Model QAP

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Document No. …………… QAP for PSC Sleepers

NAME oF FIRM
Effective From ……
ISO 9001-2008
LOGO OF FIRM
NAME OF FIRM:
OFFICE ADDRESS:
WORK ADDRESS:
MODEL
QUALITY ASSURANCE PROGRAMME
FOR
MANUFACTURING
OF
PRESTRESSED MONOBLOCK CONCRETE

SLEEPERS (PRE-TENSIONED TYPE)
Specifications: IRS: T-39 (Aug-2011)

IRS: T-45 (May-1996)
IRS:T-46(1985)
Prepared By Checked By Approved By

Quality Control In-Charge Production In-charge General Manager/Plant
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NAME oF FIRM
ISO 9001-2008
coMpANY ppRoFILE
 Brief about formation and history to be given.
 Range of product being manufactured or manufactured in the past

may be given. For example:
1. Gauge 52 Kg/60 Kg MBC Sleepers (RT-2495 & RT-2496).

2. Slack Gauge Sleepers (RT-4170, RT-4171, RT-4172 & RT-4173).
3. Bridge Approach Sleepers (RT-4088, RT-4089-RT-4097).
4. Level Crossing Sleepers (RT-4148 & RT-4148A).
5. 1 in 12 Points and Crossing Sleepers (RT-4218 & RT-4732).
6. 1 in 8.5 Points Crossing Sleepers (RT-4865).
7. Derailing Switch Sleepers (RT-6068).
8. Diamond Crossing Sleepers (Without Slip, Single Slip & Double Slip) (RT-
5362, RT-5363 & RT- 5364).
9. Rex Lock Sleepers (Special Fastening of Rex Lock provided by Escorts
India Ltd..) (A4-97-EQ41-5).
 Brief about organization & its structure may be given
 Brief about raw material and their approved sources may be given

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NAME oF FIRM
ISO 9001-2008
QUALITY POLICY AND QUALITY OBJECTIVES
1. ………………. is committed to achieve customer satisfaction of highest

order by adhering quality parameters and schedule of customer strictly.
2. To become competitive through technical up-gradation and waste

minimization.
3. To create a Team Spirit by continuous interaction with employees.
4. To be sensitive for all environmental concerns by developing greenery

throughout the plant.

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NAME oF FIRM
ISO 9001-2008
ORGANISATION STRUCTURE
GENERAL MANAGER
Name: Rakesh Sharma
BE (Civil), 1.5 years
QUALITY CONTROL IN-CHARGE Production Charge STORE IN-CHARGE MAINTENANCE IN-CHARGE

Name: ……………. Name: ………………. Name: ………………. Name: ……………….
Qualification & Experience …..
Qualification & Experience …..
Name: …….
Qualification……………
LAB ASSISTANTS (…….)
Helpers ( ………numbers)
STORE ASSISTANT-1
CERTIFIED BOILER ATTENDERS STORE ASSISTANT-2
STORE ASSISTANT-3
SHIFT –I SHIFT –II SHIFT –III

SHIFT IN-CHARGE (DET-CIVIL) SHIFT IN-CHARGE (DET-CIVIL) SHIFT IN-CHARGE (DET-CIVIL)
SUP. TENSIONING SUP.TENSIONING SUP. TENSIONING
SUP. CASTING SUP.CASTING SUP.CASTING
SUP.DEMOULDING SUP.DEMOULDING SUP. DEMOULDING
SUP. DISPATCH SUP. DISPATCH SUP. DISPATCH
SHIFT-1 SHIFT-2 SHIFT-3

MECHANIC MECHANIC MECHANIC
ELECTRICIAN ELECTRICIAN ELECTRICAIN
HELPER HELPER HELPER
LATHE OPERATOR

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NAME oF FIRM
ISO 9001-2008
LAYOUT PLAN
LAYOUT PLAN SHOULD BE ATTACHED

ALL THE LOCATION SHALL BE MARKED BY WAY OF NUMBERING
AND CLEARLY IDENTIFIED.

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NAME oF FIRM
ISO 9001-2008
ScopE
The scope of QAP for production of different type of sleepers should be mentioned. Typical
example has been tabulated below:
S N. Type of Sleeper Concrete Grade Drawing No.

1 BG- Mainline M-55 RT-2496
2 BG-Special Sleeper (Level Crossing) M-55 RT-4148
3 BG- SEJ M-55 RT-4149
4 BG- Guard Rail Straight M-55 RT-4088
5 BG- Guard Rail Flared M-55 RT-4089-4097
6 BG- Special Sleeper (Wider Gauge) M-55 RT- 4170 to 4173
BG- Special Sleeper (Wider Gauge) M-55 RT- 4183 to 4186

7
8 25 Ton Axle Load- Main Line M-60 RT-7008
9 25 Ton Axle Load- SEJ M-60 RT-8224
10 25 Ton Axle Load- Level Crossing M-60 RT-8225
11 25 Ton Axle Load- Guard Rail Straight M-60 RT-8228
12 25 Ton Axle Load- Guard Rail Flared M-60 RT-8229 to 8237

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NAME oF FIRM
ISO 9001-2008
AVAILABLE INFRASTRUCTURE
SL
Description Capacity Existing As per STR
No.
1 Cement Godown Area
2 HTS Storage
3 SGCI Insert & PVC Dowel Godown
4 Steam Curing Capacity
5 Water Curing Tanks
6 Stacking Area of Sleepers
7 Sleeper Testing Area
8 Testing Laboratory
9 Office of Inspecting Official
Rest House for Inspecting Official

10
Including Bedroom & Toilet
11 Turnout Assembly Yard
Any deviation from STR should be clearly stated here.

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NAME oF FIRM
ISO 9001-2008
List of Laboratory Equipments
S. N. Requirement of STR Availability Number Model/Make
Compression Testing Machine, 2000KN

capacity, motorized with digital interface
for real time recording of testing results.
1 The system should have sufficient memory 1 NOS.
to store data of one year production with
reporting facility in hard copy as per
format mutually agreed.
Flexural Beam (Tension) testing machine

with loading jacks, 30 KN capacities. The
machine is capable of digital display and
2 recording of data during testing with auto 1 NOS.
logging of time & date of testing. Data
storage & retrieval capability should be for
one year production.
Motorized pumping unit with 500 KN cap.

Jacks (for BG man line sleepers) and 750
KN capacity jacks (for 25 Ton axle load
sleepers), pressure gauge, rubber tubes
and test frame complete for sleeper
testing. The digital display of the load
3 1 NOS.
applied should be visible to observer
simultaneously along with observation of
crack. The data can be recorded in
computer with automatic data and time
record with Batch no. and other detail for
traceability of record.
4 15 cm cubes moulds confirming to IS:516 50 NOS.

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NAME oF FIRM
ISO 9001-2008
5 Beam moulds (10X10X50) cm size 2 NOS.
6 Slump Tester/ Vee Bee Testing Machine 1 NOS.
Electronic balance with 1gm least count

7 1 NOS.
(10/20 Kg. capacity) including weights.
8 Blain's air permeability apparatus 1 NOS.
Vicat apparatus with dash pot and various

9 1 NOS.
needles
10 Stop Watch 1 NOS.
Le Chatelier mould for soundness test of

11 1 NOS.
cement
12 Steel trowels for mixing cement paste 2 NOS.
Cement mortar cube casting machine with

13 1 NOS.
motor and time switch complete
14 7.06 cm (50cm sqr.) mortar cube moulds 06 NOS.
Metallic scoop , pan type container and

15 02 SET
china tray etc.
16 Aggregate impact testing machine 1 NOS.
17 Aggregate crushing testing machine 1 NOS.
18 Aggregate abrasion testing machine 1 NOS.
Electric thermostatic oven with display of

19 1 NOS.
temp
Set of IS Sieves 40 mm and below up to

20 1 NOS.
75 micron
21 Automatic electric sieve shaker 1 NOS.

