GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS
(RAILWAY BOARD)

SCHEDULE OF TECHNICAL

REQUIREMENT (2022) FOR

MANUFACTURE OF PSC SLEEPER

DOCUMENT NO. TDG 0046

(AUGUST 2022)

RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW – 226011
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SCHEDULE OF TECHNICAL REQUIREMENT (2022) FOR
MANUFACTURE OF PSC SLEEPER

DETAILED INFORMATION

1.0 Name of Sleeper Plant :

a) Location :
b) Railway :
c) Nearby Railway Station :
d) Nearby Main Station :
e) Distance from Main & Nearby Station :
f) Telephone / Fax No.
g) Address :
i) Office:
ii) Factory :
h) Details of Production :
i) Main Line Sleepers

ii) 1 in 8½, Turnout Sleepers

iii) 1 in 12, Turnout Sleepers

iv) Wider Sleeper

i) Whether Plant is approved for manufacturing any other type of sleeper:

2.0 Method of manufacture (Long line, Stress bench etc.):

3.0 Contract details:

S.No. C. A. No. Railway Type of Quantity Delivery

sleepers date

4.0 QUALITY ASSURANCE PLAN & ISO CERTIFICATION:

S No Item Remarks
4.0.1 QAP Approved by RDSO (Yes / No)

4.0.2 Date of approval of QAP by RDSO

4.0.3 Remarks about implementation of QAP

4.0.4 Whether Plant is having ISO: 9001-2015

(Yes / No)

4.0.5 ISO Certifying agency & Date of validity

of ISO certificate
Whether Internal Quality Audit of plant
4.0.6 is done by the firm at a frequency of
at least once a year.
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5.0 ORGANISATION STRUCTURE:

Typical organization structure chart of a Concrete Sleeper Plant is as given below -

Managing Director

Quality Control Management Representative

In-charge (For other activities related to Marketing,
(Civil Engineering Graduate) Material Procurement, Liasioning,
Logistics etc.)

Production In-charge Lab-in-Charge Maintenance-in-

One per shift/per production (One) Charge
shed (Diploma in Civil (One)
(Diploma in Civil Engineering) Engineering/BSC (Diploma in Mech. /
Elect. / Electronics /
IT/ Civil Engineering

Lab. Assistant
(Two)

Supervisors Mixture Machine Store In-charge

(Two) In-charge (One) (One)

5.1 Minimum Level of Technical Supervision:

1. Overall Quality Control In-charge: At least One Graduate Engineer with Civil Engineering degree.

2. Shift In-charge for Production:

(a) Minimum one supervisors with diploma in civil engineering for each shift per each casting
shed.
(b) Minimum one diploma engineer of mechanical/ electrical / electronic / IT /civil for
maintenance of equipments.

3. Quality Control Supervisor for Laboratory and testing: Minimum one supervisor with Diploma
in Civil Engg./ BSc .

4. Supervisors & Mixture Machine In-charge should be suitably qualified and their competency
shall be certified by the overall Quality Control In-charge of the plant.
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5.2 DETAILS FOR LEVEL OF SUPERVISION:

SNo. Item Name Qualification Experience

5.2.1 Nos. of Engineers

5.2.2 Nos. of Technical

Supervisors

5.2.3 Name of separate Quality

Control Supervisor for
Laboratory

5.2.4 Reason for any deficiency

in manpower and
planning of compliance.

6.0 LAYOUT PLAN:

S No. Item Remarks

6.0.1 Owner Ship of land/ Lease Agreement with

Railway.

6.0.2 Notarized copy of agreement

6.0.3 Remarks about deficiency , if any

6.0.4 Whether Layout plan is fully with in land owned

by plant and there is no unauthorized
construction on railway property.

6.0.5 Whether Layout plan is approved if yes then

details of approving authority & reference
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6.1 LAYOUT REQUIREMENT:

S.No. Item Minimum Requirement Existing Remarks

6.1.1 Cement Godown Min. covered godown area = 400 sq.m. (Storage
as per IS:4082- 1996)
6.1.2 HTS Storage Minimum area of covered godown with EOT for
handling of HTS wire coils= 100 Sqm.

6.1.3 Insert Godown Minimum Area of covered godown = 100 sqm.

6.1.4 Steam curing Minimum no. of chamber = (0.65*N/32) rounded
chambers off to next whole number, where ‘N’ is the
proposed daily production capacity. Chambers
shall be vertical type with continuous digital
temperature recording facility connected with
storage of data with servo control automatic
steam control arrangement. CSPs having
present arrangement of Horizontal steam
chamber may continue with existing
arrangement.
6.1.5 Submerged Minimum Submerged water curing capacity
water curing required (In no of sleeper) = (0.65 to 0.75)*N
tanks
Where, ‘N’ is monthly production capacity.
Capacity of one tank should be maximum 3
days production. Tank should have minimum 30
cm free board.
6.1.6 Stacking Area for Minimum 2 month capacity. Maximum layers of
finished sleeper sleepers in one stack should be 25. Minimum
area=0.08*N sqm. Where N is monthly
production capacity.
6.1.7 Laboratory General : Approximately 40 sqm
Sleeper testing area: Approx. 30 sqm.
The laboratory and sleeper testing area should
be illuminated should have 100% power backup.
The laboratory shall be provided with adequate
air conditioners for temperature and humidity
control.
6.1.8 Inspecting Minimum 14 sqm. Fully furnished with adequate
Officials office communication facilities (Fax, Telephone,
Computer with net connectivity etc )
6.1.9 Rest House Minimum two room sets fully furnished with
attached toilet and other amenities including
cooking facility. Min. area 25 sqm.
6.1.10 Platform for At least two platforms of 70mx6m with gantry
turnout sleepers arrangement for handling for inspection of two
sets at a time.
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7.0 Minimum requirement of Plant and Machinery for Concrete Sleeper

Plant: Production Line
S. No. Particulars Qty.

