Special Conditions for H-Beam Sleeper

ADDITIONAL SEPCIAL CONDITIONS OF CONTRACT (TECHNICAL)

1. The work covered in this tender is for manufacturing, supplying and fixing of BG
Galvanized H-Beam Sleepers along with all fittings and fixtures. (Also Galvanized)
2. The channel sleeper fittings shall conform to RDSO [Link]. T-5155 to T-5164 to T-
5197 with latest alteration.
3. Fabrication and workmanship: Fabrication, workmanship shall generally comply with
current IRS specification with latest correction/amendments thereof unless otherwise
specified in special condition of this contract or as specially directed by the Engineer in
writing.
The contractor shall submit test certificates conforming to appropriate standards of all
steel material used for fabrication. All structural steel shall be free from rust, scales,
laminations, cracks, fissure and other surface defects.
The workmanship and finish shall be equal to the best general practice in modern
structural shops. The greatest accuracy shall be observed in the manufacture of every
part of the work all similar part shall be strictly inter – changeable.
NOTE:- Only weldable steel conforming to IS 2062-1992 shall be used for steel
channels. The steel channel manufactured by SAIL,TISCO & Vizag Steel
plant only shall be used.
Following specification shall be followed:-
a) Indian Railway Steel bridge Code as corrected upto date.
b) Indian Railway welded bridge Code 1972.
c) Indian Railway Schedule of dimension for Broad Gauge-1939
( Reprinted in Metric units in 1973)
d) IS:2062-1992 GR-A, Specification for structural steel standards quality.
e) Indian Railway Specification B-1. 1979: Fabrication and erection of Steel Girder
Bridges.
f) IRS H-5 rivets.
g) IS 2155 –1962 : Rivets for General purposes (Below 12mm diameter).
h) IRS H-19, for bolts and nuts.
I) IS:102-1962, Ready Mixed paints. Brushing Red lead. Non-setting priming.
j) IS: 2339-1963 : Aluminum paint for General purposes, in dual container.
k) IS:123-1963 : Ready mixed paints, brushing, finishing Semigloss for General purposes
to Indian standard Colours, Red Oxide.
l) B.S.S.916 and /or IS: 1963-1967 : black Hexagonal Bolts/nuts etc. black hexagonal
Bolts /Nuts and lock nuts(6 to 39 mm) and black Hexagonal screws (dia 6 to 24mm).
m) IS:800-1984.
n) IS: 1148-1973: Hot Rolled steel Rivet Bars for structural purposes.
o) IS: 2062 –1992: Steel grade “B” for welded structures. The tenderer shall maintain a
master- steel tape of approved make for which he has obtained a certificate of accuracy
from the National Laboratory.
Signature Not
Verified
Digitally signed
Digitally signedby
by
SURENDRA
SYED ANWER NATH
ALI
SUNDI2024.09.26
Date:
Date: 2017.12.04
[Link] IST
[Link] IST
Reason: IREPS-CRIS
Reason: IREPS-CRIS
Location: New Delhi
Location: New Delhi
 Rolled materials before being laid off or worked, must be made straight if straightening
or flattening is necessary, it shall be done by method that will not damage the material.
Sharp kinks and bends shall be rejected.

HOLING: Holes for rivets and bolts shall be drilled to conform to CI.10 of IS:7215. All
holes, excepts as stated hereunder shall be drilled to the required size or sub-punched
2mm. Less in diameters and reamed thereafter to the required size. Thickness of the
materials for sub-punching shall not be greater than 16mm. All matching holes, for rivets
or bolts shall register with each other so that a gauge of 0.8mm less in diameter than
the holes can pass freely through the members assembled for leveling or bolting in the
direction at right angel to such members. All holes for turned and fitted bolts shall be
drilled under sized by 1mm and after assembly reamed to a tolerance of 0.13mm –0mm
unless otherwise specified. When the number of members to be riveted in assembly
exceeds three or the total thickness is 90mm or more, the holes shall be drilled or
reamed in position after assembly except when seal bushed jigs are used. The parts
shall be finally bolted together during such block drilling and taken apart for removal of
burrs after drilling. Holes in purline, side sheeting runners, packing plates and lacing
bars may be punched full size, provided the thickness of the materials does not
exceeds 13mm. All punching and sub-punching shall be cleared and accurate and all
drilling shall be free from burns. No holes shall be made by Gas Cutting process.
Bolting: All turned and fitted bolts shall be carefully turned and shall be paralleled
through out the barrel. The following limits of tolerance shall be permitted upon the
diameter of the barrels of turned bolts and holes which they are to fit.