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NAME oF FIRM
ISO 9001-2008
Proving rings of 2000 KN, 500 KN, and

22 1 NOS.
100 KN capacity
23 1.5 Volt AVO meter 1 NOS.
Glass cylinders and Beakers 50-500 cc

24 01 SET
capacity
Miscellaneous measuring gadgets like

25 02 SET
steel tape, Vernier , filler gauge etc.
Inspection gauges for dimension checking 02 SET

26 of sleepers with digital display of MECHENICAL
parameters as approved by RDSO. GAUGE
Master gauge for checking inspection

27 01 SET
gauge
28 Magnifying glass 01 NOS.
29 Level table steel for checking gauges 01 NOS.
30 pH meter & TDS meter (Digital) 01 NOS.
Any deviation from STR should be clearly stated here:

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NAME oF FIRM
ISO 9001-2008
LIST OF MACHINERY
S.N REQUIREMENT OF STR Availability, number &Model/Make
Concrete Mixer along with Automatic Batching plant

using Micro-processor based Weigh Batcher,
Pneumatically operated aggregate bins, water meter
1 NOS.
and automatic cement feeding capacity of concrete 5
1
cm/hr. It is capable of keeping digital record of
ingredients used in batch wise and data storage
capacity for one year production with print out
facility
2 Dead weights for calibration of weigh batcher 1000 kg
3 Water measuring cans or automatic water meter 01 SET
High frequency 9000 RPM (±4%) Vibrator, bottom

fixing type for PSC Line Sleepers & Turn Out
Sleepers, Vibrators of min. 1.0 KW & 1.5 KW
4 capacity are to be used. The vibrator should have 16 NOS.
recording facility for recording date and time of each
operation. RPM should be digitally displayed during
operation.
5 Low voltage high-speed converter 2 NOS.
Concrete Sleeper Moulds should be made with plate

thickness 6/8 mm with suitable stiffening 300 NOS
arrangement to avoid in service distortion of moulds. (Completed)
6 Rail seat area & end plates are to be made with 10
mm thick steel plate. Rail seat area should also be 200 NOS. (Under
made with adequate measures to ensure proper rail Fabrication)
seat slope and surface finish.
Steam boiler coal/oil fired/electrically operated

capacity 1500kg/hr, complete with valves,
7 1 NOS.
mountings and Chimney. The key parameters of
boiler such as steam pressure should be displayed.
The boiler & its operator’s certification from

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NAME oF FIRM
ISO 9001-2008
statutory authority should be ensured.
8 Cup wire brush type or any suitable type sanders 3 NOS. -
9 Air blower for cleaning moulds 1 NOS. -
10 Portable heavy-duty grinder 06 NOS.
Electric welding Arc cutting m/c for HTS cutting at

11 5 NOS.
de-molding/ Abrasive disc cutter.
MS Gantry crane electrically driven with overhead

12 wire rope Hoist 4/5 capacity for loading of sleepers 1 NOS.
and for putting sleepers in water curing tanks.
13 Wire baskets, Phowrahs crowbars and shovels 1 NOS. -
Concrete Bucket for carrying and pouring concrete in

moulds by bottom controlled discharge on Monorail
14 1 NOS.
Hoists. Movement should be Motorized and operator
Controlled.
15 Wedges & barrels 7500 NOS.
The steam curing should be regulated through servo

controlled valve with auto cut off arrangement and
regulation of steam to maintain the temperature as
per steam curing cycle. The data of time vs temp.
16 18 NOS.
Covering complete casting line should be digitally
displayed and stored. The system should have
sufficient memory to store at least one year's data
with facility to take out print shift wise.
17 Mould oil application brushes or spraying device 10 NOS. -
Diesel electric generator with suitable capacity (160

18 1 NOS.
KVA)
19 Platform type balance (cap.-500 kgs) 1 SET -
20 Drilling machine 1 NOS.

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NAME oF FIRM
ISO 9001-2008
21 Double Acting Hydraulic jacks 500KN capacity. 02 NOS.
Overhead wire rope hoist 2T capacity , Electrically

22 1 NOS.
driven, travelling on 1 Beam section for Demoulding
23 Tachometer 10000 RPM capacity. 1 NOS.
24 Trolley for transportation of finished sleepers. 1 NOS.
Workshop equipments
Lathe Machine
Tower drilling machine 1 NOS.
AG-7 Angle Grinder 1 NOS.

25
Electric Welding Set 1 NOS.
Gas cutting set 1 NOS.
Any Deviation from STR should be clearly stated here:

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NAME oF FIRM
ISO 9001-2008
MIX DESIGN

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NAME oF FIRM
ISO 9001-2008
Mix Design parameters:

1 M-55 M-60
Mix Design Proportions
Cement
Coarse aggregates, CA1
Coarse aggregates, CA2
Fine aggregates
Water
A/C Ratio
W/C Ratio
Sand : CA1 : CA2 ratio
2 Source of raw materials
Cement (Brand name)

2.1
Location of cement plant
Quarry name for CA1

2.2
Distance of quarry from the plant
Quarry name for CA2

2.3
Distance of quarry from the plant
Source name of Fine aggregates,

2.4
Distance of source from the plant
Water source
2.5
pH value of water
NOTE:

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NAME oF FIRM
ISO 9001-2008
1. In case of change of source of cement, mix design is to be rechecked & reviewed

before use.
2. In case of change of aggregates source, aggregates to be tested from external lab

and mix design is to be reviewed before use.

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NAME oF FIRM
ISO 9001-2008
MOULD MAINTENANCE & REPAIR

1. Every Bench is having unique number starting from1 to …….
2. Every Mould is having unique number designating as XY where X is bench number and
Y can be A,B,C & D
3. Every end plate is having unique number ranging from 1 to ……..
4. Every bench is having a maintenance history card as per format given in annexure A
5. Every mould is having a maintenance history card as per format given in annexure B
6. Every end plate is having a maintenance history card as per format given in annexure C
7. Moulds, bench & end plates are checked at least once in a month and conditions are
reported in form register in format as per annexure D
8. Templates are used to check section at end, rail seat &centre as per following drawing.
S N. Type of Sleeper Sleeper Drawing Mould Drawing

1 BG- Mainline RT-2496
BG-Special Sleeper (Level
2 RT-4148
Crossing)
3 BG- SEJ RT-4149
4 BG- Guard Rail Straight RT-4088
5 BG- Guard Rail Flared RT-4089-4097
BG- Special Sleeper (Wider

6 RT- 4170 to 4173
Gauge)
BG- Special Sleeper (Wider
RT- 4183 to 4186
7 Gauge)
8 25 Ton Axle Load- Main Line RT-7008
9 25 Ton Axle Load- SEJ RT-8224
10 25 Ton Axle Load- Level Crossing RT-8225
25 Ton Axle Load- Guard Rail

11 RT-8228
Straight
25 Ton Axle Load- Guard Rail
12 RT-8229 to 8237
Flared

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NAME oF FIRM
ISO 9001-2008
9. Insert pockets are checked with the help of jig as per drawing number …….
10. Rail seat slope is checked with the help of gauge as per drawing number ……..
11. The templates, jigs and gauge are checked at every 6 months and date of checking is
painted on templates, jigs and gauge.
12. End Plates are checked with the help of templates as per drawing number …………
13. Forman is responsible for repair and maintenance of bench, mould and end plates. He is
also responsible for checking of templates, jigs & gauge.
14. Production supervisor is having responsibility to use good condition bench, mould & end
plate.

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NAME oF FIRM
ISO 9001-2008
RAW MATERIAL
1. CEMENT
a) Cement as per mix design is procured.
b) In case of brand of cement is changed, mix design is reviewed before it is used.
c) Cement conforming to BIS:12269:2013 ( as well as IRS-T-40) shall be used.
d) For every consignment it is ensured that test certificates of concern manufacturing

week is received.
e) Cement is stored in go-down week wise is such a way that FIFO principle can be
followed.
f) Cement is stacked in go-down in not more than 10 layers.
g) Cement stacks are placed at least 60 cm away from wall.
h) Cement of 3 month old is not accepted.
i) Set cement bags are rejected after entering the number in register.
j) Cement go-down is checked by Plant supervisor every month.
k) Register is maintained as per format given in Annexure –C
l) For storage of cement IS: 4082 is followed.
m) Before use it is ensured that cement is tested in lab for fineness, consistency, initial
setting time and final setting time.
n) Cement not suitable for production is removed immediately from plant and the same is
entered in cement register.
2. AGGREGATE
a) Aggregate as per mix design is procured.
b) Aggregate shall conform to BIS:383
c) In case of aggregate source is changed the aggregates are tested from external lab
and mix design is reviewed before use.
d) The aggregates are checked for physical tests (Impact value, crushing value,
abrasion value, flakiness index, elongation index) at every consignment or weekly
whichever is earlier.