7.0.1 Concrete mixer along with Automatic Batching Plant using Microprocessor 1 no.
based Weigh Batcher, Pneumatically operated Aggregate Bins, Water meter
and automatic Cement feeding, Capacity of Concrete 5m3/hr. It should be
capable of keeping digital record of ingredients used batch wise & data
storage capability for one year production and should be capable of
providing output in hard copy also.
7.0.2 Standard weights of 50 Kg or highest permissible denomination totaling 50kg 1000 Kg
& Small denominations capable of measurement to the least count of 1 kg
for calibration of weigh batcher

7.0.3 Water measuring cans or automatic water meter for calibration of water meter 1,2,5,10&20
liters

7.0.4 Concrete sleeper Mould should be made with plate thickness 6/8mm with 240 nos.*
suitable stiffening arrangement to avoid in service distortion of moulds. Rail
seat area & end plates are to be made with 10 mm thick Steel plate. Rail
seat area should also be made with adequate measures to ensure proper
rail seat slope and surface finish.

*Minimum for a monthly production capacity of 5000 nos assuming one

shift per day (For higher production capacity no of mould required for
daily production plus 20 % for maintenance purpose.)

7.0.5 For Production by Stress Bench Method

7.0.5.1 Steel Stress Benches made of channel and with Jack Anchoring Pockets, for 60 nos.*
holding 4 sleeper moulds. Design of stress bench should be such so as to
have minimum distortion on account of service stresses.

*For a monthly production capacity of 5000 nos BG Line sleepers assuming

one shift per day however it may be increased in the multiples of the
required production capacity.

7.0.5.2 Hydraulically operated Pre-Stress Equipment with motorized unit, for 500KN 2 Sets
jacks along with Pressure Gauges / pressure transducer with digital display
and auto cut arrangement. The data should be displayed on monitor and
should be stored for future analysis of past six months data.

7.0.5.3 Roller and Roller Stand As per

requirement

7.0.5.4 Trolleys for Transportation of stress benches 6 nos.

7.0.5.5 Steam curing chamber of adequate size and capacity to hold not more than
eight benches containing four mould each. The steam curing should be with
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servo controlled valve with steam regulation with auto cut off arrangement
following the steam curing cycle. The thermometers should be provided at
both ends of steam chamber with digital display. The data of time vs
temperature in each chamber should be digitally displayed and stored and
system should have sufficient memory to store at least on year’s data with
facility to take out print shift wise.
7.0.6 For Production by long line method

7.0.6.1 End support embedded in ground with device permitting transfer of As per
pre stress design
7.0.6.2 Tensioning gun with digital pressure gauge, automatic cut off device and 02 nos
automatic elongation & force recording arrangement along with digital
display and logging of data on computer with data storage & retrieval for at
least six month.
7.0.6.3 Casting bed with moulds. No of moulds should be 10 % more than required As per
for daily production capacity. design

7.0.6.4 Tarpaulin hoods for covering casting beds for steam curing. With proper For each
drainage arrangement. casting
line
7.0.6.5 The steam curing should be regulated through servo controlled valve with For each
auto cut off arrangement and regulation of steam to maintain the casting
temperature as per steam curing cycle. The data of time vs temperature line
covering complete casting line should be digitally displayed and stored. The
system should have sufficient memory to store at least on year’s data with
facility to take out print shift wise.
7.0.7 Steam Boiler, Coal /oil fired/electrically operated capacity of 1000 kg/hr, 1 no.
complete with Valves, mountings and Chimney. The key parameters of
boiler such as steam pressure should be displayed. The boiler & its
operators certification from statutory authority should be ensured.

7.0.8 Double Acting Hydraulic Jacks 1000KN Capacity 4 nos.

7.0.9 Concrete Bucket for carrying and pouring concrete in moulds by bottom 1 no.
controlled discharge on Monorail Hoist, Movement should be motorized and
operator controlled.

7.0.10 High Frequency 9000 RPM (+/-4%) Vibrator bottom fixing type. For PSC 16 nos.
line sleepers and Turnout sleepers, vibrators of min 2.0KW capacity are to
be used. The vibrator should have recording facility for recording date and
time of each operation. RPM should be digitally displayed during operation.

7.0.11 Tachometer 10000 RPM capacity 2nos

7.0.12 High Frequency Converter for Vibrators 2 nos.

7.0.13 Vibrating Table for Cubes 15X 15 X 15, table 1mX 1m 1 no.

7.0.14 Electric Welding Arc Cutting M/c for HTS cutting at de-molding/ Abrasive 2 nos.
disc cutter.
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7.0.15 Trolley for transportation of Finished Sleeper 10 nos.

7.0.16 Overhead Wire Rope Hoist 2 T capacity, Electrically driven, traveling 2 nos.
on I Beam Section, One each for demoulding and curing tank

7.0.17 Overhead Wire Rope Hoist for Steam Curing Chambers 3 T capacity, 2 nos.
traveling on I Beam Section (Excluding the structure)

7.0.18 MS Gantry Crane electrically driven with Overhead Wire Rope Hoist 4/5 T 2 nos.
capacity for Loading of sleepers and for putting sleepers in water curing
tanks.
7.0.19 Diesel Generating Set for 125KVA 1 no.

7.0.20 Workshop Equipments At least

one each.
 Lathe Machine
 Tower Drilling Machine
 AG-7 Angle Grinder
 Electric Welding Set
 Gas cutting Set
 Misc. tools and dies
 Misc. measuring tapes, scales

8.0 Laboratory Equipments:

S. No Equipment Quantity

8.0.1 Compression Testing Machine, 2000KN capacity, motorized with 2 nos. of 1 no.
pressure gauges (2000KN & 500KN) with digital interface for real time
recording of testing results. The system should have sufficient memory to
store data of one year production with reporting facility in hard copy as per
format mutually agreed.
8.0.2 Flexural Beam (Tension) Testing Machine with loading Jacks, 30 KN 1 no.
capacity. The machine should be capable of digital display and recording of
data during testing with auto logging off time & date of testing. Data storage
& retrieval capability should be for one year production.

8.0.3 Motorized pumping unit with 1000KN capacity jacks, pressure gauge, 1 no.
rubber tubes and test frame complete for sleeper testing. The digital display
of the load applied should be visible to observer simultaneously along with
observation of crack. The data shall be recorded in computer with automatic
date and time record with Batch no. and other details for traceability of
record.
8.0.4 15 cm cubes moulds confirming to IS:516 50 nos.

