IRS Specification For CMS & WCMS-IRS-T-29-Revised 2023 - 20 - 01 - 2023

IRS : T–29 (Revised – 2023)
Government of India
Ministry of Railways
(Railway Board)
INDIAN RAILWAY
STANDARD SPECIFICATION
FOR CAST MANGANESE STEEL (CMS) CROSSINGS AND
WELDABLE CAST MANGANESE STEEL (WCMS) CROSSINGS
SERIAL NO. IRS: T-29 (REVISED-2023)
ISSUED
BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION

(MINISTRY OF RAILWAYS)
MANAK NAGAR, LUCKNOW – 226 011
INDEX
Clause No. Item Page No.

0 Foreword 1
PART – A : CAST MANGANESE STEEL (CMS) CROSSINGS

1.0 Scope 2
2.0 Quality Assurance Programme 4
3.0 Steel Making 5
4.0 Chemical Composition 5
5.0 Internal Development 6
6.0 Prototypes 7
7.0 Integral Test Bars 11
8.0 Various Stages of Manufacture for Bulk Production 11
9.0 Inspection Gauges/Templates & Other Equipment 17
10.0 Inspection 18
11.0 General 23
12.0 Tolerances 24
13.0 Tests 24
14.0 Rejection 28
15.0 Records for the Purpose of Inspection and Issuance of Final 28
Certificate
16.0 Stamping and Issuance of Inspection Certificate 29
17.0 Painting 29
18.0 Dispatch 30
PART – B : WELDABLE CAST MANGANESE STEEL (WCMS) CROSSINGS

1.0 SCOPE 31
2.0 General requirements for welded parts and welding operation 31
3.0 Tests on CMS Crossing 32
4.0 Tests on finished Welded Joint 35
5.0 Test for weld process approval 38
[i]
ANNEXURE FOR BOTH PART – A & PART – B

Annexure No. Item Page No.
I Proforma for Results of Metallurgical Tests and Dimensional Check 45
and Inspection Report for Internal Development of CMS/WCMS
Crossings
II Proforma Showing Inspection Memo at Various Stages (for CMS 47
Crossing)
II A Proforma Showing Inspection Memo at Various Stages (for 49
Weldable CMS Crossing)
III Procedure for Repair/Rectification of CMS/WCMS Crossings 51
IV Sketch for Showing Metallurgical Defects of CMS/WCMS Crossings 54
V Proforma for Showing Metallurgical Defects of CMS/WCMS 56

Crossings
VI Proforma for Dimensional Inspection of CMS/WCMS Crossing 57
VII Schematic Diagram and Arrangement of Impact Bend Test 59
VIII Sketch Showing Different Categories of Location to be considered 61
for Repair by Welding
IX Schemes of Film Arrangements 62
X Dye Penetration Test Locations for WCMS Crossing Indicated in 63
Diagram
XI Format for Dimension Record 64
XII Sample Welding Graph 65
XIII Section Sketch of Test Piece for Macro-Graphic Test 66
XIV Section Sketch for Micrographic Test 67
[ii]
0. FOREWORD
0.1 This specification is issued under the fixed serial number T - 29 : 2023, the
final number indicates the year of original adoption as standard or in case
of revision, the year of last revision.
ADOPTED 1974
REVISED 1997
REVISED 2000
REVISED 2016
REVISED 2022
REVISED 2023
0.2 This specification was revised in 2016 to incorporate the requirements of

corrigenda issued so far, to include the latest practices & software adopted
in testing, rationalization of inspection procedure by M&C and
Engineering officials, to include the casting of integral test bars, for better
traceability and to include latest version of IS codes relevant to
manufacturing of CMS crossings.
0.3 This specification has now been revised in 2022 to incorporate the latest
version of IS/IRS codes and to incorporate a uniform & unique
numbering system for marking on CMS Crossings including some minor
corrections.
0.4 This specification has been revised again in 2023 to incorporate the
provisions for Weldable Cast Manganese Steel (WCMS) Crossing and
special test therefor and is incorporated as Part – B of this specification.
For WCMS Crossing, Part – A of this specification wherever applicable
has been referred to therein.
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PART – A IRS : T–29 (Revised – 2023)
PART – A
SPECIFICATION FOR CAST MANGANESE STEEL (CMS) CROSSINGS
1.0 SCOPE
1.1 This specification covers the requirement of Cast Manganese Steel (CMS)
Crossings for use in Indian Railway Track.
1.2 Reference specifications
A) IS Specifications
1 IS: 2 – 2011 Rules for round off numerical values

(reaffirmed 2016)
2 IS: 210 – 2010 Specification for Grey Iron Castings

(reaffirmed 2020)
3 IS: 228 – 1987 Methods of chemical analysis of steels (plain

(reaffirmed 1997) carbon and low alloy)
4 IS: 12308 – 1991 Methods of chemical analysis of cast iron and

(reaffirmed 2018) pig iron
5 IS: 13607 – 1992 Ready mixed paint, Finishing, for general

(reaffirmed 2019) purposes, Synthetic smoke grey colour ISC No.
692 to IS: 5
6 IS: 104 -1979 Ready mixed paint, brushing, zinc chrome,

(reaffirmed 2017) priming
7 IS: 12117 -1996 Norms for classification of steel foundries for

(reaffirmed 2017) quality assurance
8 IS: 1500 -2005 Method for Brinell Hardness. Test for Metallic
(reaffirmed 2010) Materials
9 IS: 1599 -1985 Method of bend test

(reaffirmed 2010)
(reaffirmed 2019)
10 IS: 2074 -1992 Ready mixed paint, Air Dying, Red Oxide Zinc
(reaffirmed 2014) Chrome, Priming
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11 IS: 2062 – 2011 Hot Rolled Medium and High Tensile

(reaffirmed 2016) Structural Steel
12 IS: 3063-1994 Fasteners - Single coil rectangular section

(reaffirmed 2015) spring lock washers
13 IS: 7318-1974 Approval Test for Welders When Welding

(reaffirmed 2019) Procedure Approval is Not Required - Part I:
Fusion welding of Steel.
14 IS: 7739 (Part-V) - Code of practice for preparation of

1976 metallographic specimen of iron and steel and
(reaffirmed 2018) their examination
15 IS:276-2000 Austenitic-Manganese Steel Castings

(reaffirmed 2017)
16 IS:4748:2009 Steels – Micrographic determination of the

(reaffirmed 2017) apparent grain size
17 IS:3658-1999 Code of practice for liquid penetrant flaw

(reaffirmed 2020) detection
18 IS:11732-1975 Acceptance standards for liquid penetrant

(reaffirmed 2017) inspection of steel casting
19 IS:6601 Permissible deviations in chemical composition

(reaffirmed 2017) for products analysis of steel castings
B) IRS Specifications
1 IRS: T-12-2009 or latest version Flat bottom railway rails

2 IRS: T-23-1967 or latest version Track bolts and nuts
1.3 All foundries manufacturing CMS Crossing shall be „A‟ class foundries
only and they shall submit self-assessment report against every clause of
IS:12117 to enable RDSO team to verify the correctness of self-assessment
report at the time of inspection for assessment/periodical reassessment
undertaken by RDSO.
1.4 Inspecting authority shall mean RDSO/RITES or any other agency

decided by Railway Board.
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1.5 Inspecting official shall mean authorized representative of inspecting

authority.
2.0 QUALITY ASSURANCE PROGRAMME
2.1 The manufacturer shall prepare quality assurance programme (QAP) and
submit it for approval to the inspecting authority and shall obtain his
approval before commencing the manufacture of CMS Crossing. Besides
other aspects, the following salient points shall be taken into consideration
for preparation of QAP to be submitted to Inspecting Authority.
a) Type of scrap to be used.

b) Internal specification of scraps to be used and charge-mix.
c) Moulding Practice
d) Selection of sands to be used
e) Sand binder additives
f) Preparation of sand and its testing
g) Design of mould box and core boxes
h) Pattern and core making
i) Preparation of moulds
j) Melting process
k) Gas purging technique if any
l) Grain refining technique
m) Stages of testing of molten metal before tapping and at the end of
pouring
n) Shot blasting
o) Fettling i.e. knocks out and removal of risers, ingate, fins, etc.
p) Heat treatment process
q) Straightening after heat treatment and after rectification of defects
by welding
r) Removal of protruded metal if any, with the help of air arc
s) Repair by welding
t) Marking for finishing
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u) Machine finishing of bottom, fishing planes, top gauge face radius,

end section etc. including drilling holes.
v) Bend test, hardness test, radiographic test, solidity test, non-
magnetic test, D.P. test etc. at the various stages of manufacture in
reference to relevant specification.
w) Maintenance of records of tests at various stages
x) Intensity of internal inspection at different stages by Works
Inspector/Manager (QA)
y) Painting
z) Packing and dispatch
3.0 STEEL MAKING
3.1 The steel shall be made by electric arc process or such other process as
approved by the Purchaser or his representative. Keeping the limitation of
operational aspects in view, use of induction furnace for melting is not
permitted.
4.0 CHEMICAL COMPOSITION
4.1 The steel used for crossings, when analyzed as per relevant parts of IS:
12308 or any other established instrumental method, shall have the
following composition:
Constituent Percent
Carbon 1.0 to 1.4%
Silicon (Max) 0.5%
Manganese 11.0 to 14.0%
Sulphur (Max) 0.03%
Phosphorus (Max) 0.06%
The ratio of Manganese to Carbon should be minimum 10:1. In case of any

dispute, the procedure given in relevant part of IS: 12308 shall be the
reference method.
4.2 The manufacturer shall make an analysis of the sample of steel from each
melt heat batch and shall furnish the test results to the inspecting official.
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The manufacturer shall also furnish the samples free of charge for analysis
to the inspecting official, if required.
4.3 Calibration of Spectrometer
Spectrometer should be calibrated at pre-designated intervals based on

recommendations of manufacturer/service agency. However, after
standardization of spectrometer if wide variation between actual and
certified value is obtained for some elements when a certified standard is
run, the spectrometer should be calibrated more frequently for those
elements.
Wide variation for CMS Crossings will mean :
For Mn 5% of certified value or 0.5 actual variation
For C and Si 5% of certified value or 0.05 actual variation
For P and S 5% of certified value or 0.005 actual variation
5.0 INTERNAL DEVELOPMENT
5.1 In view of the sophisticated nature of work involved in casting CMS

