B&S Directorate No, CBS/G/Reg Dated 29/01/2018 Sub: Description of ISO Doc. No. BS - S- 4.2.3-2. This document contains total 27 pages The description of this is as follows: (S.No. [ Document Description | Page No. ISO Document (a) | STR for fabrication of From Page 2to ISO Document Steel girder (existing) | 12 of this No. BS-S/4.2.3-2 document | (Version 3.1) (6) [STR for fabrication of | From Page 13 |ISO Document steel girder valid from | to 27 of this No, BS-S/4.2.3-2 __|01-02-2019 | document (Version 4.0) _ It is for the information of the prospective applicants that they can apply and get listed in approved list of vendors for steel girder fabrication as per STR at S.No. (a) only up to 31.01.2019. Moreover once they are listed in approved list they have to give compliance report for provisions regarding machinery and plants as per new STR on or before 31.01.2019, failing which they will be temporarily delisted from the approved list of vendors The verification of compliance report will be done by the RDSO and in case of any false compliance given by the firm, it will be permanently delisted from approved list of vendors for a specified time Ae (Sandeep Agarwal) ADE/B&S/Inspection Page (op 27| ~1809001:2008 Doc No. BS-S-4.2.3-2 | Vers. No.: 3.1 Dale Effective: 21-09-2015 Document Tille: Schedule of Technical Requirements for fabrication of Steel Girders. RESEARCH DESIGNS AND STANDARD ORGANISATION MANAK NAGAR, LUCKNOW-226011 Document No. : BS-S-4.2.3-2 Document Title : SCHEDULE OF TECHNICAL REQUIREMENTS FOR FABRICATION OF STEEL GIRDERS. AMENDMENT HISTORY: ‘S.No. | Amendment Date Version Reasons for Amendments 45 14-09-2010 | 4.0 | STR approved by Railway Board. 2. 22-06-2012 414 Minor change in procedure for | ONLINE facility only (Facility of Hard Copy with drawn). | 3 23-40-2012 20 Modification in Para 2.2, 2.4, 2.5, | 4.3 & 7.8 and addition of Para 4.14 | 84.15 4. 27-06-2014 3.0 Modification in para 2.2.1, 2.2.2, 4.1 to 4.12, 6.2, 7.4, 7.4, 7.5 & 7. deletion of para 2.2.2 to 2.6 and addition of para 4.16 5. | 21-09-2015 a4 Minor Modification in Para 2.2 & 224 Page Do 27 ‘AE/ Insp/B&S_ DBSIT&l “Printed 2015/09/21 | Prepared by issued by Page 1 of 111809001:2008 | Doc No. BS-S-4.2.3-2 |” Vers. No.:3.1 Date Effective: 21-09-2015 Document Title: Schedule of Technical Requirements for fabrication of Steel Girders. ‘SCHEDULE OF TECHNICAL REQUIREMENTS FOR FABRICATION OF STEEL GIRDERS 1. Scope This schedule covers the norms for evaluation of both the capability and the capacity of any fim to manufacture and supply Steel Bridge Girders. Intended fabricators will be required to fabricate riveted/welded plate girders and riveted/welded open web girders. 2. Procedure for registration of firms for fabrication of girders. 2.41 The firm will ensure availabilty of i) The required infrastructure, machinery & Plant. ii) Testing and measuring equipments duly calibrated, iil) Trained technical manpower and Quality Assurance Programme iv) Equipments meeting the requirements of relevant specifications. v) Space required for manufacturing, testing and storage viz. manufacturing floor, godown, store, office and test lab etc. 2.2 In case fabricator is satisfied that the infrastructure available commensurate with the above stated requirements then firm shall apply for registration ON- LINE on the RDSO website. All relevant documents like Guidelines for Registration and Quality Audit of Vendors in Bridge & Structure Directorate, Application Form, Schedule of Technical Requirement (STR), latest version of relevant specifications (if applicable), RDSO Vendor Approval Process Guidelines, etc. are available on the RDSO website. The requisite charges as specified on website are to be deposited through the means as specified on the RDSO website. The firm has to submit ONLINE complete application form, self compliance of STR and all necessary documents in support of self compliance of STR and documents in support of other important aspects of application. The firm has also to submit the Undertakings and Documents as mentioned in Doc No. BS- G-4.2.3-1 (latest version) titled “Guidelines for Registration and Quality Audit of Vendors in Bridge & Structure Directorate.” 2.2.2 For detail procedure for Registration and other related aspects, refer to Doc No. BS-G-4.2.3-1 (latest version) titled “Guidelines for Registration and Quality Audit of Vendors in Bridge & Structure Directorate.” Page 8 27 AE/ Insp /B8S _ i OBS/T&I __ | Printed 2015/09/21 Prepared by Issued by Page 2 of 111809001:2008 | Doc No. BS-S-4.2.3-2 | Vers. No.:3.1 Date Effective: 21-09-2015 Document Title: Schedule of Technical Requirements for fabrication of Stee! Girders. 3. Norms for Acceptance 3.1. To qualify for riveted steel bridge girders production, the firm must satisfy the infrastructural requirement as laid down in para 4 to 6. 3.2 To qualify for welded steel girders production, firm must satisfy the requirement laid down in para 7 in addition to requirement of other para 4 to 6. 3.3. Fabricators who do not have established the workshop for fabrication but do have required fa at site as given in para 3.1 & 3.2 above as applicable will also be considered. 4. General and Infrastructural Requirements for Stee! Girders:- Provide Detail Information on items given below and enclose necessary documents in support as applicable ONLINE: 4.1 The fabricator must have adequate organization including supervisors, skilled workers and adequate manpower to execute the fabrication work in competent manner. (Enclose list of staff along with Qualification & experience of employees.) 4.2 A proper organization must exist to perform the functions of purchasing of various raw materials and consumables etc. and maintaining related inspection certificates, test certificates etc. (Enclose list of staff along with Qualification & experience of employees). 