8.0.5 Beam moulds 10 x 10 x 50 cm size 2nos.

8.0.6 Slump Tester/Vee Bee Testing Machine 1 no.

8.0.7 Compaction Factor test Apparatus 1 no.

8.0.8 Electronic balance with 1gm least count (10 / 20 Kg. capacity ) including 1 no.
weights.
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8.0.9 Blain’s air permeability apparatus 1 no.

8.0.10 Vicat apparatus with dash pot and various needles 1 no.

8.0.11 Stop watch 1 no.

8.0.12 Le Chatelier mould for soundness test of cement 1 no.

8.0.13 Steel trowels for mixing cement paste 2nos.

8.0.14 Cement mortar cube casting machine with motor and time switch complete 1no.

8.0.15 7.06 cm ( 50 cm2 )mortar cube moulds 2nos.

8.0.16 Metallic scoop, pan type container and china tray etc 2 sets

8.0.17 Aggregate Impact testing machine 1no.

8.0.18 Aggregate crushing testing machine 1no.

8.0.19 Aggregate Abrasion testing machine 1no.

8.0.20 Electric thermostatic oven with display of temperature 1no.

8.0.21 Set of IS Sieves 40 mm and below up to 75 micron 1no.

8.0.22 Automatic electric sieve shaker 1no.

8.0.23 Proving rings of 2000 KN,1000 KN, 500 KN, and 100 KN capacity 1 each

8.0.24 1.5 Volt AVO meter 1no.

8.0.25 Glass cylinders and Beakers 50 - 500 cc capacity 1 set

8.0.26 Miscellaneous measuring gadgets like steel tape, Vernier, filler gauge etc. 2 sets

8.0.27 Inspection gauges for dimension checking of sleepers with digital display of 2 sets
parameters as approved by RDSO. (Optional)

8.0.28 Master gauges for checking inspection gauges 1 set

8.0.29 Magnifying glass 1no.

8.0.30 Level table steel for checking gauges 1no.

8.0.31 pH meter & TDS meter (Digital) 1no.

8.0.32 Elongation and Flakiness Index Gauges 1 each

9.0 Requirement of IP based CCTV camera and sensors

9.1 IP based CCTV camera monitoring system for remote monitoring of sleeper production
in CSPs of Zonal Railways. The live feed from these cameras installed at various critical
locations (as given in the table below) shall be provided to concerned Zonal Railways
and RDSO.
9.2 Installation of Sensors to automatically measure and record various parameters of
design mix such as w/c ratio, moisture content of aggregates etc. production process
such as stressing, vibration, curing, etc. and testing parameters such as cube strength,
SBT test etc. and to automatically transmit these parameters to Zonal headquarter
continuously.
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9.3 Minimum requirement of IP based CCTV camera and sensors

S. ITEM Minimum REMARKS

No. Requirement
CAMERA SENSORS

A STORAGE OF RAW
MATERIALS
1 Cement Godown 2 - -
2 HTS Storage Area 1 - Only 1 camera can be provided if
HTS storage & Insert storage
area are at same location and can
3 Insert Storage Area 1 - be covered by one camera
properly.
4 Coarse Aggregate 1 - Only 1 camera can be provided if
Storage Area CA & FA storage area are at
same location and can be
5 Fine Aggregate Storage Area 1 - covered by one camera properly.
6 Admixture Storage Area 1 -

B CONCRETE PRODUCTION Sensor based mechanism system

should be provided to remotely
record and report weight of every
ingredient of concrete in each
batch of concrete.
1 Batching Plant Operator 1 - -
2 Coarse Aggregate CA-1 1 1 Only 1 camera can be provided if
3 Coarse Aggregate CA-2 1 1 CA & FA storage bins can be
4 Fine Aggregate (FA) 1 1 covered by one camera properly.
One Sensor each for testing
moisture content in each storage
bin.
5 Mixing of Concrete and output 1 - -

C SLEEPER PRODUCTION
1 Production line for concreting 4 1 It should adequately cover the
Sleeper casting, Mould
preparation and HTS wire
threading activities.
One sensor for bench counting
2 Extension of HTS wires 1 1 One sensor for measuring
extension of HTS wires
3 Application of Load for 1 - -
stressing of HTS Strands
4 Compaction of concrete / 1 One sensor per vibrator to
Vibration measure RPM of vibrator and
time of vibration.
5 Casting of concrete cubes / 1 1 -
vibrating table

D CURING
1 Steam Curing Chamber 2 1 Minimum 2 cameras for covering
entire steam curing area. One
Sensor per Chamber to be
provided. Temperature of steam
curing and steam characteristics
to be measured and to be
captured in the overall system
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being used at the centralized
location.
2 Water Curing 4 - Minimum 4 cameras for covering
entire water curing area.
3 De-tensioning and de- 2 - Only 1 camera can be provided if
moulding area both operations are at same
location and can be covered by
one camera properly.
E TESTING LABORATORY
1 Concrete Cube Testing 1 1 Only 1 camera can be provided if
2 Beam Testing 1 1 Concrete Cube Testing and Beam
Testing are done at same location
and can be covered by one
camera properly.
3 Static Bending Test 1 1 -
4 Testing of various ingredients 1 - Should cover entire lab activities.
of concrete viz. Fine
Aggregate, Coarse Aggregate,
Cement Water, Admixture etc.

F TURNOUT ASSEMBLY AREA 2 - -

-
G STACKING AREA 4 - -
-
H OTHERS 2 - Entrance/Exit etc.
Note: The IP based CCTV cameras should be of high resolution and sensors should be of high
sensitivity.

CERTIFICATE

1. This is to certify that the information submitted in Paras 1 to 9 above is correct.

2. Testing of raw material shall be carried out as per relevant specifications, the details of raw
material used is as given in as Annexure-I.

3. Record shall be maintained as per periodicity mentioned in annexure-II and on formats

mentioned therein.