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NAME oF FIRM
ISO 9001-2008
e) The aggregates are checked for grading at every consignment or weekly whichever is
earlier.
f) The aggregates are tested from external lab at every year for all tests including
soundness and alkali aggregate reaction.
g) The aggregates are checked for moisture before start of every shift. During rainy
season, the frequency is as per requirement.
3. WATER
a) Water is taken from approved source.
b) Water shall confirm to BIS:456

c) In case of change in source, the water is tested from external lab.
d) Water samples are tested monthly for TDS & pH value.
e) Water sample is tested every year from external lab for suitability.
f) Standard solution of known pH & TDS are available for calibration of equipment.
4. HTS WIRE
a) HTS wire from approved BIS suppliers is used.
b) HTS wire shall confirm to BIS:6006
c) On receiving it is checked and ensure that proper wrapping, tag and seal are
available and details are as given in Inspection Certificate.
d) Records are maintained in a format as per Annexure-D
e) HTS wire is stored in water proof area.

f) In case HTS wire is not as per requirement, the same is advised to Zonal Railway
official to take further decision.
5. SGCI INSERT
a) SGCI inserts are procured from approved sources as per Master list of Approved
Vendors of QAC Directorate of RDSO.
b) On receiving it is ensured that IC and test certificates are available.
c) SGCI insert are stored in covered shed
d) 10 % of SGCI insert are checked with approved gauge and hammer testing before
use.
e) Records are maintained in format as per Annexure-D

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NAME oF FIRM
ISO 9001-2008
LAB TESTING OF RAW MATERIAL

1. CEMENT
S. Characteristi Specification reference Acceptance Frequenc Format of

N c check norms y record
(Register
Number)
IS: 4031 (Pt.-2)-1988

3700 As Per
1 Fineness IS:12269-87 (Amd-6) cl.no. Format-I
cm2/gm Format
5.1
Needle
Normal IS:4031 (Pt.- 4)-1988 cl.no. reading 5 to As Per
2 Format-II
Consistency 5.1 7 mm from Format
bottom
IS: 4031 (Pt.-5)-1988

As Per Format-
3 IST 60 minutes
IS:12269-87 (Amd-6) cl.no. Format III
5.3
IS: 4031 (Pt.-5)-1988

As Per Format-
4 FST IS:12269-87 (Amd-6) cl.no. 600 minutes
Format III
5.3
IS: 4031 (Pt.-6)-1988

7 days
Not < 37.5 As Per Format-
5 Mortar cube
IS:12269-87 (Amd-6) cl.no. MPa Format IV
strength 5.4
IS:4031 (Pt.- 3)-1988

Not > 5.0 As Per Format-
6 Soundness
IS:12269-87 (Amd-6) cl.no. mm Format IV
5.2

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NAME oF FIRM
ISO 9001-2008
2. AGGREGATES
Characteristic Specification Frequency Format of

S.N Acceptance norms
check reference record
IS: 2386 (Pt.- Yearly for each

1 Impact Value < 30% Format-VIII
IV) IS:383-3.4 source.
Abrasion IS: 2386 (Pt.- Yearly for each

2 < 30% Format-VIII
Value IV) IS:383-3.5 source.
Crushing IS: 2386 (Pt.- Yearly for each

3 < 30% Format-VIII
value IV) IS:383-3.3 source.
Flakiness IS: 2386 (Pt.-I)

4 < 30% Weekly Format-VII
index IRS-T39-3.3.1
Elongation IS: 2386 (Pt.-I)

5 < 30% Weekly Format-VII
index IRS-T39-3.3.1
Individual
Should be as per
grading of As per Appendix
6 Table-2 of IS: 383- Weekly Format-VI
Course ‘A’ of IS: 383
1970
Aggregates
Individual
grading of As per Appendix
7 Zone-I Weekly Format-VI
Fine ‘A’ of IS: 383
aggregates
Combined
8 Is : 383-1970 Should be in limit Weekly Format-VI
grading
Particle finer
than 75 u -do- ,Table-1
9 <3% Weekly Format-VI
size in fine (cl-3.2.1)
aggregates
Absorbed IRS: T-39-3.4.3 Calculate moisture

Daily, before
10 moisture adjustment in Mix Format-V
each shift
content design

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NAME oF FIRM
ISO 9001-2008
IS: 2386 (Pt.- Aggregate should

Potential
11 VII) IRS-T39- ne innocuous in Yearly
Reactivates
3.3.4 nature
shall pass sodium

or magnesium
IS: 2386 (Pt.-V)
12 Soundness sulphate Yearly
IRS-T39-3.3.2
accelerated
soundness test
Maximum limit of
IS: 2386 (Pt.- deleterious
Deleterious
13 II) IRS-T39- material in Yearly
material
3.3.3 aggregates should
conform to IS: 383
The yearly test is carried out from external lab and apart from three test (at S. N. 11,12 &
13), all other tests mentioned from S.N. 1 to 10 are conducted.

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NAME oF FIRM
ISO 9001-2008
MANUFACTURING PROCESS :-
……………………… is manufacturing PSC sleeper by stress bench method. In this method a steel
structure is fabricated by using channels to hold moulds in a straight line is called bench.
The benches should be properly designed and to be fabricated carefully. The bench should
have capacity to hold 3-4 moulds for Main line sleepers and 2-4 moulds for turnout
sleepers. We have adopted the merry-go-round system in which bench will be carried to
each operation section on roller path.
1. MOULD PREPARATION :-
Moulds are cleaned by using wire cup sander or wire brush. All dirt and any old concrete
materials is removed. After cleaning, good quality mould oil is to be applied to moulds to
prevent concrete sticking to mould surface and for easy demoulding operation.
Precaution:-
a) Mould, insert pocket, mould-end, mould collar, end plate, and end plate holes
cleaning to be done properly with the help of air blower and wire brush.
b) Mould releasing agent is applied on mould and end plates. All minor gaps are filled
with putty. .
c) End plate are fitted after proper oiling.
2. INSERT FIXING :-
Dimensionally accepted inserts are used for production. Proper greasing is done in the insert
pocket before insert pin fixing to avoid sleeper damage and insert hole clogging. Fixing of
oversize inserts in the pocket forcibly is avoided to prevent damage to mould, insert pocket
as well as sleeper at the time of demoulding. At the same time under sized inserts is also
not used to prevent slurry leakage through the insert pocket.
Precaution:-
a) Inserts have been fitted properly i.e. these should not be fitted forcibly.
b) Mould releasing agent/Grease is not applied on the stem of SGCI insert as it may
lead to segregation of concrete with insert during demoulding.
3. WIRE PLACING AND FIXING OF WEDGES AND BARRELS :-
Wire is passed through end plates. Care should be taken to avoid any
overlapping/cross-pass. After placing the wire grips are to be fixed at anchor end first.
Then grips are fixed at tension end.
Precaution:-

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NAME oF FIRM
ISO 9001-2008
a) HTS wire to be cut as per bench length to avoid excess use.

b) During wire insertion, cross pulling must be avoided.
c) It shall be ensured that after placing of wire, alignment of mould is parallel to
alignment of wires.
Responsibility: - Responsibility of all these three operation will be of shift supervisor
Super Check :- By Shift Incharge /Production Incharge/Q.C.In-charge
4. STRESSING OF WIRE:-
a. Before starting of tensioning operation it is checked that machine is in working
conditions and calibration is valid.
b. Before starting, design elongation is calculated based on the young modulus & cross
sectional area given in manufacturing test certificate.
c. Tensioning Machine is started only after completion of hand-tensioning and equalize

all the four stress-bolts.
d. Graphite powder is used in Barrel-wedges before use.
e. Tensioning-guard is to be used during tensioning.
f. Initial tension of 3KN to each wire (total 54 KN, 27 KN from both side) is to be given
to MBG sleeper with drawing number RT-2496 to remove sag or overlapping etc. For
other drawings detail is given in Annexure-E.
g. After giving the initial tension, the elongation is measured at 4 points.
h. Then the wires are further stressed for 27 KN for MBG line sleeper to drawing
number RT-2496(total 486 KN, 243 from each side). For other sleepers, details are
given in Annexure E).
i. The auto cut facility is available and tensioning is stopped at desired load.
j. After completion, elongation at 4 points is again measured.
k. The average elongation is compared with design elongation. If difference is more

than 5%, GM is informed who takes the decision in writing after informing Railway
Official.
l. The points where elongation is to be measured, have been identified with paint
mark.