Crossings, adequate internal development/internal exercises of the
technique by the manufacturer is essential. Manufacturers are required to
carry out their internal development with the aim of achieving soundness
of casting and dimensional accuracy.
5.2 As a part of internal development, the manufacturers should cast a few

crossings and ensure internal soundness of such castings. Sections shall be
cut by abrasive cutter at the critical locations i.e. 7 sections at a distance of
100mm apart starting from the nose of the crossing and covering 300 mm
on either side as mentioned in Annexure-I. Non-destructive testing of
areas such as flanges, which can be subjected to radiographic tests, should
also be carried out and the manufacturer should satisfy himself that the
standards of acceptance laid down for prototypes in Clause 6 of Part – A
of this specification below are generally achieved during internal
development. The manufacturers shall thereafter approach RDSO.
Inspecting official will verify the report and satisfy himself on the basis of
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soundness of the cut sections, dimensional accuracy, records of non-

destructive testing and other tests like chemical composition, bend test etc.
that adequate internal development has been carried out by the
manufacturer. Results of detailed dimensional check shall be recorded in
the format prescribed by the inspecting official. The report of internal
development shall be recorded as per proforma at Annexure-I.
5.3 During internal development, inspection procedure detailed at Clause 6

and 10 of Part – A of this specification shall be followed by internal
department of the manufacturer and relevant records shall be maintained
for cross checks by the inspecting official.
5.4 After RDSO is satisfied with the internal development on scrutiny of the
internal exercises made by the manufacturer, permission shall be given for
casting prototype crossings. All the relevant papers/documents shall be
retained in the office of the inspecting authority for future reference.
6.0 PROTOTYPES
6.1 Manufacturing of Prototype
6.1.1 On receipt of permission for casting of prototypes, the manufacturer shall

then give 15 days‟ notice to RDSO for witnessing of melting and pouring
for casting of prototypes.
6.1.2 Various stages of manufacture for bulk production as detailed in Clause 8

of Part – A of this specification shall be followed for manufacture of
prototype crossings also.
6.2 Inspection
6.2.1 Surface inspection
All crossings shall be visually inspected for gross surface defects at various
stages of inspection. Dye penetrant methods shall be employed for
detection of finer surface defects. Castings thus inspected shall be free
from cracks, shrinkage cavities, scabs, flakes, blisters, lack of metal,
inclusion, porosities, hot tears, cold shuts and other harmful defects.
Minor scattered porosities of less than 4 mm dia and 1.5 mm depth
(provided they are not closer than 15mm from each other and not more
than three nos. at a particular location) shall be considered acceptable.
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However, all such defects have to be in a location which is at least 300 mm

away from tip of the nose on its either side. Surface of the casting shall be
reasonably smooth and free from extraneous matters.
6.2.2 Solidity Tests
10% of the prototype castings subject to a minimum of one casting of each

type shall be selected for sectioning at seven locations by abrasive cutter as
mentioned in Clause 5.2 of Part – A of this specification above. Each
sectioned face on examination, shall not show a total defective area of
more than 2% of the cross sectional area. The defect shall not be clustered
at any particular location and shall be uniformly distributed throughout.
Defects within 10mm from the surface and defects connected with the
outside and presence of cracks/hot tears shall be cause for rejection.
Hardness of the sectioned faces shall be taken at the center of the thick
section. Dye-penetrant test shall be carried out on sectioned faces for
detection of shrinkage and chequered cracks. These tests shall be carried
out physically in the presence of RDSO representative.
In solidity test, the cross sections shall be plotted on graph sheet in 1:1
scale and location of defects, if any, shown. The dimensions of flange
thickness, wall/web thickness, roof thickness, head thickness etc shall also
be mentioned to give guidance regarding major defects such as mould
disturbance etc.
Subsequent to the clearance of prototype, this test shall be carried out once
in the three years or completion of manufacturing of 1000 CMS Crossings
satisfactorily whichever is earlier.
6.2.3 Radiographic Examination
Flange portion of the crossing shall be radiographically examined.

Radiographs shall have sensitivity of minimum 2% and satisfy the
requirement of ASTM designation E-446 – Reference Radiographs for Steel
Casting – Level II in respect of blow holes, slag and sand inclusion and
shrinkage. No cracks/hot tears shall be permitted. Radiographic
examination shall be done at the rate of 1 in 20 for regular manufacture
and 1 in 5 for prototype castings subject to a minimum of one casting of
each type.
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6.2.4 After solidity test and radiographic examination have been certified as
satisfactory, the firm will prepare a document mentioning parameters
(methoding size, shape and location of runners, risers and ingates,
moulding practice, source and properties of prepared sand and metal
tapping and pouring parameters) which gave satisfactory results. This
document will be countersigned by inspecting official. Inspecting officials
will be free to verify the parameters which were used during solidity test
and which had been countersigned by inspecting official, so as to ensure
the consistency of foundry practice. These parameters shall then be
incorporated in the QAP.
6.2.5 The manufacturer will inform RDSO about any change in foundry inputs
or practice. RDSO will then decide whether fresh solidity test and higher
frequency of radiography test need to be carried out all over again after
judging the impact of change in input/practice.
6.3 Approval of Prototypes
6.3.1 After RDSO is satisfied with the production of prototypes, approval shall
be given to the firm for undertaking bulk production. All the relevant
papers/documents shall be preserved in the office of the RDSO for future
reference. Manufacturer is to get 10 prototype approved by the RDSO for
each design/type of crossing. No prototype need be produced for repeat
order, unless the existing design is modified considerably.
6.4 Before approaching RDSO for permission for bulk production, the
manufacturer should make good the deficiencies of the plant and
machinery, if any, as pointed out by the inspecting authority.
6.5 At the time of applying for approval of prototypes by new foundries, the
firm shall submit QAP incorporating records of following aspects of
methoding in duplicate after these parameters have given satisfactory
results on solidity and radiographic tests:
1. Source of
a) Moulding sand
b) Core sand
c) Facing sand
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2. Properties of above sand

a) Clay content
b) Purity (major constituents %)
c) AFS and grain fineness number
d) Shape of grains (round, semi-angular, angular)
3. Mould wash
a) Name
b) Base
c) Consistency
d) Size of particles
4. Properties of prepared sands (mould, core and facing)

a) System of sand (CO2, resin bond etc.)
b) Compression strength
c) Shear Strength
d) Collapsibility
5. Feeding system (to be shown on sketch/drawing)

a) Size and position of ingate
b) Size and position of runners
c) Size and position of risers
d) Yield percentage of good castings
6. Pouring start temperature/method of measurement
7. Pouring end temperature/method of measurement.
8. Knock out time after pouring
9. Weight of casting
These parameters shall be scrutinized by RDSO. These parameters shall

then be incorporated in the QAP. One copy shall be retained by RDSO and
the other shall be returned to the firm after duly signed by the
representative of RDSO so as to enable verification from time to time. In
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case of any change in the methoding parameters mentioned above. RDSO

shall be informed by the firm to decide whether the change is minor or
major. If the change is expected to affect the quality of the casting, then it
may require revalidation of solidity test.
7.0 INTEGRAL TEST BARS
7.1 Four number of test bars of size 200 mm X 30 mm X 30 mm (with tolerance

of ± 1 mm in each dimension) shall be cast integral to crossing. These shall
be located at toe end and heel end respectively (2 number each).
7.2 Pattern and mould shall be developed by manufacturer to accommodate

the integral test bars.
7.3 Integral test bar shall be so cast that it should not get detached during
knock out, fettling, shot blasting or heat treatment.
7.4 These integral bars shall be used for chemical composition,

microstructure/grain size determination, hardness and for impact bend
test.
7.5 Integral test bar shall be detached from crossing by suitable method to
avoid any damage to crossing. The detachment shall only be done in the
presence of inspecting official.
7.6 While detaching the integral test bar at various stages, inspecting official
shall transfer suitable marking on particular test bar so that the same may
be identified in terms of crossing number and location. A record must be
maintained for integral test bars indicating crossing number, location &
date of detachment.
7.7 The manufacturer shall preserve at least one integral test bar of each
crossing for minimum 6 months from the date of issue of inspection
certificate of particular crossing and shall present to inspecting official on
demand. In case all integral test bars are used during test/retest, one
integral test bar used in Impact Bend Test may be preserved.
8. VARIOUS STAGES OF MANUFACTURE FOR BULK PRODUCTION
8.1 Moulding
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8.1.1 The crossing shall be accurately moulded and finished to the form and
dimensions shown on the drawings to be supplied by the purchaser or
RDSO/Lucknow.
8.1.2 Unless otherwise permitted by the purchaser or the inspecting official in

writing the dimensions/tolerances shown on the drawing (s) shall be
adhered to.
8.1.3 Manufacturer should have adequate in-house facility for sand preparation,
testing and recycling as per moulding practice specified in QAP.
8.1.4 Sand selection, moulding and core practice, mould and core paint
selection shall be such that there is no metal mould reaction, which shall
cause defects with bad/rough surface finish.
8.1.5 Internal/external metallic chills or chaplets shall be avoided to ensure the

consistent internal quality requirement.
8.2 Marking ‘Unique Identification (UID) Number’ on CMS Crossing
8.2.1 Following scheme for allotting UID number to each CMS Crossing shall be
followed: The UID Number shall comprise of 11 characters. However, for
easy handling of core in order to control it from breakage, the UID number
can be cast in two separate parts comprising of 6 & 5 characters in close
proximity such that no break should appear in the UID Number.
e.g. the UID Number shall therefore be e.g. XXYYMM

where:
XX - First & Second character will denote „Firm‟s Plant ID‟
YY - Third & Fourth character will denote „Year of casting‟
MM - Fifth & Sixth character will denote „Month of casting‟ (the date
of completion of casting to be considered)
- Seventh character will denote „Type of crossing‟ (either „C‟ or