SIGNATURE OF PROPRIETOR

NAME & SEAL

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Annexure-I

1.0 Raw material details & Source of raw materials

S No. Items Remarks

1.0.1 Cement (Brand name)
Location of cement plant
1.0.2 HTS wire (BIS approved source)
Validity of BIS approval
1.0.3 6 mm MS Bar ( confirming to IS: 2265)
1.0.4 Quarry name for CA1
Distance of quarry from the plant
1.0.5 Quarry name for CA2
Distance of quarry from the plant
1.0.6 Source name of Fine aggregate
Distance of source from the plant
1.0.7 SGCI Inserts Source
1.0.8 HDPE Dowel Source
1.0.9 Water source
Quality and quantity
1.0.10 Details of Admixture being used

2.0 Characteristics of raw materials:

2.1 Coarse Aggregate (as per test report submitted at the time of approval of mix design)

S No. Item Coarse aggregates, CA1 Coarse aggregates, CA2

2.1.1 Specific gravity
2.1.2 Impact Value
2.1.3 Abrasion Value
2.1.4 Crushing Value
Combined Flakiness &
2.1.5
Elongation Index
2.1.6 Water absorption

2.2 Fine Aggregate (as per test report submitted at the time of approval of mix design)

S No. Item Fine aggregate river Fine aggregate crushed

sand stone
2.2.1 Specific gravity
2.2.2 Silt content
2.2.3 Deleterious materials
2.2.4 Zone
2.2.5 Water absorption
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2.3 High Tensile Steel

S No. Item Remarks

2.3.1 Conforming to IS: 6006 specification

2.3.2 Type (Plain, Strand): Nominal diameter

2.3.3 Breaking Load & Elongation

2.3.4 0.2% Proof Stress

2.3.5 Young Modulus

2.4 Water

S No. Item Remarks

2.4.1 Testing agency (Copy to be enclosed)

2.4.2 pH value =

2.4.2 Chloride content (mg/lit) =

2.4.2 Sulphate content (mg/lit) =

2.4.2 Inorganic Solids (mg/lit) =

2.4.2 Organic Solids (mg/lit) =

2.4.2 Suspended Solids (mg/lit) =

2.5 SGCI Inserts

S No. Items Remarks

2.5.1 Name of Suppliers

2.5.2 Cross check Heat nos. with IC issued by purchaser /

Inspection authority

2.5.3 BHN value =

2.5.4 Phosphorous content (%) =

2.5.5 Condition of storage in general

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2.6 6 mm M S Bar

S No. Item Remarks

2.6.1 Conforming to IS: 226

2.6.2 Nominal diameter

2.6.3 Breaking Load & Elongation

2.6.4 Yielding stress

2.7 Admixture

S No. Items Remarks

2.7.1 Conforming to IS:

2.7.2 Properties
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Annexure-II

MAINTENANCE OF RECORDS AND DOCUMENTATION :

Following records shall be maintained for scrutiny at future dates.

1.0 Inventory of Raw materials:

1.1 Aggregates:

a) Coarse Aggregate (CA1) 20 to 10 mm

b) Coarse Aggregate (CA2) 10 mm and down.
c) Fine Aggregate (River Sand & Crushed Stone sand)

Details of Receipt, Source, Date of receipt, Truck Nos., Quantity, Balance, Remarks about quality
and signature.

1.2 H.T.S. ( IS: 6006) :

Date of Receipt, Truck No., Nos. of Coils, Serial No. of each coil, Source (Name of the firm),
Details of test certificate, quantity, shift-wise consumption, balance and remarks whether test
certificate is OK. Each lot shall bear a lot number and it should be mentioned in the production
register to correlate, which HTS used in which sleeper.

1.3 Special Cement (IS 269):

Date of receipt, Source, quantity, Shift-wise consumption, balance, whether Test Certificate
received, Details of Lab Tests done at site, Consistency, Initial & Final setting time, Fineness and
7 days mortar cube strength. Each lot shall bear a lot number and it should be mentioned in the
production register to correlate which cement used in which sleeper.

1.4 Inserts ( IRS: T- 46 ) :

Date of Receipt, Truck No., Quantity, Source (Name of manufacturer), Consumption, Balance etc
shall be recorded. Each lot shall bear a lot number and it should be mentioned in the production
register to correlate which insert used in which sleeper.

1.5 Admixture (IS 9103):

Date of receipt, Source & conformance to IS codes, quantity, Shift-wise consumption, balance,
whether Test Certificate received shall be recorded. Each lot shall bear a lot number and it
should be mentioned in the production register to correlate with production of PSC sleepers.

2.0 Production Records:

2.1 Production Register: Batch Nos., Nos. Cast in each shift, cumulative production, Bench Nos.,
Cubes and sleeper testing details, Summary of Rejected and Usable sleepers shall be recorded
in the printed register Daily production register shall be maintained for each design of sleepers
separately (As per format no. XIV).

2.2 Tension Register: (As per format no. XII).

2.3 Steam Curing Records: (As per format no. XIII).

3.0 Testing Records:

a) Sieve analysis with combined granulometric analysis of aggregates. (As per format no. VI).
b) Combined Flakiness and Elongation indices test. (As per format no. VII).
c) Moisture content and modified (adjusted) quantities. (As per format no. V).
d) Records of Moulds and Benches and repairs.
 15

e) Details of Pressure Gauges, Proving Rings and calibration of Pressure gauges.

f) Steam curing and Release cube testing.
g) Dimensional checking. (As per format no. XV).
h) Proforma for individual batch production records.
i) Proforma for monthly progress Report.
j) Standard deviation and characteristic strength of
ii) Release cubes.
iii) 15 days water cured cubes.
iv) Sleeper cracking loads / Rail Seat bottom and center top.
k) Dispatch Register.

4.0 Statistical Analysis & Report to RDSO:

Statistical analysis along with calculations shall be submitted to RDSO every month in Format-
XVII. The statistical analysis should be carried out for following parameters –

i) Release cube strength

ii) 15 days water cured cube strength
iii) Flexural Beam strength
iv) SBT results

Similar analysis shall be carried out for each month and a consolidated report shall be submitted
for a given financial year.

5.0 Calibration records:

The record shall be maintained as per Format-IX, X & XI for calibration of weigh batcher, Water
meter, SBT machine, Concrete cube test machine, cement mortar cube testing machine, Beam
testing machine and tensioning jacks. The schedule is given in Para 6.0 below.