4.3 Previous experience of fabricating steel structures capable of with-standing dynamic loads such as bridge girders, microwave towers, heavy industrial steel structures ete. is essential. Note: () Bridge Girders:- Firm should have fabricated nof less than 1 span of 30m or above Open Web Girder or not less than 3 spans of Plate Girder for Railway Bridge or ROB's (Foot Over Bridges, Pipe Line crossings etc. will not be considered for similar experience purpose). (ii) Towers:- Fabrication of only those Microwave Tower/Power Transmission Tower/Chimneys will be considered for which height above ground level is not less than 30 meters, (ii) Gantry Girders:- Fabrication of Gantry Girders and/ or columns designed to cater for ECT crane of capacity not less than 50 tone. (iv) Heavy Industrial Structure is defined as the work in which firm has fabricated more than 1000 MT involving built up section like I-girder of Page Yap 27 AE/ Insp/B8S besiTal Printed 2015/09/21 {___._ Prepared by cs alssiied yl) Rageison tai 1§09001:2008 ] Doc No. BS-S-4.2.3-2 | Vers. No.: 3.1 iE Date Effective: 21-09-2015. Document Tile; Schedule of Technical Requirements for fabrication of Steel Girders. depth not less than 700 mm or Box section with X-sectional area of Box not less than 90000 mm’. (v) Previous experience will be considered only for the works completed during the last five financial years & upto the date of application in the current financial year. (vi) For items ()) to (iv), the applicant has to submit the concerned fabrication details along with performance certificate from client, explicitly as supporting documents for this and in absence of these, ‘experience will not be considered, Certificate issued by Govt/ Semi Govt./PSU's will be accepted for this purpose. (vii) Performance certificate from Private individuals will not be accepted except those which are reputed Pvt. Ld. firm whose tumover is more than 100 crores per annum and the applicant has to submit necessary certificate from CA and Audit Reports of CA or Income Tax retums to prove his point. Necessary documents in support of above to be enclosed. If above conditions are not satisfied, it will be deemed that firm is not having the desired experience, which in turn is essential & his application will be closed as per procedure mentioned in Guidelines for Registration/Renewal of Vendors in Bridge & Structure Directorate. 4.4 A proper procedure for maintenance of records for receipt and consumption of raw material should be in vogue or developed so as to permit verification by railway's representative. 4.5 Adequate power supply should be available through distribution agencies and adequate backup shall be available through captive generation. (Necessary documents in support to be enclosed). 4.8 Covered bay area served by EOT cranes or by mechanically operated machines should be provided to handle day today fabrication of girder components. (Necessary documents in support to be enclosed). 4.7 Enough area to store raw material, sub assemblies and finished product should be available. The area provided should be enough to store raw material to execute the work order for requirement of steel. Suitable material handling facilities in form of EOT/mobile cranes should be available. 4.8 A separate line for inspection and testing of girders should be provided for final inspection and testing of bridge girders by railway's inspecting engineers. 4.9 Covered shed area protected from rain, dust etc. should be provided for surface preparation/painting/metallising of steel! girders. As no part of the work shall be painted unless it has been finally passed and cleared by Page S of 27 ‘AE/ insp/B&S ‘| DBS/T& Printed 2015/09/21 Prepared by issued by Page 4 of 11| 1$09001:2008 | Doc No. BS-S-42.3-2 | Vers. No: 3.1 Date Effective: ___ 24-09-2015 Document Title: Schedule of Technical Requirements for fabrication of Steel Girders. inspecting officer, adequate space for storing fabricated component awaiting painting shall be available. 4.10. For full scale layout of drawings to which girders are to be manufactured, template shop with steel/concrete floor should be available. For symmetrical girders, central half of the layout may be done and for non-symmetrical Girders fulltength layout shall be required. Further, for development of jigs and fixtures this shop should have in-house jigs manufacturing facilities. Note: For para 4.6 to 4.10 Applicant has to submit ONLINE neat copy of plan of works premises & show detail of items given below: (a) Covered bay area with proper handling facilities available to handle day-to-day fabrication of Steel Bridge Girder. (b) Area for storing raw material, sub-assemblies & finished products etc. (©) Area for separate line for inspection and testing of Girder. (4) Covered shed area protected from rain, dust etc, available for surface preparation/painting/metallizing. (e) Availability of Template floor. 4.11 Sufficient space for trial erection of the girder after manufacture shall be available. For this purpose, proper handling equipment, stacking space and other facility shall be available and same should be marked clearly in the factory plan to be submitted. 4.12 An adequately equipped and staffed drawing office is required for preparation of fabrication drawings. (Enclose list of staff along with Qualification & experience of employees). 4.13. Digital Signatures: It is mandatory for all the vendors to obtain Digital Signature Certificate & get registered with IREPS at http://www.ireps.gov.in. 4.14 It should be mandatory to inform the RDSO through FAX (followed by confirmation copy through courier/speed post) as soon as any machinery is removed from the firm's premise (even for repair etc.). RDSO should be informed again, when brought back and made operational. 4.15 Firm should be required to give an undertaking at the time of seeking approval that if at any time after approval is accorded, some machinery is found deficient without intimation to RDSO, then it will be presumed that machinery was not there since beginning and firm's approval will be withdrawn immediately. qe G of 27 ‘AE/ insp/B8S_ ___ DBS/T8I Printed 2015/09/21 Prepared bj issued by Page 5 of 111$09001:2008 Doc No. BS-S-4.2.3-2 Vers. No.: 3.1 Date Effective: 21-09-2015 _ Document Tile: Schedule of Technical Requirements for fabrication of Stoel Girders. 4.16 Firm should submit the detail of Equipments/Machinery i.e. covering Quantity, Make, Model Number, Capacity, Year of manufacture/commissioning, Machine number etc. preferably in a chart form for the machineries and plants as mentioned under para-5 and 7.1 to 7.2 given below (Machinery owned by sister concern will not be accepted). 