„W‟ will be used, C for CMS crossing and W for Weldable CMS
crossing)
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ZZZZ - Eighth, Ninth, Tenth & Eleventh character will denote „Serial
number of crossing‟
i) All characters in the UID number shall be numerals except the Seventh
character which shall be an alphabet.
ii) The UID number of CMS crossing shall encompass all the designs
manufactured by an approved vendor in a particular year.
iii) The „Firm‟s Plant ID‟ i.e. „XX‟ shall be allotted by RDSO to all the
approved vendors of CMS crossing.
iv) The „Serial Number of Crossing‟ i.e. „ZZZZ‟ will be given by the firm
themselves starting from 0001 as the first crossing. Series will start from
1st of January ending on 31st of December every year.
v) The UID number of CMS crossing, as indicated above, drawing no of

crossing, Rail section designation shall be cast in raised letters 40mm high
and 3mm deep. All these markings shall be sharp clear and distinct.
vi) On one of the outer faces of web of the crossing unit, UID number of CMS
Crossing shall be provided and other outer face of web of the crossing unit
shall have the „Rail Section Designation‟ & „Drawing Number‟ as per the
existing scheme given in the respective drawing of CMS Crossings.
Marking for „Angle of crossing‟ shall be done on CMS Crossings as per

respective drawings.
8.3 Melting
8.3.1 Suitable efforts shall be made for selection of proper scrap and use of
correct melting process with proper refining operation shall be ensured so
as to control the detrimental tramp elements in steel. Moreover, the
sulphur and phosphorus contents in the steel shall be achieved as
mentioned in Clause 4.1 of Part – A of this specification.
8.4 Pouring
8.4.1 Metal should be poured by bottom pouring ladle and mould filling time
shall be recorded. Further, each manufacturer will indicate pouring start
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and pouring end temperatures in his QAP after ensuring that all castings
from first to last are sound and no adverse effect are noticed due to high or
low temperature of pouring. Pouring start and pouring end temperatures
will be measured and records kept.
8.4.2 Any casting for which witnessing of melting & pouring is mandatory, the
manufacturer shall give prior notice to the inspecting authority. Inspecting
official shall witness melting & pouring as per Clause 10.2.1 of Part – A of
this specification. Casting for which witnessing of melting & pouring is
not mandatory, the manufacturer may cast the same keeping records as
indicated in Clause 10.2.2 of Part – A of this specification.
8.5 Knock Out
8.5.1 During knock out, casting should be handled very carefully to avoid
development of cracks in the castings. Any impact shall be avoided.
8.6 Fettling and shot blasting
8.6.1 The crossing shall be free from embedded sand particles and risers, flow
off shall be knocked off, ingate at ends and other thick fins, if any, shall be
removed by Arc Air or oxy-cut. If oxy-cut, then the cut should be at least
25mm away from the crossing body. The casting shall be suitably shot
blasted thereafter, so that they are free from sand etc. and surface
inspection can be done visually by the inspecting official without any
difficulty. In no case, crossing shall be placed on shaker for removal of
sands. Fettling & shot blasting shall be done in such a way so as to avoid
any impact to the crossing.
8.6.2 When ingate riser etc. are removed by thermal operation, care shall be
taken to make the cut with sufficient allowance (at least 25mm away from
the crossing body) to prevent any defect being introduced into the main
body of the crossing due to local heating.
8.6.3 Enlargement of bolt-holes and making of any new holes by thermal

operation shall not be permitted.
8.6.4 All crossings shall be free from gas pockets, sand holes, cracks, cold shuts
and other injurious defects. Lumps and sharp fins, if any, on the edges of
the casting shall be suitably removed.
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8.6.5 Repair of defects by welding that will not ultimately impair the strength or
utility of the crossing, may be carried out with the consent of the
inspecting officer, as per approved process as mentioned in Annexure-III.
8.6.6 During fettling for removing risers, runners and ingates from castings, no
excessive heat should be generated to avoid any thermal shock to the
casting.
8.7 Heat treatment of crossings
8.7.1 All crossings along with integral test bars shall suitably be heat treated to
render them tough. It shall be ensured that integral test bars meant for
further testing is not detached from the crossing even after heat treatment
and shot blasting to facilitate inspecting officials in carrying out the test
related to particular crossing. This treatment shall consist of uniform
heating of the crossing to a suitable temperature holding it at that
temperature till uniformly heated throughout and quenching in water
within 60 seconds from a minimum temperature of 1050°C. The crossing
should be kept in the quenching tank in head down manner. The initial
temperature of water in the quenching tank shall be less than or equal to
30°C and should not rise by more than 10°C during and immediately after
quenching of crossings. Water in quenching tank shall be agitated and
circulated properly and a continuous temperature measuring system
should be installed to record before and after quenching temperature of
tank for each heat treated batches of crossings. The recording of
temperature should be kept preserved for checking of inspecting officials.
8.7.2 The heat treatment shall be done in a furnace fitted with recorder type
pyrometer. The number of castings for each heat treatment batch
indicating melt heat number shall be recorded on the heat treatment chart
and it shall be signed by the manufacturer‟s representative and produced
to the inspecting official on demand.
8.7.3 On completion of heat treatment, the crossing again shall be shot blasted.
8.7.4 A record of the heat treatment of the crossing shall be maintained by the
manufacturer, details of which shall be supplied to the inspecting official.
8.8 Surface Preparation and defects removal
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8.8.1 The castings shall be suitably prepared for the removal/rectification of

castings defects as permitted by the inspecting official without resorting to
any thermal operation.
8.8.2 Continuous grinding at one location shall not be done to avoid raising of
temperature of the surface during grinding beyond 250°C.
8.9 Straightening
8.9.1 The casting after complete repair work and certification to that effect by
the manufacturer shall only be straightened by application of gradual load
under a suitable heavy duty hydraulic press. Casting shall be summarily
rejected, if end-to- end straightening is beyond 40mm.
8.9.2 After the pressing operation is done, the casting shall be offered to the
Inspecting official for inspection by dye-penetration test and records shall
be maintained. In no case, straightening operation will be allowed before
undertaking repair welding.
8.10 Finishing
8.10.1 Surface finish shall be ensured to minimize machining on any part of

crossing. Ideal finish shall be taken as smooth finish.
8.10.2 The bottom of crossing shall be machined by milling machine so that the
bottom surface of crossing which rests on PSC sleepers shall be straight
without twists and shall be free from such imperfections which may
prevent a good and even bearing of the crossing on PSC sleepers.
8.10.3 End section faces (both toe and heel end) shall be machine-finished by
milling machine to provide machined joints in turnout as mentioned in the
drawing.
8.10.4 Fishing plane shall be finished by milling for achieving required surface
contact between fish plate and casting to have sturdy joint for proper
transfer of dynamic load.
8.10.5 Fish bolt holes shall be drilled and have a 1mm chamfer at each end to
achieve tolerances mentioned in the drawing. Bond holes in fish plate area
for DC traction shall also be drilled for getting bond wires force fitted.
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8.10.6 The top edge contour (gauge face) up to tangent points shall be machine-
finished by planer/miller in order to achieve uniform radius all through
running faces and to eliminate local misalignment.
8.10.7 Other locations shall be finished either by machining or by hand grinding
operation depending upon the facilities available. While grinding, Clause
8.8.2 of Part – A of this specification shall be adhered to.
8.10.8 Machining facility shall be generally available in the same premises to

have dedicated flow line for manufacture of this sophisticated safety
related item.
9.0 INSPECTION GAUGES/TEMPLATES & OTHER EQUIPMENT
9.1 Manufacture of inspection gauges
The manufacturer shall prepare two sets of inspection gauges/templates

as per drawings to be supplied/approved by the purchaser/Inspecting
authority for each type of CMS crossings ordered and shall submit them
for approval to the purchaser or the inspecting official and shall obtain his
approval before commencing manufacture of prototype CMS Crossing.
The crossings shall be checked with the help of approved inspection
gauges/templates at different locations as mentioned in the gauge
drawing. Out of the two sets of gauges/templates approved, one set is to
be kept as MASTER GAUGE for use in case of any discrepancy and the
other set is to be used for finishing of crossings in shop floor and by
Inspecting Officials during inspection. Extra sets of gauges shall also be
made depending upon the rate of production and got approved by the
Inspecting Authority. The inspection gauges shall be verified during
Quality Audit. These gauges may also be checked as and when considered
necessary during inspection.
9.2 Other inspection equipment/accessories
The following materials shall be made available before approval of

internal development for checking end fitments of each CMS Crossing.
9.2.1 Rail pieces of standard section 750 mm long (approx.) having standard fish
bolt holes at one end matching with the section of CMS Crossing to be
inspected. Four such rail pieces shall be made available for checking one
Page | 17 of 67
crossing. Number of rail pieces required shall depend upon the number of
crossings to be put up at a time for inspection. End face of rail pieces shall
be machined to have frozen/machined joint as mentioned in the
respective assembly drawing of CMS Crossing. Bolt holes in the back of
rails shall register with reference to the base of the rail within ± 0.8 mm
provided that fish bolt holes shall register within ± 0.6 mm in location and
+ 0.8 mm & - 0.0 mm in diameter for the purpose of machined joint.
9.2.2 Bolts of sizes as per drawing.
9.2.3 Fish plates of standard section with six bolt holes matching with the CMS
crossings. Four fish plates will be required per crossing. Second
quality/second hand fish plate shall not be used.
9.2.4 Distance blocks for ends as mentioned in drawings. These web and fishing
fit blocks shall be finished by machining before use.
9.2.5 Adequate number of spherical washers, packing pieces and tapered