6.0 CALIBRATION SCHEDULE:

Calibration of all the pressure gauges shall be done in the plant itself. Calibration of proving ring should
be got done from a Govt. approved test house or a National Test House. The frequencies of all the
pressure gauges and equipments are as follows:-

S. Equipment Frequency (For Frequency (For

N. Normal PSC Turnout
sleeper) sleeper)
1 15 cm concrete cube testing machine (2000 KNCapacity) As per As per
2 Cement mortar cube testing machine (500 KNCapacity) Annexure-I of Annexure-I of
IRS/T-39 IRS/T-39
3 Sleeper static Bend Test machine sleepers (1000
KN Capacity)
4 Pre tensioning Jacks (500 KN capacity for single mould
bench) & (1000 KN Capacity for twin mould bench)
5 Pre- tensioning Jacks ( 1000 KN Capacity)
6 Pre- tensioning Load cell
7 Concrete beam testing machine (100 KN
Capacity)
8 Aggregate weigh batcher
9 Cement Weighing Equipment
10 Water Meter
11 Admixture Dispenser
12 Master gauges for checking correctness of
dimensions measuring gauges.
13 Dimension checking gauges.
14 Proving Rings (All the Four-2000 KN, 1000 KN,500 KN,
100 KN)
15 Weights & measures
16 Tachometer
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---------------------------------------------------------------------------------------------------------------------------------------------------------------------

Note :-
1) The items referred at S. Nos. 1 to 7 above should be calibrated by proving ring the sleeper plant
itself.
2) The items referred at S. Nos. 8 & 9 should be calibrated by the dead weights and item at S. No. 9
10 by measuring cans that should be available in the plant.
3) The proving ring should be calibrated from a reputed organization like the IITs, NCCBM or NPL
etc.
4) The record of calibration of the all the above equipments should be maintained in a manner that
previous record can be easily connected.
5) The calibration can be done more frequently at the discretion of the inspecting Official.

This is to certify that the information given as above is correct and If the information is found to be
false then the firm will accept the action taken by Railway.

SIGNATURE OF PROPRIETER

NAME

SEAL
 17

Annexure III

FORMATS

This section contains different formats of recording results of various testing

/measurements prescribed. The firm should have sufficient no of serially numbered
Registers printed for each format at all times. The formats should only be filled up by the
minimum authority mentioned in QAP. The relevant pages of registers pertaining to
production of sleepers being inspected must be scrutinized and signed by Railway official
responsible for inspecting the sleepers. In addition to following formats Registers required
as per contract condition including Site order register, Officer’s Inspection Register and Over
Sight Inspection compliance Register should be promptly filled up and presented to Railway
Officials during inspection.
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Format -I

SPECIFIC SURFACE OF SPECIAL CEMENT

WITH THE HELP OF BLAINE'S AIR PERMEABILITY APPARATUS

[ IS: 4031 ( Part-II ) -1999 ]

Date:

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 sample Average Time Remarks

cement (T)

1.

2.

3.

Specific Surface of sample Cement (Fm) = Fs x cm2 / gm

Ts

= cm2/gm

 Specific Surface = cm2/gm

> 3700 cm2 / gm. OK / < 3700 cm2 / gm. NOT OK

[

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 19

Format -II

NORMAL CONSISTENCY OF
SPECIAL CEMENT FOR INITIAL AND FINAL SETTING TIME
[ IS: 4031( Part-III & Part-IV ) -1988 ]

Date:

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 mm consistency
added added adding from bottom of %
water the mould
in ml. (Minimum)

1.

Needle reading
2.
between 5 to 7 mm from
bottom of the mould
3. indicates Normal
Consistency.

4.

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.

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 20

Format -III

INITIAL AND FINAL SETTING OF SPECIAL CEMENT

[ IS: 4031 ( Part-V ) -1988 ]

Date:

Consignment of Cement =

Room Temperature = oC

i. 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 Spot of needle Remarks

No. at from bottom of the for final setting
mould in mm time

1. Initial Setting Time

2.

3. is minutes.

4.

5. > 60 minutes OK

6.

7. < 60 minutes NOT OK

8.
 21

9.

10 Final Setting Time

11

12 is minutes.

13

14 < 600 minutes OK

15

16 > 600 minutes NOT OK

17

18

19

20

Initial Setting Time = minutes

Final Setting Time = minutes

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 22

Format -IV

7 DAYS COMPRESSIVE STRENGTH OF

CEMENT MORTAR CUBES WITH STANDARD SAND

[ IS: 4031( Part - VI ) -1988 ]

&

SOUNDNESS OF CEMENT [IS: 4031-1988] (Part-III)

Date:

A: 7 Days Compressive Strength of Cement Mortar Cubes with Standard Cement

Consignment of Cement:

Room Temperature : oC

ii.
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

= ( P + 3) x 800

= ml
 23

S. Mortar cube Mortar cube Load Strength Minimum Remarks

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

< 37.5 N/mm2

2 NOT OK

3 > 37.5 N/mm2

OK.

B: Soundness of cement

Expansion of Le Chatelier apparatus needles -------------- (not more than 5 mm)

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 24

FORMAT -V

MOISTURE ANALYSIS [IS: 383-2016]

Date Shift

S.
Description Units CA1 CA2 FA Remarks
No.

Wt. of wet
A. Gms.
Sample

Wt. of dried
B. Gms.
Sample

Wt. of Moisture
C. %
Sample (A - B)

Moisture
D. %
= C x 100/B

E. Absorption %

Free Moisture
F. %
= (D - E)

G. Batch wt. (Dry) Kgs.

Free Moisture
H. Kgs.
= G x F/100

Adjusted wt.
Kgs.
= (G + H)

Wt. Adopted Kgs.

W/C Ratio =

A/C Ratio =

If aggregates are wet, moisture content in coarse and fine aggregate is to be accounted for, so as to have
total water as per approved mix design.

