QUALITY ASURANCE PLAN

AND
WELDING PROCEDURE SPECIFICATION SHEET
For 60 M CLEAR SPAN R.O.B. BOW STRING STEEL GIRDER

REFERENCE DRAWING NO.

RDSO/B-10420/R, RDSO/B-10420/1/R, RDSO/B-10420/2/R, RDSO/B-10420/3/R,
RDSO/B-10420/4/R, RDSO/B-10420/5/R, RDSO/B-10420/6/R, RDSO/B-10420/7,
RDSO/B-10420/8/R, RDSO/B-10420/9

NAME OF THE WORK:

FABRICATION OF 60M SPAN BOW STRING STEEL GIRDER FOR CONSTRUCTION OF ROB
AT 1ST KM OF CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT
RAILWAY LEVEL CROSSING GATE NO. ST-135 UNDER CONSTRUCTION OF ROBS ON
50:50 COST SHARING BASIS.

QUALITY ASURANCE PLAN : Page No. 1/9 to 9/9

WPSS FOR WORKSHOP WELDING : Page No. 1/28 To 28/28
WPSS FOR ON SITE/FIELD WELDING : Page No. 1/28 To 28/28

CLIENT
GOVERNMENT OF ASSAM
PUBLIC WORKS DEPARTMENT (ROADS), ASSAM,
CHANDMARI, GUWAHATI 781003

RAILWAY AUTHORITIES
NORTHEAST FRONTIER RAILWAY

NAME OF EPC CONTRACTOR

M/s. BADRI RAI & COMPANY
Near Radha Krishna Mandir, Station Road,
Duliajan, Dibrugarh, Assam-786602

NAME & PLACE OF FABRICATOR

M/s. ZH INDUSTRIES PVT. LTD.
32KM, Mile Stone, Delhi Hapur Road, Masuri, Ghaziabad (U.P.)
 BADRI RAI & COMPANY PUBLIC WORKS DEPARTMENT (ROADS)
QUALITY ASSURANCE PLAN (QAP)
FOR FABRICATION OF RDSO STANDARD RAILWAY STEEL COMPOSITE GIRDER
PART-A (TOP SHEET)
CONSTRUCTION OF ROB AT 1ST KM OF CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT
1 Name of Project :
RAILWAY LEVEL CROSSING GATE NO. ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.

2 Zonal Railway jurisdiction : NORTHEAST FRONTIER RAILWAY

Executing organization of the
3 : PUBLIC WORKS DEPARTMENT (ROADS), ASSAM CHANDMARI, GUWAHATI 781003
contract agreement
4 Contractor Agency : BADRI RAI & COMPANY
5 Fabricating Agency : Z.H.INDUSTRIES PVT. LTD, GHAZIABAD (U.P.)
6 Inspecting Agency : RDSO
7 QAP NO : RDSO/Infra-II/B&S/ROB/BSG
8 Contract Agreement no. & date : BRCO/ROB/23-24/2381 DATED 24.01.2024
9 LOA NO. & Date : BRCO/ROB/23-24/2381 DATED 24.01.2024
Completion date as per Contract
10 : 24.08.2024 (Six months from approval of QAP)
Agreement/LOA
Date of MoU Between fabricator
11 : 08.01.2024
and Contractor, if applicable
SUPPLY, FABRICATION, TRANSPORTATION, ASSEMBLY & ERECTION OF 60 M SPAN OF BOW STRING
12 Scope of fabrication :
GIRDER FOR ABOVE PACKAGE
13 Scope of fabrication in MT : 440 MT
14 GAD Approved by : Chief Bridge Engineer
15 RDSO Drawing Nos. used. : RDSO/B-10420/R, RDSO/B-10420/1R, RDSO/B-10420/2R, RDSO/B-10420/3R, RDSO/B-10420/4R,
RDSO/B-10420/5R, RDSO/B-10420/6R, RDSO/B-10420/7, RDSO/B-10420/8R, RDSO/B-10420/9
RDSO Drawing no. for ISMB
: RDSO/B-10413 ALONG WITH RDSO/B-10420/6R
Intermediate Cross Girders
16 Specifications IRS-B1: 2000, IS 2062:2011, ASTM SA-435/435M, WBC-2001, BS – 111, IS 9595-96, IS- 1852-85, IRS M28,
:
IRS M39, IRS M46, IS:2590, IS 7307 (Part-1), IS 7310 (Part-1), IS: 5666 IS: 51, IS: 104, IS: 2339

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 2 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1 Raw Materials
1. Grade and Quality of
Steel Plates, structural
1) Steel Plates: IS
section to be same as
2062:2011 Grade E350
mentioned in the
Quality B0 as mentioned
respective approved
in the respective
Identification and As per Mill Test drawings
approved drawing.
Corelation with Mill Certificate & test 2. For other details of
2) Plates 12mm and
Test Certificate from required by Zonal structural steel plates and
above thick are fully
Supplier. Railway or Railway Verification Of structural section A&C no.
Fabricators killed/normalized or
Source/Brand PSU from approved Challan, Mill T.C. reference PMC/NFR 100% 5 of IRS-B1: 2000, IS 2062-
Record control cooled.
of steel to be decided Laboratory/ Govt. documents. 2011 and codes referred
3) Rolled Sections or any
as per prevailing approved in these shall be complied
other structural steel
instructions issued Laboratory/ NABL/ as applicable.
member: IS 2062:2011
from Railway Board. NABCB. 3. Raw Material clearance
Grade E250 Quality B0 as
shall be done by Zonal
mentioned in the
Railway/ Railway PSUs as
Steel Plates and other respective approved
per prevailing instructions
1.1 Structural Steel drawing.
issued from Railway
Sections Board.