Limit of Tolerance Barrel of Bolts Holes

High - 0.00mm + 0.13mm
Low - 0.13mm -0.00mm
The barrels of each turned bolts shall be of such a length so that it is in full contact with
the work through out the screwed portion, being made at least 1.6mm. Less in diameter
that the barrel or to suit the next smaller size of metric screw thread. The barrel portion
shall be jointed to the thread portion by a degree chamfer within the thickness of
washer, unless otherwise specified. Faces of heads and nuts bearing on steel work
shall be machined. All such bolts shall be provided with washers having a hole of
1.5mm larger in diameter than the barrel and thickness of not less than 6mm so that the
nut, when tightened, shall not bear on the unthreaded body of the bolt. In all cases
where the full bearing area of the bolt is to be enveloped, the threaded portion of the
bolt shall not be within the thickness of the parts bolted together. The threaded portion
of each bolt shall project through the nut by at least one thread. Tapered washers shall
be provided for all heads and nuts bearing on beveled surface.

4. Welding:
General: The welding and welded work shall generally confirmed to IRS bridge code
and subject to further specification given in the following paragraphs.

Manual metal arc welding may be done only by welder possessing competency
certificate, or where access of the location of welds do not permit automatic welding.
The welding should be done by submerged arc welding process either fully
automatic or semi automatic wherever specified by the Railway.

Except for special types of edge preparation such as single and double ‘U’, Single and
double ‘J’ the fusion edges of all the parts which are to be joined by welding may be
prepared by using mechanically controlled automatic flame cutting equipment and to be
ground to a smooth finish special edge preparation should be made by machinery or
gauging.

All welding work shall be done in shops and the Layout and sequence of operation shall
be so arranged as to eliminate distortion and shrinkage stresses.

Electrodes: All Electrodes shall be kept under dry conditions. Any electrodes with parts
of its flux coating broken away or otherwise damaged shall be rejected.

Any electrode older than six months from the date of manufacture or older than the date
of expiry as specified by manufacturer should not be used.

Welding Electrodes to be used in the work should confirm to RDSO approved firm and
quality only.
The electrodes shall confirm to Class A2 of IRSM-28 and wire for CO2 Welding
shall confirm to Class-I of IRSM-46

The Electrodes to be used in the work shall be of Approved type and manufactures
approved by RDSO.
Preparation of joints: The edge shall be prepared with an automatically controlled
flame cutting torch correctly to the size and dimension of the groove prescribed in the
design and shop drawing. In case of ‘U’ grooved joints the edges shall be prepared with
an automatic flame torch in two phases following a bevel out with grounding pass or by
machining.

The welding surfaces shall be smooth, uniform and free from fine tears notches or any
other defects which may adversely effect welding and shall be free of loose scale, slag
rust, grease, paint, moisture or any other foreign material.

Welding procedure: The welding procedure shall be arranged by the contractor to suit
the details of the joints as indicated on the drawing and the position at which welding
has to be carried out. Working procedure shall cover the following:

a) Type and size of Electrodes.

b) Current and for automatic welding arc Voltage.
c) Length of run for Electrode, or for automatic welding speed of travel.
d) Number and arrangement of runs in multi run welding.
e) Position and set up of parts.
f) Preparation and set up of parts.
g) Welding sequence.
h) Pre or post heating.
i) Any other relevant information.
The welding procedure shall be so arranged that the distortion and shrinkage
stress are reduced to a minimum and the welds meet requirement and quality specified,
hereunder.

Any weld found defective shall be cut by using either chipping hammer or gouging torch
in such a manner that adjacent materials is not injured in any way.

