metel ey onl|9y 2 = Pprrorrio lel Bel ae Se aaa oS Sata, (et a) epee. FE faret-390 009 Ste te A fa GOVERNMENT OF INDIA MINISTRY OF RAILWAYS. (RAILWAY BOARD) NEW DELHI-110001 No 2003/Proj/Bangalore/2/2 (Pt) Dated#7.10.2011 Pr. Chief Engineers, All Indian Railways. Sub: Double Resi nt Base Plate Assembly Fastening System. M/s Pandrol Rahee Technologies Ltd had approached Ministry of Urban Development for examination of the “Double Resilient Base plate assembly system’ fastening system of Ballastless track. The same was refereed to MoR and got examined / MoR had conveyed the approval of this system vide letter of even number dt: 12-01- * 2011. Subsequently, after inter-ministerial consultations and discussions, and in terms of the requirements of the Performance Criterion for fastening systems dated 21-5-10, MOUD letter number K-1401 1/21/2009-MRTS dt 19-04-2011 and MoR letter of even no dt 28-04-2011 were issued. The offered system had been found to b+ a modified version of an earlier version performing service in several metros including Hongkong and Singapore for more than 35 years. :towever, in the modified version, had been usec only froin September 2009 in Dubai Metro, as per the requirements of the Perfarmance Criterion for fastening sysiem dated 21-05-2010 along with the clarifwations issued on 18-3-11. The sare wees approved on the basis of the satisfactory performance of the mother system, which had put in more than 16 years of service, but with the condition that it is to be kept under RDSO monitoring. The MoR letter no. did 18-03-2011 mentions that a change in any component of an approved fastening system will require the metro railways to approach the MoR for approval. Accordingly, to operationalize the approval given to the double resilient baseplate assembly system, the following is advised:~ 1. A copy of the Performance Gertficate of the Dubai Metro dated 28.10.2010, based on which RDSO has considered the performance of the system, is attached herewith as Annexure-1. The Metro Railways/MRTS System should verify the authenticity of the system proposed to be used by them vis-a-vis this Performance Certificate 2. The drawings and the specification of the fastening system as used in the test assembly, which has been examined and cleared, are enclosed as Annexure-2. The Metro Railways/MRTS System should make sure that the system, if used by them, matches completely with the drawing and specifications of the testassembly examined by RDSO. The metro railway/MRTS system are at liberty to carry out any tests for this as’ considered necessary. 3. Before this system is installed in the track, Metro Railways/MRTS System should satisfy themselves about their chosen fastening system meeting the physical parameters requirements of the Performance Criteria, by conducting fresh tests from an independent laboratory on samples selected by Metro Railway/MRTS ‘system. 4. The clearance is only for the “double resilient base plate assembly fastening ! system" of M/S Pandrol Limited, U.K, Metro Railways/MRTS Systems should verify themselves about the credentials of the prospective suppliers of this system 8. The other aspects of the Performance Criteria dated 21-5-10, such as those in paras 4.2()), 4.2 (v), 43 etc. amongst, others be examined by metro railways/MRTS system to ensure compliance to the requirements of Performance Criterion = 4ye" (Rajiv Chaudhry) | Executive Director, Works(Plg.) Railway Board: Enel: Annexure- 4 Annexure- 2 (32 pages including Sub-Annexures 2/1 to 2/14 showing the drawings (14 pages) & 2/15 to 2/32 (18 pages) showing the specifications) Copy to: 1. Secretary, MoUD, Ninman Bhavan. He may like to circulate this to the metro railways