A&C no. 5 of IRS-B1:

Physical Conditions, 2000, IS 2062-2011 and
Complete Visual Fabricators
pitting, rusting, rolling Visual - PMC/NFR 100% codes referred in these
inspection Record
defects, straightness. shall be complied as
applicable

Mechanical tests, as Table 2 along with notes

per IS-2062:2011 - Lab Test Report PMC/NFR - - below and other relevant
Lab test at approved
UTS,YS,%EL,Bend Test clauses of IS-2062-2011
laboratory Govt.
and codes referred in it,
approved
for quality and grade of
Laboratory/ NABL/ Heat / Cast no.
Charpy Test at 0°C for steel as mentioned in
NABCB section wise as
plates of thks 12 mm - Lab Test Report PMC/NFR - respective drawings as
per IS 2062-
and above applicable.
2011

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 3 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection
Table 1 along with notes
below and other relevant
Lab test at approved
Heat / Cast no. clauses of IS- 2062-2011
laboratory Govt.
Chemical Analysis as section wise as and codes referred in it,
approved - Lab Test Report PMC/NFR -
per IS 2062-2011 per IS 2062- for quality and grade of
Laboratory/ NABL/
2011 steel as mentioned in
NABCB
respective drawings as
applicable.
Steel Plates and other
Ultra sonic test for
1.1 Structural Steel IS-4225 or ASTM SA-
12mm and above
Sections By ASNT level- II 435/435M and codes
thick plates as per IS- - Lab Test Report PMC/NFR 100% -
operator referred in it as per
4225/ASTM SA-
applicability
435/435M

Fabricator's IS 2062: 2011 or other

Measurement of
Dimensional Measurement. Challan PMC/NFR 100% Record & Zonal relevant codes referred
dimension
Railway Record in it as applicable

Verification of
Challan , Verification Of
Manufacturer's Test Manufacturers
Visual Manufacture's reference Each Batch Test at the approved
Certificate, Inspection Test Certificates.
Test Certificate documents. IRS B1-2001, IS: 5666 IS: laboratory suitable for the
Certificate, Challan
51, IS: 104, IS: 2339 and purpose shall be done as
1.2 Paints and Primers PMC/NFR
Lab test at approved applicable codes referred per the instruction of the
laboratory Govt. in these codes therein. Zonal Railway/ Railway
Challan , Verification Of
Tests as per PSU.
approved Manufacture's reference Random Lab test report.
specification
Laboratory/ NABL/ Test Certificate documents.
NABCB

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 4 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection

Properties of
Aluminium wire such
Review of reference Challan , Verification of
as Dia, class and purity Manufacture's
documents with Manufacture's Reference Each Batch
as mentioned in Test Certificate Test at the approved
material Test Certificate Documents
appendix-VII of IRS B1- laboratory suitable for the
2001 IRS B1-2001, IS:2590 and
purpose shall be done as
1.3 Aluminium wire PMC/NFR applicable codes referred
per the instruction of the
in these codes
Lab test at approved Zonal Railway/ Railway
laboratory Govt. Challan , Verification of PSU.
Tests as per
approved Manufacture's Reference Random Lab Test Report
specification
Laboratory/ NABL/ Test Certificate Documents
NABCB

IRS Welded Bridge Code

2001, IRS M28, IRS M39,
Challan & Verification of
As Per Specification As per Fabricator's IRS M46 and other As per specification and
1.4 Welding Consumables Any Test as required Manufacturer's reference PMC/NFR
and approved WPSS requirement record applicable codes referred WPSS.
Test Certificate Documents
in these codes and
specifications

Approved Fabrication
100 % Visual
Approved Drawing, IS 9595-96,
Test as mentioned in inspection & Test Reports &
Visual Inspection , Fabrication IRSB1-2001 and codes as
1.5 Stud BS 115 (Latest verification of PMC/NFR 100% Fabricator
dimensions inspection Drawings and applicable instructions
Revision) dimension by gauge report
WPSS issued by Railway Board
and test record
also to be followed.

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 5 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection
2 Manufacturing Process
Inspection Railway as delegated vide
Approved fabrication
Measurement with Approved Measurement of Report of RDSO letter no.
2.1 Layout as applicable Dimensions. PMC/NFR 100% Drawings and relevant
calibrated steel Tape Drawings dimensions. Inspection CBS/Insp./ROB dated
IS/IRS/IRC codes.
officials 24.02.2020
Preparatory work
Inspection
such as Cutting, Approved fabrication
Visual / Inspection Report Report of
Straightening, Visual & drawings, IRS B1-2001, IS-
Dimension , free from Measurement with of Inspection Inspection
2.2 EdgePreparation,Mark Measurement of PMC/NFR 100% 1852-85 and codes
defects master plates and officials & officials &
ing,Drilling, Fit up,Pre- dimensions referred in these codes
templates fabricator's record fabricator's
assembly, End as applicable
record
finishing
3.0 Welding
IS 9595-96, IRS B1- Approved fabrication Welding to be performed
2001, IRS WBC- Verification Drawings, IS 9595-96, IRS following the different
Fabricator's
3.1 WPSS Approval of WPSS Verification 2001 and codes Reference RDSO 100% B1-2001, IRS WBC-2001 specification and
Record
referred in these Documents and codes referred in parameters mentioned in
codes as applicable these codes as applicable WPSS approved by RDSO

