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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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SCHEDULE OF TECHNICAL REQUIREMENTS
FOR
HIGH CAPACITY RUBBER BUFFER SPRINGS
FOR
SIDE BUFFERS OF B.G.LOCOMOTIVES
Supersedes specification No. MP-0.41.00.04 (Rev.0.00)
(December 2003)

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SPECIFICATION NO. MP- 0.41.00.04 (Rev .01)
AUGUST 2005

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RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR,
LUCKNOW-226 011

Price : Rs.

INDEX
SECTION A
Cl. No.

Description

Page No.

0.0

Foreward

1.0

Scope

2.0

Requirements

3.0

Stroke

4.0

Tests

5.0

Characteristics of spring stack

6.0

Sampling and acceptance

7.0

Guarantee

8.0

Markings

9.0

Packing

10.0

Storage

SECTION B
1.0

Scope

2.0

Requirements

3.0

General & Manufacturing

Facilities

4.0

Testing Facilities

5.0

Quality Control Requirements

10

6.0

Documentation

11

7.0

Training

12

Spec. No. 0.41.00.04(Rev.01)

August2005

SECTION-A
SCHEDULE OF TECHNICAL REQUIREMENTS FOR HIGH CAPACITY
RUBBER BUFFER SPRINGS FOR SIDE BUFFERS OF BG LOCOS
0.0

FOREWORD

0.1

This schedule is intended to cover in two parts i.e. Section-A & Section-B. Section-A
intends to cover the technical requirements/provisions relating to materials, constructions
and tests and does not include all the necessary provisions of the contracts. Section-B
covers the infrastructural, testing and quality control facilities to manufacture rubber
buffer springs.

0.2

This schedule draws reference to some of the relevant specifications. Latest version of
these specifications shall be taken as reference.

0.3

Whenever there is a conflict among the stipulations in the present specification, drawing
or any of the relevant specifications, the most stringent requirement will apply.

1.0

SCOPE

0.1

This specification prescribes the requirements, method of sampling and tests for
individual rubber spring as well as a pack of 4 such elements having 1500 Kg.m
minimum capacity for Side Buffer of B.G Locomotives.

2.0

REQUIREMENTS

2.1

Material

2.1.1

Rubber : - Natural Rubber or elastomers or a blend thereof suitably compounded shall

be used for the manufacture of the rubber springs so as to conform to the requirements
stipulated in this standard
Steel : - The metal plates used as integral part of the rubber spring shall be to IS:2062
Fe 410WA.

2.1.2

The metal plates shall be shot / grit blasted to IS:9139 grade, SM300 or GM-30 and
chemically cleaned before bonding with the rubber. The process adopted for bonding of
rubber to metal shall be a proven one using suitable bonding agent to achieve the required
bond strength.

2.1.3

All sharp edges & burrs shall be removed from metal plates. Rubber shall be smooth and
free from cracks, pin holes, foreign materials, trapped air blisters and other visual flaws.

2.1.4

The metal plates shall conform to geometrical dimensions as indicated on drawing.

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2.2

Dimensions
Each side buffer shall be fitted with an assembly of 4 buffer spring elements. Each buffer
spring element shall be as per RDSO drawing SK.DL-4565

2.3

Construction and Finish

2.3.1

The rubber springs shall be manufactured so as to be interchangeable as a complete pack,

meeting the manufactured height requirement of 448 +4/4 mm . The boundary
dimensions and tolerances shall be as per the drawing no SK.DL-4565 in the annexure.
Wherever tolerance on rubber has not been specified, it shall be in accordance with
clause of ISO 3302 Part I of Table I class M4.

2.3.1

All sharp edges and burrs shall be removed from the metal plate. The rubber shall be
smooth and free of pinholes, blisters and other visual flaws. The texture of the material
should be homogenous and compact.

2.3.2

The rubber for elastomers utilised in manufacture of spring shall conform to

characteristics indicated in Table-1.
Table 1

Characteristics
Hardness Shore A

Test Method
IS : 3400 Part II

Tensile Strength

IS : 3400 Part I

Elongation at Rupture

200% Modulus of
elasticity

IS : 3400 Part I

Compression set after

25% compression for 24
hrs at 70C
Specific Gravity

IS : 3400 Part X

Tensile strength 180.0 Kg/cm (min.) after

Ageing for 72 hrs at 70C
Change 20%
Elongation Min. 300 % after ageing for 3 days
in air at 70C
Change 30%
40.0 kg/cm (min)
change in modulus of elasticity after 72 hrs
ageing at 70C shall be 20%.
Compression set 30% maximum.

1.0 1.25

Ash content

2.3.3

A)
B)

Results to be obtained
Hardness = 70 5
After ageing for 72 hrs in air at 70C
Change -0
+5

5% Max.

The rubber buffer springs shall be manufactured by injection moulding.