for their information and use. 2, MD/CMRCL. The proposal sent by them for examination of their proposed system is under examination of RDSO. 3. DG, RDSO for information 4. ED/Track-ll, RDSO for information in reference to his letter No. CT/MT/BT dated 3-10-11 5. Mis Pandrol Rahee Technologies Ltd , Kolkata for information iPS EDUWPRDSO LETTER DOCTo + Whamitmay concem 2s october 20:0 ‘Dubai Metro Project Subject: Tentimony for Pandrol Resilient Baseplate Assembly ~ ‘Ac RTA Rall Project Construction Deparment. Dubai Metro, we contirn tat Pan LUxéed, Gatafond Road - Worksop, Notts Set 7AX.Engfand have suooled reien! “e--cip baseplate assembles on the Dubal Metro standard gauge mals inetacks 67 path ture sab in Tunnefsard Viaduct tras. ‘We aso confirm tratintial train runing commenced on Sth Septembes 2029, S¢ Aileeratersaf doulle trace which operates based on 3rd ral OC current Dower st want at ale ads of 14 fom per al a speeds uo to 90Km/r and that, thus fr, In the required specifications Laois sae \ us,PILES : SAS Ue Assmbly Dre/ IssueNo. ems Drg.No._| spectvo Jassesiate a6 | &CK [aaseplote Pad) aa6i3_| _0ce [Eva Ral Pad) aeia_|_0cD. [22007 Paadrol Clip 2759 AA insulator 8 ar s720_| 8c insulator 6mm 360s | _scH 35 insulator 10mm 3604 | BCH, eccentric Bush 3263 |_6ce [Compression Soring ao10s__|_Kce Pisctic Colaved Washer a7740_| GCC far Nylock Nut a271 | tee M27 Anchor Stud mn | 1s Coporat office: Pansrol Rahee Technologies Pvt Ut, 107, Lakhinarayan Ta Road, Shafmar. Howrah ~711103, W.B PhoneNo. «81 33 2668 3543 /34, Fax No. . +94 38 2568 4727, E-miat.-info@pandrorane2.com(g)96151 oe es ee Tujausy sratiorsy 0} poreios Sukerp yuauodmo:argon ga BOPemaeR 5 apenas pp uy OF on ‘Bupsbsp Apquisesy 03 poguros Buyvap uovoduroo effi yes PUTI!20 -AnavOano9 OXMaISYA We GHYEE OHO ¥ i oO GOOOOSOOOOSOOOGOOOOOSOOOOO f |; OOOCOOOSGOOOOOOO00G006000 [7 ik OOCOCOOCOOOHG0000000000C000! v WX - DODNOONONOOOOOOOOO00O000000 Whe ww MH £O090099900900000000995999000009805000} i (0) SSSSSESSSSS CESSES SSSSSSSOSO| i ) \COOOOCOOOOOSOO00CCO0000000, S ) a J BQEE989990009999900000000 CON / SG600OCOOCOOSOOOOOVOOOOOO ARpAcSanesAccaconoseaeNAonN0KRiel ee af] 022g... \ anya otn0e ins o1 doav7 “lOHONVd SG > sevens “Shp tp oF 2 Buymosp quouedwos sip Jay pouTseO arRata ahartis UA INSNOdNOD ONINSISY4 TVA GNYHE TOUGNVE (2h) Waa we pons my ep cw one EE Ow Ssyauap ditienee 03 poyeos Syaadp yuauoces anal Done fe eee u JD Ssnivis”anssi-0b Sukh MOLY TNSNI 10 pasiast —~=5— poo onent —SKPEp— o# Iujmerp kiqutowee 0} poreios Hujadap yuouodcy +p 9 ——— Ca aeANDROL, RAND RAL TASTEnNG cle Yee tooN ‘Hsp ‘SINIO03 Q/2y=Se=EE_ He povses Fy poo anssy —x pep ou Buyavsp d[quiosse 0} payerox Suyesp yuouodur ious "INSNOdNCO ONINGLSV4 IVE ONVEa TONOWe ¥ 22 Nowses eeapo) ansey yoou Bupavsp quouoduros sya Jey POT snivis ansst ANANOANOD ONINALSY4 IVY CNYYA TONGWWd ¥ are SeOleh Satz wo )——2P0 ones “ET ep- ou ae Sutmesp Aiquiess quauodwos sy Jey) paize9 2BHSVM CRWVTIO sULsvig Snuvis Sissi ANSNOdWOD ONINSISV4 “IVY ONVYa TOuGNYE ¥ a | eee ds fi ce asfae 00 ocala Gea ius ESIeae its SOR UTS aetya Ss PANDROL STUDDED RUBBER BASEPLATE PAD Supply Spetification DC-E bsue 3 ‘SUPPLY SPECIFICATION "PANDROL' BRAND' STUDDED RUBBER RESILIENT - 34 32 33 BASEPLATE PADS Reference : DC-E Issue 3 SCOPE This specification covers the supply requirements studded rubber resilient baseplate pads manufactured using the injection moulding or compression moulding process. The design and manufacture will be undertaken by companies certified to ISO 9001: 2000. RAW MATERIAL Base polymer shall be Natural Rubber. QUALITY ASSURANCE INSPECTION Dimensional accuracy TThe pads shall conform to the dimensions detailed on the appropriate Pandrol copyright