Visual DT and NDT at

1. Witnessing of IS 7307 (Part-1), IS 7310
approved WPQR Sheet to
established WPSS. Verification (Part-1), IRS B1-2001, IRS Only RDSO certified
laboratory/ Govt. As per Codal be recorded in
3.2 WPQR 2. Witnessing of Reference RDSO 100% WBC-2001 and codes welders to be engaged in
approved Requirement presence of
Welder qualification Documents referred in these codes the job
Laboratory/ NABL/ RDSO.
test as applicable
NABCB

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 6 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection

IS 9595-96, IRS B1-2001,

Visual with thermal Verification of
Measurement of IRS WBC-2001 and codes
3.3 Preheating Chalk or Infrared Approved WPSS Reference PMC/NFR 100%
Temperature referred in these codes
Thermometer Documents
as applicable

Visual check of As per Verification of

Baking of Electrode, To have moisture free IRS B1-2001 and other
3.4 Electrodes and Manufacture's Reference PMC/NFR 100%
flux electrode and flux applicable codes.
heating Recommendation Documents

Inspection IRS Welded Bridge Code

report of 2001, IRS M28, IRS M39,
Verification of
Selection of Correct As per Approved Inspecting IRS M46 and other As per WPSS and other
3.5 Reference to WPSS. Visual Reference PMC/NFR 100%
Electrodes & flux WPSS officials and applicable codes referred codes applicable.
Documents
Fabricators in these codes and
record. specifications

Verification of
Measurement of Visual with Ammeter As per Approved As per WPSS and other
3.6 Current Condition Reference PMC/NFR Random IS 9595-96, IRS B1-2001,
Amp./Voltage and Voltmeter WPSS codes applicable.
Documents IRS WBC-2001 and codes
referred in these codes
as applicable
Verification
As per Approved
3.7 Sequence of Welding Controlling Distortion Visual Reference PMC/NFR Random
WPSS
Documents

IS 9595-96, IRS B1-2001,

Verification
Provision of Run-on To avoid crater As per Approved IRS WBC-2001 and codes
3.8 Visual Reference PMC/NFR Random
and Run-off Plates defects WPSS referred in these codes
Documents
as applicable

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 7 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection
Inspection

It is to be ensured during
fabrication process that
fabrication has been done
1. For Fillet Welds -
as per the WPSS approved
Visual, D.P. Test, Fillet
by RDSO and Welders
Size, Penetration, Leg Approved fabrication
approved by RDSO. This is
length, Throat Approved Visual Inspection & Drawings, IRS B1-2001,
Inspection of Welded Visual, Gauge and Fabricator's to be ensured n by Zonal
4.0 thickness etc fabrication Verification of RDSO 100% IRS WBC-2001 and codes
components Macro etching Record Railway/ Railway PSUs and
Drawings & WPSS Dimension by Gauge referred in these codes
certificate to this effect
2. For butt welds – as applicable
(By Minimum JAG officer)
RT/UT test from
shall be given in the form
approved lab.
of four point certification
along with inspection call
raised to RDSO

1. Welding to be
Visual Inspection,
Approved Fabrication performed following the
dimensions 100 % Visual
Approved Drawings 9595-96, IRSB1- different specification and
inspection, ring test Test as mentioned in inspection & Test Reports &
Fabrication 2001 and codes as parameters mentioned in
4.1 Stud Welding and bend test etc. As BS 115 (Latest verification of PMC/NFR 100% Fabricator
Drawings and applicable instructions WPSS approved by RDSO
applicable, for good revision) dimension by gauge report
WPSS issued by Railway Board 2: For details of Stud
penetration & crack and test record
also to be followed. welding refer BS 115
free weld.
(latest revision)

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 8 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection

1. Half laydown assembly

of first span to be checked
by RDSO.
2. There after only
Inspection
components of first and
Components Report of IRS B1-2001, IRS WBC-
Complete subsequent spans to be
Inspection of first a) Overall length Approved Inspection 2001 and applicable
5.0 Visual & Dimensional Dimensional Check RDSO First span checked by RDSO.
span and 2nd span b) Cross – section etc. Drawings officials & codes referred in these
of Assembly 3. RDSO inspection call to
onward fabricator's codes
be raised by Zonal
record
Railway/ Railway PSUs in
the form of 4 point
certification after
satisfactory quality checks.