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NAME oF FIRM
ISO 9001-2008
m. The records are maintained in format given in annexure Format-XII In case of

digital storage of data, printout is taken and filed after cross verification by shift in
charge.
n. The data is taken out monthly basis and backup is created and given to Railway
Authority.
o. Responsibility of correct tensioning operation and record keeping is of Tensioning

supervisor.
5. BATCH MIXING:-
a) Mixing is done in high speed pan mixer.

b) Feeding of mix proportions after moisture adjustment is done at least once for each
shift. During monsoon this is done as per requirement. The feeding is done by lab
in-charge only.
c) Mixing time is also pre-fed based on trial during mix design.

d) For Each shift mixing of concrete as per approved mix design, pouring of concrete
and compaction of concrete takes place.
e) Before any starting of batch mix, batching plant operator ensures that calibration of
plant is correct and valid.
f) Before any starting of batch mix, batching plant operator ensures that batching
proportion incorporating moisture correction has been received.
g) The format of batching proportion for concreting will be as per format V.

h) The lab in charge shall ensure that cement and aggregate being used have been
tested in lab
i) Any deviation in mix proportion other than moisture correction shall be done by GM
after recording the reason.
j) The batching records for each batch shall be maintained in a format given in
Annexure-F. The backup of digital records shall be taken monthly and handed over
to Railway Authorities.
6. CONCRETE PLACING
a. After batch mixing the concrete is transported in a bucket and poured in moulds by
bottom controlled discharge on Monorail Hoists. Movement is motorized and operator
Controlled.
b. Concerting is done in at least three layers.

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NAME oF FIRM
ISO 9001-2008
c. Before pouring, the shift supervisor shall ensure that 2 hours have not been passed
since stressing of wire. It 2 hours have been passed then GM should take decision
after recording the same.
d. Vibration is ensured with the help of 8 vibrators bottom mounted having RPM as
9000 +4%. RPM is digitally displayed at the location. It is also cross checked with
tachometer every week. Vibrator is started only after pouring of first layer.
e. Smooth contact of vibrator with Rail seat plate is ensured by regular cleaning of top
plate of vibrator.
f. In case the RPM is not within limit, the vibrator is immediately removed for repair
and replaced with working vibrator.
g. Vibration is done for 2-4 minutes. In case of vibration time is more than 4 minutes
GM decides after recording the same.
h. Records of vibration is maintained in digital form in format given in Annexure-G.
The backup of digital records is submitted to Zonal Railway monthly.
i. Troweling is done to remove the projection beyond 5 mm. The top of surface is kept
rough.
j. Cubes are cast for each batch and placed in steam chamber along with bench. For
every chamber one cube is cast. The marking of cubes is XDDMM( X is the number of
chamber, DD is date & MM is month)
k. Cubes are cast @ 3 per batch randomly and same are kept in water curing tank for
14 days. The marking is XY where X is serial number ranging from 1 to 3 and Y is
batch number.
7. STEAM CURING
a) After a last bench is cast for a particular steam chamber, the operator starts the
steam curing system.
b) The steam curing cycle shall be as approved by Railway authority. The approved
curing cycle shall be displayed in lab as well as near steam chambers.
c) Benches are placed in chamber with hoist. Utmost care is taken to ensure that is no
damage to sleeper which is cast recently.
d) Steam curing cycle is fully automatic with servo controlled valve. The pre steaming
period is fixed as 120 min or IST of cement whichever is higher.
e) The increasing temperature gradient has been kept at 200C/hr. Maximum

temperature has been kept as 700C.
f) The soaking period at maximum temperature has been kept as 4 hours.

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NAME oF FIRM
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g) After soaking period, the temperature is made to ambient temperature with smooth
temperature gradient.
h) The data of time vs temperature in graphical form is taken and kept as record.
i) The digital data of time vs temperature is stored and backup is made and handed
over to zonal railway monthly.
j) Temperature is cross checked with external thermometer for at least one chamber at
three different time.
k) In case of steam curing chart is not as per approved one, the GM decides after
recording the reasons.
l) The responsibility of working of boiler is of boiler attendant. The responsibility of
recording of data is of lab in-charge. The responsibility of effectiveness of system is
of shift supervisor.
m) GM can modify the steam curing for different type of sleeper only after permission
from Railway Authority and incorporating the same in QAP.
n) Record of steam curing is maintained as per format XVIII.
8. DEMOULDING AND TRANSFER OF PRE STRESS :-
1. After steam curing cycle, cubes from each chamber will be tested for concrete
strength.
2. If the strength comes out to be 40 MPa, sleepers are assumed ready for transfer of pre-stress.
In case of strength is less than 40 MPa, GM will take decision after recording the reason.
3. Benches are removed from chamber for demoulding operation.
4. De-stressing of bench is carried out by diagonally loosing of stress bolt.

5. Cutting of HTS wire is carried by electrodes.
6. De-moulding of sleeper is done by demoulding tackle to avoid damage to sleeper.
7. Holes of insert are cleaned.
8. Batch number marking is being done by paint with the help of stencil as per drawing
umber RT-2496.
9. Surface defects and visual check are carried out. Any defective sleeper is removed
and marked as per drawing RT-2496. Random sleepers are also checked for
dimensional accuracy.

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NAME oF FIRM
ISO 9001-2008
10. First coat of end paint is applied and sleeper will be shifted to curing tanks for water
curing.
11. Responsibility for testing is of lab incharge. Responsibility of demoulding is of shift

incharge.
9. INSPECTION AND TESTING OF SLEEPERS :-

1. After curing period of 14 days 3 cubes for the particular batch is taken out.
2. Sleepers are tested for compressive strength.
3. For M-55 & M-60 Grade Concrete: To be done in the presence of Railway
Official
a) Wherever minimum strength of the three cubes is 55N/sq.mm and above for M55
& 60 N/sq.mm and above for M60 – One sleeper per lot
b) For M-55 Grade: - Wherever average strength of the three cubes is less than 55
N/sq.mm but up to 48 N/sq. mm – Two sleepers per lot.
For M-60 Grade: - Wherever average strength of the three cubes is less than 60
N/sq.mm but up to 55 N/sq. mm – Two sleepers per lot.
c) In case, 15 days average strength of concrete in three cubes for a lot is

less than 48 N/sq mm for M55 Grade and 55 N/sqmm for M60 Grade, the lot shall
be rejected and no testing for moment of resistance or moment of failure will be
conducted
4. Static Bend Test: To be done in the presence of Railway Official

All the sleepers which are selected for static bend test are tested for center bottom
and rail seat test. For acceptance of batch every sleeper should pass the test. The
acceptance values are given in table. In case of any failure, retesting is done with
double the sample size and every sleeper should pass the test.
SLEEPER CENTER RAIL SEAT BOTTOM
TOP (KN) CRACKING FAILURE
(KN) (KN)
BG Line Sleeper 60 230 370
to RT-2496

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NAME oF FIRM
ISO 9001-2008
5. Moment of failure test is conducted after production of every 2500 sleepers. In case
the value is less than acceptance value, Railway Authority takes the decision.
6. For other sleepers, the value shall be as per drawings or as approved by Railway
Authorities.
7. Records of cube test & SBT tests are entered in production register (Format-XIV)
The backup of digital records are submitted to Railway Authority every month.
8. After passing of static bend tests all the sleepers are particular batch are taken out
for offering for dimension check. All the sleepers are checked for critical dimensions.
Defective sleepers are removed and marked as per drawing RT-2466 or Rt-2416 as
the case may be.
9. After removing defective sleepers, sleepers are offered to Railway Authorities.

Railway Authorities check 1% of lot for General Dimension and 10% of lot for critical
dimension and 100% dimension between outer inserts. The records are maintained
in Format-XV
10. After dimension, each and every sleeper is checked for FTC (Fit for track circuiting)
in a manner prescribed in annexure V of IRS T-39. All passed sleepers shall be
marked as per drawing RT-2466.
11. In case of defective sleepers are noticed, and then rechecking is done and again
offered for sample check as mentioned above.
12. Once the inspection by Railway Authority is satisfactory, sleepers are stacked over
wooded sleepers. The sleepers are loaded on rake/truck with the help of gantry
crane.
Responsibility:-Despatch Supervisor.
Super check:-By Q.C.In-Charge
DISPATCH
1. Before dispatch it is ensured that marking with stencil has been done on all sleepers as
per drawing number RT-2466.
2. It is ensured that all rejected material has been removed and is not mixed with passed
sleepers.