drawing. ‘Visual Inspection ‘The area of the pads studs shall be clean and free from any blemish. Minor blemishes are allowed on all other areas of the pad as agreed between the moulder and Pandrol.. Hardness Pads will be hardness iested to ensure they are in the range 60+/-5 IRHD or 70+/-5 IRHD test Method BS 903 : Part A26 Method M. Note. The pad hardness will be specified by the Pandrol Lté Technical Development Department. Note. It is usual for VIPA SP baseplate pads to have a barduess of 70+/-5 IRHD. Certified that this component drawing related to assembly drawing Bett Ss Oe eeceade CN Gewecaon ete “lake\b PANDROL STUDDED RUBBER BASEPLATE PAD Supply Specification DC-E fssue 3 34 Electrical Resistance (Volume Resistivity) Minimum electrical resistivity 1 x 10° Ohm em Pads shall be unconditioned and uncoated. The central portion of the pad shall be used for the electrical resistance test. Test to be undertaken with studs in place. Test Method BS 903 : Part C2 IDENTIFICATION Pads will be marked with an identification code PACKAGING Pads will be supplied in Lo-lift bags or Tri-wall cartons or as directed onthe purchase arder. RECORDS All Quality Assurance Records shall be available for a minimum of seven years. CERTIFICATION A certificate of conformity will be supplied with each consignment confirming that the products meet the requirements of this specification and the appropriate Pandrol copyright drawing. Issue recora Product Spevfication Reference: DC-E issue 3 WIP Ref: E\Technc!\Techspe\pacs\DC-Fi3 Prepared By RIH(3 1/68/2006 Product Specification consists of2 pages Last Mod No, 3071 Certified that this component trawing related to assembly drawing /©) issue code __C revised on 22.05. 20164Product Specification Title: ‘PANDROL! Cast Baseplates Product Specification Reference: EC-KfssueNo: 6 Page 1 oof Proctuct Specification Material Development ies Meee Aathorised by: QA Rep 2 4 Date of 12th March issue: 2007 cory STATUS ‘This copy, although cosrect at issue will not be Kept upto date. Mamofatires shoo check that the specification No. and issue code on this document corresponds exactly to the codes on the Pandrol purchase order. ‘The use of equivalent Intemational Standards to these quoted is permissible subject so agresmes’ between the customer aad Pandrol. The design and manufacture will Be undertasen by companies certified to ISO 9001: 1994 and ISO 9002: 1994 respectively (or ISO 9001: 2000), SCOPE ‘his specification covers the misimm spenuiacuring and testing requremenis of cat baseplits | a een ephevoidal graphite cast iron. The Pandrol baseplate provides 2 rail heating face 10 ‘alntan track gange and a housing forthe installation ofthe “Pandzol Rail Fastening Clips MATERIAL SPECIFICATION National Standards Pandrol material code EN 156: grade EN-GIS-500-7 SG5 ASTM A536: grade 80/55/06 sas AS 1831 grade 500/7 S65 Ora Pandral approved equivalent QUALITY ASSURANCE TESTING ppased on the baseplate manufacturer (hereafter refered 10 as the manufactures) JTomonstrating that the production process and associated tests are so comirolled that conformity to visual and dimensional requirements are assured, the frequency of visual | cor anersional inspection (paragraph 3.1 and 3.2) may be reviewed by Pandrol and | subsequently amended only with Pandrol’s pemission. This review may take place at the contractlorder stage or after an agreed number of processed batches of baseplates. __-Cortifjed-that-this-component-drowing related to-assembly- no AS1US” issue code ©. revised on 29 TS-Po!0Product Specification Title: ‘PANDROL' Cast Baseplates Product Specification Reference: EC-K _IssueNo= 6 Page 42 «of 4 Product Specification Material Development Date of 12th Mareh uthorised by: QA Ra > Owner: Manager Authorised by: QAReP issue: 2007 3.1 Visual (Surface Irregularities) 4.11 Only minor surface iregularities, psotmsions or cavities are permed Ox he complete baseplates. 