Page 01 of 12 Effective from Feb.

2011 M&C/PCN/044/2011

Government of India
Ministry of Railways

SCHEDULE OF TECHNICAL REQUIREMENTS FOR

INFRASTRUCTURE,MANUFACTURING,TESTING &QUALITY
CONTROL REQUIREMENTS

FOR

Antigraffiti Clear coat for Exterior painting of Railways

Coaches, Disel and Electric Locomotives
as per RDSO Spec.no. M&C/PCN/127/09

STR No. - M&C/044/2011

Feb.2011

Issued By

METALLURGICAL &CHEMICAL DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW-226 011
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TABLE OF CONTENTS

1. FOREWORD
2. SCOPE
3. APPLICABLE/REFERENCE DOCUMENTS
4. TERMINOLOGY/ABBREVIATIONS
5. GENERAL REQUIREMENTS
6. M&P REQUIREMENTS
7. TESTING FACILITIES
8. QUALITY CONTROL REQUIREMENTS & TRAINING FACILITIES
9. REPAIR/SERVICE CENTRE
10. MAJOR STEPS INVOLVED IN GETTING THE FIRMS
APPROVED/REGISTERED

11. ANNEXURE-I
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Schedule of Technical Requirements of

Antigraffiti clear coating system for Exterior painting of Railway
Coaches, Diesel & Electric Locomotives as per RDSO Spec.no.
M&C/PCN/127/09

1. FOREWORD

1.1 This document has been prepared to lay down the eligibility and capability
of suppliers seeking approval for manufacturing & supply Antigraffiti clear
coating system for Exterior painting of Railway Coaches ,Disel & Electric
Locomotives as per the recommendation of design directorate.

2. SCOPE

2.1 This document covers the infrastructure facilities for manufacturing of

Antigraffiti clear coatings at works, procurement of raw materials, quality
control etc. These coatings will be used in exterior painting of coaches
diesel and electric locomotives.

3. APPLICABLE/REFERENCE DOCUMENTS
(i) IS: 101
(ii) ASTM D 2794
(iii) ASTM D 3359
(iv) ASTM G-155

4. TERMINOLOGY

STR – Schedule for Technical Requirements

NTH – National Test House
ISO – International Standards Organisation
M&P – Machinery & Plant
NABL –National Accredited Board of Laboratories
NSIC – National Small Industries Corporation Limited
FTIR - Fourier Transform Infrared Spectroscopy
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5. General Requirements

5.1 Any firm seeking approval of this organisation:

(i) shall possess valid ISO 9001 & ISO: 14000 Environmental
maintenance system installation certificate for the products for
which approval is sought
(ii) shall have minimum manufacturing experience of these paints for 3
years
(iii) shall procure these resins from reputed indigenous or international
sources.
(iv) shall have valid clearance from Pollution Control Board.
(v) Shall have the record of supplying the products to the reputed
national and international organisation like defence, heavy &
earthmover industries like BEML, BHEL, railway and major
automotive industries.
(vi) Shall have minimum turnover of 10 crores per annum for last three
years.
(vii) Shall have ERP/SAP supported multimodule application software
for managing the important parts of business
(viii) Firm should have R&D facilities approved by Govt. Agency and
copy of valid certificate should be available. Otherwise the firm
should have tie up with Govt. R&D Laboratory/University
(ix) The firm should have valid capacity certificate issued by NSIC
/Other approved agency for small scale industries.
(x) In case of medium & large scale industries, if capacity certification
is not possible by any approved agency, capacity shall be declared
by the firm itself detailing the points to arrive at the capacity and
subsequently assessing officer will verify the capacity during the
assessment of the firm.
The above information should be furnished by the firm in registration form.

5.2 Covered area with adequate space for storage of raw materials,
intermediate and finish products like pigments, extenders, resins,
hardeners, varnish, thinners, additives, paints etc. including bond room
facilities should be available, free from dampness and humidity in the
same campus of the factory. There should be one bond room with locking
arrangement for storage of finished products for purchase inspection.
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5.3 Approval of a firm will be given as per laid down procedure given in vendor
approval guideline of M&C Dte only after Inspection of the factory
premises to assess the capacity/capability of the firm and samples of
paints drawn during inspection (comprising of a system painting if any)
meets the norms and requirements of the relevant RDSO specifications on
testing at RDSO. The initial approval shall be given in Pt-II and further up
gradation to Pt-I will be given after meeting the requirement given in DOP/
vendor approval guidelines of M&C Dte.

5.4 The firm should submit the Brand Names of the applied products.

6. Manufacturing Machines & Plants

Firm should possess the following minimum machines and plants for
manufacture coatings based on Polysilazane resins.

Table-I

Sl. No. Equipments Quantity (min.)