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NAME oF FIRM
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3. It is ensured that dispatch lot has been passed by inspecting official after conducting
tests and visual and dimension checks.
4. It is ensured that sleepers are laid with wooden blocks as separator.
5. It is ensured that all the loading is done in day time under close supervision to avoid and
damage to edges.
6. It is ensured that dispatch is being done to consignee as given in inspection certificate.
Responsibility:-Despatch Supervisor

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NAME oF FIRM
ISO 9001-2008
CALIBRATION OF EQUIPMENTS
The frequency of calibration of equipment and machinery has been given below:
S. Name of Equipment Specificatio Format of record

N. n reference (Register No.)
Frequency
IRS: T- Once every week or after
Aggregate Weigh
1 39,Annexur casting 2000 sleepers, Calibration-I
Batcher
e-1 whichever is earlier.
Cement Weighing In Register assigned by
2 -do- -do-
Equipment the plant.
3 Water Meter -do- -do- Calibration-II
Once every 15 days or after
Dimension Checking In Register assigned by
4 -do- inspecting 5000 sleepers,
Gauges the plant.
whichever is earlier.
Once a month or after casting
Pre-tensioning Jacks
5 -do- 5000 sleepers, whichever is Calibration-III
( 500 KN capacity )
earlier.
Pre-tensioning Load
6 -do- -do- Calibration-IV
Cell
15 cm Concrete Cube
-do-
7 Testing machine ( Once in 3 months Calibration-V
2000 KN capacity )
Sleeper Static Bend Once in 3 months or after
8 Test machine -do- testing 250 sleepers, whichever Calibration-VI
( 650 KN capacity ) is earlier.
Cement Mortar Cube
9 Testing machine ( 500 -do- Once in 6 months Calibration-VII
KN capacity )
Concrete Beam
10 Testing Machine ( 100 -do- Once in 6 months Calibration-VIII
KN capacity )
Master Gauges for
checking correctness In Register assigned by
11 -do- Once in 6 months
of dimensions the plant.
measuring gauges

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NAME oF FIRM
ISO 9001-2008
Proving Rings
12 (2000 KN,1000KN, -do- Once in 18 months -do-
500 KN and 100 KN)
The summery of calibration record is prepared and maintained in Lab in a

format given below
S. N. Name of Instruments Mak Periodi Last calibration Next Format of
e city Certificat Agenc Dat due record
e No. / y e date of (Register
Referenc calibrat No.)
e ion
(1) (2) (3) (3) (4) (4) (5) (6) (7)
1 Aggregate Weigh Batcher
2 Cement Weighing Equipment
3 Water Meter
4 Dimension Checking Gauges
Pre-tensioning Jacks
5
( 500 KN capacity )
6 Pre-tensioning Load Cell
15 cm Concrete Cube Testing
7
machine ( 2000 KN capacity )
Sleeper Static Bend Test
8
Cement Mortar Cube Testing
9
Concrete Beam Testing
10
Machine ( 100 KN capacity )
Master Gauges for checking
11 correctness of dimensions
measuring gauges
Proving Rings (2000 KN, 500
12 KN and 100 KN)
NOTE: THE PROCEDURE OF CALIBRATION AND ACCEPTANCE CRITERIA IS

DISPLAYED NEAR THE EQUIPMENT.

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Format -I
Date:
SPECIFIC SURFACE OF SPECIAL CEMENT
WITH THE HELP OF BLAINE'S AIR PERMEABILITY APPARATUS
[ IS: 4031 ( Part-II ) -1988 ]
Consignment of Cement = ________________________

Room Temperature = ________________________ 0C
Weight of Sample taken = ________________________ gms.
Liquid falling time of standard cement (Ts) = ____________ Seconds
Specific surface of the standard cement (Fs) = ____________ cm2 /gm
S. No. Liquid falling time of Average Time Remarks

sample cement (T)
Specific Surface of sample Cement (Fm) = Fs x T cm2 / gm
Ts
= ____________ cm2/gm
 Specific Surface = _________________________ cm2/gm
> 3700 cm2 / gm. OK / < 3700 cm2 / gm. NOT OK
Signature of Lab In-charge Signature of Railway Inspector Countersigned by AEN/XEN

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NAME oF FIRM
ISO 9001-2008
Format -II
Date: NORMAL CONSISTENCY OF
SPECIAL CEMENT FOR INITIAL AND FINAL SETTING TIME

[ IS: 4031( Part-IV ) -1988 ]
Consignment of Cement : ________________________________
Room Temperature : ________________________________ oC
Weight of Sample taken = ________________________________ gms
S. % of Volume Time Reading Needle Normal Remarks

No. Water of Water of Time reading in consistency
added added adding mm from %
water bottom of the
in ml. mould (Minimum)
1.
Needle reading
2.
between 5 to 7 mm
3. from bottom of the
mould indicates Normal
4. Consistency.
Normal Consistency = ___________________________ %
Quantity of water to be added for making paste of special cement for determination of initial and final
setting time is 85 % of the normal consistency.
 Quantity of water to be added = 85 % of ____________ ml = _______ ml.

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NAME oF FIRM
ISO 9001-2008
Date: Format -III
INITIAL AND FINAL SETTING OF SPECIAL CEMENT

[ IS: 4031 ( Part-V ) -1988 ]
Consignment of Cement = _________________________________
Room Temperature = _________________________________ oC
Weight of sample taken =__________________________________gms
Normal consistency = _________________________________ %
Quantity of water added = _________________________________ ml
Time of adding water = _________________________________ minutes
Mould ready for needling at = _________________________________
S. Reading Time Reading of needle from Spot of needle for Remarks
No. at bottom of the mould in mm final setting time
1 Initial Setting Time

2
3 is -----------
4 minutes.
5
6 > 60 minutes OK
7
8 < 60 minutes NOT OK
9
Final Setting Time
10
11
is ------------
12
minutes.
13
14
> 600 minutes OK
15
16
< 600 minutes NOT OK
17
18
19
20
Initial Setting Time = _______ minutes :
Whether any modification is required for steaming curing cycle (Y/N)………….
Final Setting Time = _______ minutes

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NAME oF FIRM
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Date: Format -IV
7 DAYS COMPRESSIVE STRENGTH OF

CEMENT MORTAR CUBES WITH STANDARD SAND
[ IS: 4031( Part - 6 ) -1988 ]
&
SOUNDNESS OF CEMENT [IS: 4031 (Part-3)-1988]
A: 7 Days Compressive Strength of Cement Mortar Cubes with Standard Cement

Consignment of Cement : __________________________________
Room Temperature : __________________________________oC
Normal Consistency (P) : _________________ % (See Normal Consistency test)
(i) Standard sand = 600 gms.
(3 parts, one part of each grade)
(ii) Cement 1 part = _____________________ 200 gms.
Total = _____________________ 800 gms.
 Water required for the preparation of mortar cubes in ml.
= ( P + 3) x total weight of sample
4
= ( P + 3) x 800
4
= ____________________ ml
S. Mortar cube Mortar cube Load Strength in Minimum Remarks

No. casting testing N/mm2 Strength
In KN in N/mm2
Date Time Date Time
1 < 37.5 N/mm2

NOT OK
2
> 37.5 N/mm2
3 OK.
B: Soundness of cement
Expansion of Le Chatelier apparatus needles: ------------- (not more than 5 mm)

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NAME oF FIRM
ISO 9001-2008
FORMAT -V
MOISTURE ANALYSIS
[ IS: 383-1970 ]
Date …………………………. Shift ………………………
S.
Description Units CA1 CA2 FA Remarks
No.
Wt. of wet
A. gms.
Sample
Wt. of dried
B. gms
Sample
Wt. of
C. Moisture %
Sample (A - B)
Moisture
D. %
= C x 100/B
E. Absorption %
Free Moisture
F. %
= (D - E)
Batch wt.
G. Kgs.
(Dry)
Free Moisture
H. Kgs.
= G x F/100
Adjusted wt.
Kgs.
= (G + H)
Wt. Adopted Kgs.
I. Water content as per approved mix design:
J. Adjusted water content after correction:
W/C Ratio =
A/C Ratio =
If aggregates are wet, absorption is to be deducted. Similarly if aggregates are dry, absorption is to be
added.