5.12. Note. Surfice oxidation of cast baseplates isa normal pemnitted constion of supply. Surface oxidation aots deuimental to the performance of the baseplate o the Pandol Rall Fastening assembly 3.2. Dimensional Aceuracy Atl aimensions of as made baseplate’ (pfore the addition of any coating) must be fa accordance with the appropriate Pandrol copyright drawing. 3.3 Hardness 5.1.1. Cast baseplates shall be hardness tested to ensure that fey mest the required hardness range. 4.5.2 The method of hardness testing will be as detailed in Table 1 4. COATING Castings shall be supplied without coatings unless spevifically requested. 5, PACKAGING ‘Unless olherwise specified on the purchase oxter Pandral baseplates will be strapped to pallets and | shuink wrapped. Weight isnot to exceed | tonne, JDENTIFICATION The baseplate will be macked with the prodact drawing num>er and other markings specified on the ppropeiate Pandrol copyright drawing o 2s agreed by Fandrol _certinied-that- this component draging-related-to assembly $awio6 UL-O> .2410 no 1344S issue code __revised on _*Product Specification Title: "PANDROL' Cast Baseplates Page 3 of 4 Date of 12th March 2007 Product Specification Reference: EC-K Issue No.: 6 Product Specification Material Development ae ee Authorised by: QA Rep Se 7, RESPONSIBILITY FOR TESTS 7.1 All tests detailed in paragraph 3 are the responsibility of the manufacturer and shall be carried out by the manufacturer or a mutually acceptable independent testing authority. 72 Pandrol however reserves the right to mdertake or repeat all tests detailed in section 3. RECORDS All Quality Assurance records shall be retained by the manufacturer for a minimum of seven years. 9. CERTIFICATION 9.1 The manufacturer will submit with each batch of baseplates (or order if agreed) a | certificate of conformity and associated test results confirming that the baseplates supplied have met the requirements of this specification and conform to the appropriate | Pandrol copyright drawing. 92 For manufacturers who have been assessed and allocated an approved supplier status | the documentation requirements may be modified subject to prior agreement between | Pandrol and the manufacturer. ome record Supply Specification Reference: FC-K Issue 6 Fie Plprejects20000numbera 20051 ISO ile\preduct spees\EC-Ki5 Modified By. PH 0603/2007 Swpply Specification consis of 3 pages & Teble 1 Last Mod No. 3091 ortified that thie component: drawing-related-to-assembly-drawing- no_AZ{#5 *_. issue code _© revised on 2+ S420!3B Product Specification Title: "PANDROL" Cast Baseplates Product Specification Reference: EC-K _IssieNo: 6 Page 4 of 4 Product Specification Material Development 57 " Dateof 12th March Ouner: Manager Authorised ty Oia ‘issue: 2007 Table 1 Paragraph Subject ‘National Standard (3) BS EN ISO 6506-1 ASTMEI0 ASTM 1815 33 Hardness: De}; aa‘es stamped Conoled Cory © PANDROL Es i) 2/30 ee car | Product Spec Title: Compression spring. Product Spec Reference: KC-G Issue No.: 1 Page 2 of 2 Created by: PHewlett Checked by; (@ “Approved by: Date of issue: 08/09/06 ‘Where specified by Pandicl, springs will be Sherardized to BS 4921 class 1. Local deposit thickness of 50 microns Min to 80 microns Max to ensure a Class I deposit thickness of 30 Microns with a smooth grey and continious finish (without fumps and runs). Alternative costings may be applied with the approval of Pandrol. 