washers as mentioned in the relevant drawings.
9.2.6 Other standard equipment such as tape (steel 10 m), straight edge (steel 1
m long), scale steel (305 mm – 610 mm), Nylon cord (10 m), filler gauge
having strips of 0.5mm to 1.0mm and scale vernier of 600 mm long.
9.2.7 Any other equipment specified by purchaser/inspecting authority.
9.2.8 These accessories/other equipment shall be maintained for regular

inspection also.
10.0 INSPECTION
10.1 The CMS crossing is related to the public safety in the railway transit. The
process of manufacture is most intricate both from the foundry and
metallurgical point of view. Considering the basic characteristic of the
steel i.e. the thermal sensitivity, low diathermic character, mould metal
reactivity of the steel, and the work hardening and high shrinkage
characteristics of the steel, rigorous inspection (both metallurgical and
dimensional) at different stages of manufacture shall be carried out as
detailed herein.
10.2 Chemical composition
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10.2.1 For casting of prototypes, the manufacturers shall intimate the inspecting
authority well in advance (at least 15 days) so as to enable him to witness
sampling of molten steel at different stages for chemical analysis and shall
furnish details of charge, pouring temperature etc. Inspecting official shall
witness such pouring and ensure that temperature and chemical
composition as mentioned in QAP has been met with. The bath samples
shall be taken at different stages and chemical composition shall be carried
out. The same shall be recorded with other parameters in inspection
memo-I as given in Annexure-II.
10.2.2 For casting that does not require pouring witness, the manufacturer may
go ahead with the casting and record the parameters in inspection memo-I
as given in Annexure-II The records shall be presented to the inspecting
officials for cross check during subsequent stages of inspection. Chemical
composition of such crossings at any stage shall be determined as per
Clause 10.4.2.2 of Part – A of this specification.
10.3 Identification of cast and correlation of heat numbers
10.3.1 The castings shall bear manufacturer‟s identification marks, drawing

number, serial number and date of cast. A register shall be maintained by
the manufacturer correlating the casting serial number and heat number
and register shall be produced to the Inspecting Authority for their
verification on demand.
10.4 STAGES OF INSPECTION
10.4.1 Inspection shall be carried out in four stages i.e. Stage-I, Stage-II and
Stage-III and Stage IV (final stage). Sampling of molten metal may also be
witnessed by Inspecting Official, if available in shop-floor during pouring.
However, it shall be ensured that pouring must be witnessed at-least once
in every 6 months. Prior to Stage-I inspection, wherever applicable,
chemical composition shall be checked as per Clause 10.2.1 of Part – A of
this specification.
For the designs of CMS Crossing manufactured by any firm, consistency

of quality of which has been established as per norms prescribed by
inspecting authority, inspecting official(s) shall begin inspection at Stage-
II. The internal inspection shall, however, be carried out by the
Page | 19 of 67
manufacturer at Stage-I which shall be verified by the inspecting official(s)

at Stage-II.
10.4.1.1 Stage–I: Inspection shall be carried out after knockout/oxy-cutting/shot

blasting etc. as per Clause 10.4.2 of Part – A of this specification.
10.4.1.2 Stage–II: Inspection shall be carried out after heat treatment and shot
blasting etc. as per Clause 10.4.3 of Part – A of this specification.
10.4.1.3 Stage–III: Inspection shall be carried out after removal/rectification of

defects and straightening as per Clause 10.4.4 of Part – A of this
specification.
10.4.1.4 Stage–IV (Final stage): Inspection shall be carried out after final finishing
for final acceptance as per Clause 10.4.5 of Part – A of this specification.
10.4.2 Metallurgical & Chemical inspection (Stage–I)
10.4.2.1 After fettling and shot blasting as per Clause 8.6 of Part – A of this
specification, the defective areas of the surface of crossing, if any, shall be
marked with the dimension of defects (i.e., length, width and depth) and
shown in isometric view as shown in Annexure-IV and their locations
indicated from a datum line. These details are to be tabulated by the
manufacturer in a proforma as per Annexure-V and shall be submitted to
the inspecting official for the verification and inspection. The inspecting
official shall be vigilant about foundry defects like cracks, sand holes, cold
shuts, pin holes porosity, extra metal, sand fusion etc. Crossing having
cracks shall be straight way rejected.
10.4.2.2 One integral test bar shall be detached randomly from any crossing in a
melt heat batch in a manner prescribed in Clause 7.5 & 7.6 of Part – A of
this specification. The chemical composition shall be determined by taking
sample from the integral test bar so detached which shall represent the
entire melt heat batch. In cases where inspection is started by inspecting
official at Stage-II as mentioned in Clause 10.4.1 of Part – A of this
specification, integral test bar shall be detached for determination of
chemical composition in presence of inspecting official at Stage-II only i.e.
after heat treatment and shot blasting.
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10.4.2.3 The castings which are considered processable both metallurgically and
chemically at this stage by the „manufacturer and inspecting official‟ or the
„manufacturer‟ as the case may be, shall be permitted for heat treatment as
per Clause 8.7 of Part – A of this specification and Inspection Memo-II as
mentioned in Annexure-II shall be signed.
10.4.3 Metallurgical & Dimensional Inspection (Stage-II)
10.4.3.1 After heat treatment as per Clause 8.7 of Part – A of this specification and
shot blasting, the castings shall be offered to the inspecting official in the
similar manner as in Stage-I for metallurgical and dimensional checkup.
Surface inspection shall be carried out as detailed in Clause 6.2.1 and
10.4.2.1 of Part – A of this specification & defects shall be marked on
isometric view & recorded in proforma given in Annexure-IV & V
respectively. The chemical composition of crossing shall be determined by
taking sample from the integral test bar as detailed in Clause 10.4.2.2 of
Part – A of this specification, if not done earlier.
10.4.3.2 Crossings having crack(s) shall be rejected.
10.4.3.3 Integral test bars shall be detached from crossing in a manner prescribed
in Clause 7.5 & 7.6 of Part – A of this specification. Impact bend test on
integral test bar shall be conducted as per Clause 13.1 of Part – A of this
specification in presence of the inspecting official and record of test shall
be maintained. Suitable hardness test shall be conducted at this stage on
casting/integral test bar as per Clause 13.2 of Part – A of this specification
in presence of inspecting official and record shall be maintained.
10.4.3.4 The micro test piece shall be cut from the integral test bar duly heat treated
along with CMS crossing as per Clause 8.7 of Part – A of this specification
for determination of grain size and microstructure as per Clause 13.4 of
Part – A of this specification.
10.4.3.5 At this stage, gross dimensions such as overall length, distance between
actual nose and heel, actual nose and toe end, height at different locations,
flange thickness at different locations, flange way clearance, throat
clearance, flange well depth, wheel tread at toe end, nose thickness, nose
depression and off sets bottom, bottom width, tie thickness, extent of
vertical bend etc. shall be checked and recorded in Inspection Memo-IV as
mentioned in Annexure-II.
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10.4.3.6 The castings after metallurgical and dimensional inspection, shall be

considered for further processing as per Clause 10.4.4 of Part – A of this
specification and Inspection Memo- III & IV as mentioned in Annexure-II
shall be signed by the inspecting officials along with the isometric view.
10.4.4 Metallurgical Inspection (Stage-III)
10.4.4.1 Before putting up to the inspecting officials, the castings shall be suitably
prepared for the removal/rectification of defects as identified during
Stage-I/Stage-II as per Clause 8.8 and straightened as per Clause 8.9 of
Part – A of this specification. No crack shall develop on locations repaired
by welding, due to straightening operation & the same shall be verified by
conducting dye penetration test.
10.4.4.2 Repair welding shall be done strictly as per the procedure for
repair/rectification of CMS crossing at Annexure-III. The manufacturer
will produce a certificate to this effect.
10.4.4.3 The castings shall be offered to the inspecting official in the manner as in
Stage-I and Stage-II for metallurgical inspection, if necessary. For the
designs of CMS Crossing manufactured by any firm, consistency of quality
of which has been established as per norms prescribed by inspecting
authority, casting shall be offered to inspecting official for inspection
during Stage IV/Final Inspection. In such cases, the internal inspection
shall, however, be carried out by the manufacturer at Stage-III which shall
be verified by the inspecting official(s) at Stage-IV/Final Inspection.
10.4.4.4 The crossings which are considered processable shall be permitted for
final finishing by the „manufacturer and inspecting official‟ or the
„manufacturer‟ as the case may be and Inspection Memo-V as mentioned
in the Annexure-II shall be signed.
10.4.5 Final dimensional check-up and magnetic test (Stage-IV/Final Stage)
10.4.5.1 After final inspection and certification by the Works Inspector of the firm
as per Clause 15 of Part – A of this specification, the crossing shall be
offered finally for dimensional checkup (as per sequence shown in
Annexure-VI) on the inspection table/marking table with the approved
gauges/templates/equipment as mentioned in Clause 9.2 of Part – A of
this specification.
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10.4.5.2 The castings shall be visually inspected for surface defects employing dye-
penetrant tests as necessary. The casting shall also be tested for its non-
magnetic character either by portable magnet or by suitable electro-
magnet. The check will be done on head surface.
10.4.5.3 Dimensions of crossings shall be checked with the help of

gauges/templates, fishing cord, straight edge, filler gauge etc.
10.4.5.4 At the discretion and as per directives of the inspecting official, the
manufacturer shall produce the non-destructive test result (to be done in
presence of inspecting official) at the frequency of 1 in 10 castings as
detailed in Clause 6.2.3 of Part – A of this specification.
10.4.5.5 After the inspecting official(s) is (are) satisfied that the crossing conforms
to relevant drawing and specifications, the crossing shall be accepted
finally and the Inspection Memo-VI as mentioned in the Annexure-II shall
be signed.
11.0 GENERAL
11.1 During inspection, no grinding operation, oxy-cutting and fettle-arc

gauging shall be carried out in the area earmarked for inspection by the
inspecting officials and no material shall be carried by any overhead crane
over the area in the interest of safety. Crossings shall be placed 1 m apart
(i.e. 1 m distance between centre lines of crossings) for easy application of
gauges/templates and for turning of crossings for the purpose of
inspection. Suitable lighting arrangement and adequate handling facilities
as considered necessary for conducting proper inspection, shall be
provided.
11.2 The purchaser or inspecting official(s) shall have free access to the
manufacturer‟s works at all reasonable times. He shall be at liberty to
inspect the process of manufacturing at any stage and to reject any
material that fails to conform to the provisions of the specifications.
11.3 All the provisions contained in RDSO‟s procedures laid down in