Surface condition Visual checking with

Approved
after blasting reference to surface IRS B1-2001 Appendix- Two coats of metalizing
Surface Preparation Fabrication 100% by
(SA 2-1/2) preparation Verification of Stage Fabricator's VII IS: 6586, IS:5905 , shall be applied. nominal
6.0 by Blasting & Drawing & IRS - B1- PMC/NFR fabricator &
clearance Record Record IS:2590 and codes DFT-150 Local DFT shall
Metalizing Surface finish after 2001 and codes Random NCR
Visual checking referred in these codes not be less than 110
metalizing referred in these
DFT checking Measurement

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 9 of 68
PART-B (QUALITY ASSURANCE PLAN) RDSO/Infra-II/B&S/ROB/BSG/ZH/BR&C/NFR/60M/QAP-001
Inspection Details
Sl. Component / Characteristic to Frequency & Reference Fabricators Type of
Inspection Extent of Acceptance Criteria Remarks
No. Operations be checked type of check Documents Quality Control record
Agency Inspection
One coat of Etch/Wash
Visual checking with primer (IS:5666) Thickness
Surface condition
reference to surface of DFT of 6 – 8 microns.
before painting
preparation
Zinc Chrome Primer
Clause 39.2.1 and (IS:104) thickness of 25 –
Approved
appendix VII of IRS B1- 35 microns.
Fabrication 100% by
Surface finish after Verification of Stage Fabricator's 2001, IS: 5666, IS:51,
7.0 Cleaning & Painting Visual checking Drawing & IRS - B1- PMC/NFR fabricator &
painting clearance Record Record IS:104, IS: 2339 and Aluminum Paint (IS:2339)
2001 and codes Random NCR
applicable codes referred Thickness of DFT of Final
referred in these
in these codes Coat shall be 15-20
microns.

DFT checking Measurement Total Dry Film Thickness

(201-250)
Final coat at site.

Final inspection
RDSO inspection call to be
in assembled Approved Approved Fabrication
raised by Zonal Railway/
Fabrication Drawing & Clause 42, 43
condition before Visual & Fabricator's Railway PSUs in the form
8.0 Complete Assembly
Measurement Record
PMC/NFR 100% Drawing& and 44 of IRS - B1-2001
of 4 point certification
launching at Fabricator's and codes referred in
after satisfactory quality
site. (Including record these
checks.
Site welding)

NOTE
1. During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry
out welding as per approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to
satisfy itself before sending Inspection call to RDSO for Assembly or components inspection etc.

for ZH Industries Pvt. Ltd. Badri Rai Company PWD NEFR Approved by RDSO Page 10 of 68
 WELD JOINT DETAILS FOR WORKSHOP WELDING
For 60 M CLEAR SPAN R.O.B. BOW STRING STEEL GIRDER
(CONSTRUCTION OF ROB AT 1ST KM OF CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR
TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO. ST-135 UNDER CONSTRUCTION OF
ROBS ON 50:50 COST SHARING BASIS.)
Client : GOVERNMENT OF ASSAM, PUBLIC WORKS DEPARTMENT (ROADS), ASSAM,
Railway Authority : NORTHEAST FRONTIER RAILWAY
EPC Contractor : M/s. BADRI RAI & COMPANY
Name of Fabricator : Z.H. INDUSTRIES PVT. LTD
Fabrication workshop : 32 KM DELHI-HAPUR ROAD, MASOORIE, GHAZIABAD-201015

WELD JOINT DETAILS FOR WORKSHOP WELDING

SL Type of Weld Welding
WPSS NO. Weld Description Page No.
NO. Weld Size(MM) Process

1 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-01 Bottom Long Beam Section Fillet 10 SAW 1/28 To 2/28

2 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-02 Top Arch Beam Section. Fillet 8 SAW 3/28 To 4/28

3 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-03 Hanger Beam section Fillet 10 SAW 5/28 To 6/28

4 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-04 End Bottom Cross beam section Fillet 8 SAW 7/28 To 8/28

Double V Butt Weld

5 ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-05 Bottom center cross beam (Web) FCAW 9/28 To 10/28
With Grinding Finish

Bottom center cross beam

6 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-06 Fillet 10 SAW 11/28 To 12/28
(Additional Flange).

7 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-07 Tie Beam section Fillet 8 SAW 13/28 To 14/28

8 ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-08 Top Bracing section. Fillet 8 SAW 15/28 To 16/28

Diaphram (DP-1 & DP2) In Arch

9 ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-09 Member & Bottom Beam & Fillet 10 FCAW 17/28 To 18/28
Applicable Whereas
Diaphram (DP-3) In Arch Member &
10 ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-10 Bottom Beam & Applicable Fillet 10 FCAW 19/28 To 20/28
Whereas
Bracket in Bottom Cross Beam &
11 ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-11 Fillet 16 FCAW 21/28 To 22/28
Applicable Whereas

Hanger Flange with Web End

12 ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-12 Fillet 16 FCAW 23/28 To 24/28
Portion
Shear stud welding on top Flange Drawn
13 ZHIPL/BR&C/PWD/NFR/60M/DASW/WS-13 of End Cross & Intermediate Fillet 7 arc Stud 25/28 To 26/28
Bottom Cross beam Welding

14 ZHIPL/BR&C/PWD/NFR/60M/TACK/WS-14 Tack welding of girder components Fillet 5 MMAW 27/28 To 28/28

 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-01

1 Weld joint description : Fillet weld in Bottom Long Beam Section (10 mm Fillet Weld four
side of box between top bottom flange & web-28mm thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of Bottom

6.1 Joint design details :
Long Beam. Welding of four side of box section.

10

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-01 Page 1 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)
Controlled by
2 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence : 10 10