1. High Speed Disburser, min. capacity 500 lts. 1 No.
2. Formulation vessel 1 No.
3. Inertising plant 1 No.
4. Thinning Pump 1 No.
5. Automatic Filling Machine 1 No.
6. Weighing Machine, 300 Kg., Least count 0.100 Kg. 2 No.
Weighing Machine, 60 Kg., Least count 0.050 Kg. 1 No.
Weighing Machine, 10 Kg., Least count 25.00 gm 1 No.
7. Electronic Balance, 2.00 Kg., Least count 2.00 gm. 1 No.
8. Industrial Vibrator or agitator 1 No.
9. Resin Transfer Pump 2No.
10. Solvent Pump 3 Ns.
11. Sprinkle Cooling Tower 3 No.
12. Unloading Pump 2 No.
13. Condenser 2 No.
14. Separator 2No.
15. High/Slow Speed Premixer 2No.
16. Circulating pumps 2No.
17. Scrubbers 2No.
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18. Hoist 2 ton 1 No.

19. Filter press with variable mesh size filter 2 No.
20. Diesel Generator of adequate capacity 1 No.
21. Solvent handling system 1 No.
22. Nitrogen Inertising system 1 No.

7. Testing facilities

Quality Control Facilities

7.1 The firm should have proper air conditioned laboratory to maintain lab test
conditions at 27 ± 20C and 65 ± 5% relative humidity, for which suitable
indicating/measuring instruments will be available in the lab.

7.2 There should be full testing facilities with equipments which are covered as
per requirements of IS: 101 latest version or as per ASTM. Other
equipments not covered in IS /ASTM shall be of reputed make and these
should have valid calibration certificate. It is mandatory for a firm seeking
approval of RDSO to have equipments listed in table –II at their end.

Table-II

Sl Name of the Equipment Quantity (min.)

No.
1. FTIR - Fourier Transform Infrared Spectroscopy 1 No.
2. Humidity Chamber as per IS : 101 1 No.
3. Cross cut adhesion tester as per ASTM 1 No.
4. Gloss-O-Meter of 600 angle of incidence as per IS : 101 1 No.
5. Abel’s Flash Point Apparatus as per IS : 101 1 No.
6. Flexibility & Adhesion Apparatus as per IS : 101 1 No.
7. Weight/10 Litre Cup as per IS : 101 1 No.
8. Dry Film Thickness Measuring Equipment as per IS : 101t 1 No.
9. Accelerated Weathering Tester viz QUV to ASTM G-53 1 No.
10. Hygrometer 1 No.
11. Chemical Balance up to 4 decimal places (in gms.) 1 No.
12. Physical Balance up to 2 decimal places (in gms.) 1 No.
13. Hot Air Electric Oven 1 No.
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14. Air&Air less spray gun 1 No each

15. Stormer/Brooke Field Viscometer as per IS : 101 1 No.
16. Drying time recorder as per ASTM 1 No.
17. Ford cup No 4 1 No.
18. Impact resistance tester as per ASTM 1 No.
19. Pencil Harness tester 1 No.
20. Wet Scrub Resistance Tester 1 No.
21. Distillation Plant 1 No.
22. Hot Plates 3 Nos.
23. Micronized Sieves, Thermometers, Glass Wares, In adequate
Crucibles, Reagents & Chemicals for Testing of Raw Qty./Nos.
Materials, Intermediate and Finished Products as per
relevant specifications
24. Mild Steel, Tinned and Glass Panels and Test Racks In adequate number as
per relevant specification.
25. Heating Mantles 3 Nos.
26. Water Bath 2Nos.
27. Muffle Furnace 1 No.
28. Mild Steel, Tinned and Glass Panels and Test Racks In adequate number

8. Quality Control Requirements

8.1 There should be a well designed system for traceability and identification
of the materials from raw material, intermediate and finished product
stages.
8.2 The quality manual of the firm for ISO should clearly indicate at any stage
the quality control over procurements of raw materials, manufacturing of
intermediate and finished products by computerized process control
technique.
8.3 The technical supervisors/managers responsible for production & quality
control activities related to manufacturing of subject paint item should have
the minimum qualification of B.E. / B.Tech (Paint /Polymer
Technology/Chemical Engg.) with a minimum of 3 years experience or
M.Sc. (Chemistry) with a minimum of 7 years experience in relevant
fields to look after the production, quality control and testing activities
 Page 08 of 12 Effective from Feb. 2011 M&C/PCN/044/2011

and should have knowledge of paint manufacturing, testing of raw

materials etc. They should be able to take corrective steps in case of
difficulties in maintaining quality control.

8.4 The firm should ensure that proper analysis is being done on monthly
basis to study the rejection at various levels and it is documented.
Process capability should also be studied.

8.5 The firms should ensure that all the relevant RDSO/BIS/ASTM and other
specifications, standards, manuals etc. are available with them.

8.6 The firm should have test certificates issued by approved test house viz
NTH, RTC, HBTI, Shri Ram Test House, NABL accredited National
Laboratories under CSIR for finishing paint based on Polysiloxane resins.

8.7 A frequent Quality Audit check may be carried out regularly at consignee
end to check the quality of paint and other infrastructure and testing
facilities mentioned in the STR.