Planning of the welds involving deformation of the surface either during de-slagging
operation or thereafter shall not be allowed.

Fusion faces and surrounding surfaces within 50mm of welds shall be free from all mill
scale and free from oil, paint or any substance which might effect the quality of the
welds and impede the quality/progress of welding. They shall be free from irregularities,
which interfere with the deposition or specified size of weld or be the cause of defects.

All mill scale within 50mm of welds shall be removed on welding either by picking
followed by through power weld brushing or by other approved methods. If preparations
or cutting of the fusion faces is necessary the same shall be carried out by sheering,
chipping, gas cutting or flame gouging. Where no gas cutter or hand gouging is
employed the blow pipe or gouging blow pipe shall be properly guided.

Assembly for welding: Before taking of mass production of nay type of sleeper the
production of 20 sleepers shall be taken up and the dimensions thereafter shall be
checked by means of a test track 13Mtrs. Long assembled at the Railway at a point
convenient to the Railways. Transport of the Rails and sleepers from this point to the
contractor’s workshop and returning the same to the point of collection shall be done by
the contractor at his own cost. The parts to be welded shall be properly assembled and
held firmly in position by means of jigs and fixtures prior to and during welding.

Automatic submerged arc welding shall be employed for fabrication of welded steel
channel sleepers wherever specified.

Accuracy of fit up: Parts to be fillet welded shall be brought into as close contact as
practicable and the gap due to faulty workmanship or incorrect fit up shall not exceed
[Link]. If greater separation occurs at any position the size of fillet weld shall be
increased at such position by the amount of the gap.

Jigs and manipulators: Jigs and manipulators shall be used where practicable and
shall be designed to facilitate welding and to ensure that all welds are easily accessible
to the operators.
Minimum leg length and throat thickness in fillet welds:

The minimum leg length of a fillet weld as deposited shall not be less than the specified
size. In no case shall a concave weld be deposited unless specifically permitted. Where
permitted, leg length shall be increased above that specified, so that the resultant throat
thickness remains the same, as would have been by the deposition of a flat facased
weld of the specified leg length.
 De-slugging:- After making each run of welding all slag shall be thoroughly
removed and the surface cleaned.
Quality of welding: The weld metal as deposited, including track weld if to be
incorporated, shall be free from cracks, slag inclusion, porosity, cavities and other de-
position faults. The weld steel shall be property fused with the present steel metal
without undercutting or over lapping at the toes of the weld. The surface of the weld
shall have a uniform consistent contour and regular appearance.
Weather conditions: Welding shall not be done under open weather conditions which
might adversely effect the efficiency of the welding. It should be done only under a
covered shed in a workshop.
Qualification and testing of welders: The contractors shall satisfy the Engineer that
the welders are suitable for the work for which they will be employed and shall produce
evidence to the effect that welders have satisfactorily completed appropriate tests as
prescribed in I.S.877. The Engineer may at his own discretion order periodic tests of the
welder and / or of the welds produced by them. Such tests shall be at the expense of
the contractor.

Supervisor: The Contractor shall employ a competent welding supervisor to ensure

that the standard of workmanship and the quality of materials comply with the
requirements laid down in the specifications.

5. Erection Marking: Each fabricated member whether assembled prior to dispatch or not
so assembled shall bear an erection mark which will help to identify the member and its
position in respect of the while structure to facilitate re-erection at site.
These erection marks shall be suitably incorporated in the shop detail and erection
drawings.
6. Control In The Fabrication And Assembley Of Various Structures:

Criteria for testing: The contractor shall conduct tests in accordance with
following norms.

a) Visual examination 100% (one hundred percent).

b) Mechanical Test.
c) Dye penetrant Examination.
Tests:

a) Visual Examination: The contractor shall conduct the visual examination and
measurement of the external dissension of the weld for all joints. Before
examining the welded joints surface area close to it on both side of the weld for a
width not less than 20 mm, shall be cleaned of slag and other impurities.
Examination shall be done by a magnifying glass which has a magnification
power of 10 and measuring instrument which has an accuracy of +0.1 mm or by
weld gauges. Welded joints shall be examined from both sides.
 The contractor shall examine the following during the visual checks.
a) Correctness and shape of the welded joint.
b) Incomplete penetration of weld metal.
c) Influx
a) Burns
b) Unwelded craters.
c) Undercuts
d) Cracks in welded parts and heat effected zones.
e) Porosity in welds and spot welds
f) Compression in welded joints and a result of electrode while carrying out contact
welding
g) Displacement of welded elements.
The contractor shall document all data as per sound Laboratory Practices.