4 2

10 Provision Of Run- On & Run-Off Tabs : YES

3
10

11 Cleaning Of Weld Bead before laying next Bead : YES

10
Root preparation before welding other side of groove : Not applicable 1
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-01 Page 2 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-02

1 Weld joint description : Fillet weld in Top Arch Long Beam Section (08 mm Fillet Weld four
side of box between top bottom flange & web-28mm thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of Top Arch

6.1 Joint design details :
Beam. Welding of four side of box section.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-02 Page 3 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence : 8 8

4 2

10 Provision Of Run- On & Run-Off Tabs : YES 3

8

8
11 Cleaning Of Weld Bead before laying next Bead : NA
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-02 Page 4 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-03

1 Weld joint description : Fillet weld in Top Hanger Beam Section (10 mm Fillet Weld four side
of box between top bottom flange-36MM & web-32MM thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
: N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of Hanger.

6.1 Joint design details :
Welding of four side of box section.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-03 Page 5 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)
Controlled by
2 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence : 10 10

4 2

3
10

10 Provision Of Run- On & Run-Off Tabs : YES

10
11 Cleaning Of Weld Bead before laying next Bead : YES 1
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-03 Page 6 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-04

1 Weld joint description : Fillet weld in End Bottom Cross Beam Section (08 mm Fillet Weld
four side of box between top, bottom flange & web-25MM thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of End Bottom

6.1 Joint design details :
Cross Section. Welding of four side of box section.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-04 Page 7 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence :

4 2
8 8

8 8
10 Provision Of Run- On & Run-Off Tabs : YES 1 3
11 Cleaning Of Weld Bead before laying next Bead : NA
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-04 Page 8 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-05

1 Weld joint description : 10 mm Filled-up weld in V-cut portion of the web centre of Cross
Beam Section for maintaining camber.
2 Base metal : IS:2062–2011, E250 B0 (Fe410), NPB

3 Welding process : FCAW

4 Welding Position : Flat (Double V Butt Weld, Filled up-1G/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of V-cut portion in the web of of

6.1 Joint design details :
cross beam section. Reffer Drg No. RDSO/B-10413

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-05 Page 9 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16

2 1.2 MM 220-270 28-31 8.6 NA 10-12 16

3 1.2 MM 220-270 28-31 8.6 NA 10-12 16

4 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : NA
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual, D.P. Test & UT

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-05 Page 10 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-06

1 Weld joint description : Fillet weld in End Bottom Cross Beam Section (08 mm Fillet Weld
four side of box between top, bottom flange & web-25MM thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Bottom flange of NPB-

6.1 Joint design details :
600

10

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-06 Page 11 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)
Controlled by
2 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence :

NPB 600

10 10
1 2
10 Provision Of Run- On & Run-Off Tabs : NA
MS PLATE 25 MM
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual inspection & D.P. Test

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-06 Page 12 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-07

1 Weld joint description : Fillet weld in Tie Beam Section (08 mm Fillet Weld four side of box
between top bottom flange & web-25MM thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of Tie Beam.

6.1 Joint design details :
Welding of four side of box section.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-07 Page 13 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence : 8 8

4 2

10 Provision Of Run- On & Run-Off Tabs : YES 3

8

8
11 Cleaning Of Weld Bead before laying next Bead : NA
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-07 Page 14 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/1R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-08

1 Weld joint description : Fillet weld in Top Bracing (08 mm Fillet Weld four side of box
between top bottom flange & web-25 MM thk).
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Submerged Arc Welding (S.A.W.)
4 Welding Position : Flat (45° Inclined) (2F/PB)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : W2 as per IRS M.39 – 2020
Dia : 4mm (Copper Coated MS Wire)
Drying Method : N.A.
5.2 Flux : Class : F2 as per IRS M.39 – 2020
Type : Agglomerated
Drying Method : 250° to 350°C for 1Hour as per manufacture
recommendation, Holding Temp.: 100°C
5.3 Shielding gas : Not applicable
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Outside of Top Bracing.

6.1 Joint design details :
Welding of four side of box section.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-08 Page 15 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : EP (Electrode Positive)
8 Welder qualification : SAW (As per IS: 7310 (Part – 1)-1974,IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
Controlled by
1 4mm 450-550A 28-32 0.4-0.45 10-15 NA
current (1.6-1.8)

9.2 Welding sequence : 4 2

8 8

8 8
10 Provision Of Run- On & Run-Off Tabs : YES 1 3
11 Cleaning Of Weld Bead before laying next Bead : NA
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.
Visual, D.P. Test, Weld Size, Profile & Macro
17 Inspection of weld :
etching
18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/SAW/WS-08 Page 16 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/2R, 4R, 5R, 6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-09

1 Weld joint description : 10 MM Fillet Weld (Both Side) on Diaphram (DP-1 & DP2) to Arch
Member & to Bottom Beam 3 sides. Hanger side complusary
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts, three sides of Bottom

6.1 Joint design details :
Beam/Arch Member. Hanger side complusary.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-09 Page 17 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16

2 1.2 MM 220-270 28-31 8.6 NA 10-12 16

3 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-09 Page 18 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/2R, 4R, 5R, 6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-10

1 Weld joint description : 10 MM Fillet Weld (Both Side) on Diaphram (DP3) to Arch Member
& to Bottom Beam 3 sides. Hanger side complusary
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts, three sides of Bottom