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NAME oF FIRM
ISO 9001-2008
COMBINED GRANULOMETRIC CURVE (M60) FORMAT -VI

Date Time Next Due on
Wt. of CA1 (20 mm) = Wt. of CA2 (10 mm) = Wt. of FA (Sand) = Combined
gms. gms. gms. Passing Co Grad
Wt. mbi ing
Cum. Cum. Cum.
Siev Retai % % Wt. % % Wt. % % C C ned Ran
Wt. Wt. Wt. FA
e ned retain Pass Retai retain Passi Retai retain Passi A1 A2 Pas ge
Retaine Retai Retai %
Size gram ed ing ned ed ng ned ed ng % % sing
d ned ned
s %
1 1
1 2 3 4 5 6 7 8 9 10 11 12 15 16 17
3 4
20
mm
10
mm
4.75
mm
2.36
mm
1.18
mm
600
µ
300
µ
150

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NAME oF FIRM
ISO 9001-2008
µ
75 µ
Signature of Railway Official Signature of Lab In-charge

Name Name
Designation Designation
Countersigned by AEN/XEN/CSP
Name:
Designation

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NAME oF FIRM
ISO 9001-2008
FORMAT -VII
A: DETERMINATION OF FLAKINESS INDEX [ IS: 2386 ( Part-I ) -1970 ]
SAMPLE TAKEN : COARSE AGGREGATE
Retained Weight of Gauge Weight of Remarks

on I.S. consisting Width (mm) aggregate in each
sieve in at least 200 fraction in passing
(mm) nos. (gm) through thickness
gauge (gm)
1 2 3 4 5
W1 = w1 =
W2 = w2 =
W3 = w3 =
Total W = w=
Flakiness Index = w / W x 100 = x 100 = %

As per IRS: T -39 if the above result of flakiness index is less than 30%, it is considered
satisfactory.
B: DETERMINATION OF ELONGATION INDEX
Retained Weight of Gauge Weight of aggregate Remarks
on I.S. fraction length in each fraction
sieve in consisting at size retained on
(mm) least 200 nos. (mm) corresponding
(gm) Gauge length (mm)
1 2 3 4 5
W1 = w1 =
W2 = w2 =
W3 = w3 =
Total W = w=
Elongation Index = w / W x 100 = x 100 = %
As per IRS: T -39 if the above result of Elongation index is less than 30%, it is considrded
satisfactory.

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NAME oF FIRM
ISO 9001-2008
FORMAT –VIII
A: DETERMINATION OF CRUSHING VALUE [ IS: 2386 ( Part-IV ) -1970 ]
Aggregate crushing value= (B/A) x100…………………
Where, B= Weight of fraction passing appropriate sieve………………………..
A= Weight of surface dry sample, when carried out as per provision of para 2.4 IS:2386(Pt.
IV)…………………….
B: DETERMINATION OF IMPACT VALUE [ IS: 2386 ( Part-IV ) -1970 ]
Aggregate crushing value= (B/A) x100………………..
Where, B= Weight of fraction passing 2.36mm IS sieve……………………
A= Weight of oven dry sample, when carried out as per provision of para: 4.4 IS:2386(Pt.
IV)…………………………………
C: DETERMINATION OF ABRASION VALUE [ IS: 2386 ( Part-IV ) -1970 ]
Aggregate crushing value= (B/A) x100………………………
Where, B= Weight of fraction passing 1.7mm IS sieve………………………
A= Weight of oven dry sample, when carried out as per provision of para: 5.2 of IS:2386(Pt.
IV)………………………….

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NAME oF FIRM
ISO 9001-2008
FORMAT - IX
PROFORMA FOR CALIBRATION OF MACHINES / EQUIPMENTS AT CONCRETE SLEEPER PLANT
Calibration – I
Calibration of Weigh batcher/Cement load Cell by Standard Dead Weight
Dead Observed load Average Error % Remarks
S.
load observed Variation
No. 1 2 3
(Kg) load
1 50
2 100
3 150
4 200
5 250
6 300
7 350
8 400
9 450
10 500
FORMAT - X
Calibration – II
Calibration of Water meter
Actual Observed water content Average Error % Remarks
water ( in litres ) Observed Variation
S.
content water
No.
( in litres ) 1 2 3 content
( in litres )
1 5
2 10
3 15
4 20
5 25
6 30
7 35
8 40
9 45
10 50

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FORMAT – XI
Calibration – III to VIII
Calibration of Static Bend Testing Machine, Concrete Cube Testing Machine,
Tensioning Jacks and Cement Mortar Cube Testing Machine
PROVING RING NO………………… Date of Calibration ………………… Valid up to………………………
Calibration of M/c ………………… Date & Time……………………. Next Due…………………………
Name of machine / equipment :

Proving Actual Observed load Averag Error % Remarks
S. Ring load e Variatio
N. Deflection observ n
1 2 3
Reading ed load
1
2
3
4
5
6
7
8
9
10

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NAME oF FIRM
ISO 9001-2008
Format –XII
TENSION REGISTER
Batch No. : _______ Shift : ______Date of Cast : ______ No. of Cast : _______
Elongation in mm
Young’s Modulus of the
Length of Wire (Bench)
Area of HTS Wire mm2
Total Prestress Force =

Elongation from 50KN
(P+50)KN (Note Less

Total Cross Sectional
Measured Elongation
Based on Measured
Prestrassing force
Reading at Final
P=E[(B-A)*a]/L
Initial reading
lot KN/ mm2
2x25 reading
(B-A) (mm)
Bench No.
KN 2x243KN
S. No.
mm
then 486KN)
(A} (mm) (B) (mm)
Left
Remarks
Left Right Right
Sid
Side Side Side
e
U L U L U L U L
1
2
3
4
5
6
7
8
9
10
*P=E[(B-A)*a]/L Where P(KN)=Prestressing forced (from 50KN to final

Prestressing Value)
a(mm2)= Total Cross Sectional Area of HTS Wire mm2
(B-A)(mm)=Measured Elongation
E(KN/mm2)= Young’s Modulus (Lot Wise / IC wise)
L(mm)=Effective Wire Length (from wedge clear Length)
Note : Breakage or slippage of HTS wire, if any shall be recorded.
Signature of Shift-incharge Signature of Railway Inspector Countersigned by AEN/XEN

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NAME oF FIRM
ISO 9001-2008
STEAM CURING REGISTER
Format -XIII
Name of Plant: Name of Boiler Attendant: ___________________ Batch No. ______________
Shift : 1 _____________ Date: ______________
Shift : 2 _____________
Shift : 3 _____________ Shift: Day / Night
Chamber No. 1 2 3 4 5 6 7 8 9 10 11 12
No. of Bench
Last Bench
Cast at
Cube No.
Temperat Temperat Temperat Temperat Temperat Temperat Temperat Temperat Temperatur Temperat Temperat Temperat
Time
ure ure ure ure ure ure ure ure e ure ure ure
07.00
07.30
08.00
08.30
09.00
09.30
10.00
10.30
11.00
11.30
12.00
12.30

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NAME oF FIRM
ISO 9001-2008
13.00
13.30
14.00
14.30
15.00
15.30
16.00
16.30
17.00
17.30
18.00
18.30
19.00
19.30
20.00
20.30
21.00
21.30
22.00
22.30
23.00
23.30
24.00
00.30
01.00

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NAME oF FIRM
ISO 9001-2008
01:30
02:00
02:30
03:00
03:30
04:00
04:30
05:00
05:30
06:00
06:30

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ISO 9001-2008
PRODUCTION REGISTER Format-XIV
On Date
Monthly Production
Cumulative
Batch Date of
Shift :
No. : Casting :
Steam
Chamber
No.
Bench No.
Time of
L.B.C
RELEASE CUBE STRENGTH (STEAM CURED)
Remarks
(in Hrs.)
(in Hrs.)
(in Kgs)
Date of
Testing
(in KN)
N/mm2
Weight
Cube
Time
Load
Age
No.
WATER CUBE STRENGTH (WATER CURING)

(in days)
Remarks
(in Hrs.)
(in Kgs)
Date of
Testing
(in KN)
N/mm2
Weight
Cube
Time
Load
Age
No.

