Galvanised Structural

Steelwork
Formerly OEE 156/020

Issue 1.1
31 October 2017

Document Number:
141667-FAF-REP-EOH-000007
31/10/2017
Contents
Contents ............................................................................................................................... 3
1 Introduction and Scope .................................................................................................. 4
2 Definitions ...................................................................................................................... 5
3 Related Documents and references ............................................................................... 6
3.1 Governing Specifications ........................................................................................ 6
3.2 Other Referenced Specifications............................................................................. 6
4 Requirements ................................................................................................................ 7
4.1 Reliability ................................................................................................................ 7
4.1.1 Certification ...................................................................................................... 7
5 Inspection and Testing ................................................................................................... 8
5.1 Control of Quality .................................................................................................... 8
5.1.1 Physical Examination ....................................................................................... 8
5.2 Tests ....................................................................................................................... 8
5.2.1 Visual/Dimensional Check ............................................................................... 8
5.2.2 Welding............................................................................................................ 8
5.2.3 Mechanical Tests and Chemical Analysis and/or Metallurgical Examination .... 8
5.2.4 Visual/Dimensional Inspection after Galvanising .............................................. 8
5.2.5 Check Assembly after Galvanising ................................................................... 9
5.2.6 Galvanising ...................................................................................................... 9
5.2.7 Galvanising shall be in accordance with Spec No. OEE 156/033. .................... 9
5.2.8 Rejection.......................................................................................................... 9
5.2.9 Re-Submission ................................................................................................ 9
6 Quality Assurance ........................................................................................................ 10
6.1 QA Policy .............................................................................................................. 10
6.2 QA Classification of Products ................................................................................ 10
7 Acceptance .................................................................................................................. 11
7.1 Inspection and Release ........................................................................................ 11
7.2 Acceptance of Type Testing .................................................................................. 11
7.3 General Conditions of Acceptance ........................................................................ 11
7.4 Certificates of Conformity ...................................................................................... 11
7.5 Packaging and Delivery ........................................................................................ 12

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1 Introduction and Scope
This supplementary specification has been prepared to supplement the provisions of the
relevant European and British Standards and codes of practice for the Galvanised Structural
Steelwork for Railway Electrification purposes using UK Master Series.
This documents updates OEE 156/020. The European and British standards and materials
specified within are general updates to the equivalent standards in the OEE documents and
should be used on a case-by-case basis.

This Specification applies to galvanised structural steelwork for the Network Rail UK Master
Series overhead line equipment design range.
Disclaimer: This documents makes no allowance for likely changes to British and/or
European standards as a result of the pending Brexit process.

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2 Definitions
The Purchaser and/or his Customer and/or Inspecting Agent will in this Specification be
referred to as the "Inspecting Authority".
The appointed representative of the Inspecting Authority will in this Specification be referred
to as the "Inspector”.

For the purpose of this specification the following definitions shall apply:

Term Definition

Audit Audits are performed to verify conformance to processes,

systems, standards, specifications and drawings through review
of objective evidence

Component An item manufactured from a product

Material A substance from which a product can be manufactured

OEE Overhead Electrification Equipment

Product Material formed into lengths with regular cross section

Supplier Confidence in a suppliers’ ability to deliver goods or services that

satisfy the customers’ needs. Achievable through interactive
Quality
relationship between the customer and the supplier. SQA aims at
Assurance ensuring the product’s ‘fit’ to the customer’s requirements and
meets the product or materials specifications, drawings and/or
(SQA)
standard with little or no adjustment or inspections

Quality Assurance The ranking of products or materials where the result of failure
(QA) Classification impacts on the safety, reliability, performance and cost
associated with the day-to-day operation of the Railway

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3 Related Documents and references
3.1 Governing Specifications
This Specification applies to the Galvanised Structural Steelwork for Railway Electrification
purposes.
The governing Specifications shall be:
3.1.1 BS EN 10025-1:2004 - Hot rolled products of structural steels. General technical
delivery conditions
BS EN 10025-1 S235
BS EN 10025-1 S275 (Legacy Grade 1)
BS EN 10025-1 S355J0 (Legacy Grade 2)
BS EN 10025-1 S355JR (Legacy Grade 3)
3.1.2 BS EN 10056-1:2017 - Structural steel equal and unequal leg angles. Dimensions
3.1.3 BS EN 10056-2:1993 - Specification for structural steel equal and unequal angles.
Tolerances on shape and dimensions
3.1.4 BS EN 10365:2017 - Hot rolled steel channels, I and H sections. Dimensions and
masses
3.1.5 Spec No. OEE 156/022 - Welding of Steel
3.1.6 Spec No. OEE 156/033 - Galvanising by the Hot-Dip or Spray Process
Where conflict occurs between any of the aforementioned documents and this
specification, this specification shall take precedence over all others.