6.1 Joint design details :
Beam/Arch Member. Hanger side complusary.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-10 Page 19 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16

2 1.2 MM 220-270 28-31 8.6 NA 10-12 16

3 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-10 Page 20 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/5R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-11
16 MM Fillet weld between Bracket-20MM THK & bottom of Bottom
1 Weld joint description : Cross Beam (04 Nos. each side) & Applicable for all stiffeners
(Workshop & Field Welding)
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts, between bracket &

6.1 Joint design details :
cross beam.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-11 Page 21 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-11 Page 22 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/5R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-12

1 Weld joint description : 16 MM Fillet Weld On Flange with Web Plate at both the end
portion of Hanger

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts, Flange with Web Plate

6.1 Joint design details :
at end portion of Hanger
16

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-12 Page 23 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : IS: 7307 Para 5.2

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/FCAW/WS-12 Page 24 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/DASW/WS-13

1 Weld joint description : 07mm Arc Stud Weld on top flange of the End Cross Beam &
Intermediate Bottom Cross Beam
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Drawn arc Stud Welding with ceramic ferrule technique broken type
4 Welding Position : Straight Downward
5.0 Welding consumables : --
5.1 Electrode/wire : Class : N.A.
Dia : N.A.
Drying Method : N.A.
5.2 Flux : Class : N.A.
The Stud tip shall be supplied with flux in the
Type : form of Pre-Fitted aluminium ball with ceramic
ferrule
Drying Method : N.A.
5.3 Shielding gas : N.A.
Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

Provide sketch. Marking to be done as per drawing using center

6.1 Joint design details :
punch prior to stud welding.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/DASW/WS-13 Page 25 OF 28
 6.2 Joint preparation WELDING PROCEDURE
: DownwardSPECIFICATION SHEET
(As per EN ISO 14555)
7 Welding current : Type : DC
Polarity : ---
8 Welder qualification : Downward (As per EN ISO 14555)
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Weld Stud Tip Dia Current Downward Lift Plung
Cycle
Pass No. (in mm) (amp.) Hand (Sec) (mm) (mm)
1 4mm up to 1900 amp. 1.4 1.4 0.125 250

9.2 Welding sequence : NA

10 Provision Of Run- On & Run-Off Tabs : Not applicable

11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By rewelding using IRSM-28, A3 Class Electorde

16 Rectification of weld defects : as Per C1.32.2 of IS: 9595 -96 after total removal
of defective weld.
Visually, Appearance Test, Bend Test (Testing
17 Inspection of weld : rate should be 1 in 50 By 6 Kg. hammer), Ring
Test By 2 Kg hammer
18 Any other relevant details : IS-3935-1966, ISO_13918, EN ISO 14555

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/DASW/WS-13 Page 26 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/TACK/WS-14
1 Weld joint description : Tack Welding
Tack Welding
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : Manual Metal Arc Welding (MMAW)
4 Welding Position : Horizontal-Vertical
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : CLASS-A2 of IRS-M-28
Dia : 3.15 & 4MM Rutile Coated
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : N.A.

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

Tack Weld in horizontal position suitably clamped duly positioned

6.1 Joint design details : 50mm long at 300mm spacing using IRS M28-A/A2 Class electrode

5
5

50mm tack welds

each @300mm.
50 mm tack welds
50 mm tack each @300mm.
welds each 5
@300mm.
5 5

5
5

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/TACK/WS-14 Page 27 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes ARC Travel speed Electrical
Weld Current Wire feed speed
diamete voltage m/min stick out Gasflow rate litres/min
Pass No. (amp.) m/min
(in mm) (volt) (mm)
1 3.15MM 110-180 22-24V NA NA NA NA
2 4mm 110-180 24-26V NA NA NA NA

Welding from end typical-50-300-50mm tack

9.2 Welding sequence :
weld (chain welding) to other end.

10 Provision Of Run- On & Run-Off Tabs : Not applicable

11 Cleaning Of Weld Bead before laying next Bead : Not applicable
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : Not necessary
14 Peening : Not applicable
15 Post weld treatment : Not necessary
16 Rectification of weld defects : Not applicable
17 Inspection of weld : Not applicable
18 Any other relevant details : -------

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/TACK/WS-14 Page 28 OF 28
 WELD JOINT DETAILS FOR ON SITE/FIELD WELDING
For 60 M CLEAR SPAN R.O.B. BOW STRING STEEL GIRDER
(CONSTRUCTION OF ROB AT 1ST KM OF CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT
RAILWAY LEVEL CROSSING GATE NO. ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.)

