PART LIST of IMPROVED SWITCH EXPANTION FOR LONG WELDED RAIL (With 80mm Max: GAP) 60 KG. ON PSC SLEEPERS TO DRG. NO. RDSO/T-6902 ALT-2 ~ MECHTECH GURU

PART LIST of IMPROVED SWITCH EXPANTION FOR LONG WELDED RAIL (With 80mm Max: GAP) 60 KG. ON PSC SLEEPERS TO DRG. NO. RDSO/T-6902 ALT-2

PART LIST of IMPROVED SWITCH EXPANTION FOR LONG WELDED  RAIL (With 80mm Max: GAP) 60 KG. ON PSC SLEEPERS TO DRG. NO. RDSO/T-6902 ALT-2 

Sl.

No.

Description

Drawing

No.

Qty. /

Set

1

Stock rail Right (6180 mm)

RDSO/T-6902/1

01

2

Stock rail Left (6180 mm)

RDSO/T-6902/1

01

3

Tongue Rail Right (6780 mm)

RDSO/T-6902/2

01

4

Tongue Rail Left (6780 mm)

RDSO/T-6902/2

01

5

GAP Avoid Rail Right (2380mm)

RDSO/T-6902/3

01

6

GAP Avoid Rail Left (2380mm)

RDSO/T-6902/3

01

7

Check Rail (2700mm) 52Kg.

RDSO/T-6903

02

8

C .I. Chair

RDSO/T-6904

10

9

M.S. bracket

RDSO/T-6905

06

10

M.S. bracket

RDSO/T-6906

10

11

M.S. bracket

RDSO/T-6907

02

12

M.S. bracket            

RDSO/T-6908

02

13

HTS Bolt with Nut 10.9 (M27 X 90)

RDSO/T-6909

08

14

Bolts (25 X 90) with SCS washer

RDSO/T-8604

10

15

Bolts (25 X 95) with SCS washer

RDSO/T-6910

20

16

Bolts (25 X 145) with SCS washer

RDSO/T-6911

30

17

Plate screw

RDSO/T-3916

20

18

Plate screw

RDSO/T-3915

20

19

Single Coil Spring Washer

T - 10773

40

20

Split pin (Ø 6.3 x 40mm long)

--

40

21

Plain Washer for 25 Ø bolt

--

10

22

Hardened washer

RDSO/T-6912

08

23

Hardened washer

RDSO/T-6913

08


Joint Inspection Report (Dimensional) for Improved Switch Expansion Joints BG 60 Kg to RDSO Drg. No. T-6902,Alt. 2

SL

No

PARAMETERS

DRG. DIM. (MM)

1

Length of Stock Rail

6180+3

2

Length of Tongue Rail

6780+3

3

Length of Gap avoid Rail

2380+1

4

Overall length of SEJ

13000+3

5

Alignment

+1

6

Matching of Tongue / Stock Rail

0.5mm filler

7

Composite head width of  Stock and Gap avoiding Rail

91+1

8

Composite Foot width  of Stock and Gap avoiding Rail

169+1

9

Half head width of Tongue Rail

45+0.5

10

Half  Head width of Gap Avoiding Rail

46+0.5

11

Machining length  of Tongue Rail

1200+1

12

Machining length  of Stock Rail

1180+1

13

Topping of Tongue / Stock Rail

 

3/378

14

Side Slope of Tongue  / Stock Rail

3/378

15

Topping of Gap avoid Rail

6/378

16

Topping of Gap avoid Rail

6/100

17

20R Tongue /Stock  Rail

20

18

43R (in side) Tongue  Rail

43

19

43R (Out side) Gap avoid Rail

43

20

Tapering slope on Non Gauge side

4/19

21

Length, width  & hole position of C.I.Chair (RT-6904)

533 +2/-0

22

Hole Dia. of CI Chair

27

23

Size.of square head of CI Chair

28Φ /47 sq.

24

Top machining of C.I. Chair & slope of 1 in 20

As per Drg

25

Rail seat groove depth   a) at outer side

                                       b) at inner side

13.9±0.5

14.8±0.5

26

Overall Length of Check Rail

2700+5

27

Hole Height in Check Rail

79+1

28

Check Rail Head M/C

30+1

29

40 Gap Bet. Stock/ Tongue rail

40

30

Hole Dia of Check Rail

28.0+.08

31

Spacing of  Check Rail holes

600+.08

32

Length of Head M/C from Extreme end of Check Rail

600+2.5

33

Chamfering 3x3 & removal of sharp edges not more than 2R

-----

34

End Squareness

--

35

Condition of M.S. Brackets

--

36

Surface Roughness on Planning Surface

3-7 micron

Assembly of Improved SEJ to drawing no. RDSO/T-6902

SL

No

PARAMETERS

DRG. DIM.