33. Compression test ‘he spring will produce tne designated force and its associated compression valve in accordance with that stated on the Pandrol Copyright drawing, 4. RESPONSIBILITY FOR TESTS All tests detailed in paragraphs 3.1, 3.2 and 3.3 are the responsibility of the spring manufacturer and shall be carried out by the spring manufacturer or a mutually acceptable independent testing authority. ‘Pandrol however reserves the sight to undertake or repeat all tests detailed in section 3. 5. RECORDS All Quality Assurance records shall be retained by the manufacturer for a minimum of seven years, j. CERTIFICATION ‘The manufacturer will submit with each batch of springs (or order if agreed) a cettificate of conformity and associated test results confirming that the springs supplied have met the requiremeats of this specification and conform to the appropriate Pandrol copyright drawing. approved supplier status the For manufactures who have been assessed and allocated an agreement between Panirol documentation requirements may be modified subject to the prior wri and the manufacturer. seu record Product Specification Refercnce: KC-G Tesw> 1 Fle: projects20000 number29051 180 fles\preductspeesveshspeo\mise rf KKC Prepared By: PH 05/09/2008 | ricact Specification consists of 2 pages Certified that tls component drawing related to assembly drawing no 134YS" issue code © revised on 2-31 70/0 ausIa H Pye ‘Product Specification Tile: Pandrol Anchor Components Product Specification Reference: LC-B Issue No: 3 Page | of 2 Product Specification Owner: Senior Engineer Authorised by: QA Rep Date of issue: 17.02.09 1. SCOPE ‘This specification covers the supply requirements for components such as the Anchor Bolt, Dise Spring, Plain Washer, Plain Nut and Locking Nut. 2. GENERAL NOTE. ! Unless stamped as control copy, this copy will not be kept up to date. ‘The use of equivalent international Standards to those specified below are subject 10 agreement of Pandrol. 3. COMPONENIS 3.1 M24 Anchor Bolt ‘Description Specification 5 M24 Anchor bolt M24 thread, Grade 8.8, galvanised or equivalent finish to (Part No, 11027) BS EN ISO 10684, SOjim batch average thickness. (Based on DIN 529 ‘Masonry and Foundation Bolis’ ~ Type D) | 32 M24 Dise Spring ‘Description ‘Specification as M24 Disc Spring DIN-2093/A. 50 diameter (M-24) Mechanical plate and art No. 11242) yellow passivate to BS7371 Pert 7, 20um minimum thickness. jj 33 M24 Plain Washer Description ‘Specification 7 = M24 Plain Washer | BS4320, form C flat washer, galvanised or equivalent (Part No. 11244) finish to BS EN ISO 10684, 50m batch average thickness. 34 M24 Plain Nut Description Specification M24 Plain Nut DIN 934, Grade 8, fit OF, galvanised or equivalent finish (Part No. 11368) to BS EN ISO 10684, Sum batch average thickness. Certified that this component drawing related to assembly drawing no A344 9. ue code CS revised on 22°©>-2010 HouEe | «oduct Specification Title: Pandrol Anchor Components Product Specification Reference: LC-B Issue No: 3 Page Product Specification Owner: Senior Engineer Authorised by: QA Rep Date of issue: 35 M27 Anchor Bolt Description es a =a M27 Anchor bolt M27 thread, Grade 8.8, galvanised or equivalent finish to (Part No. 12717) BS EN ISO 10684, 50um batch average thickness. (Based L on DIN 529 ‘Masonry and Foundation Bolts” — Type D) 3.6 M27 ‘Nyloc’ Locking Nut [Description ‘Specification a M27 Locking Nut | DIN 985, Grade 6, fit I, galvanised or equivalent Tash (Part No. 12791) to BS EN ISO 10684, 50um batch average thickness. Isoue record Product Specification Reference: LCR Ismie3 Prepared By’ RIH 17/02/2009 |i ModNo, 3169 "Certified that thin component drawing slated to anseapbly drawing no 3445 issue coce__C _ revised on 97-51 2019. ss 17.02.09,