b) Mechanical Test: The Contractor shall carryout various mechanical tests to determine
weld ability, the metal alloy ability, nature of break, correct size and type of electrodes,
degree of pre-heat treatment etc. the type, cope and sample of various mechanical
tests shall be determined in agreement with the Engineer that the correct type and size
of electrode, degree of pre-heating and post –heating and weldability of different metal
are being followed.

c) Dye Penetrate Examination: All welds as desired by Engineer will be examined by

dye penetrates for detection of discontinuities as per IS-3658-81, IS-12889-89 and
RDSO’S SPC. No. MRC/NDT/4/91/APPD.

7. Inspection and testing of fabrication: The Engineer shall have free access at all
reasonable times to the Contractor’s works where the fabrication of steel work is carried
out and shall be afforded be all reasonable facilities by the contractor for satisfying
himself that the fabrication is being under-taken in accordance with the provisions of the
drawings of the drawings and specifications.

The contractor shall continuously inform the Engineer of the progress in fabrication as
and when the individual pieces get ready for inspection. The contractor shall give a
minimum of three working days notice to the Engineer for inspection of the individual
pieces.

Unless directed other –wise, inspection shall be made at the place of manufacture prior
to dispatch by an authorised representative of Railway, should any structure found not
to comply with any of the provisions of this specification it shall be liable for rejection.
No structure or part of the structure, once rejected shall be re-submitted for
inspection/test, except in cases w3here the Engineer considers the defect as rectifiable
 Defects which may appear during fabrication shall be made good with the
consent of and according to the procedure laid down by the Engineer. All gauges and
templates necessary to satisfy the Engineer shall be supplied by the contractor. The
engineer , may at his discretion, check the test results obtained at the contractors works
by independent tests at the Government Test House or elsewhere and should the
material so tested be found to be unsatisfactory the costs of such tests of such tests
shall be borne by the contractor.
8. Marking, packing and dispatching:- Each piece shall be distinctly marked before
delivery in accordance with the approved marking diagram and shall be a such other
marks as will facilitate erection. For easy identification at site a small distinguishing
mark shall be painted on each and every member before dispatch from fabrication shop.
The fabricated steel work shall be dispatched by the contractor in such portions as may
be found convenient for erection or as ordered by the Engineer to meet the time
schedule.
All projecting plates or bars and all ends of members at joint shall be stiffened, all
straight bars and plates shall be bundled, all screwed ends and machined surfaces shall
be suitable packed and all rivets, bolts, nuts, washers and small loose parts shall be
packed separately in boxes so as to prevent damage or distortion during transit.

9. Template: Templates need through out the work shall be of steel packed in such
cases as the inspecting officer may consider necessary.
10. Supervision of work: During the entire progress of the work the contractor shall
have a competent supervisor in personal charge of the work. All works shall be done by
skilled competent workmen.
11. Fixing of H-Beam Sleepers at site: The H-Beam sleepers shall be provided on the
nominated bridges by the contractor.
Working in the vicinity of Railway Track: All works, which may affect the safety of
Railway working, shall only be done under traffic block & written authority and also
under the direct supervision the Engineer-in –charge at site or his authorized
representative for the said bridge. The contractor shall in consultation with the Engineer
decide the Engineer decide the sequence of work required to be done for efficient
provision of channel sleeper.
The gauge, level, alignment of the track shall be adjusted by the contractor suitably as
per satisfaction of the Engineer, and as per tolerances laid down in Indian Railway
Permanent Way Manual for New Track.
12. The fabricator’s name & Drg. No. should be indicated on all channel sleeper suitably on
a plaque fixed on the web of the channel sleeper at one end.