3.2 Other Referenced Specifications

3.2.01 OEE Specification 155/001 - Inspection and quality control procedure
3.2.02 BS EN ISO/IEC 17050-1:2010 - Conformity assessment. Supplier's declaration of
conformity. General requirements
3.2.03 Relevant Manufacturing Drawing(s)

3.2.04 Relevant Inspection and Release Certificate(s)

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4 Requirements
4.1 Reliability
4.1.1 Certification
All steel sections and plate will be inspected at the steel manufacturer's works. Mill
test certificates shall be presented by any Supplier prior to inspection of components
in the self-colour state.

The Inspector will require the signature of the Supplier's Representative on the
Certificate of Compliance No. OEE 157/020 before proceeding with inspection;
components will not be inspected until this has been done.

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5 Inspection and Testing
5.1 Control of Quality
5.1.1 Physical Examination
Sampling for Visual/Dimensional Inspection Before and After Galvanising:

A visual/dimensional inspection will be carried out on all components offered for

inspection.
Sampling for Mechanical Tests and Chemical Analysis and/or Metallurgical Examination:
The Inspector may select samples from each batch offered for inspection on the basis
of 1.0% ( subject to a minimum of three unless otherwise specified). These samples at
the discretion of the Inspecting Authority may be subject to mechanical tests and
chemical analysis and/or metallurgical examinations
Sampling for Galvanising Tests:
The Inspector will select test samples from each batch offered for inspection on the basis of
0.1% (subject to a minimum of three unless otherwise specified).

5.2 Tests
5.2.1 Visual/Dimensional Check
The Inspector will ensure that the hard marked reference number is the correct number for the
component offered for inspection. The Inspector will verify that dimensions are in accordance
with the drawing/s and tolerances for sections and plate are in accordance with BS EN 10365,
BS EN 10025-1, and BS EN 10210-2 respectively unless otherwise stated.
The Inspector will ensure that all burrs and sharp edges have been removed.
The Inspector will ensure that universal column and channel sections have at least one end
cold sawn and that the hard marked reference number appears on a cold sawn end.
5.2.2 Welding
Welding shall be in accordance with OEE Spec 141667-FAF-SPE-EOH-000003.
5.2.3 Mechanical Tests and Chemical Analysis and/or Metallurgical Examination
Mechanical Tests and chemical analysis and/or metallurgical examination shall be in
accordance with the provisions of BS EN 10025-1.
5.2.4 Visual/Dimensional Inspection after Galvanising
The Inspector will ensure that the reference numbers applied after galvanising are legible and
holes are clear of spelter.
The Inspector will verify that tolerances for sections and plate are in accordance with BS EN
10365, BS EN 10025-1, and BS EN 10210-2 respectively unless otherwise stated.

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5.2.5 Check Assembly after Galvanising
In the case of structures which will be assembled on site, one complete prototype structure of
each type will be assembled horizontally (unless otherwise specified) at the Supplier’s Works
before quantity manufacture is commenced.
Quantity manufacture shall not commence before approval of check assembly is given by the
Inspector.
5.2.6 Galvanising
5.2.7 Galvanising shall be in accordance with OEE Spec 141667-FAF-SPE-EOH-000007.
5.2.8 Rejection
Should any component fail any of the foregoing tests, the Supplier shall be required to show
cause and reason why the component/batch should not be rejected.
All rejected components shall be hard marked adjacent to the reference number with the
stamp provided by the Inspector.
Should the Supplier so wish, they may at their own expense rectify the rejected component
and re-submit it for formal inspection.
5.2.9 Re-Submission
On any un-galvanised component re-submitted under Clause 5.2.8 on which tests have
proved satisfactory the rejection hard marking shall be cancelled by a further hard marking
with a stamp provided by the Inspector.
On any galvanised component re-submitted under Clause 5.2.8 on which tests have proved
satisfactory the rejection hard marking shall be cancelled by the Inspector's signature indelibly
marked adjacent to the rejection mark.