Document No. QO- D-7.1-11 dated 19.07.2016 (titled” Vendor–Changes in
approved status”) and subsequent versions/amendments thereof, shall be
binding and applicable on the successful vendor/vendors in the contracts
floated by Railways to maintain quality of products supplied to Railways.
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12.0 TOLERANCES
12.1 Fishing Surface: The standard template for fishing surface shall not stand
away from the contour of web by more than 1.20mm and the clearance at
the fishing surfaces shall not exceed 0.2 mm at any point as per Clause
9.1.1 of IRS: T-12- 2009.
12.2 End Squareness: The deviation from square at both heel and toe end shall
not exceed 0.2 mm in both axes.
12.3 Concavity/convexity (Both top and bottom surface)
(a) Overall length: It shall not exceed ± 1 mm.
(b) Local: It shall not exceed ± 0.5mm. It shall be checked using 1 m

straight edge at any point.
12.4 Alignment
(a) Overall length: It shall not exceed ± 1mm.
(b) Local misalignment: It shall not exceed ± 0.5 mm over a length of

1m at any point.
12.5 Bolt Holes: The holes in the web of crossing in fish plated area shall
register with reference to the base of the crossing within ± 0.8mm
provided that the fish bolt holes shall register within ±0.6mm tolerance in
location and +0.8mm & -0.0 mm in diameter for machined joint.
12.6 Kink at fish plated joint: While checking end fitment of crossing in shop
floor, the kink at fish plated joint shall not exceed ± 0.5mm.
13.0 TESTS
13.1 Impact Bend Test
13.1.1 Sample size
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a) One test per cast (melt heat) per heat treatment batch shall be carried
out on integral test bars.
b) The test bar for impact bend test shall have a 30 x 30 mm (tolerance ±
1mm) cross section and be 200mm in length. Four pieces, two from
toe end and two from heel end, wherever available shall be taken for
this test. Out of these four pieces, two (preferably one from toe end
and one from heel end) shall be for the usual acceptance tests and
two for any extra tests.
There may be cases where only three test bars are available (e.g.
single crossing of particular melt heat and heat treatment batch, one
test bar of which has been detached for chemical composition
determination earlier). In such case, three pieces shall be taken, out of
which two shall be used for usual acceptance test and balance one
piece for retest.
c) Casting and detachment of integral test bar shall be done in a manner

prescribed in Clause 7.0 of Part – A of this specification.
13.1.2 Execution of Tests:
a) The impact bend test pieces shall be of un-machined bar, the edges of
which may have a chamfer not exceeding 1 mm. Prior to the test, bars
shall be notched in a press to a semi-circle (r=1.5mm, depth=1.5mm)
on one face at the centre across throughout the width in the presence
of inspecting official.
b) The test pieces shall then be placed horizontally on two knife-edge

supports spaced 160 mm apart, notch downwards and midway
between the two supports. The knife edge supports shall have a
radius of 2mm. The test pieces must withstand 3 successive blows of
a 50 kg weight falling freely from a height of 3m onto the surface
opposite the notch. The part of the falling weight coming into contact
with the test piece shall be rounded to a radius of 50 mm. The test
arrangement shall be as per Annexure-VII.
13.1.3 Acceptance Criteria
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(i) The test pieces must withstand three impacts. They may crack but the
crack must not extend more than 7 mm up.
(ii) Both test pieces must comply with the above acceptance conditions
for the castings of particular melt heat & heat treatment batch to be
acceptable.
(iii) In case only three test pieces are available for impact bend test as
mentioned at Clause 13.1.1(b) of Part – A of this specification, if both
test pieces give unsatisfactory results, then castings of particular melt
heat & heat treatment batch shall definitely be rejected.
13.1.4 Extra Tests– Further Heat Treatment
If one (in case of availability of only three test pieces as mentioned at

Clause 13.1.1(b) of Part – A of this specification) or one/both (in other
cases) impact bend tests give unsatisfactory results, the supplier may opt
to request an extra test to be performed.
(i) On the casting as it is.
(ii) On the casting after further heat treatment. This, however, shall be
possible only on a casting in the unfinished stage.
(iii) The extra test shall be carried out on the remaining two/one test
piece subject to the same conditions as set out above for the first two
tests. If one or both extra tests, gives unsatisfactory results, the
castings of particular melt heat & heat treatment batch shall definitely
be rejected.
13.2 Hardness Test
13.2.1 Sample size
On every crossing, two locations shall be selected at thin & thick section
respectively.
13.2.2 Method of execution and acceptance criterion
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13.2.2.1 The crossing, when tested for hardness by a portable hardness testing
method approved by inspecting official, shall have a Brinell Hardness
number not more than 229 or equivalent.
13.2.2.2 The integral test bar used for impact bend test shall also be selected for
making sample for hardness test representing particular melt heat. The
sample representing the particular melt heat shall be tested for hardness,
in accordance with IS 1500 or the latest adopted revision in vogue and it
shall have a Brinell Hardness number not more than 229 or equivalent.
13.3 Retest
13.3.1 Should any of the samples tested fail to meet the requirement of Clause
13.1 or 13.2 or both of Part – A of this specification, the manufacturer with
the approval of the purchaser or the inspecting officer may reheat-treat the
castings together with the test bars and resubmit for test.
13.3.2 Re-testing procedure shall be as prescribed in Clauses 13.1 and 13.2 of Part
– A of this specification.
13.4 Grain size and microstructure
13.4.1 Sample size
Micro test piece shall be prepared from the integral test bar used for
making samples for impact bend test.
13.4.2 Method of execution and acceptance criterion
13.4.2.1 Grain size of the micro structure of sample shall be 4 or finer as per IS 4748
and it should be single phase austenite, free from Carbide precipitation.
13.4.2.2 The manufacturer will keep an album of micro-photographs showing ideal

structure acceptable structures and unacceptable structures either from
literature or from his own heat-treated castings. The photographs should
be approved by RDSO. Inspecting officials will judge the suitability or
acceptability of micro structure with the help of these micro photographs
and decision in regard to acceptability shall then be taken.
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13.4.2.3 Software for determination of grain size can also be used. However before
use validation with existing data should be approved by inspecting
authority.
14.0 REJECTION
Any batch of crossings produced from the same melt and/or heat-treated
together under the same conditions which fails to comply with the
requirements of the specifications, shall be rejected. All rejected crossings
shall be painted red on both sides of the web for a distance of 300 mm
from each end, in addition to such stamp marks as may be desired by the
inspecting official. These rejected crossing shall be cut by gas cutting or by
any other means into minimum two pieces preferably near middle of the
crossing in order to avoid mixing up with the crossings under
processing/finishing/inspection and shall be kept stacked separately till
their verification by inspecting official. A certificate to this effect shall be
enclosed with the next inspection call. The inspection of CMS crossing
based on next inspection call shall be taken up only after verification of
cutting of rejected CMS crossing in at least two pieces by inspecting
official.
15.0 RECORDS FOR THE PURPOSE OF INSPECTION AND ISSUANCE OF

FINAL CERTIFICATE
15.1 Inspection Memo (I to VI) for pouring, Stage-I, Stage-II, Stage-III and
Stage-IV inspection shown in Annexure-II shall be got printed by the
manufacturer in sufficient numbers. These will be bound in booklet form
with all pages duly machine numbered in triplicate. One set of inspection
memo (in triplicate copy) shall be used for recording details of only one
crossing during its different stages of manufacture/inspection
15.2 A register shall be maintained by the manufacturer giving the details of

crossing, i.e. date of casting, batch number, date of inspection at different
stages and date of issue of inspection certificate.
15.3 Before the crossings are submitted to the inspecting official for inspection,
the manufacturer shall have examined these crossings and all defective
crossings shall be disposed of in a manner specified in Clause 14 of Part –
A of this specification.
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15.4 The manufacturer shall provide to the inspecting official free of charge all
tools and labour and gauges/templates required for inspection and also
office accommodation with sitting arrangements, light, fan etc. for doing
necessary paper work. The manufacturer shall also provide industrial
helmet to inspecting official for use during inspection on shop floor.
15.5 No crossing shall be packed until it has been inspected,

approved/accepted, stamped by the inspecting official. Crossings shall be
dispatched only after issue of Dispatch Memo/Inspection Certificate by
the authorized inspecting official.
16.0 STAMPING AND ISSUANCE OF INSPECTION CERTIFICATE
16.1 Crossing thus cleared shall be offered to the inspecting official for
necessary stamping with inspecting official‟s steel stamp insignia.
Inspection stamp shall be marked on top surface of the left-hand wing
25mm away from heel end.
16.2 After acceptance of crossing as per Clause 10.4.5.5 and stamping as per
Clause 16.1 of Part – A of this specification above, inspection certificate
shall be issued by the inspecting official authorized by the competent
authority.
17.0 PAINTING
17.1 Stamped crossing shall be thoroughly cleaned to remove rust, scale dirt
and oil and received primer coats on each surface to one of the following
schedules:
(a) One coat of ready-mixed paint, brushing zinc chrome priming to