13. The existing track on the bridge is to be dismantled including guard rails running rails
and Bridge timbers. New channel sleepers are to be fixed as per provided RDSO
Drawing. The track is to be re linked over the H-Beam sleepers with the same running
and guard rails by the fittings and fixtures supplied by the contractor.

14. Works has to be executed in the running traffic condition or under the traffic blocks.
These will be made available as per the convenience of the Railway depending on the
 position of the trains. Block and caution orders will be taken and cancelled by the
authorized Railway officials only.

15. Released U/S small fittings, Steel Channel Sleepers/Bridge Timbers and worn-out –rails
(if any) etc. will have to be transported by the contractor to the nearest store depot of
SSE([Link])/ concerned at his own expenditure.

16. Dip Lorries for the transpiration of the materials will be supplied by the Railway as per
the convenience and free of hire/charges.

17. Carrying of materials and protection of Dip Lorries by trained staff will have to be done
by contractor ensuring safe running of traffic under the supervision of Rly.’s
representative.

18. Contractor has to arrange for adequate number of skilled workers and competent
supervisors for the execution of this work, their safety during dismantling, transporting
and linking of the track over the girders will be the sole responsibility of the contractor.

19. Serviceable materials released form dismantling of the track should be properly
accounted and kept in the custody of contactor for reuse. Unserviceable materials will
be made good by the Railway (For rails, F/bolts fish plates etc.)

20. Materials supplied free by the Railway to the contractor will not form part of the value of
the contract entered into and will fall outside the preview of the price variation clause.

21. All the mild steel fittings and fixtures have to be galvanized at the contractors cost
before use.

.
 ANNEXURE NO. I

TABLE FOR FITTING & FIXTURE AND SPECIFICATION.

SL. Description of Fittings & DRG No. Specification No. per

NO. Fixtures sleeper.

1. [Link] BEARING RDSO /T-5155 I.R.S.-T.5-1965 2

PLATE
2. GROOVEDRUBBER PAD RDSO/T-5156 I.R.S. SPECIFICATION 2*
10MM THICK FOR 10MM THK
GROOVED RUBBER PAD
(PROVISIONAL –1989)
3. [Link](OUTER) RDSO/T-5157 I.S. 226-1962 2
4. [Link](INNER) RDSO/T-5158 -DO- 2
5. ANNULAR CAP RDSO/T-5159 -DO- 4
6. T-HEAD BOLT &NUT RDSO/T-5160 I.R.S.T-10-1968 4
& DD. SK. NO.
387/93
7. TAPERED WASHER (FOR RDSO/T-5161 I.S.226-1962 4
GUARD RAIL)
8. TAPERED WASHER (FOR RDSO/T-5162 I.S.226-1962 4
GUARD RAIL)
9. GROOVED RUBBER PAD RDSO/T-5163 I.R.S. SPECIFICATION 4*
6MM THICK (FOR G/RAIL) FOR 6MM THK
GROOVED PUBBER PAD
(PROVISIONAL –1987)
10. BOLT & NUT (FOR RDSO/T-5164 I.R.S. T-10 4
GUARD RAIL )
11. SINGLE COIL SPRING T-10773 I.R.S.T-42-1988 8
WASHER
12. [Link] PLATE - I.S.226 1962 4
(150X75X30)
13. TAPERED SPLIT PIN. CE’S NO. 1.S.226 1962 8
22994/8

14. HOOK BOLT D/D/[Link].38 I.S.226-1962 OR 2062 2

9/93
15. ELASTOMERIC PAD UNDER ST. SPECIFICATION FOR 2
230X270X10 MM CH. SLEEPER NYLON CHORD
REINFORCED PAD NO.
RDSO/M&C/RP/174/92(PR
OVISIONAL)
16 ELASTOMERIC PAD UNDER GR. -DO- 2
230X400X5 MM PAD PLATE

N.B: THESE ITEM SHALL BE PROCURED ONLY FROM RDSO APPROVED SOURCES
AS CIRCULATED UNDER RSSO’S LETTER NO. CF/EF/PLICY DT.13.03.96 OR
AMENDED UP TO