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Spec. No. 0.41.00.04(Rev.01)

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3.0

STROKE
The buffer spring shall have a stroke of 110 +0/5 mm

4.0

TESTS
Four buffer elements as per SK.DL-4565 of manufactured height 448 + 4 /4 mm shall
meet the following test requirements in static condition when tested as per item 5.1

Pre-compression force at 423 mm

height
Compressive force at 398 mm
height
Compressive force at 363 mm
height
Compressive force at 313 mm
height
Stored energy We*
Absorbed energy with injection
moulding

750 Kg

<F<

2000 Kg

1000 Kg.

<F<

4000 Kg

5000 Kg

<F<

15000 Kg

50,0000 Kg

<F<

100,000 Kg

>= 1500 Kg-m

>=50% of Stored energy

Note:- The energy absorption capacity is to be calculated from the area under the load
displacement characteristic curve drawn from pack height after three compressions to
pack height of 313 mm. For calculating the absorbed energy the graph is drawn in reverse
releasing the load from pack height of 313 mm and obtaining the area under the load
displacement curve. The difference in energy as a percentage of stored energy is the
absorbed energy.
The stored energy is measured in kilogram meter (kgm)
5.0

CHARACTERISTICS OF SPRING STACK.

5.1

Static Characteristics Procedure

Four buffer spring elements (Each conforming to RDSO SK.DL-4565) shall be clamped
together to simulate the actual working condition. This spring assembly shall be placed in
a rig to act as a guide during compression test or when under dynamic load. The guide
will be either through the central hole or the external guide. The spring elements shall be
centrally placed with reference to the guide. It must be ensured that during the test, the
spring assembly shall not come in contact with either the central guide or the external
guide which might interfere with the compressive load applied and the stress rate.
The compressive load shall be applied at a speed of 15 mm 5 mm per minute.

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Spec. No. 0.41.00.04(Rev.01)

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The load displacement curve from original height to the height at 313 mm is to be
recorded at 4th stroke. 3 compression strokes upto a height of 313 mm is to be given on
Buffer Springs. The zero settings for measurement for displacement should be done prior
to 4th compression by putting weight of 50 Kg so as to close any gap between the pads.
Results:
Values required in Item 4.0 shall be read from the graph plotted above. Assembly should
satisfy stipulations of Item 4.0
5.2

Test of Compression Strength after clamping

Procedure:
The Spring assembly shall be clamped to a height of 423 mm + 2 mm ( pre compressed
height).It must be kept in this manner for 72 hours at room temperature.
It will then be compressed from free height to a height of 313 mm mm at a rate of 15mm
+ 5 per minute.
The Test Results i.e. force / displacement diagram shall be drawn during the 4th cycle of
compression.
Results:
The assembly should satisfy the characteristics mentioned in Item 4.0.

5.3

Endurance Test
Procedure:
The Spring Assembly of four pads shall be subjected to endurance test as follows:
Repeated compression will be made between load range 2t to 10t.
i.)

The Spring Assembly shall be compressed 10000 times in the load range 2t to 10t
at frequency of 30 cycles/minute minimum.

ii.)

The Spring in unclamped condition shall be kept for 24 hours for stabilisation.

iii)

Compression curve shall be plotted after the third cycle of compression in the
load of range 2t to 10t. The compression speed shall be 15mm 5mm per minute.

iv)

The Load necessary to obtain height of 423 mm shall be plotted based on (iii).

Note :- The Manufacturer should have necessary facilities for carrying out endurance
testing on such lot.

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Results:

5.4

i)

Stored energy in the load range of 2t to 10t recorded in this test shall not be less
than 80% of the corresponding stored energy recorded during the compression
test after clamping in item 5.2

ii)

The force required to obtain the height of 423 mm shall not be less than 750 Kg.

Impact Endurance Tests:

A pack of four springs pre-compressed to 423 mm and two parting plates of 3.0 mm
thickness (each) shall be subjected to 500 blows by a 1000 Kg load falling freely from a
height of 1 m . The number of blows shall not be less than 30 per hour. The capacity
when measured after half an hour after completion of this test should not be less than
85% of the capacity recorded under item 4.0. Bond failure in any individual spring of the
pack shall be considered as failed pack.

6.0

SAMPLING AND ACCEPTANCE

6.1

Acceptance test shall consists of following tests:

1.
Dimension check
2.
Visual examination
3.
Physical properties of elastomer before and after heat ageing ( as Per Table I)
4.
Static Characteristics.
5.
Compression after clamping
6.
Endurance test
7.
Impact endurance test
8.
Compression set
9.
Specific gravity
10.
Ash content

6.2

A batch shall consists of spring elements of the same type and of the same overall
dimension coming from the same production series in accordance with the provision of
the order. The spring element shall be tested as under :

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Nature of
Inspection

No of samples (packs)
Up to
500

No of
measurement
per sample

: More Than
500

1. Physical properties in as delivered condition and also after heat ageing.

Hardness

Tensile Test

Compression

Specific Gravity

Ash Content

2. Dimensional
check on element

10

Visual Examination.

