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Page 1 of 5 Effective from 11.12.2002 TI/STR/021 Rev. 0 (For PSC Mast)
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
No. TI/STR/ 021
(Revision 0)
Schedule of Infrastructure Requirements for
Manufacturing & testing facilities and Quality
Control Requirements.
For
SPUN PRESTRESSED CEMENT CONCRETE (PSC)
OHE. TRACTION MAST. (Specification No.
ETI/C/2(8/84).
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ISSUED BY
TRACTION INSTALLATION DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANIZATION
MANAK NAGAR, LUCKNOW - 226011
Page 2 of 5 Effective from 11.12.2002 TI/STR/021 Rev. 0 (For PSC Mast)
1.0 SCOPE
This schedule covers the technical requirements for manufacturing, testing
and supply of spun prestressed conerte (PSC) traction masts for Railway
Electrification.
2.0 GENERAL INFRASTRUCTURE & MANUFACTURING FACILITY:
2.1 DESIGN/DRAWINGS.
There shall be a design/drawing cell with facility of CAD for dealing with
the design/drawing of the product.
2.2 Manufacturer should have adequate covered accommodation for storing
raw material, finished masts awaiting dispatch and arranging inspection.
Manufacturer should have system to ensure that product conforms to the
requirements of RDSO Specification No. ETI/C/2(8/84). The manufacturer
should have an effective quality control system to monitor quality control of
- Inward raw material.
- Stage inspection at various stage.
- Inspection of the final product to confirm adherence of the
requirements/specifications.
2.3 The firm should have a clean and pollution free environment and should
be taking adequate safety precautions during the production. The firm must have
the item like fire extinguishers, safety warning board, shock treatment charts and
medical first aid kit in the premises.
2.4 The management should organize regular training programs for
upgradation of the knowledge and skills of the employees.
2.5 PLANT & MACHINERY
The manufactures should have the following plants/machines/equipments
of suitable capacity/rating required for manufacturing of the PSC masts in
different stages as per RDSO specification in its works.
- Main plant building.
- Steam curing machine/chamber
- Cement Godown
- Stocking Yard
Page 3 of 5 Effective from 11.12.2002 TI/STR/021 Rev. 0 (For PSC Mast)
- D.G. set building.
- DM plant building/shed
- Site office room
- Site Lab.
- Water supply arrangement.
- Power arrangement.
- Mechanised Batching Plant for concrete mixing
- Automatic wire cutting machine.
- Button Heading machine.
- Cage forming facility.
- EOT crane for material Handling.
- Spinning equipment/Machines.
- Pre-tensioning Machine.
- Boiler with Dimineralising plant.
- Cube test Machine.
LABORATORY EQUIPMENT
- Standard sieves.
- Hydraulic cube testing machine.
- Cube moulds
- Cylinder moulds
- Spinning machine
- Oven.
- One lathe machine- long bed (It is used for rectification of defects
in moulds)
- Mobile road crane.
- Mould of various size for casting spun concrets masts.
- D.G. set
- Spiral wire machine.
- Pneumatic wrenches.
- All BIS specifications required in manufacturing PSC marts, steel,
cement, Aggregate & its testing etc.
2.6 TESTING FACILITIES
The firm should have the following testing and measuring equipments.
These instrument should be calibrated with the standard master instruments,
accountable to National Physical Laboratory or a similar reputed agency. Each
instruments should have a valid calibration certificate.
- Suitable rig machine.
- Tools
- Chain Pulley block.
- Gauges.
Page 4 of 5 Effective from 11.12.2002 TI/STR/021 Rev. 0 (For PSC Mast)
- Pressure gauges.
- Jacks
- Measuring dials on the compression test machine.
- Test cubes.
- Pretensioning equipment.
- Weigh batching machine.
- Dynamometer.
And all other things which may be considered necessary or required by the
Inspecting officer for carrying out any or all the checks and tests mentioned in the
RDSO specification and shall render all assistance in making such checks and
tests.
2.7 TEST
The following checks and tests and the results obtained supplied to the
inspecting officer.
- Cube Test.
- Type test.
- Acceptance test.
- Compressive strengths test of concrete
- Flexural strength of concrete
- Check for dimensional tolerance and finish.
- Bend Test.
- Modulus of rupture test of concrete.
- Transverse and longitudinal test etc. as mentioned in RDSO
specification
2.8 QUALITY CONTROL REQUIREMENTS.
- The firm should have acquired ISO-9000 series certificate for the
product for which approval is sought and it should be broadly
covered in the scope of the certification for manufacture and
supply.
- Quality manual of the firm for IS0-9000 should clearly indicate at
any stage the control over manufacturing and testing of the said
Rly. product.
- There exists a system of easy tracetability of the products from
shearing stage to finished product stage.
- The manufacturer should have a system of monitoring the
complaints for supplied product. The complaints made by the
customer should be identifiable to the various manufacturing
stages of the products and linking the complaints for corrective and
preventive action of the product.
Page 5 of 5 Effective from 11.12.2002 TI/STR/021 Rev. 0 (For PSC Mast)
- Quality Assurance plan for the product detailing various aspects
like.
a) Organizational chart.
b) Flow process chart.
c) Stage inspection details.
d) Various parameters to be maintained to ensure control.
e) Policy of disposal of rejected material should be
implemented and record is maintained for documentary
evidence.
- A Degree/diploma holder must be head of the inspection/final
control section with 5 years experience in the relevant field.
- There exists a quality manual of firm indicating the extent of
control over production and testing.
- There exists a system of documentation in respect of rejection at
customer end and warranty replacement.
- System should exist for documentation of the following.
i) Incoming raw material with TC reference of supplier as
well as internal test/ audit checking form the outside
agency.
ii) Ensure that details regarding stage inspection and test
results are available.
iii) Ensure that a system exists for calibration of testing &
measuring equipment and record is maintained.
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