NO Wagon no. Make of Month & year of Date of Cause of failure
EMpad manufacturing failure
Bond failure
Rubber failure
Rubber
perished
Rubber
cracked
Permanent set
Other defect
(Please
specify)
*****
STR No. WD-20-Misc-95(Rev.3)
8. PROCEDURE OF APPROVAL
8.8 Based on successful completion of above tests, the firm shall be approved as Part II
vendor for supply of elastomeric pads. The firm shall submit a copy of the first purchase
order (issued by purchaser) to wagon directorate of RDSO. First 1500 (one thousand and
five hundred) numbers of elastomeric pads manufactured by the firm shall be inspected
by wagon directorate of R.D.S.O. Lucknow and supplied for performance monitoring.
The wagon depot(s) where these elastomeric pads will be supplied and fitted will be
nominated by RDSO in order to monitor their field performance for a period of 12 (twelve)
months from the date of fitment. The firm shall be generally permitted to supply a total of
10000(Ten thousand only) Elastomeric pads until the field performance is certified by
RDSO. Balance quantity supply shall be inspected by I&L directorate of RDSO.
STR No. WD-20-Misc-95(Rev.3)
1. Clause 3.4.2
In this clause one more para shall be added after Note: same as in 3.4.1
After ageing at 701 deg. C in an air oven for 72+0/-2 hrs, the hardness, tensile strength
and elongation at break (%) shall not vary from the values obtained with the unaged
specimens by more than the following.
2. Clause 9.1
After fourth line of this para one more line shall be added as follows:
L -30
Where „L‟ stands for life and „30‟ stands for guarantee period in months
***
STR No. WD-20-Misc-95(Rev.3)
INDEX
S.NO. DESCRIPTION Page No.
0.0 FOREWARD 1
1.0 SCOPE 1
2.0 DEFINITIONS 1
3.0 REQUIREMENTS 2
3.1 MATERIAL 2
3.2 DIMENSIONS AND TOLERANCES 2
3.3 CONSTRUCTION & FINISH 2
3.4 TECHNICAL REQUIREMENTS 3
4.0 LOT SIZE, SAMPLING AND PURCHASE INSPECTION 6
5.0 PROCESS AUDIT CHECK 8
6.0 QUALITY ASSURANCE PROGRAMME 9
7.0 RECORD KEEPING 10
8.0 PROCEDURE OF APPROVAL 10
9.0 MARKING 11
10.0 PAINTING 11
11.0 GUARANTEE 12
12.0 PACKING 12
13.0 STORAGE 12
14.0 SKETCH NO. WD2-7561-S/1 (TESTING RIG FOR ELASTOMERIC PAD)
INDIAN RAILWAYS
SPECIFICATION OF ELASTOMERIC PADS
FOR
CASNUB – 22W , 22W (M), 22NL, 22NLB & 22HS BOGIES
0.0 FOREWORD
0.1 This specification is intended to cover the technical provisions relating to material,
construction and tests and does not include all the necessary provisions of the contract.
0.2 This specification draws reference to specifications IS:3302, IS:2, IS:228, IS:3400 and
IS:9319. The latest version of these standards shall be taken as the reference.
0.3 For the purpose of deciding whether a particular requirement of this standard 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. The number of significant places retained
in the rounded off value should be the same as that of the specified value in this standard.
1.0 SCOPE
1.1 This standard specifies requirements and methods of tests for metal bonded elastometic
rubber pads to Drg. No. WD-95005-S/1 latest alteration. This is applicable to Casnub
22W (modified adopter), 22W(M), 22NL, 22NLB and 22HS Bogie.
1.2 The rubber pad placed between side frame and adapter is subjected to compressive and
shear forces of the order of 15 and 4 tonnes respectively. It also acts as an anti-vibration
member. The pad shall be capable of withstanding wide climatic variation prevailing in
the country without physical deterioration and any marked change of rubber
characteristics.
2.0 DEFINITIONS
2.1 Purchaser - means Zonal Railways/Workshop/PU or any other agency procuring the
material on behalf of the President of India.