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NAME oF FIRM
ISO 9001-2008
FLEXURAL STRENGTH
Date of Age ( in Load ( in Strength ( in
Beam No. Remarks
Testing days ) KN ) N/mm2 )
STATIC BENDING TEST

Date CENTRE MR MF Remarks Initial
Sleeper
of Top Bottom I II I II
No.
Testing
(KN) (KN) (KN) (KN) (KN) (KN)
Cement Source Week No.
Cement MTC No. Cement Test register S.N.
HTS Source IC Number & Heat No.
SGCI insert IC No./Heat No.
HDPE Dowel IC No./Batch No.
Moisture Slip No. Batching Slip No.
Tensioning Steam Curing Reference

Reference
Total Rejected No. of Sleepers passed

as usables
REJECTION DETAILS OF SLEEPERS
IC No.: DATE OF ISSUE:
Signature of QA In-charge Signature of Railway Inspector Countersigned by AEN/XEN

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NAME oF FIRM
ISO 9001-2008
Format –XV
DIMENSION REGISTER
Date of Casting : ________________ No. of Cast : _________________

Batch No. : _______________ Offered for inspection : __________
Nos. of useable sleepers : _________ Date for inspection : ____________
Rail Height Wind

Toe Gap Slope
Slee Oute Seat Sur Gauge Gauge FT Remar
per r Firm fac C ks
Fir RT side Rai Fir Fir
No. Gau RT side e E Ce RT RT
m l m m
ge sid In def n ntr si sid
sid Ou Inn Ou Se sid sid
e ne ect d e de e
e ter er ter at e e
r s
1A
1B
1C
1D
2A
2B
2C
2D
3A
3B
3C
It should be ensured that the rejected (Red Marked) and MF tested (Yellow Marked) sleepers should
not be dispatch.
Nos. of Rejected =
Nos. of Usable =
Nos. of MF tested =

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NAME oF FIRM
ISO 9001-2008
DIMENSIONAL & WEIGHT CHECK LIST OF INSERT Format –XVI
Description: SGCI insert to RDSO/T-6901 & specification IRS/T-46 (1996)

SGCI Supplier:
RDSO Approval of supplier valid up to ________
Gauge Employed: Gauge and fixtures conforming to ____________
Heat Number : Pattern No: IC number:
Total Number of supply:
Lengt Thickne Widt
Hole
Hea Patter Jig h of ss of h of Top Gating Squar Wt
S dia
t n head stem head radiu positio e in
N
No. No. G G s n gauge Kg.
G
1 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
No. of Inserts Checked ____________. No. of Inserts passed ____________.

No. of Inserts rejected ____________. Rejection Rate :
Note:
1. Railway Inspector will check 1% inserts on random basis.
2. AEN/XEN will check at least 20 inserts, once in 2 weeks on random basis. He will also ensure that
tests prescribed for Rly inspectors are being conducted.
3. Other Instructions contained in Board’s letter no. 98/Tk-II/22/11/17/Pt. Policy, dtd.11.08.2003 are
adhered to.

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NAME oF FIRM
ISO 9001-2008
Format – XVII(STATISTICAL)
SLEEPERS FOR THE PERIOD: FROM_________________ TO _______________
i) NAME OF THE FIRM_____________ ________ LOCATION OF PLANT __________________ RAILWAY_________
ii) TYPE OF SLEEPERS (MBC) TO DRG. NO RDSO/T–7008, RDSO/T-8228, RDSO/T-8224, RDSO/T-8225, RDSO/T-8229-8237.
A. CUBE STRENGTH:
Batch No. No. Range Mea Standar Characteri Coefficie No. of No. of batches Rema
From of N/mm2 n d stic nt observations rks
______ Cub Valu Deviatio value of below the
To_______ es e n (N/mm2) variatio minimum
__ Ma Min N/m SD n specified Dou More than
2 2
x m (N/mm CV (%) values ble double
) 60 (N/mm2) Testi testing
ng
Steam cube
(Release
strength)
Water cube
(15 days
strength)
B. FLEXURAL STRENGTH OF CONCRETE BEAM:
S. Batch No. Load (P) (KN) Flexural strength (N/
No. mm2 )

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NAME oF FIRM
ISO 9001-2008
C. STATIC BEND RESULTS UPTO CRACKING LOAD OF MBC, TURNOUT, OTHER SLEEPER. :
Descrip Bat No. of Ran Mean Standard Characte Coefficient No. of No. of Upto
tion ch sleeper ge value Deviation ristic of observations sleeper date No.
No. s tested (KN) (KN) (KN) Strength variation below the s & No. of
(KN) % min. of sleepers
specified batche
values s
Min Max Sle B Sle Ba
ep at ep tch
er ch er
Center
top
Rail
Seat
Bottom
D. CONCRETE MIX DESIGN USED DURING THE PERIOD: FROM________ To_________

(A) A/C Ratio ______ (B) W/C ratio _____ (C) Mix Proportion CA-I: ___ % CA-II ____ %, FA ____ %
E. SOURCE OF CEMENT USED DURING THE PERIOD:
F. MEASURES TAKEN TO IMPROVE UPON THE DEFICIENCIES OBSERVED IN ABOVE TEST:
Note: 1. Separate analysis shall be submitted for MBC..
2. The analysis should be for one calendar month.
3. Indicate change of source of raw materials, water etc, if any furnish a photocopy of their test report (s).
Asst. Inspecting Engineer

Signature, Date & Seal

p A g E | 56

NAME oF FIRM
ISO 9001-2008
FORMAT -XVIII
YEARLY STATISTICAL ANALYSIS
OF CONCRETE STRENGTH AND STATIC BENDING STRENGTH OF PSC SLEEPERS
SLEEPERS FOR THE PERIOD: FROM_________________ TO _______________

a) Name of The Firm : _____________________________________
b) Location of Plant : __________________
c) Railway : _________
d) Type of Sleepers (MBC, Turnout & Other) To Drg. No RDSO/T -7008 RDSO/T-8228, RDSO/T-8224,
RDSO/T-8225, RDSO/T-8229-8237.
Month
Nos. of Max Nos. of Max Min Mean Min Mean Nos. of Max Min Mean
cubes cubes cubes
April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
AIE/AXEN/CSP
XEN/CSP/TSO
Dy. CE/TS

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NAME oF FIRM
ISO 9001-2008
Format -XIX
HTS Inspection Summary
Source: BIS approval validity:
IC No. Date of supply: Quantity:
Heat Number: Coil Number: Tag Number:
S.N. Description
1 Lay length
2 Weight/meter
3 Breaking load
4 % elongation
5 0.2% proof stress
6 Sulphur & phosphorus
content
7 Coil dia
8 Packing condition
9 Sealing of coils
10 Any sign of rusting of HTS
wires
11 Young Modulus
12 Cross Sectional Area
Note:
1 Item 1-5, 11 &12 are to be recorded from the Tests Conducted at HTS factory and
recorded in original IC.
2. Item 6 is to be recorded from the Manufacturer’s test certificate.
3. Item 7-10 are to be tested at CSP.
Signature of Store-In- Signature of Railway Inspector Countersigned by AEN/XEN

Charge

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NAME oF FIRM
ISO 9001-2008
Annexure-A
Maintenance History card for Bench/Mould/End Plates
Bench Number/Mould Number/End Plate Number: …….
S.NO. Brought for Work carried out Work Done Checked By Repaired on
repair on date by
Signature of Production In-charge Signature of Foreman

Name Name

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NAME oF FIRM
ISO 9001-2008
Annexure-B Mould Checking Register
Date of Checking
MOULD NUMBER
S.N. Parameters Requirement
1 Full Length 2750 ± 3
Outer Length - Insert to

2 1921 + 1.5
Insert
3 Between Rail Seat 162 + 1.5
Centre of Mould to centre

4 880.5 ± 0
of Rail Seat
Centre of Rail Seat to

5 494.5 ± 0
Mould End
Centre of Mould to Side

6 150 mm ± 0
(Flat Surface )
End of Mould (either

7 50 mm ± 0
straight Position )
8 End Height 235 + 4.5 , -3
9 Centre Height 180 +4.5 , -3
10 Rail Seat Height 210.25 ± 0
11 Slope gauge .08 mm
12 End Plate Height 40 mm
Remarks
Signature of Production in-charge Signature of Foreman/Supervisor

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NAME oF FIRM
ISO 9001-2008
Bench Checking Register
Date of Checking
S. N. Parameters Requirement Bench Number

1 Length 11300 MM
2 Width inside bench 500 MM
Distance between fixed end of
3 240MM
first channel
Distance between first channel &

4 2500 MM
second channel
Distance between second

5 325 MM
channel & third channel
Distance between third channel

6 2500 MM
& fourth channel
Distance between fourth channel

7 325 MM
& fifth channel
Distance between fifth channel

8 2500 MM
& six channel
Distance between six channel &
9 325 MM
seven channel
Distance between seven channel

10 2500 MM
& eight channel
Distance between eight channel

11 200 MM
& nine channel
12 Distance between lifting hook 8000 MM
Distance between liftng hook to