IS:104 (latest adopted revision in vogue) followed by one coat of
ready mixed paint and drying red oxide-zinc chrome, priming to
IS:2074 (latest adopted revision in vogue).
Or
(b) Two coats of ready-mixed paint, air drying red oxide, zinc chrome
priming to IS: 2074 (latest adopted revision in vogue).
Or
(c) Two coats of red-oxide, zinc chromate primer to IRS specification no.
P-31 (latest adopted revision in vogue).
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17.2 The primer coats as indicated in Clause 17.1 (a), (b) and (c) of Part – A of
this specification shall be protected by one finishing coat of ready-mixed
paint, finishing, general purposes, Synthetic to IS: 13607-1992, smoke grey
colour ISC No. 692 to IS:5 (latest adopted revision in vogue).
17.3 The paint shall be applied by brush. The first priming coat shall be applied
within four hours after cleaning etc. The second priming coat shall be
applied when the first priming coat has dried. The finishing coat shall be
applied when the second priming coat has dried. The dry film thickness of
the two coats of primer shall not be less than 40 microns and the complete
system inclusive of finishing coat not less than 80 microns. Record of
painting process shall be maintained.
17.4 The inspecting officials shall check the quality of paints that will be used
as per relevant specifications once in two months or after painting of every
lot of 200 crossings.
17.5 Quality of painting shall be checked at random once in a month as and

when inspecting official is available in shop floor.
18.0 DISPATCH
All crossings, after approval, shall be loaded in a systematic manner to the

satisfaction of inspecting official to avoid any damage in transit.
*******
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PART – B IRS : T–29 (Revised – 2023)
PART – B
SPECIFICATION FOR WELDEDALE CAST MANGANESE STEEL

(WCMS) CROSSINGS
1.0 SCOPE
1.1 This specification is intended to provide necessary guidelines for design,

manufacture and use of Weldable Cast Manganese Steel (WCMS)
Crossings for Indian Railways System. Weldable CMS Crossing eliminates
the use of fishplate joints; therefore, it is a step towards provision of
continuous welded rail track. This results in better transition between rail
and crossing with gradual variation of inertia, requiring lesser
maintenance efforts, resulting into increase in life span. It also provides
improved safety and comfort to passengers.
1.2 This section of the specification covers design of Weldable CMS Crossing,
welding of CMS crossing with normal 90 UTS/R-260 grade rail using an
intermediate piece, physical and chemical testing and special tests
required for welded joints. Manufacture of CMS crossing is covered by
relevant provisions of this specification. Specification of rail to be welded
with CMS crossing shall be covered under IRS:T-12/2009 with its latest
amendments. It also defines geometrical tolerances for finished welded
joints and their acceptance criteria to ensure quality.
1.3 Wherever current specifications or recommended practices of other

standardizing bodies, such as American Society for Testing and Material
(ASTM), American Railway Engineering and Maintenance-of-Way
Association (AREMA), EN and other relevant codes are appropriate, same
is made part of this specification by reference.
2.0 GENERAL REQUREMENTS FOR WELDED PARTS AND WELDING

OPERATION
2.1 Weldable CMS crossing consists of 3 parts i.e., the CMS crossing casting,
an intermediate piece and connecting rail. The rail is first welded to the
intermediate piece which in turn is welded to CMS crossing casting.
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2.2 Fatigue test shall be done in RDSO or Structural Engineering Research

Centre (SERC), Chennai or any of IITs. Other Tests shall be conducted in
manufacturer‟s premises/Central Government Lab/Any IIT/NABL
accredited lab/RDSO. The cost of testing shall be borne by the
manufacturer.
2.3 CMS CROSSING
Manufacturing process of Weldable Cast Manganese Steel (WCMS)

crossing is covered by Part – A of this specification and for metallurgical
composition and other activities related to WCMS specifically shall be
governed by Part – B of this specification.
2.4 CONNECTING RAIL
Normal 90 UTS rail of UIC-60 profile/ R-260 grade rail of 60E1 profile
shall be used for welding. The rail shall be cut to proper length providing
adequate extra length of 15mm since during welding process rail burn off
takes place. The cut shall be performed at an angle of 90º ± 0.5º to the
longitudinal axis. All cuttings shall be deburred carefully before welding.
Specification of this rail will be covered by IRS: T-12/2009 with its latest
amendments.
2.5 INTERMEDIATE MATERIAL
Intermediate material profile shall be prepared matching the shape of rail.

Intermediate material shall normally be either cast or rolled to the shape of
the rail. The cross section of intermediate rail shall be normally kept larger
by around 0.5 mm at head and web portion and by around 1.5 mm at rail
foot. This size of intermediate piece is kept larger, to take care of grinding
after welding. Normally each firm may be having patent for this item.
2.6 After welding, alignment of the crossing should be checked and corrected
using suitable straightening machine.
3.0 TESTS ON CMS CROSSING
For all purposes Part – A of this specification will be followed for CMS
crossings except for tests/inspections mentioned in Clause 3.1 to 3.4 below
for which Clause 3.1 to 3.4 of Part – B of this specification as under will be
applicable:
Page | 32 of 67
3.1 DIMENSIONAL CHECK
Dimensional check as per drawing shall be carried out. Special care

should be taken for dimensional tolerances at the end of crossing which
should be same as of normal rail and will be governed by IRS:T-12/2009
with its latest amendments.
3.2 CHEMICAL ANALYSIS
Chemical analysis shall be carried out to verify specified chemistry of

Weldable Cast Manganese Steel (WCMS) either by spectrometer or any
other method specified. Chemical composition of liquid metal shall be
within the following limits:
Element Wt.%
Carbon 0.95 – 1.30
Silicon 0.65 max
Manganese * 11.5 – 14.0
Phosphorus 0.050 max
Sulphur 0.030 max
Nickel 1.75 max
Molybdenum 0.75 max
Chromium 0.50 max
Copper 0.30 max
Aluminum 0.045 max
* Manganese shall not be less than 10 times the carbon content.
Other alloying elements shall not be deliberately added. The total

percentage of unspecified elements shall not exceed 1 (one)%. Test
procedure will be governed by Clause 4.0 of Part – A of this specification.
3.3 RADIOGRAPHIC EXAMINATION
3.3.1 Radiographic examination of flange portion of CMS crossing will be

governed by Clause 6.2.3 of Part – A of this specification.
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3.3.2 In addition, ends of 80mm of CMS crossing to be welded with rail shall be
tested radiographically in entire cross section at frequency as specified in
Clause 6.2.3 of Part – A of this specification. Following method will be
used:
Surface Condition
 The surface must be machined or ground.
 No surface defects shall be visible with the unaided eye
 Before radiographic testing, the weld side ends of castings may be
subjected to dye penetrant examination
Technique
Radiation source: Co 60 or Ir 192 radiation or 1-2 MV X-rays Film

Agfa Structurix D5 or Agfa Structurix D7
Acceptance Standard
According to ASTM E-446 Maximum:

A1, B1, C1
Schemes of film arrangements are enclosed as Annexure-IX.
3.4 DP TEST
Dye penetration (DP) examination shall be undertaken after machining in

accordance with IS 3658 : 1999 or latest version.
The areas to be examined comprise the machined surfaces on top of the

crossing as follows:
i) Lengths of 400mm centred on the changes of section

ii) On the vee, as length of 400mm extending back from the crossing
nose(s) plus the adjacent wing rails
iii) A length of 400mm in the throat (knuckle) area, extending from the
tip of the nose
iv) Fastening locations
Page | 34 of 67
These locations are indicated in diagram enclosed as Annexure-X.
Acceptance criteria
All crossings shall qualify the acceptance criteria laid down in Clause 6.2.1
of Part – A of this specification. In addition, maximum dimension of any
linear defect indication shall not exceed 5 mm.
4.0 TESTS ON FINISHED WELDED JOINT
Following tests are required to be done on finished welded joints:
4.1 DP TEST
4.1.1 Extent
100% of the flash butt weld shall be checked.
4.1.2 Surface Condition
Test shall be performed after profile grinding and straightening. Rust,

loose scale shall be removed by grinding. Oil, grease etc. shall be removed
with cleaning liquids commonly used for Dye Penetration Test, acetone or
equivalent oil-soluble liquids.
4.1.3 Test Procedure
 Surface cleaning
 Penetrating (as specified by the manufacturer)
 Cleaning
 Developing (As specified by the manufacturer)
 Evaluation of indications starts right after drying of developer
4.1.4 The chemicals used for DP test shall conform to IS 3658: 1999 or latest
version.
4.1.5 A single indication must be considered to be linear if its length is more

than or equal to 3 times its average width. A single indication must be
Page | 35 of 67
considered to be a surface indication if its largest dimension is less than 3

times its average width. Two indications must be considered to be
grouped and only forming a single indication if the distance separating
them is less than or equal to the smallest length of both indications.
Acceptance Criteria:
Isolated indications with biggest dimension no greater than 0.5mm must
not be taken into account unless they are aligned and or a quantity greater
than 3 along a distance of less than or equal to 3mm in this case, they must
be considered to be a group of indications.
Following must not be accepted:

 Any linear indication
 Any isolated surface indication or group of indications of >3mm
 The total surface area of the indications must be less than 10mm2/dm2.
4.2 DIMENSIONAL
Dimensional check shall be conducted on 100% finished welds by using a

1m and 10cm steel straight edge and feeler gauge. Following tolerances
are permitted:
 Vertical +0.30mm at the centre of 1m

misalignment - 0mm straight edge
 Lateral misalignment ± 0.25mm at the centre of 1m straight edge

at running edge
 Head finishing Side of rail should be finished to ± 0.20mm

(in width) on gauge side at the centre of 10cm
straight edge
 Finished of top table +0.20mm at the centre of 10cm

surface - 0mm straight edge
(For above (+) indicates hump and (-) indicates cupping)
Page | 36 of 67
Welds not meeting these standards, if rectifiable by grinding can be re-

ground, failing which they shall be rejected. Results shall be maintained
as per proforma given in Annexure-XI.
4.3 ANALYSIS OF WELDING GRAPH