2.2 Engineers - means Wagon Directorate, Research Designs and Standards Organisation,
Ministry of Railways, Lucknow – 226 011
2.3 Inspecting Officer – means the person, firm or department nominated by the purchaser
to inspect the work on his behalf and the deputies of the Inspecting Officer so nominated.
STR No. WD-20-Misc-95(Rev.3)
3.0 REQUIREMENT
3.1 MATERIAL
3.1.1 RUBBER : Natural rubber or elastomers or a blend thereof suitably compounded shall
be used for the manufacture of elastomeric pads so as to conform to the requirements
stipulated in this standard.
3.1.2 STEEL : The end mounting plates and stiffening plates shall be manufactured using
steel to IS:2062-Fe 410 WA.
The rubber pads shall be manufactured as per RDSO Drawing No. WD –95005-S/1 latest
alteration. The dimensions and tolerances shall be as per the drawing. Untoleranced
rubber dimensions shall have tolerances as per ISO 3302 (Gr. M4 of Table I).
3.3.1 The metal plates shall be shot /grit blasted and chemically cleaned before bonding with
rubber. The metal plates must be degreased before mechanical cleaning. It has to be
ensured before bonding that the metal surface is free from rust, moisture, metal oxide,
non-oily contaminants and other foreign matter. The process adopted for bonding of
rubber to metal plate shall be a proven one using “Chemlok” as bonding agent or any
other equivalent bonding agent with specific approval of Director General (Wagon),
RDSO to achieve the required durable bond strength. The process of adhesive
application should be got audited regularly by the firm supplying the bonding agent. The
manufacturer of EP will mention it in QAP alongwith periodicity of audit as decided in
consultation with the firm supplying bonding agent.
3.3.3 The construction shall be as per Drg. No.WD-95005-S/1. In case of any deviation,
drawing shall be sent to the Engineer for approval before taking up bulk manufacture.
3.3.4 The rubber shall be smooth and free from pin holes, blisters and other visual flaws. All
sharp edges and burrs shall be removed from the steel plates. The metal to rubber
bonding shall be uniform and to the standard laid down later in this specification.
STR No. WD-20-Misc-95(Rev.3)
Note: Tests shall be as per IS:3400 and shall be carried out from the finished product.
Wherever it is not possible to cut the Elastomeric Pad for rubber sample, required
number of sample pads without the application of adhesive to the steel plates may be
moulded and then the rubber sample cut from it for tests.
Properties:- Values
(i) Tensile strength (Kg/Sq. Cm), minimum 225
(ii) Elongation at break (%) minimum 400%
(iii) Compression set (%) at 70 +10 C for 24+0 hrs. 20%
maximum
(iv) Hardness (shore “A”) 72 (maximum)
(v) Ash Content not to exceed 5%
(vi) Specific gravity not to exceed 1.22
Note: Variation of hardness on entire surface of pad and at core shall not be more than
20 shore “A”.
The values of hardness, tensile strength and elongation shall be read as follows:-
(i) Hardness (Shore “A”) +5
-0
(ii) Tensile strength + 20%
The test shall be carried out at a machine speed of 10 +5 mm/minute. The pad shall be
subjected to three successive loadings of 20 tonnes. During the fourth cycle, the
deflection at a load of 10.0, 15.0 and 20.0 tonnes tones shall be recorded with the help of
dial gauges(s) / digital readout. At the beginning of the fourth cycle, the elastomeric pad
should be compressed with a load of 50 kg. and deflection taken as zero at this point. The
resultant load-deflection value shall lie within the range bounded by standard values as
given in Table-1. The gauge for measuring load shall be suitably calibrated to be able to
indicate the required loads.
TABLE – 1
The test shall be carried out at a machine speed of 10+5 mm/minute. The pads shall be
subjected three times to a compressive load of 12 tonnes at a rate of 10+5 mm/ minute
machine speed in a suitable jig as shown in RDSO Sketch No. WD2-7561-S/1 (copy
enclosed). During the fourth compression, the pad shall be held at a compressive force of
12 tonnes. This assembly then shall be subjected to shear force in the lateral direction.