10

3. Testing on the whole Spring assembly (consisting of 4 elements as used)

Static characteristics

Compression

Endurance test

Impact
Endurance test

6.3

The test pieces selected at random will be marked with indelible ink. The test pieces as
selected above shall be prepared for 24 hours at 27C 2C

6.4

The test pieces to be tested after accelerated ageing shall be cut up and then oven heated
upto 70C for 3 days. They shall then be prepared for 24 hours at 27C 2C. The test
shall be carried out in accordance with IS:3400 part IV-1987.

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6.5

If the sample fail on one or more of the criteria ' double' the number of the sample will be
drawn & tested against the criteria in which the failure has occurred. If the ' double'
sample passes the test, the lot shall be accepted. Failure of 'double' sample will however,
result in rejection of the entire lot.

7.0

GUARANTEE
The firm shall stand guarantee for a period of 24 months from the date of supply
regarding performance of Rubber Buffer Spring Element.
The spring elements, which during the guarantee period show manufacturing defects
making them unsuitable for use or liable to shorten their service life shall be rejected.
Joint inspection between the suppliers and the Railways will be carried out before final
rejection of the supplies by the Railways. The supply will stand finally rejected if the
joint inspection confirms that spring element had inherent manufacturing defects.

8.0

MARKINGS

8.1

Each Rubber Spring shall be embossed in raised letters on the Rubber portion as follows :
1.
Drawing Number
2.
Manufacturer's Name (Initial, Trade mark can also be embossed)
3.
Quarter and Year of manufacture
The embossing shall be of the size and on the location shown in the drawing.

9.0

PACKING

9.1

Rubber Spring shall be dusted with french chalk and packed as multiple of four Rubber
Spring Elements for Side Buffer Assembly to avoid any distortion and to prevent any
damage during transit & storage.

10.0

STORAGE

10.1

The Rubber Spring shall be stored in a cool and dry place.

10.2

Pads shall be kept covered and free from exposure to bright light particularly sunlight.

10.3

Do not expose to Grease, Oil, Solvent Fumes or sources of Ozone such as Electric Motors
or Generators.

10.4

Pads should be stocked and arranged in such order to ensure use of old stock first.

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SECTION-B
REQUIREMENT OF INFRASTRUCTURE FACILITIES TO
MANUFACTURE RUBBER SPRING ELEMENTS
1.0

SCOPE

1.1

This part covers the infrastructural requirements for manufacture of elements for rubber
buffer spring for side buffers of locomotives.

2.0

REQUIREMENTS

2.1

All vendors seeking registration

Schedule.

3.0

GENERAL & MANUFACTURING FACILITIES

3.1

Covered area with adequate space for storage of raw rubber, carbon and chemicals should
be available, which is free from dampness and humidity.

3.2

The following weighing facilities for measuring various raw material constituents and the
product at various stages should be available .
a)
b)

with

RDSO must fulfill the requirements of this

Electronic weighing balance of 2 to 5 Kg Capacity.

Mechanical Spring Balance or Platform Weighing Machine of the capacity of
minimum 50 Kg of reputed make.

3.2.1

It should be ensured that the Weighing Machines are calibrated regularly as per
manufacturers / IS specifications.

3.3

At least one power press of capacity 150T should be available for punching steel plates.

3.4

At least two sets of closed dies, fixtures and templates for cutting, blanking, punching of
steel plates as per the drawing requirements should be available.

3.5

Minimum one numbers Bench grinding machine to remove sharp edges from the
sheared/blanked or bent steel plates should be available.

3.6

At least two sets of Go & No-Go gauges should be available to check the dimensional
accuracy of the steel plates as also to check the product at intermediate stage & final
stage.

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3.7

Minimum one numbers Shot Blasting Machines with table dia of at least 3 feet should be
available. The shot blasting machine shall have in-built facility of sieving to screen under
size shots.

3.8

Facility for degreasing should be available. The process of cleaning should be a proven
one and must be capable of removing accumulated dirt/dust, black spot etc.

3.9

Suitable spraying facility for application of adhesive should be available. The spraying
machine shall have an in-built provision of stirring the adhesive.

3.10

Measuring equipment to measure the thickness of adhesive coats at primer application &
final application stage should be available.

3.11

A Suitable capacity close mixing mill (Banburry) is preferable. However availability of at

least one kneader /internal kneader is essential.

3.12

One extruder to ensure uniform mixing should be available.

3.13

Minimum one number open mixing mill for sizing of rubber sheets is available. The open
mixing mill should be equipped with suitable cooling arrangements and digital
temperature indicator.