13 1650 MM
fixed end
Distance between liftng hook to

14 1650 MM
free end
15 Jack height (L) 170 MM

16 Jack Height (R) 170 MM
17 Jack Length (L) 285 MM
18 Jack Length (R) 285 MM
19 End Box Stand length (L) 900 MM
20 End Box Stand length (R) 900 MM

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NAME oF FIRM
ISO 9001-2008
10mm thickness tie plate on

21 120 x 190 mm
channel
22 10 mm thickness tie 270x90x20 mm
Distance between Jack & end box 60 MM
23
stand
24 Free End box hole position As per gauge
25 Fixed End box hole position As per gauge

26 Dab bolt and nut position OK/NOT OK
27 Visual inspection welding check OK/NOT OK
Visual inspection fresh material

28 OK/NOT OK
used/ not used
29 Main Channel (ISMC 300) OK/NOT OK

30 Bottom Channel (ICMS 100) OK/NOT OK
31 Rail below lifting hook OK/NOT OK
32 Height of Rail below lifting hook 75 mm
Remarks
Signature of Production in-charge Signature of foreman/Supervisor

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NAME oF FIRM
ISO 9001-2008
END PLATE CHECKING REGISTER

DAYE OF CHECKING
S.N PARAMETERS END PLATE NUMBER
1 Whether Size is ok (Y/N)

2 Whether position of holes are correct (Y/N)
3 Whether there is any Bending(Y/N)
4 Whether elongated holes(Y/N)
Remarks
Signature of Production in-charge Signature of foreman/supervisor

Name Name

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NAME oF FIRM
ISO 9001-2008
Annexure-C
Cement Register
INCOMING MATERIAL USED MATERIAL
Signature/Re
Consumption
No. of Bags
Cumulative
Chalan No.
MTC No.
Balance
marks
Week
Week
Make
Make
Date
Date

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NAME oF FIRM
ISO 9001-2008
Annexure-D
Stock Register
Material Ceme HTS Inse Part Plac Bill Rate Amoun Inspectio Excise Gross
S.N. Receipt nt(in Wire rt y e No.& t n Duty Total
Date MT) (in (in Nam Date Charges @12.
MT) Nos. e 36%
)
TOTAL
Signature of General Manager Signature of Storeman/Inventry In-charge

p A g E | 65

NAME oF FIRM
ISO 9001-2008
Annexure-E
Detail of Initial & Final Tension to be given to each tendon
S N. Drawing No. Initial Tension Final Tension

1 RT-2496 3 KN/each wire 27KN/each wire
3 KN/each wire 27KN/each wire
2 RT-4148

4 RT-4088
5 RT-4089-4097 3 KN/each wire 27KN/each wire

6 RT- 4170 to 4173

RT- 4183 to 4186
7
9 RT-8224

10 RT-8225

11 RT-8228

12 RT-8229 to 8237

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NAME oF FIRM
ISO 9001-2008
Annexure-F
Batching proportion for concreting

Batch Number: Date: Shift:
S.N. Time 20 MM 10MM SAND CEMENT Water Plasticizer

(In KG) (In KG) (In KG) (In KG) (In Ltr.) (In Ltr.)

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NAME oF FIRM
ISO 9001-2008
Annexure G
Vibration Speed Record
Batch Number : Date: Shift:
S.N. Time Bench V-1 V-2 V-3 V-4 V-5 V-6 V-7 V-8
No. (RPM) (RPM) (RPM) (RPM) (RPM) (RPM) (RPM) (RPM)

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NAME oF FIRM
ISO 9001-2008
METHOD OF TESTING & FLOW CHART AS PER ANNEXURE III & IV of IRS T-39
NOTE:
1. All dimensions are in millimeters.

2. The load “P‟ will be applied at centre line of Rail Seat through pressure
distributing M.S. Plate with 1 in 20 slope and size 130X25mm for 52kg rail and
145x25mm for 60kg rail, covering the full width of sleeper.
3. One rail seat bottom shall be tested at a time. It shall be ensured that the other end is
not restrained in upward direction. The rate of loading is 30-40KN per minute.
4. Cracks shall not appear up to the load mentioned in column 2, 3 & 4 of table II when
retained for one minute.
5. A coat of lime wash shall be applied on the sleeper surface before testing.

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NAME oF FIRM
ISO 9001-2008
PROCEDURE FOR CHECKING FITNESS OF CONCRETE

SLEEPERS ON TRACK CIRCUITED STRENGTH (AT THE
TIME OF INSPECTION IN THE CONCRETE SLEEPER
MANUFACTURER‟S PREMISES)
1. All the sleepers shall be tested.

2. The sleeper shall be checked for electrical
resistance at 230 volts AC supply. The
circuitry to be followed will be shown in
sketch at Annexure-V (Contd.).
3. The 230 volts AC supply will be passed through a
not less than 300 W test lamp in series with the
pairs of inserts being tested. For the sake of
comparison, another comparator bulb of the
same wattage directly connected to the 230
volts AC supply will be fitted alongside.
4. Since the testing is being done at a higher
voltage, removal of the rust layer by grinding
shall not be necessary.
5. Resistance will be checked against 2 rail seats.
6. If the test lamp emits light dimmer than the
comparator lamp in the sleeper, the sleeper
shall be accepted and marked „FTC‟ ( Fit
for Track circuit). If it emits light with the
same brightness as the comparator lamp,
the sleeper will be rejected and marked
„NFTC‟ (Not fit for track circuit). In case the
test lamp does not emit light at all, it indicates
that the circuitry is defective and should be
rechecked.
7. In the event of doubts regarding comparison
of brightness, such sleepers will not be
marked. They will be retested with 1.5 V
Avometer and marked for fitness, if found fit
with 200 ohms resistance.
8. The ‟NFTC‟ marked sleepers should be
stacked separately. The FTC/NFTC marking
shall be done on top of sleepers in middle
portion, as shown on Drawing No.RDSO/T-
2466.
9. As the testing is done at higher voltage, all
precautions such as use of gloves in the
hands, insulated boots and insulated chairs
for operator and other necessary precautions
shall be taken for the safety purpose.

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NAME oF FIRM
ISO 9001-2008


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pAgE |1

Document No. …………… QAP for PSC Sleepers

PRESTRESSED MONOBLOCK CONCRETE

Specifications: IRS: T-39 (Aug-2011)

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

 Brief about formation and history to be given.

 Range of product being manufactured or manufactured in the past

1. Gauge 52 Kg/60 Kg MBC Sleepers (RT-2495 & RT-2496).

 Brief about organization & its structure may be given

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

QUALITY POLICY AND QUALITY OBJECTIVES

1. ………………. is committed to achieve customer satisfaction of highest

2. To become competitive through technical up-gradation and waste

3. To create a Team Spirit by continuous interaction with employees.

4. To be sensitive for all environmental concerns by developing greenery

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

QUALITY CONTROL IN-CHARGE Production Charge STORE IN-CHARGE MAINTENANCE IN-CHARGE

SHIFT –I SHIFT –II SHIFT –III

SHIFT-1 SHIFT-2 SHIFT-3

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

LAYOUT PLAN SHOULD BE ATTACHED

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

S N. Type of Sleeper Concrete Grade Drawing No.

6 BG- Special Sleeper (Wider Gauge) M-55 RT- 4170 to 4173

BG- Special Sleeper (Wider Gauge) M-55 RT- 4183 to 4186

10 25 Ton Axle Load- Level Crossing M-60 RT-8225

11 25 Ton Axle Load- Guard Rail Straight M-60 RT-8228

12 25 Ton Axle Load- Guard Rail Flared M-60 RT-8229 to 8237

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

1 Cement Godown Area

3 SGCI Insert & PVC Dowel Godown

4 Steam Curing Capacity

5 Water Curing Tanks

6 Stacking Area of Sleepers

7 Sleeper Testing Area

9 Office of Inspecting Official

Rest House for Inspecting Official

11 Turnout Assembly Yard

Any deviation from STR should be clearly stated here.

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

List of Laboratory Equipments

S. N. Requirement of STR Availability Number Model/Make

Compression Testing Machine, 2000KN

Flexural Beam (Tension) testing machine

Motorized pumping unit with 500 KN cap.

4 15 cm cubes moulds confirming to IS:516 50 NOS.

Prepared By Checked By Approved By

Document No. …………… QAP for PSC Sleepers

5 Beam moulds (10X10X50) cm size 2 NOS.

6 Slump Tester/ Vee Bee Testing Machine 1 NOS.

Electronic balance with 1gm least count

8 Blain's air permeability apparatus 1 NOS.

Vicat apparatus with dash pot and various