Client : GOVERNMENT OF ASSAM, PUBLIC WORKS DEPARTMENT (ROADS), ASSAM,

Railway Authority : NORTHEAST FRONTIER RAILWAY
EPC Contractor : M/s. BADRI RAI & COMPANY
Name of Fabricator : Z.H. INDUSTRIES PVT. LTD
Fabrication workshop : 32 KM DELHI-HAPUR ROAD, MASOORIE, GHAZIABAD-201015

WELD JOINT DETAILS FOR ON SITE/FIELD WELDING

SL Type of Weld Size Welding
WPSS NO. Weld Description Page No. Remarks
NO. Weld (MM) Process

1 ZHIPL/BR&C/PWD/NFR/60M/OSW-01 Bottom Long Beam to splice at joint Fillet 20 FCAW 1/28 To 2/28

2 ZHIPL/BR&C/PWD/NFR/60M/OSW-02 Arch Beam to splice at joint Fillet 20 FCAW 3/28 To 4/28

Cover Plate-30MM THK to Bottom

3 ZHIPL/BR&C/PWD/NFR/60M/OSW-03 Long Beam, Arch Beam & Cross Fillet 22 FCAW 5/28 To 6/28
Beam @ L0
Jacking Plate to to Bottom Long
4 ZHIPL/BR&C/PWD/NFR/60M/OSW-04 Fillet 10 FCAW 7/28 To 8/28
Beam@ L0

Stiffener Plate to Bottom Long

5 ZHIPL/BR&C/PWD/NFR/60M/OSW-05 Fillet 16 FCAW 9/28 To 10/28
Beam@ L0

Hanger to Bottom Long Beam

6 ZHIPL/BR&C/PWD/NFR/60M/OSW-06 Fillet 22 FCAW 11/28 To 12/28
Connection

7 ZHIPL/BR&C/PWD/NFR/60M/OSW-07 Hanger & Stiffener to Arch Beam Fillet 22 FCAW 13/28 To 14/28

Top Bracing, Tie Beam to Top Arch

8 ZHIPL/BR&C/PWD/NFR/60M/OSW-08 Fillet 16 FCAW 15/28 To 16/28
Member & Hanger Connection

9 ZHIPL/BR&C/PWD/NFR/60M/OSW-09 Cover Plate with Ach & BLB Fillet 6 FCAW 17/28 To 18/28

10 ZHIPL/BR&C/PWD/NFR/60M/OSW-10 Arch Beam to BLB at L0 Joint Fillet 16 FCAW 19/28 To 20/28

11 ZHIPL/BR&C/PWD/NFR/60M/OSW-11 Stiffner Plate with BLB & Hanger Fillet 22 FCAW 21/28 To 22/28

12 ZHIPL/BR&C/PWD/NFR/60M/OSW-12 BLB, Hanger with ICB BC Fillet 12 FCAW 23/28 To 24/28

Int. Cross Girder BC-1 & Fillet Weld

all around BLB, Hanger with ICB BC-
13 ZHIPL/BR&C/PWD/NFR/60M/OSW-13 2/ Bottom Cross Beam ISA 150 Fillet 10 FCAW 25/28 To 26/28
x150x12 to Bottom Long Beam (BCB-
3)
Bottom Long Beam with End Cross
14 ZHIPL/BR&C/PWD/NFR/60M/OSW-14 Fillet 16 FCAW 27/28 To 28/28
Girder
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/5R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-01
1 Weld joint description : 20 MM Fillet weld - Bottom Long Beam to splice at joint

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Bottom long beam to

6.1 Joint design details :
splice at joints for web & flange all four side.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-01 Page 01 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-01 Page 02 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/2R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-02
1 Weld joint description : 20 MM Fillet weld - Arch Beam to splice at joint

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Arch Beam to splice at

6.1 Joint design details :
joints for web & flange all four side.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-02 Page 03 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-02 Page 04 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/4R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-03
1 Weld joint description : 22 MM Fillet weld - Cover Plate-30MM THK to Bottom Long Beam,
Arch Beam & Cross Beam @ L0
2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Cover Plate to Bottom

6.1 Joint design details :
Long Beam, Arch Beam & Cross Beam @ joints L0.

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-03 Page 05 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16
7 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-03 Page 06 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/4R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-04
1 Weld joint description : 10 MM Fillet weld - Jacking Plate to Bottom Long Beam@ L0

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Jacking Plate to to

6.1 Joint design details :
Bottom Long Beam@ L0
10

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-04 Page 07 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16

2 1.2 MM 220-270 28-31 8.6 NA 10-12 16

3 1.2 MM 220-270 28-31 8.6 NA 10-12 16

4 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-04 Page 08 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/4R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-05
1 Weld joint description : 16 MM Fillet weld -20MM Stiffener Plate to Bottom Long Beam@ L0

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Stiffener Plate to

6.1 Joint design details :
Bottom Long Beam@ L0

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-05 Page 09 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-05 Page 10 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/5R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-06
1 Weld joint description : 22 MM Fillet weld all around- Hanger to Bottom Long Beam @ L1-L4

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Hanger to Bottom Long

6.1 Joint design details :
Beam@ L1 to l4

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-06 Page 11 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16
7 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-06 Page 12 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/9
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-07
1 Weld joint description : 22 MM Fillet weld all around- Hanger & Stiffener to Arch Beam

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of parts. Hanger & Stiffener to

6.1 Joint design details :
Arch Beam. (Joint U1, U2, U3, U4 & U5)

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-07 Page 13 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16
7 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-07 Page 14 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/3R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-08
16 MM Fillet weld all around- Top Bracing, Tie Beam to Top Arch
1 Weld joint description :
Member & Hanger Connection

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Top Bracing, Tie Beam to Top

6.1 Joint design details :
Arch Member & Hanger Connection

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-08 Page 15 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-08 Page 16 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/4R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-09
6 MM Fillet weld all around- Cover Plate with Arch Member &
1 Weld joint description :
Bottom Long Beam