The load shall be applied to the wooden block and the end plates of pads three times
successively upto 5 tonnes and load-deflection at an interval of 1 tonne and upto 5 tonnes
shall be recorded during the fourth cycle.
The bond strength between metal and rubber shall be minimum 35.14 kg/cm2. To assess
the bond strength method „B‟ as given in IS:3400 (part 14) 1984 (Reaffirmed in 1993)
shall be followed. All the precautions taken for metal preparation and bonding for
preparing TEST PIECE shall also be followed for batch production. The unvulcanised
rubber disc for preparing the TEST PIECE shall be taken from the rubber compound
prepared for batch production. Record of batch member & test results should be
maintained by the manufacturer and in case of any doubt the Inspecting officer shall also
get a fresh test piece prepared and tested in his presence.
The test pad shall be shear fatigue tested for 5,00,000 cycles to determine the fatigue
life. The load to be applied for this purpose on the elastomeric pad shall be varying
from 7 to 22t as per RDSO Drg. No. WDX-91/7 Alt.1 (copy enclosed). The load has to
be applied at a frequency of 2 Hz. The pad should not show signs of any failure. Pad
should be inspected for following items.
(i) There should be no visual crack at any surface of the rubber.
(ii) Rubber of the pad should not take a permanent set exceeding the value given
below at any location-
Nominal Dimension Dimension after permanent set
46 mm 44.5 mm
This test shall be carried out in the supplier‟s premises, for which necessary testing
machine shall be installed. Fatigue testing machine should satisfy following parameters –
i) It should be able to apply fatigue load as per RDSO Drg. No. WDX-91/7
Alt.1.
ii) It should be possible to read load applied as well as number of cycles directly
on the machine.
iii) The loading cycle should be sinusoidal.
iv) The pad should be placed in such a direction that shear component of the
force applied is in same direction as stated in para 3.4.4 (SK No. WD2-7561-
S/1).
v) The dynamic load may get relaxed as the fatigue loading test progresses.
The maximum load should not be allowed to relax below 20t and should be
readjusted to 22t using shims if necessary.
3.4.7 For infrastructural, Manufacturing, Testing and Quality Control requirements for Metal
Bonded Rubber Components (Elastomeric pads), the supplier should comply with latest
IL-05:2000 issued by I&L Directorate of RDSO.
STR No. WD-20-Misc-95(Rev.3)
4.1 The lot size of elastomeric pads to be offered in one inspection shall be:- 1500 nos. to
3000 nos.
4.2 From the above lot offered for inspection, the following samples shall be drawn by
Inspecting Officer for various tests :-
4.2.1 For the manufacturers who have been approved for the supply of elastomeric pads for
more than one year and against whom there have been no adverse reports during
purchase inspection of the last five lots in the previous six months, the samples size can
be reduced for various tests as follows:-
4.3 Material shall be offered for inspection within two months of its manufacture.
4.4 Material offered for inspection shall not be withdrawn during the course of inspection.
Any move to withdraw the material or interfere with the inspection in any way shall
render the entire lot being rejected.
4.5 If the samples fail in one or more of the criteria in para 4.2, “ double” the samples will be
drawn and tested against the criteria in which the failure had occurred. If the “double”
samples pass, the lot shall be accepted. Failure of the “double” sample will, however,
result in the rejection of the lot. No further inspection shall be carried out until the firm
has investigated and come up with satisfactory reason for the failure as well as the
remedial action to improve the quality of material and also implemented the same.
STR No. WD-20-Misc-95(Rev.3)
4.5.1 A certificate to the effect that the remedial measure suggested by the firm have been
implemented must be furnished by the Inspecting official to the DG (QA), RDSO,
Lucknow for approval before undertaking inspection again. This procedure shall be
followed for all the items of para 4.2 except para 4.2 (vi) i.e. shear fatigue test which will
be curried out at RDSO as per the prescribed norms.
4.6 In the event of rejection, the entire lot offered for inspection shall be made unusable for
Railway application in the presence of the inspecting /purchasing authority.