5. Machinery & Plants: Following machinery and plants shail be available with the fabricator: 5.1 EOT/Portal/mobile crane of min. 10t capacity or suitable material handling facility to serve the handling of material for fabrication of girders, unloading of raw material and loading of finished product. 5.2 Compressors of adequate capacity suitable for riveting and for other simultaneous applications. 5.3 Oxy-Acetylene gas cutting equipment a) Profile cutting equipment of adequate size. b) Self propelled straight cutting equipment preferably consisting of multiple torches. 5.4 Radial drilling machines of adequate capacity to drill holes of 12 to 50 mm diameter. 5.5 End milling machine. 5.6 Plate & structural sections straightening machine. 5.7 Pneumatic/hydraulic yoke riveting machine. 5.8 Adequate number of portable pneumatic tools such as grinders, drilling machines, chipping machines, wrenches etc. 5.9 Dumpy level or theodolite instrument for recording of camber/deflection of trial erected girder. 5.10 Facilities for surface preparation/painting/metallising as per IRS B-1 specification. 5.11 A) To test the raw material and girders to conform it for relevant specification, testing facilities for the following must be provided:- (a) Elcometer for measuring thickness of paint. (b) Stee! measuring tape duly calibrated Page 1 o¢ 27 AE/ Insp. /B8S DBS/T&l Printed 2015/09/21] Prepared by issued by Page 6 of 111S09001:2008 | Doc No. BS-S-4.2.3-2 | Vers.No:3.1 | Dale Effective: ne : 21-09-2015 Document Title: Schedule of Technical Requirements for fabrication of Steel Girders. 6.11. B) Following facilities for testing of material can be in house or may be arranged from extemal agencies: (a) Equipments required for testing of mechanical properties, chemical composition and microstructure etc. Note:- If facility is in house provide details of Equipment like, Make, Model Number, Capacity, Year of manufacture/ commissioning and copy of test certificates issued earlier. if outsourced, submit copy of MOU with NABL Lab and copy of some previous Test Certificate issued by NABL Lab. The MOU should have validity of minimum 30 months. (b) Ultrasonic flaw detection testing facilities for checking intemal flaws and thickness of section. Note:- If facility is in house provide details of Equipment like, Make, Model Number, Year of manufacture commissioning, Proficiency Certificate of minimum level-Il of personal conducting UT Test and copy of some test certificates issued earlier. If outsourced, submit copy of MOU with NABL Lab /approved agency, Proficiency Certificate of minimum level- Il of personal conducting UT Test and copy of some previous Test Certificate issued by NABL Lab/approved agency. The MOU should have validity of minimum 30 months. 5.12 System of periodical maintenance of M&P must be in vogue and proper records maintained. 6. Quality Infrastructure: 6.1 Fabricator shall have proper quality infrastructure to ensure the quality product as required under latest issue of IRS B1 Specification and IRS Welded Bridge Code as applicable. ISO certified firms would be preferred. 6.2 A-system should be in force for analysis of defects notiged during intemal and external inspections of the final product and sub-asspmblies. A dynamic arrangement for a feed back to the source of defects and for rectification ‘should be in vogue. Necessary performas followed to be enclosed. 6.3 The fabricator should have adequate infrastructure and facilities like checking gauges, templates etc. during fabrication required from time to time so as to ensure that the finished product is as per requirement of IRS: B1 and Welded Bridge Code 6.4 Following specifications/codes commonly referred in connection with fabrication of riveted steel girders must be available with fabricator. IRS B-1 Fabrication and erection of steel Girder Bridges } Page 827 ‘AE/Insp./B&S DBS/Tal Printed 2015/09/21) Prepared by Issued by "Page 7 of 11 HIcapaci [ 1§09001:2008 | Doc No. BS-S-4.2.3-2 |” Vers. No.: 3.1 Date Effective: 21-09-2015 | Document Title: Schedule of Technical Requirements for fabrication of Steel Girders. fiRs Steel Bridge Code 1S: 1148 | Hot rolled steel rivet bars ( upto 40mm dia) for structural purpose. 1S: 1149 _| High tensile steel rivet bars for structural purpose IS: 1852 __| Rolling and cutting tolerance for Hot Rolled Steel Products. 1S: 2062 | Hot rolled low, medium and high tensile structural steel. The latest version of BIS Code/Specifications referred herein including their amendments issued from time to time are to be followed, 6.5 All equipments must meet the requirements of corresponding BIS or other international Specifications. 7. Additional general and infrastructural requirements for fabrication of welded girders. 7.1 The following facilities should be available for fabrication of welded girders. a) Welding transformers/rectfier for Manual Metal Arc Welding (MMAW) b) _Inert gas (Carbon Dioxide) welding equipment sets. ce) Automatic sub-merged arc welding equipment. ¢) Suitable welding manipulators. e) _ Macroetching /Dye Penetrant or Magnetic Particle testing fa f) Arrangement for radiographic test either in house or from external agency. Note:- If facility is in house provide details of Equipment like, Make, Model Number and Year of manufacture/commissioning and provide copy of proficiency Certificate of minimum level-Il of personal conducting RT Test and copy of Test Certificates issued earlier. If outsourced, submit copy of MOU with approved Agency by BARC/Atomic Energy Regulatory Board and copy of Proficiency Certificate (preferable which should be minimum level-Il) of person trained for Radiography Testing and copy of previous Test Certificates issued earlier by approved agency. The MOU should have validity ‘of minimum 30 months. 9) Tongue tester for measuring current and voltage. h) Gauges for checking weld size, throat thickness and edge preparation ete. 7.2 Machine for edge preparation before welding. 7.3. Fabricators must ensure that welding and gas cutting equipment/accessories meet BIS or other international standard requirements, It will be fabricators Page I of 27 [ ‘AE! Insp./B&S_ DBS/T& Printed 2015/09/21 4 (- Prepared by Issued by al Page 8 of 111809001:2008 | Doc No. BS-S-4.2.3-2 | Vers.No:3.1 | Date Effective: 21-09-2015 Document Tile: Schedule of Technical Requirements for fabrication of Steel | Girders. responsibility to satisfy the inspecting engineer that all the welding equipment/accessories conform to the BIS standard or any other standard in the absence of proper marking on such equipmenvaccessories. 