8.8 The firm should prepare and submit Quality Assurance Plan for products,
which they intend to supply to Indian Railway and Production Units as per
format QMF 0024, detailing various aspects:
- Organisation chart
- Write up on manufacturing process of paints
- Process flow chart for paints
- Recipe of various products
- Trace ability of various products.
- Inspection and testing plan for all the products starting from
raw materials, in process and final product.
- Details of non-conformity and
- Covering other clauses of ISO manual

9. Repair / Service Centre

The firm should have 24X7 customer complaint registration & redressal
mechanism through website.
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10. Major steps involved in getting the firms approved/registered:

10.1 Firm shall obtain fresh application form, vendor approval guidelines,
specifications, STR and other relevant documents after depositing
Rs.15000/- vendor registration fee from M&C Dte/Online.

10.2 Firm shall submit the application form duly filled along with copies of all
relevant documents to M&C Dte.

10.3 The application form and other relevant documents shall be scrutinized at
M&C Dte and if any deficiencies are found, the firm shall be asked to
comply the deficiencies.

10.4 After all deficiencies are complied by the firm, the capability of the firm
shall be assessed by nominated official. Samples shall also be drawn from
the firms premises and shall be tested at RDSO/Outside approved lab, as
applicable.

10.5 If all the test results are satisfactory and all other requirements are fulfilled,
the firm shall be approved for a period of 2 years in Part-II only.
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ANNEXURE –I

SN Description of Capacity Total No.of Operation to Capacity of Year & Present

Machine/Equipment/Manp requirement/ requirem Machine be performed available Make of Status—
ower Qualification ent s by Machine machine Working/
available Machine/Equi Underco
pment mmencin
g/Not
working
1 2 3 4 5 6 7 8 9
1 High Speed Disburser, 500 kg. 1 No.
min. capacity 500 lts.
2 Formulation vessel Suitable 1 No.
capacity
3 Inertising plant 1 No.

4 Thinning Pump 1 No.

5 Automatic Filling 1 No.
Machine
6 Weighing Machine, 300 ., Least count 2 No.
Kg 0.100 Kg. 1 No.
Weighing Machine, 60 Least count 1 No.
Kg.,. 0.050 Kg
Weighing Machine, 10 Least count
Kg., 25.00 gm
7 Electronic Balance, Least count 1 No.
2.00 Kg., 2.00 gm.
8 Industrial Vibrator or 1 No.
agitator
9 Resin Transfer Pump 2 No.
10 Solvent Pump 3 Ns.
11 Sprinkle Cooling Tower 3 No.
12 Unloading Pump 2 No.
13 Condenser 2 No.
14 Separator 2 No.
15 Slow Speed Premixer 2 No.

16 Circulating pumps 2 No.

17 Scrubbers 2 No.
18 Hoist 2 ton 1 No.
19 Filter press with 2 No.
variable mesh size filter
20 Diesel Generator of 1 No.
adequate capacity
21 Solvent handling 1 No.
system
22 Nitrogen Inertising 1 No.
system
23 FTIR - Fourier 1No.
Transform Infrared
Spectroscopy
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24 Humidity Chamber as per 60° Angle 1No.

IS : 101
25 Cross cut adhesion tester 1No.
as per ASTM
26 Gloss-O-Meter of 600 1No.
angle of incidence as per
IS : 101
27 Abel’s Flash Point 1No.
Apparatus as per IS : 101
28 Accelerated Weathering 1No.
Tester viz QUV to ASTM
G-53 / G-155
29 Hygrometer 1No.
30 Chemical Balance up to 4 1No.
decimal places (in gms.)
31 Physical Balance up to 2 1No.
decimal places (in gms.)
32 Hot Air Electric Oven 1No.
33 Air&Air less spray gun 1No.
34 Stormer/Brooke Field 1 No.
Viscometer
35 Drying time recorder as 1 No.
per ASTM
36 Ford cup No 4 1 No.
37 Impact resistance tester 1 No.
as per ASTM
38 Pencil Harness tester 1 No.
39 Wet Scrub Resistance 1 No.
Tester
40 Distillation Plant 1 No.
41 Hot Plates 3 No.
42 Micronized Sieves, 1 No.
Thermometers, Glass
Wares, Crucibles,
Reagents & Chemicals for
Testing of Raw Materials,
Intermediate and Finished
Products as per relevant
specifications
43 Mild Steel, Tinned and adequat
Glass Panels and Test e
Racks number
44 Heating Mantles 3 No.
 Page 12 of 12 Effective from Feb. 2011 M&C/PCN/044/2011

1 2 3 4 5 6 7 8 9

48 Manpower— The 1 No.

technical supervisors/ each
managers responsible for
for production & quality Product
control activities related ion &
to manufacturing of Quality
subject paint item Control
should have the respect
minimum qualification ively.
of B.E. / B.Tech (Paint
/Polymer
Technology/Chemical
Engg.) with a minimum
of 3 years experience
or M.Sc. (Chemistry)
with a minimum of 7
years experience in
relevant fields to look
after the production,
quality control and
testing activities and
should have knowledge
of paint manufacturing,
testing of raw materials
etc.

Note: Information in column 1 to 4 shall be indicated by RDSO whereas information in

column 5 to 9 shall be furnished by vendor.