3.14

Minimum one number injection moulding machine of adequate capacity along with
suitable dies and moulds to manufacture high capacity buffer pack in accordance with the
specification.

3.15

It should be ensured that the moulds are measured for its accuracy for various dimensions
and profile at least on weekly basis or after a production of 500 packs which ever is later
and the observations of the mould are recorded.

3.16

In-house availability of minimum infrastructure for maintenance and polishing of dies

and moulds should be available.

4.0

TESTING FACILITIES

4.1

Controlled atmosphere laboratory to maintain standard temperature for rubber testing as

per IS:13867 should be available.

4.2

Tensile testing machines capable to read the load and elongation as per the requirement
of the product should be available. The tensile testing machine should have all the
provisions in accordance with para 4.2 of IS:3400 part I.

4.3

One testing machine with load indicator having a least count of minimum 20 Kg should
be available. The capacity of the machine should be adequate to work the same at
specified speeds and it should be capable to apply the required load for testing of the
products for various deflection parameters with in the stipulated specifications.

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Spec. No. 0.41.00.04(Rev.01)

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4.4

One Rheometer should be available and must be used regularly. The record of batches
which are checked on Rheometer should be maintained.

4.5

Suitable Tup Hammer as per product test requirement should be available.

4.6

Suitable Fatigue Test machine as per product Testing requirement should be available.

4.7

Minimum two numbers air ovens should be available to facilitate the testing in
accordance with para 4.2 & 6.2 of IS:3400 Part X.

4.8

Minimum one number muffle furnace should be available.

4.9

Ensure that minimum two numbers Shore Hardness tester with standard test pieces are
available.

4.10

At least one number specific gravity testing apparatus should be available.

4.11

Facility to check the viscosity of the adhesive should be available.

4.12

Facilities for preparing test specimen as per IS:3400 Part I should be available.

4.13

Below mentioned measuring instruments in adequate number should be available :

a.
Micrometer
b.
Dial Gauges
c.
Vernier calipers
d.
Go-No-Go gauges for all the important dimensions for a specific product

4.14

Minimum one number chemical balance and a crucible for measuring ash content should
be available.

4.15

Compression set testing apparatus in accordance with para 4.1 of IS:3400 Part X should
be available.

4.16

Minimum two sets suitable fixtures for compression load deflection test as per the
drawings specified in the relevant specification of product should be available.

4.17

Suitable facilities for cutting the test specimen from the product should be available.

5.0

QUALITY CONTROL REQUIREMENTS

5.1

The manufacturer shall have their own valid ISO:9000 series certification for the product
for which an approval is sought.

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Spec. No. 0.41.00.04(Rev.01)

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5.2

There should be the system to ensure the tracebility of the product beginning with raw
material stage to finish product stage.

5.3

There should be the system to ensure 'first-in first-out' for all raw materials and
intermediate stages to finish products.

5.4

It should be ensured that there is a Quality Assurance Plan for the product detailing the
following various aspects:

Organisation chart
Process flow chart
Stage inspection details from raw materials stage to finish product stage
Various parameters to be checked and level of acceptance of such parameters
indicated and method to ensure and control over them.
Disposal system of rejected raw material and components.

5.5

The quality manual of the firm for ISO:9000 should clearly indicate the control over
manufacturing at every stage and testing of the said Railway product.

5.6

There shall be at least one graduate degree holder person in relevant technology with
field experience of at least 5 years or a diploma holder with experience of 10 years on
rubber technology for regular production and quality control.

5.7

It should be ensured that proper analysis is being done on monthly basis to study the
rejection at various stages of production and is documented.

5.8

Latest version of all the relevant specification IS, ASTM and RDSO standards and
drawings with latest alterations should be available with the firm.

5.9

It should be ensured that a minimum of 2 Nos. GO and NO GO gauges are available for
checking the dimensional accuracy of the products and these gauges are being calibrated
at regular frequency.

6.0

DOCUMENTATION
Firm shall maintain following documents/records:

6.1

A well documented Quality Plan.

6.2

Incoming raw material register should be checked as per approved QAP.

6.3

Maintenance of stock register for use and balance of raw materials, bought out items etc.

6.4

Stage inspection results including finished products results, as per approved QAP.

6.5

Records of internal rejection and its analysis vis-a-vis action plan.

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6.6

Records of final products inspection by external agencies (like RDSO), NCR and case
analysis as well as action taken thereof.

6.7

Records for maintenance of dies/moulds.

6.8

Ensure that proper system are available for dealing with customer complaint.

7.0

TRAINING

7.1

Training need should be identified for all concerned officials and regular training shall be
organised and imparted on maintenance of machines, quality assurance, safety
parameters etc.

-x-x-x-x-x-x-x-

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