4.7 Each pad which has been passed by the Inspector shall be stamped.
This is an audit check regarding firm‟s adherence to its own quality assurance
programme and its general quality consciousness. For establishing this, Inspecting officer
shall collect samples for carrying out the audit check at RDSO as detailed below.
5.1 Three sets of samples each consisting of 4 pads, six dumbles per tensile stress-strain
properties (as per IS:3400 Pt 1), 3 button for compression set ( as per IS: 3400 Pt 10),
2 samples for shear bond test, 2 samples for specific gravity and 2 samples for ash
content to be submitted.
Samples for tensile test, compression set, specific gravity and ash content are to be cut
from finished pad. Wherever it is not possible to cut the sample from finished product,
the samples shall be prepared from the moulded pad without adhesive application on the
steel plate.
The pads shall be drawn at random from a lot offered for inspection and one set of
samples shall be sent to Engineer, once in six months.
All tests listed under para 4.2 to be conducted on these samples except for para 4.2 (vi),
regarding which para 5.2 may be referred.
5.2 Out of 4 pads, two shall be shear fatigue tested for 500,000 cycles once in a year to
determine the fatigue life. The load to be applied for this purpose on the elastomeric pad
shall be varying from 7 to 22t as per RDSO Drg. No. WDX-91/7 Alt.1. The pad should
not show signs of any failure as described in para 3.4.6.
5.3 If any of the samples sent to RDSO,Lucknow for testing as referred in Para 5.1 and 5.2
fails in one or more attributes, future inspection at the firm‟s premises shall be
discontinued and the double sample drawn earlier shall be sent for testing against the
attributes in which the failure had occurred. If the double sample fails , the process audit
check will be deemed to be unsatisfactory and the inspection shall not be recommended
until the firm has investigated and come up with satisfactory reasons for the failure,
taken remedial action to improve the quality of material and has also implemented the
same, in addition to successfully going through the test prescribed in Clause 5.1 and 5.2
on fresh set of samples.
STR No. WD-20-Misc-95(Rev.3)
5.4 In case the firm has successfully gone through the previous three of such tests as
mentioned in para 5.1 consecutively at RDSO, Lucknow without any adverse test results,
the frequency of the test can be reduced to once in two year.
5.5 Inspecting officer at his discretion can draw samples (2 nos.) at random basis from field
i.e. Depots/Workshops/Wagon Builders/E.M. Pad manufacturers‟ premises and get them
tested in RDSO for compression, shear load- deflection and fatigue tests.
5.5.1 Any failure in attributes checked on 100% of pads internally as per the firm‟s own
quality assurance plan will be considered very serious as it will indicate the failure of
firm‟s own quality assurance plan. In that case, manufacturers will have to review their
internal quality assurance programme and take corrective action accordingly and get re-
registered with RDSO.
5.7 Inspecting officer will take results of audit checks also in consideration while reviewing
registration of the manufacturer.
6.1 The firm‟s internal Quality Assurance Programme for the product must detail the
following aspects:-
Organisational chart
Process flow chart.
Stage inspection details
Various parameter and control over them.
6.2 The organisational chart shall show the different key positions, personnels manning the
positions, their qualifications & experience.
6.2.1 There should be at least one full time rubber technologist having a minimum bachelors
degree in relevant field with 5 yrs experience or a diploma in relevant field with 12 yrs
experience. He should be free from day to day production, testing & quality control
responsibility. He should be mainly responsible for development of a product, analysis of
products, control over raw material, corrective action in case of difficulties in achieving
the parameters.
6.2.2 Ensure that the incharge of the Quality Control Section I s having a qualification of
minimum bachelor‟s degree in the relevant field and have minimum 5 yrs. experience or
a diploma holder with min.12 yrs experience. He should be actively involved in day to
day activities of quality control/stage inspection/compliance of QAP etc.
6.3 There should be a system to ensure use of correct raw material and traceability of the
product from raw material stage to finished product stage. This system should also
facilitate to identity the raw material composition from the finished product stage.