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 25

FORMAT -VI
COMBINED GRANULOMETRIC CURVE (M55/M60) [IS: 383-2016]
Date Time Next Due on
Wt. of CA1 (20 mm) = Wt. of CA2 (10 mm) = Wt. of FA (Sand) =
Combined Passing Combined Grading
gms. gms. gms.
Passing % Range
Wt. Cum.
Sieve Cum. % % Wt. Cum. Wt. Cum. % % Wt. Cum. Wt. Cum. % % CA1 CA2 FA
Retained Wt.
Size retained Passing Retained Retained retained Passing Retained Retained retained Passing % % %
grams Retained
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

20 mm

10 mm

4.75
mm

2.36
mm

1.18
mm

600 µ

300 µ

150 µ

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by AEN/XEN/CSP
Name
Designation
 26

Format –VII

A. COMBINED FLAKINESS AND ELONGATION INDEX OF 20 MM AGGREGATE

(IS: 383, 2016, CL:5.3) & (IS:2386, PART-1)

IS SIEVE FLAKINESS INDEX ELONGATION INDEX

Passing Retained Wt. of sample Weight of Wt. Wt. of
through 20 on IS taken (At passed Retained Retained
Sieve(mm) Sieve(mm least 200 material on material on material on
) piece thickness Thickness gauge
s) gauge gauge (D)
(A) (B) (C)=A-B
20 16
16 12.5
12.5 10
TOTAL
Combined Flakiness and Elongation Index=[{B/A}+{D/C}]x100 %

Combined Flakiness and Elongation Index <40% (ok)

B. COMBINED FLAKINESS AND ELONGATION INDEX OF 10 MM AGGREGATE

(IS: 383, 2016, CL:5.3) & (IS:2386, PART-1)

IS SIEVE FLAKINESS INDEX ELONGATION INDEX

Passing Retained Wt. of Weight of passed Wt. Retained Wt.
through 20 on IS sample taken material on material on Retained
Sieve(mm) Sieve(mm) (At least 200 thickness gauge Thickness material
pieces) (B) gauge on gauge
(A) (C)=A-B (D)
12.5 10
10 6.3
TOTAL
Combined Flakiness and Elongation Index=[{B/A}+{D/C}]x100 %

Combined Flakiness and Elongation Index <40%

(ok)

As per IRS-T-39 the above result of combined flakiness and elongation Index is less than 40 %.

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Countersigned by
AEN/XEN/CSPName
Designation
 27

Format –VIII
A: DETERMINATION OF CRUSHING VALUE [ IS :2386 (Part –IV) – 1963]

Aggregate crushing value = (B/A) x 100

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)

Note: 1. For aggregates passing through 20mm sieve, 3.35mm sieve size for separating
finer to be used.
2. For aggregates passing through 10mm sieve, 1.70mm sieve size for separating
finer to be used.

B: DETERMINATION OF IMPACT VALUE [ IS: 2386 ( Part-IV ) -1963 ]

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 ) -1963 ]

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)

Signature of Railway Inspector Signature of Lab In charge

Name Name
Designation
Signature by AEN/XEN/CSP
Name
Designation
 28

FORMAT - IX

PROFORMA FOR CALIBRATION OF MACHINES / EQUIPMENTS AT CONCRETE

SLEEPER PLANT [ IS: 516 ]

Calibration – I
Calibration of Weigh batcher by Standard Dead Weight

Date Time Next due on

Dead Observed load Average Error % Remarks

S. load observed Variation
No. 1 2 3 load
(Kg)

1 50

2 100

3 150

4 200

5 250

6 300

7 350

8 400

9 450

10 500

Signature of Railway Inspector Signature of Quality control In charge

Name Name
Designation
Signature of AEN/XEN/CSP
Name
Designation
 29

FORMAT - X
Calibration – II

Calibration of Water meter

Date Time Next Due on

Actual water Observed water content Average Error % Remarks

content Observed Variation
S. ( in liters ) water
No. ( in liters ) content
1 2 3
( in liters )

10

Signature of Railway Inspector Signature of Quality control In charge

Name Name
Designation

Signature of AEN/XEN/CSP
Name
Designation
 30

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 Ring Actual Observed load Average Error % Remarks

S.
Deflection load observe Variation
No.
Reading 1 2 3 d load

10

Signature of Railway Inspector Signature of Quality control In charge

Name Name
Designation

Signature of AEN/XEN/CSP
Name
Designation
 31

TENSION REGISTER Format –XII (A)

[IS: 6006 - 2014]

For Stress Bench method

Batch No. : Shift: Date of Cast: No. of Cast:

S. Bench Length Total Young’s Initial Elongation in mm Measured Pre-stressing Total

No. of Wire cross Modulus Reading force based on prestress
Final reading at 2 x
No. section al of the Lot ( KN) Elongatio measured force= Remarks
Reading at 2x25 KN 243 KN (B) (mm)
( Bench) area of n elongation (P+50)KN
(A) (mm)
mm HTS wire KN/ from
mm2 mm2 Left Right Left Side Right Side (B-A) 50KN (Not less
Side Side (mm) than486KN)
U L U L U L U L *P=E{(B-
A)*a}/L

*P=E{(B-A)*a}/L,
where P(KN), = pre stressing force (from 50KN to final pre stressing value),
(B-A)(mm),=measured elongation
a(mm2), = total cross sectional area of HTW wires
L (mm) = effective wire length (from wedge to wedge clear length),
E(KN/mm2)= Young’s modulus (lot wise/IC wise)
Note: 1. Breakage or slippage of HTS wire, if any shall be recorded.
2. Values of ‘A’ & ‘B’ shall be based on the respective sleeper drawings

Signature of Railway Inspector Signature of Shift Production In charge

Name Name
Designation
Counter signed by AEN/XEN/CSP
Name
Designation
 32

TENSION REGISTER Format –XII (B)

[IS: 6006 - 2014]
For Long Line Method

No. of Cast: Batch No. : Batch: Shift: Date of Cast:

Line HTS Length Cross Young’s Initial Elongation in mm Measured Pre- Total
no. wire of Wire sectional Modulus Reading Elongation stressing prestress Remarks
no. (Bed) area of of the Lot (KN) Reading at Final reading (mm) (B-A) force based force=
mm HTS wire KN/ 3 KN (A) (mm) at on (P+3)KN
mm2 mm2 27 KN (B) measured (Not less
(cm) elongation than27KN)
*P=E{(B-
A)*a}/L

*P=E{(B-A)*a}/L, where, P= pre stressing force(KN), (B-A)=measured elongation (mm),

a= total cross sectional area of HTW wires(mm2),
L= effective wire length for entire length of bed( from wedge to wedge clear length)(Meter.)
E= Young’s modulus (lot wise/IC wise)
Note: 1. Breakage or slippage of HTS wire, if any shall be recorded.
2. Values of ‘A’ & ‘B’ shall be based on the respective sleeper drawings

Signature of Railway Inspector Signature of Shift Production In charge

Name Name
Designation
Counter signed by AEN/XEN/CSP
Name
Designation
 33

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.