7.4 Only trained and qualified Welders shall be deployed for welding. The welders must be trained in accordance with the provisions of IS: 817. They must be trained either from recognized welding institutes or by in-house training, if proper facilities exist. The welders must be tested as per requirements of IS: 7310 and proper records maintained. Applicant to submit copy of some welding procedures and Welders Qualification followed at their works. 7.5 All welding shall be carried out under the overall supervision of a qualified welding supervisor who has been trained in Welding Technology from any recognized welding institute. Submit details of staff & their Qualification and experience, 7.6 Welding instructions shall be prominently displayed on the shop floor. Requirement of the job in hand must be clearly explained to the welder before he is permitted to work. 7.7 Following specifications/codes commonly referred in connection with fabrication of welded steel girders must be available with fabricator. IRS Welded Bridge Code Code of practice for training and testing of metal arc welders. Code of Practice for Safety and health requirements in electric and gas welding operations 1S: 622, Code of Procedure for inspection of welds. IS: 4353 Recommendations for sub-merged arc welding of mild steel and low alloy steels. 1S:7307 (Pt) | Approval tests for welding procedure 1S:7310(PL1) | Approval tests for welders working to approved welding procedure-fusion welding of steel. 1S:9595 Recommendations for metal arc weiding of carbon and _| carbon manganese steel. The latest version of BIS Code/Specifications referred herein including their amendments issued from time to time are to be followed. Wherever to the standards mentioned above appears in the specification it shall be taken as a reference to the latest version of the standard. 7.8 Quality Audit of the Registered Vendors will be done every three years for which following are the requirements: Page (Or sp 27 AE! Insp /B&S DBS/Tal Printed 2015/09/21 __ Prepared by _ Issued by Page 9 of 111$09001:2008 | Doc No. BS-S-4.2.3-2 | Vers. No:3.1 Date Effective: 21-09-2015 Document Title: Schedule of Technical Requirements for fabrication of Steel 7.84 782 (a) © Girders. The firm should continue to maintain the faci time of initial approval. The firm should have participated in at least one of the tender of Railway Bridge Girder Fabrication, OR The firm should have carried out any one work satisfying criteria 4.3 of this STR during the last five financial years & upto validity of current financial year at the time of Quality Audit. ‘The firm should not have any adverse report from any of the Railways. ies as required at the For Quality Audit, firm firm will be inspected for facilities provided under para 5 to 7 of this STR, which in tum will be verified after inspection by the RDSO team. Regarding para 4 of STR, the firm should give undertaking that organizational and infrastructural requirement mentioned in para 4 of STR have been maintained as existing at the time of initial approval. It the firm does not satisfy either of the criteria given in para 7.8(b), its name will be removed from list and firm shall have to apply afresh. Page Nef 27 AE/ Insp /B&S DBSIT&l Printed 2015/09/21 Prepared by _ issued by Page 10 of 11[ 1809001:2008 Doc No. BS-S-4.2.3-2 Vers. No at Date Effective: 21-09-2015 Document Titie: Schedule of Technical Requirements for fabrication of Steel Girders. 8.0 RESPONSIBILITY AND AUTHORI The following table indicate responsibility related to this document:- ‘Activity Responsible | Approve | Supportin | Consulte Informed = t g_ d Creation, | DBS/T&i__— | ED/BES [DD Insp.,|- Through maintenance AEzInsp. intranet! eof this and Staff soft copy. document of DD/nsp. Compliance | DD/B&S/insp | DBS/TBI | Directorat | - - of Directive e staff contained in this document | __ Reauiremen | DBS/T&l ED/B&S | DDiinsp., |- Through t of AE/insp. intranevsof Deviation t copy from Directive es 9.0 ABBREVIATION: ED — = Executive Director/B&S DBS. Director/Joint Director(B&S)/Insp. DD/insp. = Deputy Director/Inspection AE Assistant Engineer/Insp. SE = Section EngineeriInspection Page 1D 4 27 ‘AE? Insp. /B&S: DBS/T&I [Printed 2015/09/21 Prepared by issued by Page 11 of 14ISO 9001:2008 | Doc No. BS~ S$ ~4.2.3-2 | Date Effective: Vers. No. : 4.0 01-02-2019 Document Title: Schedule of Technical Requirements for fabrication of Stee! Girders. RESEARCH DESIGNS AND STANDARD ORGANISATION MANAK NAGAR, LUCKNOW ~ 226014 Document No. a BS-S-4.2.3-2 Document Title E SCHEDULE OF TECHNICAL REQUIREMENTS FOR FABRICATION OF STEEL GIRDERS. AMENDMENT HISTORY: S.No.| Amendment Date | Version | Reasons for Amendments i 14-09-2010 70 _| STR approved by Railway Board 2 22-06-2012 7.1 | Minor change in procedure for ONLINE facility only (Facility of Hard Copy with drawn) ee 23-10-2012 20 Modification in Para 2.2, 2.4, 2.5, 4.3 7.8 and addition of Para 4.14 & 4.15 Board 4 2014 30 | Modification in para 2.2.1, 222,47t0 412,62, 7A, 7.4, 7.5 &7.8, deletion of para 2.2.2 to 2.6 and addition of para 4.16. 5. 21-09-2015 34 Minor Modification in para 2.2 & 2.2.1 6. (25-01-2018 4.0 ‘Complete revision of STR as approved by Railway It will be effective from 01.02.2019. Page 13 ef 27 AE/insp/B&S DBSiinsp. Prepared by Issued by Printed 25-07-2018 Page 1 of 151.0 20 24 22 3.0 40 4A 42 43 Schedule of Technical Requirements (STR) for fabrication of Open Web, ‘Composite and Other Stee! Plate Girders (PART-A) ‘Scope: This schedule covers the norms for evaluation of the capability and the Capacity of any firm for fabrication and supply of Open Web, Composite and Other Steel Plate Girders. Intended fabricators will be required to fabricate fiveted?bohediwelded plate girders and riveted/boltediwelded open web girders. Requirements for registration of firms for fabrication of girders: Tae ow sen Smt of tir Ex eiatn BO ) The required infrastructure, Machinery & Plants. ji) Testing and measuring equipments duly calibrated. ii) Trained technical manpower and Quality Assurance Programme (QAP) iv) Equipments meeting the requirements of relevant specifications, ¥) Space required for manufacturing/fabrication, testing