Welding graphs shall be analyzed with respect to set parameters by the
shift supervisor and should be available for scrutiny during inspection.
Both the welding graphs of each joint shall be checked simultaneously.
(Sample graph enclosed as Annexure-XII). Firm should preserve these
welding graphs for record for 04 years in digital form and will produce to
RDSO representatives / inspecting officials on demand.
4.4 HARDNESS TEST

The purpose of this test is to verify the absence of marked heterogeneity
between the hardness of the basic constituents and those of the molten
areas or areas thermally affected by the welding operation. In particular,
it must make it possible to ensure that no continuous microstructure
phase, hard and fragile, has been formed following the welding operation:
The hardness test (in BHN) must be carried out in accordance with the
standard IS 1500 : 2005 or latest version.
Indentations may be made on the surface (head) at 5 mm interval of

welded length of CMS crossing, on condition that they cover a width of at
least 20 mm beyond the thermally affected areas, both on the cast
manganese steel side and on the rail steel side. The hardness indentations
for above will be with +10mm of longitudinal centre line of the head.
4.4.1 Results to be obtained:

In the warm treated area (Heat Affected Zone) the hardness of rail steel
grade R 260 may deviate from the basic hardness by -30/+60 BHN.
Frequency of this test shall be 1 in 100 crossings initially upto 1000

crossing and thereafter 1 in 300 crossings.
4.5 ULTRASONIC TEST

The firm will solely be responsible for defect free welding in Weldable
CMS Crossing (WCMSC). In this regard, the firm will ensure Ultrasonic
Testing as per their own Internal Test Protocol (ITP) on 100% of WCMSC.
Page | 37 of 67
Firm‟s Internal Test Protocol should be duly certified by their expert

technology provider (Collaborator/ JV partner). After
USFD/UT/Radiographic testing the firm is required to submit a
certificate to Railways with supply stating that:
“The WCMSC no.___ Lot ___Cast dated _____has been tested by

Ultrasonic testing/Radiographic testing and the results are meeting the
criteria as per our Internal Test Protocol (ITP) in this regard. This
WCMSC is safe and sound for use in IR Track.”
Results of Ultrasonic Testing (UT) testing shall not be used for passing /
rejection of the WCMSC by the Inspecting Official. Instead, the Firm will
maintain and preserve the data of USFD testing of each WCMSC and
radiographic testing (wherever required). Such Data of USFD includes
printout / softcopies of recorded signal patterns along with horizontal
signal movement and vertical peak heights for each WCMSC. Firm will
use such data for records and analysis purposes and shall be ready to
share such data and analysis to Indian Railway whenever asked for the
same.
5.0 Test for weld process approval

Before starting actual welding, weld process approval is required to
ensure a constant quality of welding (calibration and maintenance,
function tests etc.). This welding process approval shall be done once in a
year or 1 in 1200 WCMSC whichever is earlier. For weld process approval,
sample test pieces should be welded as under:
Cast Manganese Rail Intermediate Material IRS:T-12/2009, 90 UTS

(e.g. Inox, etc.) Rail/ R 260 grade rail
Its profile shall be the same as the rail on its total length. It shall be made
of 3 elements welded in the same conditions as the CMS crossing and
intermediate piece. The length of the sample should be minimum
1200mm (600mm normal rail, 600mm cast manganese rail and
intermediate piece of suitable length). Initially before starting of actual
welding for manufacturing of weldable CMS crossing, 05 weld samples
are to be prepared for testing purpose for weld process approval. Flash
butt welding for preparation of weld samples shall be done in presence of
Page | 38 of 67
RDSO representatives / inspecting officials. A computerized graph shall

be obtained for different parameters for each weld of entire welding
process which is recorded by auto weld recorder for Weld Process
Approval. A copy of same shall be provided to RDSO for record. The
three important parameters current, force and feed travel shall be plotted
with respect to time.
For welding process approval, tests mentioned at Clause 5.1 to 5.5 of Part –
B of this specification shall be conducted. Out of the 05 samples, 02
samples shall be used for Macro Examination, Micrographic Examination
and Hardness Test. 01 sample shall be used for Static Bending Test and 01
for Fatigue Test. Remaining 01 sample shall be kept as spare which may
be used in case of damage during testing arrangements etc.
Fatigue test shall be required during initial approval. Once the weldable
CMS crossing, manufactured after weld process approval, performs
satisfactorily in field trial, the same shall not be required again. After that,
during quality audit, no fatigue testing/field trial shall be required, even
though 04 samples shall be required for welding process approval.
However, in case of change in rail section or grade the Fatigue test shall be
invariably conducted.
Weld process shall be approved only if weld samples pass all the 05 tests
mentioned in Clause 5.1 to 5.5 of Part – B of this specification. In case of
failure of weld samples to meet the acceptance criteria in any of these tests,
the entire process of preparing weld samples and testing shall be repeated.
Total two chances shall be given to any tenderer for weld process approval
failing which Performance Guarantee Bond shall be forfeited and the
contract shall be rescinded.
Additional ‘Static Bending Test‟ is to be carried out under supervision of

Inspecting Authority during bulk production of WCMS crossings:
Static Bending test on one test weld, prepared in the same manner as
done for developmental stage, at the time of starting the bulk production
of WCMSC crossings and then after every 100 nos. of WCMS crossings
initially upto 1000 nos. of WCMS crossings. After production of 1000 nos.
of WCMS crossings, Static Bending test shall be on one test weld after
every 300 nos. of WCMS crossings.
5.1 MACRO EXAMINTION
Page | 39 of 67
The metallurgical quality of the weld area shall be verified by means of a

macro graphic examination. The examination shall be carried out on a
sample in accordance with Annexure-XIII.
5.1.1 The surface being examined shall be vertical section cut along the entire
height of the profile and in the longitudinal direction on the profile axis of
the sample. The length of the preparation must cover at least the length of
the weld area. Polishing of the surface to be examined must be done using
abrasive paper up to grade 220. Etching shall be carried out using FRY
reagent (for 10 litres of compound : 1.875 kg of copper chloride, 5 litres of
hydrochloric acid, 4.2 litres of distilled water) of any other reagent suitable
to visualize the macro structure.
The duration of etching (30 minutes minimum) shall be set in order to

make the whole weld show no excessive etching effect i.e. the thermally
affected areas, the connection areas between the various constituents of
the welded joint (cast manganese steel – intermediate piece – rail). The
inspection of etched surfaces shall be carried out with the naked eye, or
possibly complemented using a G x 10 magnifying glass.
5.1.2 Welded defects of the following types shall not be accepted: folded
bonding, crack, crescents with crack indications.
Isolated non-cracked crescents of a length of ≤ 3 mm shall not be taken

into account.
The following shall be accepted along the length of the connection zone or
zones:
- Isolated non-cracked crescents of a length of ≤ 7 mm provided that the

distance separating them is > 3mm;
- Isolated non-crescents of a length of > 7mm and ≤ 15 mm provided that

their number does not exceed 4 and that the distance separating them
is > 7mm.
A photograph must be attached to the examination report.
5.2 MICROGRAPHIC EXAMIANTION
Page | 40 of 67
These are intended to complement the macrographic examination by an

analysis of the structure of the various metallurgical constituents. They
shall be implemented on longitudinal sections removed from the elements
having been subjected to macrographic examination.
The samples are removed from the rail head area, in the core and in the
rail foot area as shown in the diagram in Annexure-XIV. These three basic
removed samples may be complemented by samples removed from single
zones that may have been exposed during the macrographic examination
in Para 5.1 of Part – B of this specification.
The width of the surfaces to be examined must make it possible to observe

the totality of the heat affected zone (in particular on the steel side of the
rail) and must not be less than 20mm from both sides of the connection
zones.
The preparation of the surfaces to be examined is carried out according to

the requirements of the standard.
NF A 05-150 or equivalent polishing is done to the „diamond 3 μm‟ finish.
Etching of polished sections must be done using the reagent NITAL 4% or

equivalent.
The end-post part may be etched using a reagent more appropriate to its
microstructure. The structures and their constituents must be clearly
exposed after etching. The examination shall be done using a
metallographic microscope for enlargement of x50, x100, x200 and possible
beyond if necessary, for example in order to better identify a particular
metallurgical phase.

The following shall not be accepted:
 Inter-or intra- granular carbide precipitations visible upon enlargement
by 50 (manganese steel side)
 Micro cracks resulting directly from the welding operation as well as
bonding
 Crescents of a significant size, which are shrunk and/or cracked
Page | 41 of 67
 Continuous inter-granular carbide film and acicular shaped carbide

Martensitic non tempered structure presence
The following will be acceptable:
 Localized structures on micro-crescents, the presence of carbides,

provided that these components are at a stage where they will not
cause weakening.
Photographs of various enlargements from 50 to 200 must be attached to

the examination report.
5.3 HARDNESS TEST

The purpose of this test is to verify the absence of marked heterogeneity
between the hardness of the basic constituents and those of the molten
areas or areas thermally affected by the welding operation. In particular,
it must make it possible to ensure that no continuous microstructure
phase, hard and fragile, has been formed following the welding operation:
The hardness test (in BHN) must be carried out in accordance with the
standard IS 1500 : 2005 or latest version.
Indentations may be made on the removed samples having been subjected

to the macrographic or micrographic examinations stipulated in Clause 5.1
and 5.2 of Part – B of this specification, on condition that they cover a
width of at least 20mm beyond the thermally affected areas, both on the
cast manganese steel side and on the rail steel side.
Indentations are executed at 5mm apart following a parallel line and

situated 5mm from the rail head running surface and from the non-
thermally affected area of the cast manganese steel, passing through all the
weld connection.