Time Temperature Temperature Temperature Temperature Temperature Temperature Temperature Temperature Temperature Temperature Temperature Temperature

07.00

07.30

08.00

08.30

09.00

09.30

10.00
 34

10.30

11.00

11.30

12.00

12.30

13.00

13.30

14.00

14.30

15.00

15.30

16.00

16.30

Signature of Railway Inspector Signature of Shift Production In charge

Name Name
Designation
Counter signed by AEN/XEN/CSP
Name
Designation
 35

Format-XIV
PRODUCTION REGISTER
On Date

Monthly Production

Cumulative

Batch No. : Date of Casting : Shift :

Steam
Chamber {1} {2} {3} {4} {5} {6} {7} {8} {9} {10}
No.

Bench No.

Time of
L.B.C

RELEASE CUBE STRENGTH (STEAM CURED) to be tested by Lab in charge and Railway Supervisor.

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

WATER CUBE STRENGTH (WATER CURING)

Date of Time Age Weight Load N/mm2

Cube No. Remarks
Testing (in Hrs.) (in days) (in Kgs) (in KN)

FLEXURAL STRENGTH

Beam No. Date of Testing Age ( in days ) Load ( in KN ) Strength ( in N/mm2 ) Remarks
 36

STATIC BENDING TEST

CENTRE MR MF Remarks Initial

Date of
Sleeper No.
Testing
Top Bottom I II I II

(KN) (KN) (KN) (KN) (KN) (KN)

Cement Source IC NO week no

HTS Source IC NO Heat No/s

SGCI Insert Source IC NO Heat No

HDPE Dowel Source IC NO Batch no

REJECTION DETAILS OF SLEEPERS I.C. No. : DATE OF ISSUE :

Total Rejected

No of sleepers passed as usables

Signature of Railway Inspector Signature of Shift Production In charge

Name Name
Designation

Signature of AEN/XEN/CSP Signature of Quality Control In charge

Name Designation
Designation
 37

Format -XV

DIMENSION REGISTER

Date of Casting : No. of Cast :

Batch No. : Offered for inspection :

Nos. of useable sleepers : Date for inspection :

Rail Seat Toe Gap Height Gauge Slope Wind Gauge

Sleep Outer Firm side RT side Surf F Re

E
er Gauge Firm RT ace Rail Cen Firm RT Firm RT T mar
n
No. side side defe Seat tre side side side side C ks
Outer Inner Outer Inner d
cts

1A

1B

1C

1D

2A

2B

2C

2D

3A

3B

3C

Nos. of Rejected = , Nos. of Usable = , Nos. of MF tested =

Note: 1. It should be ensured that the rejected (Red Marked) and MF tested (Yellow Marked) sleepers should not be
dispatched.

2. AEN/XEN to do Dimension check as and when possible.

Signature of Railway Inspector Signature of Shift Production In charge

Name Name
Designation

Signature of AEN/XEN/CSP Signature of Quality Control In charge

NameDesignation Designation
 38

Format -XVI
SGCI Insert : DIMENSIONAL & WEIGHT CHECK LIST

Description: SGCI insert to RDSO/T-381 Alt.9 (or latest alteration) & specification IRS/T-46
(latest version)

SGCI Supplier:

Gauge Employed: Gauge and fixtures conforming to RDSO/T-454 Alt.9

IC no. and date (As issued by Purchaser/Inspecting authority)

S. Heat Patt Jig Length Thickness Hole Width of Top Gating Square Wt in Soundness
No. No. ern of of stem dia head radius position gauge Kg. through
No. G G1 G2 head 1.55-3% hammer
20/25+2/ 22+1/-0 67+1/-0.5 test
75±1 -1

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 to
be adhered to.

Signature of Railway Inspector Signature of Quality Control In charge

Name Designation
Designation

Signature of AEN/XEN/CSP
Name
Designation
 39

Format –XVI A

SGCI Insert : DIMENSIONAL & WEIGHT CHECK LIST

Description: SGCI insert to RDSO/T-6901 Alt.5 (or latest alteration) & specification IRS/T-46 (1996) (latest version)

SGCI Supplier:

Gauge Employed: Gauge and fixtures conforming to RDSO/T-6943 Alt.3 IC no. and date (As issued by
purchaser/Inspecting authority)

S. Heat Patt Jig Length Thickness Hole Width of Top Gating Square Wt in Soundness
No. No. ern of of stem dia head radius position gauge Kg. through
No. G G1 G2 head 1.484-3% hammer
25/35 +2/ 23+0.5/ 71+1/-0.5 test
76 +1/- -1 -0
0.5

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 to
be adhered to.

Signature of Railway Inspector Signature of Quality Control In charge

Name Designation
Designation

Signature of AEN/XEN/CSP
Name
Designation
 40

Format -XVII
STATISTICAL ANALYSIS OF CONCRETE STRENGTH AND STATIC BENDING STRENGTH TEST ON PSC SLEEPERS

SLEEPERS FOR THE PERIOD: FROM TO

i) NAME OF THE FIRM LOCATION OF PLANT

RAILWAY

ii) TYPE OF SLEEPERS (MBC, TURNOUT & OTHER) TO DRG. NO RDSO/T – 2496 OR Drg. No.

ii. Mix design approved by RDSO Vide letter----------------------------------

iii. Compliance of last Over site inspection pending if any--------------------
iv. Last inspection of Railway official on------------------------------------------

A. CUBE STRENGTH :

Batch No. No. of Rang Me Standard Characterist Coefficien No. of No. of batches Remarks
From Cube s e an Deviation ic value t of observations
N/m Val (N/mm2) variation below the
m2 ue SD CV (%) minimum
To M Min (N/mm2) specified values Double More than
a N/mm2 i.e. 55/ 60 Testing double
x (N/mm2) testing

Steam
cube
(Release
strength)

Water
cube (15
days
strength)

B. FLEXURAL STRENGTH OF CONCRETE BEAM:

S. No. Batch No. Load (P) (KN) Flexural strength (N/ mm2 )
 41

Format – XVII Contd..