STR No. WD-20-Misc-95(Rev.3)
6.4 Ensure that there is a system to identify defective components at various stages of
manufacture, the reasons for occurrence of defects and also a system for disposal of those
defective rejected components.
6.4.1 Ensure that proper analysis is being done on monthly basis to study the rejection/defect
at various in internal stages, and to take corrective action thereafter.
6.4.2 Ensure that a proper documentation of all the above steps is there, which is to be
presented on demand by the engineer.
6.5 Ensure the proper record of complaints received from customers of Railway and
corrective action take thereof, is maintained.
7.0 RECORD KEEPING
7.1 The manufacturer shall keep all the relevant records of Internal Quality Programme for
future reference /investigations. The manufacturer shall present their records as and
when asked by Purchaser / Inspecting Official or Engineer.
7.2 Manufacturer shall submit a half yearly statement to Inspecting Officer giving
particulars of number of pads supplied to the consignee, failure detail , warranty disposal
and corrective action taken thereon. .
8. PROCEDURE OF APPROVAL
The procedure to be followed for approving firms desiring to supply this item is given
below.
8.1 A request for registration should be made to Engineer alongwith list of M&P, copy of
complied orders in last three years etc.
8.2 The firm shall have all the facilities including steel fabrication shot/grit blasting
facilities, cleaning facilities, injection moulding facilities, rubber testing facilities and
fatigue testing machine in-house as per STR IL:05:2000 (latest). Firm shall have
minimum 5 years experience in manufacturing of rubber to metal bonded components
for heavy duty operations.
8.3 The firm shall have trained manpower to produce quality product as given in para 6.0.
8.4 On ascertaining the compliance of STR and QAP of the firm, the firm shall be required
to submit in house test results of their product to Director General (Wagon), RDSO. The
details of tests are shown in para 8.6 below.
STR No. WD-20-Misc-95(Rev.3)
8.5 On successful completion of para 8.4, samples shall be submitted to RDSO for
confirmatory testing for which necessary charges shall be paid by the firm in advance.
The sample shall consist of six dumbles for tensile stress strain properties as per the
IS:3400 part-I, three buttons for compression set (as per IS:3400 part-10) two samples
for shear bond test (as per para 3.4.5),two samples for specific gravity and two
samples for ash content. All these samples except for shear bond test are to be cut
from finished pad. 10 no. elastomeric pads are also to be submitted which shall be
drawn by the Inspecting Officer from a minimum lot of 50 numbers.
8.7 The test results of para 8.6 shall be put up to Director General (Wagon), RDSO for
approval of the firm.
8.8 Based on successful completion of above tests, a field trial of at least 500 numbers will
be conducted for a period of 24 months before final approval of the firms, which have
not supplied this pad as per last amendment of this specification.
9.0 MARKING
9.1 Top plate and flange of the Elastomeric Pad shall be punched with the information as
given below:-
Manufacturer‟s name (initials /trade mark).
Month and year of Manufacture.
9.2 The markings shall be of the size and the location as shown in the drawing/approved
drawing.
10.0 PAINTING
Each Elastomeric Pad shall be painted with “Signal Red” (IS:5-1994, No.537) on the
steel plates only after application of primer etc. to ensure long durability of the
paint/colour.
STR No. WD-20-Misc-95(Rev.3)
11.0 GUARANTEE
The firm shall stand guarantee for a period of 30 months from the date of supply
regarding performance of Elastomeric pads. In case of any premature failure of pads,
firm will be liable to make free replacement to the depot where failure has been reported
within reasonable time. Whenever, repeated failures are reported, firm shall investigate
and come up with satisfactory reasons for failure and take remedial action to improve
the quality. The Zonal Railways will send the information in the following format while
claiming guarantee replacement.
12.0 PACKING
12.1 The rubber pads shall be dusted with French Chalk and suitably protected against
damage during transit and storage.
12.2 In the event of sublet orders from bogie manufacturers, packing shall be as agreed to
between purchaser and the supplier.
13.0 STORAGE
The rubber pads shall be stored in a cool and dry place.