(mm)

1

Overall length of SEJ

13000+3

2

Composite head width of  Stock / Tongue Rail

91+1

3

Composite Foot width  of Stock / Tongue Rail

169+1

4

Matching of Tongue / Stock Rail

0.5mm filler

5

Center to center distance of CI Chair

600

6

Mean position of tongue rail

Centre of CI chair

7

GAP between Stock and Tongue Rail at mean position

40mm

8

Removal of Sharp edges

< 2R

9

Alignment

±1

10

Flange Way Clearance

41

11

Check Rail Flare

71


Stock Rail (Drg. No. RDSO/T-6902/1)

SL

No

PARAMETERS

DRG. DIM.

(mm)

1

Length of Stock rail

6180+3

2

Machining length  of Stock rail

1180 +1

3

Half head width of Stock rail

45+0.5

4

Foot width of Stock rail

84+0.5

5

20R Radius of Stock rail

20

6

43R (in side) Radius of Stock rail

43

7

Top slope of Stock rail

3/378

8

Side Slope of Stock rail

3/378

9

Chamfering 3x3 on head

3x3

10

Chamfering 3x3 on foot

3x3

11

Hole Dia.

30+0.8

12

Hole Height

76.25+0.8

13

Distance of  Ist hole from machined edge

240+0.8

14

Distance between 1st& 2nd  hole

80+0.8

15

Distance between 2nd& 3rd  hole

520+0.8

16

Distance between 3rd& 4th hole

80+0.8

17

Distance between 4th hole from start of machining

260+0.8

18

End Squareness

--

19

Alignment of Stock rail

±1

20

Surface Roughness of Stock rail

3-7 Micron


Tongue Rail (Drg. No. RDSO/T-6902/2)

SL

No

PARAMETERS

DRG. DIM.

(mm)

1

Length of Tongue rail

6780+3

2

Machining length  of Tongue rail

1200 +1

3

Half head width of Tongue rail

45+0.5

4

Foot width of Tongue rail

84+0.5

5

20R Radius of Tongue rail

20

6

43R (in side) Radius of Tongue rail

43

7

Top slope of Tongue rail

3/378

8

Side Slope of Tongue rail

3/378

9

Chamfering 3x3 on head

3x3

10

Chamfering 3x3 on foot

3x3

11

End  Squareness

--

12

Alignment of Tongue rail

±1

13

Surface Roughness of Tongue rail

3-7 Micron


Gap Avoiding Rail (Drawing No. RDSO/T-6902/3)

SL

No

PARAMETERS

DRG. DIM.

(mm)

1

Length of Gap Avoiding Rail

2380+1

2

Half head width of Gap Avoiding Rail

46+0.5

3

Foot width of Gap Avoiding Rail

85+0.5

4

43R (Out side) Radius of Gap Avoiding Rail

43

5

Top slope of Gap Avoiding Rail

6/378

6

Top slope of Gap Avoiding Rail

6/100

7

Tapering slope on non gauge face side Gap Avoiding Rail

4/19

8

Chamfering 3x3 on head

3x3

9

Chamfering 3x3 on foot

3x3

10

Hole Dia.

30+0.8

11

Hole Height

76.25+0.8

12

Distance of  Ist hole from edge

260+0.8

13

Distance between 1st& 2nd  hole

80+0.8

14

Distance between 2nd& 3rd  hole

520+0.8

15

Distance between 3rd& 4th hole

80+0.8

16

Alignment of Stock rail

±1

17

Surface Roughness of Gap Avoiding Rail

3-7 Micron


Check Rail (Drawing No. RDSO/T-6903)

SL

No

PARAMETERS

DRG. DIM. (MM)

1

Overall Length of Check Rail

2700+5

2

Hole Height in Check Rail

79+1

3

Check Rail Head M/C

30+1

4

Hole Dia of Check Rail

28.0+.08

5

Spacing of  Check Rail holes

600+.08

6

Length of Head M/C from Extreme end of Check Rail

600+2.5


C. I. Chair (Drawing No. RDSO/T-6904)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

533 +2,-0.0

2.