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Cover Plate with Arch

6.1 Joint design details :
Member & Bottom Long Beam

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-09 Page 17 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-09 Page 18 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/4R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-10

1 Weld joint description : 16 MM Fillet weld all around- Arch Member with BLB (at L0 Joint)

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Cover Plate with Arch

6.1 Joint design details :
Member & Bottom Long Beam

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-10 Page 19 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-10 Page 20 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/5R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-11
22 MM Fillet weld all around- Stiffner Plate with Bottom Long Beam
1 Weld joint description :
& Hanger

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Stiffner Plate with Bottom

6.1 Joint design details :
Long Beam & Hanger

22

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-11 Page 21 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16
7 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-11 Page 22 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-12
12 MM Fillet weld all around- Bottom Long Beam with Int. Cross
1 Weld joint description :
Girder BC-1 & Fillet Weld all around BLB, Hanger with ICB BC-1

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Bottom Long Beam with Int.

6.1 Joint design details :
Cross Girder

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-12 Page 23 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-12 Page 24 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/OSW-13
10 MM Fillet weld all around- Bottom Long Beam with Int. Cross
1 Weld joint description :
Girder BC-1 & Fillet Weld all around BLB, Hanger with ICB BC-2

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement of Bottom Long Beam & Hanger

6.1 Joint design details :
with Int. Cross Girder

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-13 Page 25 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-13 Page 26 OF 28
 WELDING PROCEDURE SPECIFICATION SHEET
NAME OF WORK: CONSTRUCTION OF ROB AT 1ST KM OF MADHAVPUR TIPPLING ROAD AT RAILWAY LEVEL CROSSING GATE NO.
ST-135 UNDER CONSTRUCTION OF ROBS ON 50:50 COST SHARING BASIS.
Reference Drg. No. RDSO/B-10420/6R
Name and Address Construction agency : M/s. Badri Rai & Company
C Block, Phase 2, Industrial Area, Sec- 62, Noida-201309(U.P.)
Name of Fabricator/Manufacturer : M/s. ZH Industries Pvt. Ltd.
32KM, Delhi-Hapur Road, Masoori Ghaziabad-201302 (U.P.)
Welding procedure specification No. : ZHIPL/BR&C/PWD/NFR/60M/FCAW/OSW-14
16 MM Fillet weld all around- Bottom Long Beam with End Cross
1 Weld joint description :
Girder

2 Base metal : IS:2062–2011, E350 B0 (Fe490), Plates 12mm and above thick are
fully killed/normalized or control cooled.
3 Welding process : FCAW
4 Welding Position : Flat (1F/PA)
5.0 Welding consumables : As per below details
5.1 Electrode/wire : Class : Class-1 (IRS M 46 2013 grade E71-T-12 FCAW wire
Dia : 1.2 MM
Drying Method : N.A.
5.2 Flux : Class : N.A.
Type : N.A.
Drying Method : NA

5.3 Shielding gas : CO2

Fusion faces and adjacent surfaces are cleared and made free from
6.0 Base metal preparation : cracks, notches, mill scale grease, paint, rust etc. which might affect
weld quality.

As per sketch showing arrangement ofBottom Long Beam with End

6.1 Joint design details :
Cross Girder

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-14 Page 27 OF 28
 WELDING PROCEDURE
Fillet JointSPECIFICATION SHEET
as per IS4353-1995 CL-7, IRS B1-2001, CL-17 & WBC-2001
6.2 Joint preparation :
& IS 9595-2003
7 Welding current : Type : DC
Polarity : Reverse
8 Welder qualification : FCAW (As per IS: 7310 (Part – 1)-1974, IS : 7307 (part-I)-1974
9.0 Welding parameters and technique : AS BELOW
9.1 Welding parameter
Electrodes/ ARC Electrical
Weld Current Wire feed speed Travel speed
Wire diamete voltage stick out Gasflow rate litres/min
Pass No. (amp.) (m/min) (m/min)
(in mm) (volt) (mm)
1 1.2 MM 220-270 28-31 8.6 NA 10-12 16
2 1.2 MM 220-270 28-31 8.6 NA 10-12 16
3 1.2 MM 220-270 28-31 8.6 NA 10-12 16
4 1.2 MM 220-270 28-31 8.6 NA 10-12 16
5 1.2 MM 220-270 28-31 8.6 NA 10-12 16
6 1.2 MM 220-270 28-31 8.6 NA 10-12 16

9.2 Welding sequence : Not applicable

10 Provision Of Run- On & Run-Off Tabs : Not applicable
11 Cleaning Of Weld Bead before laying next Bead : YES
Root preparation before welding other side of groove : Not applicable
12
weld
13 Preheating & interpass temperature : 100°C & ≤250°C
14 Peening : Not applicable
15 Post weld treatment : Not necessary

By grinding of the defective weld & reactifying

the weld as per cl-32.2 of IS-9595-96, using A2
16 Rectification of weld defects :
class of electrode of specification (MMAW) IRSM-
28 2002 after conducting D.P.Test.

17 Inspection of weld : Visual & D.P. Test

18 Any other relevant details : On Site/Field Welding

For ZH Industries Pvt. Ltd For Badri Rai & Co. PWD NFR Approved By RDSO
ZHIPL/BR&C/PWD/NFR/60M/OSW-14 Page 28 OF 28