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6 Quality Assurance
Products critical to Network Rail’s business will normally be procured from Suppliers who have
been certified by an accredited third party as meeting the quality management system
requirements of BS EN ISO 9000 Series for the specified services and products.
In exceptional circumstances, where a Supplier does not hold BS EN ISO 9000 certification,
Network Rail may carry out an assessment against these requirements as appropriate.

6.1 QA Policy
The Network Rail Supplier Quality Assurance Policy requires all new products used on
Network Rail infrastructure to be subject to quality assurance activities.
The assurance activities and level of surveillance required within the process are dependent
on a classification applied to the product.
All products purchased by Network Rail fall into one of five QA Classifications. These reflect
the relative importance of the product to the Company’s business (safety, performance and
cost), the nature of the supply chain, and dictate the associated level of quality assurance and
material certification required.

6.2 QA Classification of Products

Classifications QA1 to QA4 relate to products directly affecting the day-to-day operation of the
Railway where failure, or non-conformity to specification, could result in disruption or risk to
the rail system.
Classification QA5 relates to other products purchased under standard commercial
arrangements.
The QA classification depends on the ‘impact of failure’ as follows:

• QA1 - very high impact

• QA2 - high impact
• QA3 - moderate impact
• QA4 - low impact
• QA5 - insignificant impact
All new products, systems and materials purchased by Network Rail are assigned one as part
of the Product Acceptance process through System Review Panel SRP and successful
completion of associated quality assurance activities will be required prior to the product being
added to the Network Rail’s Approved Products Catalogue.
Network Rail reserves the right to change any QA Classification assignment.

The individual quality assurance plan of each project will specify how inspections and testing
requirements will change depending on the QA classification.

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7 Acceptance
7.1 Inspection and Release
Following completion of his inspection the Inspector will enter the total number of components
which have passed his inspection on the relevant Inspection and Release documentation.
Following the recording of the accepted quantities the document will be signed by the
Inspector and the Suppliers Representative.

The Supplier will then be free to despatch this material as directed.

No material shall be despatched until a signed Inspection and Release Certificate is in the
hands of the Supplier.
Where material is to be subjected to the tests described under clause 7 above, the Inspection
and Release Certificate will not be issued until the results of these tests are known to be
satisfactory.
The batch of material from which samples referred to in clause 7 above, have been selected
shall be kept separate and identifiable from all other material until the Inspection and Release
Certificate is received by the Supplier.

7.2 Acceptance of Type Testing

On completion of type testing the supplier shall issue a certificate/declaration of compliance
against relevant clauses and sub-clauses of the appropriate standards. This certificate should
also outline the requirements for future sample and batch-sample testing.

7.3 General Conditions of Acceptance

For products covered by Classification QA1 to QA4 Network Rail requires that a Certificate of
Conformity shall accompany each consignment, signed by a qualified party affirming that, at
the time of assessment, the product or service met the stated requirements.
Products so classified that are not accompanied by Certificates of Conformity are deemed not
to have been delivered.

7.4 Certificates of Conformity

The Certificate of Conformity should contain the following info as appropriate to the material
being supplied:
o The Supplier’s name and address
o The Serial Number and date of the Certificate of Conformity
o The Network Rail delivery address
o The Network Rail Purchase Order Number and/or the Contract reference
o A description of the material and quantity supplied

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 o The Network Rail Catalogue Number and any other identification and/or Serial
Number
o The identification of the specification/drawing to which the material is supplied
o Reference number of the manufacturer’s Test Certificate and any other supporting
documentation
o The condition of the material on despatch
o Any necessary further treatment
o Any agreed variation from contract
o Where appropriate, the expiry dates of limited shelf life material
o Special storage and handling instructions
o A statement signed by the Supplier’s nominated representative responsible for
Quality, to the effect that the products supplied conform to the information
recorded thereon
7.5 Packaging and Delivery
The Supplier will arrange delivery of all components within a consignment in such a manner
that the components arrive at the delivery point free from damage.
Where packaging is used to protect components from damage during transit, the Supplier
should ensure that such packaging is made from sustainable resources and is reusable
wherever possible, by collecting empty packaging and transportation containers as part of
every delivery.

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