and storage viz manufacturing/fabrication For detailed procedure for Registration and other related aspects, refer to Doc No. BS-G-42341 (latest version) tiled “Guidelines for Registration and Quality Audit of Vendors in Bridge & Structures Directorate.” Norms for Acceptance To qualify for steel bridge girders production, the firm must satisfy the requirements as laid down in Para 4 to 6 as under: General and Infrastructural Requirements-Detaiied information on items ‘given below should be furnished enclosing necessary documents in support as applicable:- ‘The fabricator must have proper organization including supervisors, skilled workers and adequate manpower to execute the fabrication work in ‘competent manner. (Enclose list of staff along with qualification & experience of employees) ‘A proper organization must exist to perform the functions of purchasing of Various raw materials & consumables etc. and maintaining related inspection Certificates & test certificates etc. (Enclose list of staff along with Qualification & experience of employees) Previous experience of fabricating stee! structures such as bridge girders, heavy industrial steel structures etc. as under: (a) Firm should have fabricated minimum 1 Span of Open Web Girder of Railway Bridges of not less than 0.5m. Page 1H ef 27OR (b) Firm should have fabricated minimum 3 Spans of Plate Girders of Railway Bridges not less than 9.15m OR (€) Firm should have fabricated minimum 3 Spans of Composite Girders of ROB not less than 9.15m OR (@) Firm should have fabricated minimum 1000 MT heavy Industrial Structures involving built up |-Girders of depth not less than 700mm or Box section with X- ‘sectional area of Box not less than 90000 mm’, OR (e) Firm should have fabricated minimum 1000 MT Railway Foot Over Bridges, Plate Form Shelters & Bridge Girder Pathways etc. Note: () Previous experience wil be considered only for the works completed ‘during the last five financial years & upto the date of application in the current financial year. (For items (a) to (e), the applicant has to submit the concemed fabrication details along with performance certificate from client, explicitly a8 supporting documents and in absence of documents, experience will not be considered. Certificate issued only by Govt’Semi GovvPSU's will be accepted for this purpose. (ii) Performance certificate from Private individuals can also be accepted Chartered Accountant or Income Tax returns. (v) In case of (b) & (c), only one time approval for two years may be given to firms which have fabricated not less 300MT Plate Girders or Composite Girders or both during last three financial years subject to futfling other requirements. Thereafter regular approval will only be given after completion of fabrication of minimum one Open Web Girder for Raitway Bridge of not less than 30.5m span & passing by (Y) Incase of (d) & (¢), the approval will only be given after fabrication of ‘one Open Web Girder for Railway Bridge of not less than 30.5m span, by the firm at its own cost which is to be passed by RDSO. 44 A proper procedure for maintaining records for receipt and consumption of raw materials should be in vogue or developed so as to permit verification by railway's representative. Page 1S gf 2745 46 47 48 49 4.10 444 412 51 5.2 $3 54 Adequate power supply should be available through power distribution agencies. In addition to above adequate power backup shall also be available through captive generation. (Necessary documents in support to be enclosed) Covered bay/shed area duly protected from rains/wind and dust for fabrication should be available. (Necessary documents in support to be enclosed) Enough area to store raw materials, sub-assemblies and finished products should be available. A separate line/space for inspection and testing of girders by railway's inspecting engineers should be available. factory plan to be submitted along with application for registration. ‘An adequately equipped and sefed drawing office is requed fer preparation of fabrication drawings. (Enclose list of staff along with Qualification & experience of employees) Note: For the above paras, applicant has to submit neat copies of plans of works premises & details of items. Machinery & Piants: Following machinery and plants shall be available with the fabricator: CNC Cutting Machine (Gas /Piasma) or CNC Cutting Cum Drilling Machine CNC Beam Welding Machine CNG Plate Drilling Machine or CNC Cutting Cum Drilling Machine ‘Shot Blasting Machine/Grit Blasting Machine/Sand Blasting Machine and Metalizing Guns Page (6 of 2755 56 57 58 59 5.10 5.11 5.12 5.13 5.14 5.18 5.16 EOT/Porta/Mobile Crane of minimum 20 T capacity for handling of materials {for fabrication of girders, unloading of raw materials and loading of finished products etc. Compressors of adequate capacity suitable for riveting/bolting and other Radial Driling Machines of adequate capacity to drill holes up to 50 mm diameter. End Milling Machine. Plate & Structural Sections Straightening Machines Minimum three numbers of portable pneumatic tools such as grinders, driing machines, chipping machines, wrenches, elcometers, calibrated stee! measuring tapes etc. Minimum one number Dumpy Level /Theodolite/Total Station for recording of camber/defiection of tial assembled girder etc. Facilities for surface preparation/painting/metalzing 38 per IRS B-1 specification Testing facilities for testing of mechanical properties, chemical composition, microstructure etc. which can be in-house or may be arranged from outside. Note- if facility is in house, details of equipments like make, model number, capacity, year of manufacture/commissioning and copy of test i issued earlier etc. should be provided. In case in-house facility is not available then testing can also be got done from outside agencies provided the agency is accredited by NABL Laboratory INABCB Laboratory. An undertaking to that effect should be submitted. “Testing facilities for ultrasonic flaw detection which can be in-house or may be arranged from outside. Note- If facility is in house, details of equipments like, make, mode! number, year of manufacture/commissioning, and proficiency minimum level-ll of personal conducting UT test and copy of some test certificates issued eartier should be provided. In case in-house facility is