C. STATIC BENDING STRENGTH TEST RESULTS UPTO CRACKING LOAD OF MBC,
TURNOUT, OTHER SLEEPER. :

Description Batch No. of Range Mean Standard Characteristic Coefficient No. of No. of sleepers & Up to date No. of
No. sleepers (KN) value Deviation Strength (KN) of observations No. of batches sleepers
tested (KN) (KN) variation below the min.
% specified values

Min Max Sleeper Batch Sleeper Batch

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, Turnout and other sleepers.

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)

Signature of Railway Inspector Signature of Quality Control In

Name charge
Designation Designation

Signature of AEN/XEN/CSP Counter Signature of

Name Dy.CE/CSP/HQ
Designation Name
 42

Format -XVIII

YEARLY STATISTICAL ANALYSIS

OF
CONCRETE STRENGTH AND STATIC BENDING STRENGTH TEST 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 -2496 or Drg. No.

Month Concrete Strength Water cured SBT(Rail Seat) MF

Nos. Max Min CS CV Max Min CS CV Max Min CS CV

of
cubes

April

May

June

July

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Signature of Railway Inspector Signature of Quality Control In charge

Name Designation
Designation

Signature of AEN/XEN/CSP Counter Signature of Dy.CE/CSP/HQ

Name Name
Designation
 43

Format -XIX

HTS Inspection Summary

Source: BIS approval validity:

IC No. Date of supply:

Sl. Description
No.
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

Note

1. Item 1-5 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 Railway Inspector Signature of Quality Control In charge

Name Designation
Designation

Signature of AEN/XEN/CSP
Name
Designation
 44

Format -XX
Details of Mix Design

Mix Design parameters :

1 M-55 M-60
Mix Design

RDSO Authority of approval

Date of approval
Kg Kg
Cement
Kg Kg
Coarse aggregates, CA1
Kg Kg
Coarse aggregates, CA2
Kg Kg
Fine aggregates
kg kg
Admixture
Liters Liters
Water
A/C Ratio

W/C Ratio

Sand : CA1 : CA2 ratio

11.0 Granulometric limits for combined aggregates:

To be prepared for each Design mix separately as below:

Sieve Size %Limits (lower – higher) Limits % passing.

20 mm …. - ….. …..

10 mm …. - ….. …..

4.75 mm …. - ….. …..

2.36 mm …. - ….. …..

1.18 mm …. - ….. …..

0.60 mm …. - ….. …..

0.30 mm …. - ….. …..

0.15 mm …. - ….. …..

 45

COMBINED GANULOMETRIC CURVE OF AGGREGATES

Name of Plant: M/s ……………………………..., location, ................... Railway

Actual cumulative percentage passing upper limit lower limit

100.00

90.00

80.00

70M.0U0LATIVE % PASSING
CUM

60.00

50.00

40.00

30.00

20.00

10.00

0.00
0.1 1 10 100
SIEVE SIZE IN MM

12.0 Steam Curing Cycle: The steam curing cycle for winter season and summer seasons, if varies may be given
separately.
The following cycle is approved as follows:

1. Pre steaming = …. hrs. [> IST of cement]

2. Rise in temperature = …. hrs.
3. Constant Temp. = …. hrs.
4. Cooling time = …. hrs.

Total = ….. hrs.

13.0 Submerged water curing: …. days.

14 / 21 days compressive strength on the basis of 40 nos. of submerged water cubes & 40 nos. of steam cured
cube analysis is found …… N/mm2 and ……. N/mm2 respectively.

14.0 Statistical Analysis of Steam cured and water cured cubes: following details shall be submitted -

S.
R M SD CS CV Remarks
No.
1 Steam cured cubes

2 Submerged water cured cubes

Statistical analysis is done to assess the variation in test results. This analysis contains standard deviation, range of
maximum & minimum, coefficient of variation (CV). By knowing the standard deviation, one can obtain characteristic value
of corresponding item. Statistical analysis brings out overall health of the concrete sleeper plants. If the testing for working
out statistical analysis is not done correctly the basic purpose of doing this whole exercise would be defeated.
 46

Formulae are given below to calculate the mean value, standard deviation & coefficient of variation.

SAMPLE CALCULATION OF STATISTICAL ANALYSIS

S. Compressive Frequency Remarks

No. Strength (x)
in N/mm2 (f) F*x ABS(X- Xmean) f * ABS( x-xmean )2

1 52.00 1 I 52.00 5.82 33.87

2 53.33 2 II 106.66 4.49 40.32 1) Nos. of observations,

3 55.56 2 II 111.12 2.26 10.22 N = 40 nos.

4 56.00 3 III 168.00 1.82 9.94

2) Mean, Xmean = f*x / N
5 56.89 2 II 113.78 0.93 1.73
= 2312.91 / 40
6 57.33 5 IIIII 286.65 0.49 1.20
= 57.82 N/mm2
7 57.78 6 IIIIII 346.68 0.04 0.00

8 58.22 2 II 116.44 0.40 0.32 3) Standard Deviation

9 58.67 6 IIIIII 352.02 0.85 4.34 SD = SQRT{f * ABS( x-xmean )2 /N}

10 59.56 4 IIII 238.24 1.74 12.11 =1.9598

11 60.00 4 IIII 140.00 2.18 19.00

4) Characteristic Strength, CS
12 60.44 3 III 181.32 2.62 20.59
Fck = ( Xmean – 1.96 * SD )
13

14 5) Coefficient of Variation,
15 Cv = (SD x 100) / Xmean
16

17 6) Range = 8.44 N/mm2

18 (from 52.00 to 60.44)

19

20

21
 47

22

23

24

25

..

..

Total 40 2312.91 153.64

Signature of Railway Signature of Quality Control In charge

InspectorName Designation
Designation

Signature of AEN/XEN/CSP
Name
Designation