Width

300±1

3

Hole position for  Plate Screw

445±1& 120±1

4

Hole dia for Plate Screw

27±0.8

5

position of  Square for bolt

105/105

6

Size of  Square hole for bolt

47×47

±1.5

7

Top machining/Profile of CI Chair

As per drg.

8

Thickness at Rail Seat

39.5

9

Dia& depth of  slot for bolt

25

10

Condition of CI Chair

---

M. S. Bracket (Drawing No. RDSO/T-6905)

SL  No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

300

+0,-2

2.

Height of Bracket

116.7±0.5

3

Width of Bracket

139.5 ±0.5

4

Thickness of  Bracket at bottom

25±0.5

5

Hole dia

28±0.8

6

Distance of hole centre from edge

32±0.5

7

Thickness & spacing of stiffener

20±0.5, 97.5±0.5 & 105±0.5

8

Spacing of hole from edge & C/C

45,

105±0.5


M. S. Bracket (Drawing No. RDSO/T-6906)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

300

+0,-2

2.

Width of Bracket

226.6±0.5

3

Thickness of  Bracket

20±0.5

4

Hole dia

28±0.8

5

Height of check rail resting plate

119.8 +1/-0

6

Width of check rail resting pad

83.5

7

Spacing of hole from edge & C/C

45,

210±0.5

M. S. Bracket (Drawing No. RDSO/T-6907)


SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

300

+0,-2

2.

Height of Bracket

116.7±0.5

3

Width of Bracket

139.5±0.5

4

Thickness of  Bracket at bottom

25±0.5

5

Hole dia

28±0.8

6

Distance of hole center from edge

32±0.5

7

Thickness & spacing of stiffener

20±0.5, 97.5±0.5 & 105±0.5

8

Spacing of hole from edge & C/C

45,

105±0.5

9

Size of Stopper

60×60

10

Thickness of Stopper Plate

19 ± 0.5

M. S. Bracket (Drawing No. RDSO/T-6908)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

300

+0,-2

2.

Height of Bracket

116.7±0.5

3

Width of Bracket

139.5±0.5

4

Thickness of  Bracket at bottom

25±0.5

5

Hole dia

28±0.8

6

Distance of hole center from edge

32±0.5

7

Thickness & spacing of stiffener

20±0.5, 97.5±0.5 & 105±0.5

8

Spacing of hole from edge & C/C

45,

105±0.5

9

Size of Stopper

60×60

10

Thickness of Stopper Plate

19 ± 0.5

Hardened Washer (Drawing No. RDSO/T-6912

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Length

102.7 +0.0/-0.8

2.

Width

50

+0.8/-0.0

3

Dia. of  hole

30

+0.52/-0.0

4

Width of slot

47

+0.8/-0.0

5

Thickness

10 +0.6

6

Depth of  slot

3

7

Hole centre

51.4+0.8

Hardened Washer (Drawing No. RDSO/T-6913)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Length

102.7 +0.0/-0.8

 

2.

Width

50

+0.8/-0.0

3

Dia. of  hole

30

+0.52/-0.0

4

Thickness

10 +0.6

5

Hole centre

51.4+0.8

HTS Bolt (Drawing No. RDSO/T-6909)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length of bolt

90 +3/-0

2.

Thread length of bolt

43 +2/-1

3

Diameter of bolt

27±0.8

4

Head width of bolt (A.F.)

45 +1/-0

5

Head width of bolt (C.C.)

50.85 Max.

6

Head Thickness of bolt

17±0.9

7

Thickness of  nut

27±0.6

8

Head width of nut (A.F.)

45 +1/-0

9

Head width of nut (C.C.)

50.85 Max.

Bolt (Drawing No. RDSO/T-6910)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

95±3

2.

Thread length

60

3

Dia. of bolt

25+1/-0.4

4

Head width of bolt

41 +0/-1

 

5

Thickness of  head

22±0.65

Bolt (Drawing No. RDSO/T-6911)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

145±3

2.

Thread length

95

3

Dia. of bolt

25+1/-0.4

4

Hole dia.for Split pin

6.3

5

Distance of hole for split pin from bottom of  head

137

6

Head width of bolt

41 +0/-1,

7

Thickness of  head

22±0.65

Bolt (Drawing No. RDSO/T-8604)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Total Length

90±1

2.