not available then testing can also be got done from outside ‘agencies provided the agency is accredited by NABL Laboratory / NABGB Laboratory / Authorized Institute. The testing will be done only by authorized persons having proficiency certificate of minimum level- Il, An undertaking to that effect should be submitted. ‘System of periodical maintenance of M&P must be in vogue and proper records shail be maintained. ‘The following facilities should also be available for fabricaton of welded girders: Page 7 of 275.17 5.18 5.19 5.20 a) Welding Transformers/Rectifiers for Manual Metal Arc Welding (maw) - b) —_-MIGICO Welding Equipment sets c) Single headed or Multi headed Automatic/Semi Automatic Submerged ‘Are Welding (SAW) Machine/Equipment ¢) —_Sultabie Welding Manipulators ©) Macro Etching, Dye-Penetrant or Magnetic Particle testing facilities f) Stud Welding Machine in house or from extemal agency with Generator Rectifier of appropriate capacity. 9) Areva or me oMpnNs tea er fuee 1: FSt rick: # ech hoon, Solas of expiprosets Me, make, model number ‘and year of manufacture/commissioning, and proficiency certificate of sian levelll of peteonel ‘conducting, RT Test and copy of test certificates issued earlier should be provided. In case in-house facility is not available then testing can also be got done from outside agencies provided the agency is approved by BARC/Atomic Energy Regulatory Board. The testing will be done only by authorized persons having proficiency certificate of minimum level-ll. An undertaking to that effect should be submitted. h) Tongue testers for measuring current and voltage. ) Guinn for cheching wad non, Svber Sicizwee sel ee rapernton Fabricators must ensure that welding and gas cutting equipmentiaccessories meet BIS or other intemiational standard requirements. It will be fabricator’s responsibility to satisfy the inspecting engineer that all the welding equipmentiaccessories conform to the BIS standards or any other Intemational standards in the absence of proper marking on such equipments/accessories. Oniy trained and qualified Welders shal be deployed for welding. The welders must be trained in accordance with the provisions of IS: 817. They must be trained either from recognized welding institutes or by in-house training, if proper facilities exist. The welders must be tested as per requirements of IS: 7310 and proper records shall be maintained. The welders engaged should be atleast high school pass and preferably rained from (7 or reputed welding training institutes. Fabricators to submit copy of welding procedures and Welders Qualification followed at their works. AN welding shell bo canied out under the overall supervision of quelled welding supervisors who have been trained in welding technology from govemment approved welding institutes. Details of staff, their qualification and experience should be submitted by Fabricators. ‘Welding instructions shall be prominently displayed on the shop floor. Page I8 sf 2760 61 62 63 Note: (i) Machinery & Plants owned by sister concem will not be accepted. (i During the inspection by RDSO officials, if any machinery is found deficient from the requirement, the firm's registration will be withdrawn. Quality Infrastructure: Fabricator shall have proper infrastructure to ensure the quality product as per requirement of latest issue of IRS - B1 Specification and IRS - Welded Bridge Code as applicable. A system should be in force for anatysis of defects noticed during intemal and ‘extemal inspections of the final products and sub-assembiies. A dynamic for a feed back to the source of defects and for rectification should be in vogue. Performa being followed should be enclosed. Following specificationsicodes (latest version) commonly referred in les ‘connection with fabrication of stee! girders must be available with fabricator. [IRS B7 | Specification for fabrication and erection of steel Girder) Bridges and locomotive Tum Tables firs | (iS4448 Steel rivet “bars (medium & high tensile) for structural purposes 1S: 1149 | Specification for High tensile steel rivet Bars for structural purpose 1S: 1682 | Specification for Rolling and cutting tolerances for Hot | Rolled Stee! Products [1S: 2062 Hot rolled medium and high tensile structural steel- ioe ee, [Code of practice for Waining and testing of metal arc welders, Code of Practice for Safety and health requirements in | electric and gas welding and cutting operations ‘Code of Procedure for inspection of welds. ~~] Submerged are welding of mild steel and low alloy steels- recommendations [1S:7307(F4) ‘Approval tests for welding procedures-fusion welding of TS:7310(Pt1) | Approval tests Ge aaiiars working Yo approved welding steel [1S:9595" ~~ Metal-are welding of carbon and carbon manganese steels- | Fecommendations Pose 19 of 2770 7A 72 73 74 Code of mechanical properties of Stud Shear Connector EN Welding - Studs and ceramic ferules for arc stud welding 18013918 1S:3757 ‘Specification for. high Strength structural bolts | Code of practice ‘strength bolls in steel structures | 11596623 | High Strength Structural Nuts-Specifications el 1556649 Hardened and Tempered Washers for High Strength Structural Boits and Nuts fT _ BS-117 RDSO guidelines for use of Hig! Grip(HSFG) bolts on bridges on Indian Railways Quality Audit Quality audit of the Registered Vendors will be done every five years. ‘The firm should satisfy the following requirements to continue as approved vendor: (2) The firm should continue to maintain the infrastructure, facilities’ and Machineries & Plants as required at the time of Quality Audit as per prevailing STR. (©) The fim should have executed/completed at least one work of Railway Bridge Girder Fabrication. For the purpose of this clause, fabrication of at least one span against a multiple span will be considered/treated as completed work. (©) The firm should not have any adverse report from any of the Railways. For Quality Audit, firm will be inspected for facilities provided as per para 4 to 6 of this STR, which in tum will be verified after inspection by the RDSO team. The firm should also give an undertaking that organizational and loessuuchelroubeyment 0, omy at wie ne of Chel ES HES if the firm does not satisfy the criteria given in para 7.2 & 7.3 above, its name will be removed from approved list and