Thread length

70

3

Dia. of bolt

25+1/-0.4

4

Hole dia.for Split pin

6.3

5

Distance of hole for split pin from bottom of  head

82±0.8

6

Head width of bolt

41 +0/-1,

7

Thickness of  head

22±0.65

Single Coil Spring Washer (Drawing No. T-10773)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Outer Dia

44.4 Max

2.

Inner Dia

27 +1/-0

3

Gap Bet. Two Edge.

2.5±1

4

Free Height

14± 0.75

5

Thickness

8±0.2

Plate Screw (Drawing No. RDSO/T-3916)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Length

190±5

2.

Shank Dia.

24+0.2, -0.1

3

Head height

38 +2,-1

4

Dia. of circular head

48±0.5

5

Thread Pitch

12.5

Plate Screw (Drawing No. RDSO/T-3915)

SL

No

PARAMETERS

DRG. DIM. (mm)

1.

Length

180±5

2.

Shank Dia.

24+0.2, -0.1

3

Head height

38 +2,-1

4

Dia. of circular head

48±0.5

5

Thread Pitch

12.5

CHEMICAL REPORT

SL.

No.

Description of Material as per Specification

C %

Mn %

S %

P %

Si %

1.

Specified ValueIS 1875 Cl-3/ IRS T-23

0.25-0.35

0.60-0.90

0.040 Max.

0.040 Max.

0.15-0.35

Track Bolt

RDSO/T-6910, RDSO/T-6911,

RDSO/T-8604

0.29

0.28

0.27

0.72

0.74

0.72

0.026

0.027

0.027

0.026

0.027

0.025

0.20

0.22

0.21

2.

Specified Value IS 1875 Cl-2A /IRS T-23

0.20-0.30

0.60-0.90

0.040 Max.

0.040 Max.

0.15-0.35

Track Nut 

RDSO/T-6910, RDSO/T-6911,

RDSO/T-8604

0.22

0.22

0.23

0.72

0.75

0.72

0.025

0.025

0.024

0.0.27

0.026

0.028

0.20

0.23

0.21

3.

Specified Value IRS  T- 10,

IS 2062: 2011 Gr. E250 Quality : BR

0.22 Max.

1.50 Max.

0.045 Max.

0.045 Max.

0.40Max.

MS Plates for M.S. Bracket

RDSO/T-6905, RDSO/T-6906,

RDSO/T-6907 & RDSO/T-6908

Plate Size 14mm

Plate Size 16mm

Plate Size 20mm

Plate Size 25mm

 

 

 

0.19

0.18

0.18

0.17

 

 

 

0.92

0.82

0.83

0.90

 

 

 

0.024

0.026

0.026

0.027

 

 

 

0.027

0.029

0.028

0.028

 

 

 

0.21

0.22

0.22

0.23

4.

Specified Value IS 1367 Part-3

0.20– 0.55

N.A

0.035 Max.

0.035 Max.

N.A

H.T.S  Bolt 27dia x 90 ( P. Cl. 10.9 )

RDSO/T-6909 (From Lot)

0.33

--

0.024

0.022

--

H.T.S  Bolt 27dia x 90 ( P. Cl. 10.9 )

RDSO/T-6909

(From Assembled Imp. SEJ)

0.34

--

0.023

0.024

--

5.

Specified Value IS 1367 Part-6

0.58 Max.

0.45 min.

0.058 Max.

0.048 Max.

N.A

H.T.S Nut  (P. Cl. 12)

RDSO/T-6909 (From Lot)

0.32

0.50

0.034

0.032

--

H.T.S Nut  (P. Cl. 12)

RDSO/T-6909

  (From Assembled Imp. SEJ)

0.33

0.52

0.032

0.030

--

6.

 

Specified Value IS  6649 Gr.45 C 8

0.40-0.50

0.60-0.90

0.040 Max

0.040 Max

0.15-0.35

Hardened Taper Washer

RDSO/T-6912, RDSO/T-6913

0.44

0.43

0.66

0.68

0.032

0.030

0.031

0.029

0.23

0.24

7.

Specified Value  IRS T- 42 Ref. IS 4072 Gr. 55Si7 

0.50-0.60

0.70-1.00

0.050 Max

0.050 Max

1.50-2.00

Single Coil Spring Washer T-10773

0.54

0.82

0.031

0.033

1.68

8.