firm shall have to apply afresh in case it desires to be registered again. Page 2o of 27Schedule of Technical Requirements (STR) for fabrication of Composite & Other 10 N 22 40 42 43 ‘Steel Plate Girders (PARTS) Scope: This schedule covers the norms for evaluation of the capabil capacity of any firm for fabrication and supply of Composite & Plate Girders. Intended fabricators will be required to Requirements for registration of firms for fabrication of girders: ‘The firm will ensure availabilty of the following for registration as fabricator of girders - i) The required infrastructure, Machinery & Plants. ji) Testing and measuring equipments duly calibrated. ji) Trained technical manpower and Quality Assurance Programme (QAP) iv) Equipments meeting the requirements of relevant specifications. v) Space required for manufacturing/fabrication, testing and storage viz ‘manutacturing/fabrication floor, godown, store, office and test lab etc. For detailed procedure for Registration and other related aspects, refer to Doc No. BS-G-4.23+1 (latest version) tiled “Guidelines for Registration and Quality Audit of Vendors in Bridge & Structures Directorate.” Norms for Acceptance To qualify for steel bridge girders production, the firm must satisfy the requirements as laid down in Para 4 to 6 as under: General and Infrastructural Requirements-Detailed information on items given below should be furnished enclosing necessary documents in support as applicable:- “The fabricator must have proper organization including supervisors, skilled workers and adequate manpower to execute the fabrication work in ‘competent manner. (Enclose list of staff along with Qualification & experience ‘of employees) 'A proper organization must exist to perform the functions of purchasing of various raw materials & consumables etc. and maintaining related inspection certificates & test certificates etc. (Enclose list of staff along with Qualification & experience of employees) Previous experience of fabricating steel structures such as bridge girders, heavy industrial stee! structures etc, as under- id (2) Firm should have fabricated minimum 3 Spans of Plate Girders of Railway Bridges not less than 9.15m Page 2 of 2744 45 47 48 49 OR (b) Firm should have fabricated minimum 3 Spans of Composite Girders of ROB not less than 9.15m (©) Firm should involving OR have fabricated minimum 1000 MT heavy industrial Structures uill up Giders of depth not less than 700mm or BOx section with X-sectional area of Box not less than 90000 cs OR (@)Finm shoud have fabricated minimum 1000 MT Raiway Foot Over Bridges, Plate Form Shelters & Bridge Girder Pathways etc. Note: (i) a Previous experience will be considered only for the works during the last five financial years & upto the date of application in the current financial year. i) Performance certificate from Private individuals can also be accepted fnancial years of private firm is not less than SO crores. In Support of this, the applicant has to submit necessary Gentficates and Audited Balance Sheets of Chartered ‘Accountant or income Tax returns. 1k proper procedure for maintaining records for receipt and consumption of prmatenals should be in vogue or developed 80 as fo permit verification by raitway's Adequate should be available through power distribution power supply Agersies. In addition to above adequate power backup shall also be available Taough captive generation. (Necessary documents in support to be enclosed) shed area duly protected from rainsiwind and dust for Covered bay/t fabreation should be available. (Necessary documents in support to be enclosed) Enough area to store raw materials, sub-assemblies and finished products should be available. 'A separate line/space for inspection and testing of girders by railways inspecting engineers should be available. Covered shed area protected from rains/wind, dust etc. should be available for surface ‘of steel girders. As no part of the > preparation/painting/metalizing fabscated item shall be painted unless it has been finally passed and cleared Page 22 of 27410 4a 442 54 52 53 54 55 56 57 58 53 5.10 by inspecting officials, Adequate space for storing fabricated component awaiting painting shall be available. For full scale layout of drawings to which girders are to be manufactured, template shop with level steeliconcrete floor should be available. For symmetrical girders, central haif of the layout may be done and for non- symmetrical girders full-length layout shall be required. Further, for development of jigs and fixtures, this shop should have in-house jigs manufacturing facilities. Sufficient space for trial erection of the girder after manufacture shall be available. For this purpose, proper handling equipment, stacking space and other facilities shall be available and same should be marked clearly on the factory plan to be submitted along with application for registration. ‘An adequately equipped and staffed drawing office is required for preparation of fabrication drawings. (Enclose list of staff along with Qualification & ‘experience of employees) Note: For the above paras, applicant has to submit neat copies of plans of ‘works premises & details of items. Machinery & Plants: Following machinery and plants shall be available with the fabricator: CNC Cutting Machine (Gas /Plasma) or CNC Cutting cum Driling Machine CNC Beam Welding Machine CNC Plate Drilling Machine or CNC Cutting cum Drilling Machine ‘Shot Blasting Machine/Grit Blasting Machine/Sand Blasting Machine and Metalizing Guns EOT/Porta/Mobile Crane of minimum 20 T capacity for handling of materials for fabrication of girders, unloading of raw materials and loading of finished products etc. Compressors of adequate capacity suitable for riveting/bolting and other applications etc. Radial Drilling Machines of adequate capacity to drill holes up to 50 mm diameter. Plate & Structural Sections Straightening Machines Minimum three numbers of portable pneumatic tools such as grinders, drilling measuring tapes etc. Facilites for surface preparatiovpainting/metalizing as per IRS 6-1 ‘specification Page 23 ef 27r 5.14 5.12 $.13 5.14 ‘Testing facilites for testing of mechanical properties, chemical composition, microstructure etc. which can be in-house or may be arranges from outside. Note- If facility is in house, details of equipments like make, mode! number, capacity, year of manufacturelcommissioning and copy of test issued earlier etc. should be provided. In case in-house facility is not avaitable then testing can also be got done from outside agencies provided the agency is accredited by NABL Laboratory INABCB Laboratory. An undertaking to that effect should be submitted, Testing facilities for ultrasonic flaw detection which can be in-house or may be arranged from outside, Note- If facility is in house, details of equipments like, make, mode! number, year of manufacture/commissioning, and proficiency certificate of minimum level-II of personal conducting UT test and copy of some test certificates issued earlier should be provided. In case in-house facility authorized persons having proficiency ‘An undertaking to that effect should be submitted. ‘System of periodical maintenance of M&P must be in vogue and proper records shall be maintained. ‘The following facilities should also be available for fabrication of welded girders: 8) Welding Transformers/Rectifers for Manual Metal Arc Welding (MMAW) by —_ MIG/CO; Welding Equipment sets ©) Single headed or Multi headed Automatic/Semi Automatic Submerged ‘Are Welding (SAW) Machine/Equipment ‘Suitable Welding Manipulators 3 ing, Oye-P = Pei sc ms f) Stud Welding Machine in house or from extemal agency with ee S 9) Arrangement for radiographic test either in house or from extemal agency Note- If facility is in house, details of equipments like, make, mode! number ‘and year of manutacture/commissioning, and proficiency certificate of minimum level-ll of personal conducting RT Test and copy of test certificates issued earlier should be provided. In case in-house facility is not available then testing can also be got done from outside agencies provided the agency is approved by BARC/Atomic Energy Regulatory Board. The testing will be done only by authorized persons Page 24 of 275.15 5.16 5.17 5.18 60 61 62 having proficiency certificate of minimum level-ll. An undertaking to that effect should be submitted. h) Tongue testers for measuring current and voltage. j) Gauges for checking weld size, throat thickness and edge preparation etc, Fabricators must-ensure that welding and gas cutting equipment/accessories meet BIS of other intemational standard requirements. It will be fabricator's Tesponsibilty to satisfy the inspecting engineer that all the welding i ‘conform to the BIS standards or any other imemational standards in the absence of proper marking on such equipments/accessories. Only trained and qualified Welders shail be deployed for welding. The welders must be trained in accordance with the provisions of IS: 817. They must be trained either from recognized welding institutes or by in-house training, if proper facilities exist. The welders must be tested as per requirements of IS: 7310 and proper records shall be maintained. The welders Welding instructions shall be prominently displayed on the shop floor. Note: () Machinery & Plants owned by sister concem will not be accepted. i) During the inspection by RDSO officials, if any machinery Is found deficient from the requirement, the firm's registration will be withdrawn. Quality Infrastructure: Fabricator shall have proper infrastructure to ensure the quality product as per requirement of latest issue of IRS - B1 Specification and IRS - Welded Bridge Code as applicable. ‘A system should be in force for analysis of defects noticed during intemal and ‘external inspections of the final products and sub-assemblies. A dynamic for a feed back to the source of defects and for rectification ‘should be in vogue. Performa being followed should be enclosed. Following specifications/codes (latest version) commonly referred in ‘connection with fabrication of steel girders must be available with fabricator. Page 25 of 27IRS: B-1 ‘Specification for fabrication and. erection of steel Girder Bridges and locomotive Tum Tables \'s 148 (Steel Bdge Code ‘Stee! rivet bars (medium & high tensile) for structural re: 149 purposes _ ‘Specification for High tensile steei rivet bars for structural 1S: 4852 1S: 2062 Steel zs ~ [Hot rolled medium and high tensile structural steel purpose. ‘Specification for Rolling and cutting tolerances for Hot Rolled Products ‘Code of practice for ng and testing of metal arc welders. Code of Practice for Safety and health requirements in electric and gas welding and cuting operations Code of Procedure for inspection of v bmerged arc welding of mild steel and low alloy steels- recommendations ‘Approval tests for welding procedures-fusion weiding of steel 15:7307(P- 1) 18:7310 ‘Approval tests for welders working to approved “welding (Put) procedures-fusion welding of steel 1S:9595 | Metal-arc welding of carbon and carbon manganese steeis- | recommendati ‘Specification for. high strength structural boits Code of practice for high strength bolts in steel structures __| High Strength Structural Nuts- Nuts-Specifications Hardened and Tempered Washers for High Strength Structural Bolts and Nuts TRDSO guidelines for use of High Strength Friction | Grip(HSFG) bolts on bridges on Indian Railways 7.0 Quality Audit 7.1 Quality audit of the Registered Vendors will be done every five years. 7.2 The firm should satisfy the following requirements to continue as approved vendor: {@) The firm should continue to maintain the infrastructure, facilities’ and Machineries & Plants as required at the time of Quality Audit as per prevailing STR. Page 26 + 2773 74 (b) The firm should have executed/compieted at least one work of Railway Bridge Girder Fabrication. For the purpose of this clause, fabrication of at least one span against a multiple span will be considered/treated as completed work. {) The firm should not have any adverse report from any of the Railways. For Quality Audit, firm will be inspected for facilities provided as per para 4 to 6 of this STR, which in turn will be verified after inspection by the RDSO team. The fim shouki also give an undertaking that organizational and infrastructural requirement as required at the time of Quality Audit have been maintained. If the firm does not satisfy the criteria given in para 7.2 & 7.3 above, its name will be removed from approved list and firm shall have to apply afresh in case it desires to be registered again. Page Pied oy