Specified Value IRS  T- 10,

 IS 2062: 2011 Gr. E250 Quality : A

0.23 Max

1.50 Max

0.045 Max

0.045 Max

0.40Max

Plate Screw RDSO/T-3915, RDSO/T-3916

0.20

0.17

1.08

1.10

0.034

0.033

0.029

0.030

0.22

0.23

9.

Specified Value IRS  T- 10,

IS 2062: 2011 Gr. E250 Quality : BR

0.22 Max

1.50 Max

0.045 Max

0.045 Max

0.40Max

Split Pin & Plain Washer

0.20

1.14

0.032

0.030

0.25

PHYSICAL REPORT

S.

No.

Description of Material as per Specification

Tensile Strength

(U.T.S) (Mpa)

Elongation

(%)

Yield Stress

(Mpa)

Charpy

Impact (J)

Bend

Test

Remarks

1.

Specified Value IRS  T 10,

 IS 2062: 2011 Gr. E250

Quality : BR

410 Mpa (min.)

23% (min.)

250 Mpa min

(< 20mm)

240 Mpa min (20- 40mm)

27J

 (min.)

2t

 

MS Plates for M.S.Bracket

 RDSO/T-6905, RDSO/T-6906, RDSO/T-6907 & RDSO/T-6908

Plate Size 14mm

Plate Size 16mm

Plate Size 20mm

Plate Size 25mm

 

 

 

452

460

468

465

 

 

 

27

28

26

28

 

 

 

268

266

273

275

 

 

 

30

29

28

31

 

 

OK

 

 

Satisfactory

2.

Specified Value IRS  T 10,

 IS 2062: 2011 Gr. E250

Quality : A

410 Mpa (min.)

23% (min.)

24 Kgf/mm2 (Min)

-----

45°  

 

Plate Screw

RDSO/T-3915, RDSO/T-3916

448

438

26

28

25

26

NA

OK

Satisfactory

3.

Specified ValueIRS  T 23 /IS-1875 , Cl 3 (Bolt), Cl 2A (Nut)

Tensile Strength

(U.T.S)

55 – 68 Kgf/mm2

Head Soundness

At 300

No Crack

Unscrewing

2kg. - 12kg.

Drifting

 1.5 times of original dia.

(No crack)

Remarks

 

 Track Bolts & Nuts assembly

RDSO/T-6910,RDSO/T-6911, RDSO/T-8604

60

59

62

NA

9

8

8

NA

Satisfactory

Track Bolts

RDSO/T-6910,RDSO/T-6911, RDSO/T-8604

NA

OK

NA

NA

Satisfactory

Track Nuts

RDSO/T-6910,RDSO/T-6911, RDSO/T-8604

NA

NA

NA

OK

Satisfactory

4.

Specified ValueIS 1367 Part-3

Tensile Strength (U.T.S)

1040 Mpa (min.)

 

Elongation (%)

9% (min)

Proof Load

381 Mpa

 

Wedge

Test

60

Hardness

32-39 RC

Remarks

H.T.S  Bolt ( P. Cl. 10.9 )

RDSO/T-6909      (From Lot)

1088

13

OK

OK

34

Satisfactory

 

H.T.S  Bolt ( P. Cl. 10.9 )

RDSO/T-6909

(From Assembled Imp. SEJ)

1085

12

OK

OK

36

Satisfactory

5.

Specified ValueIS 1367 Part-6

Hardness  27-36 HRC

Remarks

H.T.S Nut  ( P. Cl. 12)

RDSO/T-6909   (From Lot)

32, 30

Satisfactory

H.T.S Nut  ( 12 )

RDSO/T-6909

(From Assembled Imp. SEJ)

33, 34

Satisfactory

6.

Specified Value IS  6649

Gr.45 C 8

Hardness

35- 45 HRC

Remarks

Hardened Taper Washer

RDSO/T-6912, RDSO/T-6913

42, 39

Satisfactory

7.

Specified Value IRS-42/

 IS  4072 Gr. 55Si7

Hardness

43- 49 RC

Flattening Test

Decrease height <0.5mm

Twist Test

No sign of fracture through an angle of 900

Depth of De-curb

0.10 max

Decompression Test

Remarks

Single Coil Spring Washer

T-10773

46

OK

OK

OK

OK

Satisfactory

8.

 

Specified Value IS:210 Gr.FG200

Hardness

180 – 220 BHN

Tensile Strength (U.T.S) 200 Mpa min.

Remarks

C.I. Chair

RDSO/T-6904

195

234

Satisfactory


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