In the warm treated area the hardness of rail steel grade R 260 may deviate
from the basic hardness by -30/+60 BHN. This has to be checked via a
“hardness line” (distance of checking 5mm) on the head (2-5mm under the
surface) in the vertical longitudinal rail axis.
Page | 42 of 67
The hardness line must contain at least 3 measuring points on the non-
treated basic material. The mean value of these 3 measuring points is
taken as basic hardness.
The hardness on the manganese steel side shall be recorded for

information.
The indentation hardness curves must be attached to the test report giving
details in abscissa of the connection area.
5.4 STATIC BENDING TEST

The sample shall be placed on its foot supported on two rigid cylindrical
supports (with a radius of between 23 and 80mm) at a distance of one
meter, equally apportioned in comparison with the weld axis. The force of
pressure must be applied vertically on the running surface in the weld axis
using a punch placed between the sample running surface and the head of
the test machine.
The punch must rest on the width of the running table along a length of
40mm ±2mm in order not to create a punching force. Its edges shall be
rounded by a minimum radius of 40mm.
The load must be applied progressively, without interruption, at a

maximum 60kN/second, from the beginning of the test until the sample
breaks.
The equipment must make it possible to ensure recording of the load and
deflection at the centre until the sample breaks.
 General testing arrangement shall be as given below:-
Page | 43 of 67
The sample must show minimum deflection of 18mm at the centre before
breaking. The minimum bend test force at breakage must not be less than
850 KN.
The breakage faces must not show weld defects of the bonding, oxidation
and fusion craters of volume when examined with the naked eye.
The recording of the load-deflection curve and photographic illustration of

the breakage faces must be attached to the test report.
5.5 FATIGUE TEST
This test shall be conducted to check the fatigue strength of the weld joint.
Following test scheme shall be followed for fatigue testing of weld joints:-
(i) One weld sample out of 05 weld samples already prepared in

presence of RDSO representatives/inspecting officials shall be used
for fatigue test.
(ii) The test sample must correctly bear 2 million cycle of load as shown
in the following table. Frequency of load applied shall be 8.33 – 10
hertz.
Profile Max. Load Min. Load
UIC 60kg - 880 Grade/60E1 R-260 Grade 300 kN 30 kN
(iii) General testing arrangements shall be as given below:-
The test sample shall not develop any cracks on the surface which may be
shear, flexural or torsional rupture (due to local buckling) in nature.
Hairline localised cracks may be permissible provided there is no
reduction in the load carrying capacity of sample.
*******
Page | 44 of 67
ANNEXURE – I
PROFORMA FOR RESULTS OF METALLURGICAL TESTS AND

DIMENSIONAL CHECK AND INSPECTION REPORT FOR INTERNAL
DEVELOPMENT OF THE CMS CROSSINGS BY M/S
1 Cast-on-serial number on crossing
2 Type of crossing and section
3 Drawing number
4 Date of casting
5 Heat number
6 Date of heat treatment
7 Date of material inspection
8 Chemical analysis of metal (sample

taken at the end of pouring)
C% Mn% Si% S%
Solidity test after sectioning at 7 Defects if any with %age of cross-

9
locations as indicated in Clause 6.2.2 sectional area
of Part – A of this specification
From toe, end
Location – 1 Face A
Face B
Face B
continued…
Page | 45 of 67
Face B
Face B
Face B
Face B
Face B
10 Results of bend tests conducted on

integral test bar
11 Surface condition (visual)

(Defects, if any, shall be shown on a
sketch at Annexure-IV).
12 Result of Radiographic test conducted

on flanges as indicated in Clause 6.2.3
of Part – A of this specification
13 Result of Hardness test (BHN) on top

and sectional faces of pieces (7 Nos.)
obtained after solidity test.
14 Result of dimensional check recorded

in the format prescribed by the
inspecting official.
Manager (QC) of the Firm
Page | 46 of 67
ANNEXURE – II
INSPECTION MEMO FOR CAST MANGANESE STEEL CROSSING
continued…
Page | 47 of 67
Page | 48 of 67
ANNEXURE – II A
INSPECTION MEMO FOR WEDABLE CAST MANGANESE STEEL CROSSING
continued…
Page | 49 of 67
Page | 50 of 67
ANNEXURE – III
PROCEDURE FOR REPAIR/RECTIFICATION OF CMS CROSSIGNS BY

WELDING
1.0 LIMITATIONS
1.1 Crossings which are found metallurgically acceptable by the inspecting

official, shall only be put up for dimensional inspection. The details of
dimensional deviations of the crossings, if any, may be indicated on the
sketch as shown in Annexure-IV and put up to the inspecting official.
1.2 Crossing surfaces/areas/locations i.e. running surfaces, non-running

surface, highly stressed locations, nose, wings on either side of nose shall be
broadly classified in the following categories (as shown in Annexure-VIII)
depending upon their criticality from the service considerations, for the
purpose of repair by welding:
Category-I: 300mm of the top of nose, 300mm of the wings on either side of
actual nose of crossing and edges of both top and bottom flanges (upto
25mm from edge).
Category-II: Running surface other than the area mentioned in Category-I.
Category-III: Non-running surface other than the area mentioned in

Category-IV and top surface of “Vee” not coming in contact with running
wheels of rolling stock.
Category-IV: Non-vulnerable areas like bearing plates, walls of end

sections (excluding head portion).
1.2.1 At locations covered in Category-I, no casting defects shall be permitted.
1.2.2 At locations covered in Category-II, no rectification shall be allowed on

the running surface. Scattered minor defects (excluding cracks) of size less
than 4mm dia and upto 1.5mm depth anywhere on this area of the casting
shall be left as such, provided these defects are at a minimum distance of
15mm from each other and not more than 3 numbers in a particular
location.
continued…
Page | 51 of 67
1.2.3 At locations covered in Category-III, defects appearing in the crossing

surface shall be permitted to be rectified by welding adopting the usual
procedure and precautions at the discretion of the inspecting official.
1.2.4 At locations covered in Category-IV, surface defects of size <30mm in

diameter and depth <1/3 of thickness may be permitted to be rectified by
welding taking necessary precautions and with the knowledge of the
inspecting official and to be recorded in the final inspection certificate.
2.0 PROCEDURE FOR WELDING
2.1 Before carrying out weld-reclamation, the defective areas shall be removed
by grinding/gauging. The locations shall be tested by dye-penetrant to
ensure complete freedom from the cracks. These operations,
grinding/gauging and testing shall be repeated till the area is free from the
defects and cracks.
2.2 Only those crossings which are considered suitable for rectification by
welding shall be rectified by using any of these brands of electrodes
approved by RDSO under Class H3B.
These crossings can also be reconditioned/ rectified by using H3C hard
facing electrodes. Maximum upto 4mm dia electrodes shall only be used to
avoid high heat input.
2.3 The electrodes shall be dried at the specified temperature and time as per
the recommendations of the electrode manufacturer. The electrodes having
cracked and damaged flux covering shall be discarded.
2.4 Welding shall be carried out using DC welding generator with reversed
polarity using the lower limit of the current range or as recommended by
the electrode manufacturer and shortest possible arc length practicable
during welding, so as to reduce the heat input in the base metal, thereby
reducing the dilution of the weld metal which would otherwise cause
embrittlement of the weld.
2.5 Welding shall be intermittent so that at no time more than one run is
deposited simultaneously and welding is not done continuously for more
than 2 minutes at a stretch.
2.6 For ensuring quick cooling of the weld deposit and the heat affected zone,
compressed air shall be used just after welding or the crossing shall be kept
submerged in a water bath during welding.
continued…
Page | 52 of 67
2.7 Peening of the weld deposit shall be carried out just after welding so as to
minimize residual stresses.
To minimize the heat buildup more than one crossing shall be welded at a
time by rotation welding being restricted to one or two widely separated
areas on each casting at a time. If necessary, welding at one area may also
be done intermittently by a rotation to ensure and intervals of at least 25
minutes between two weld deposits in the same location/area.
3.0 WELDERS:
3.1 Only highly skilled welders, qualified as per IS:7318/3991 (MTI) II size A5
P28 Corr. 71 or as per the latest revision in vogue, from some reputed
testing Authority shall be engaged to undertake the work of weld
rectification Welding shall be carried out under the supervision of the
Metallurgical/Quality Control Officer of the firm.
4.0 INSPECTION
4.1 The details of welding rectification carried out on the crossing shall be
recorded in a sketch shown in Annexure-IV and put up to the inspecting
official.
4.2 Rectified crossings after cooling and grinding shall be subjected to by dye-
penetrant for ensuring that no surface defects remain after repair welding.
4.3 The Metallurgist/Quality Control Officer of the firm shall issue a test
certificate to the Inspecting Officials stating that the welding has been
carried out strictly in accordance with the provisions laid down in this
procedure.
5.0 PROCEDURE OF RE-WELDING OF LEGS FOR WCMS CROSSINGS
5.1 In case defected rail weld in Weldable CMS Crossing, the CMS Crossing can
be re-welded once with normal rail after removal of INOX & heat affected
zone of CMS Crossing.
5.2 The crossing, INOX & normal rail which is to be re-welded shall be
internally tested by the firm for ascertaining suitability for re-welding.
5.3 To maintain overall length of the WCMS crossing, longer length of rail to be
welded to compensate length lost in milling/cutting/removal of defect.
5.4 Finishing of the re-welded joint of WCMS crossings shall be such that
dimensionally it conforms to Clause 4.2 of Part – B of this specification.
Page | 53 of 67
ANNEXURE – IV
SKETCH FOR SHOWING METALLURGICAL DEFECTS OF CMS CROSSINGS
Serial No. of Crossing: Section:
continued…
Page | 54 of 67
Page | 55 of 67
ANNEXURE – V
PROFORMA FOR SHOWING METALLURGICAL DEFECTS OF CMS

CROSSINGS
Crossing number: Design:
Drawing No.: Date of Casting:
Date of Examination:
Reference Location Type of defect Remarks

Number of (cracks, sand holes,
Annexure-IV
cold shuts, pin
holes porosity,
extra metal, sand
fusion, others)
Inspecting Official (Signature & Seal) Manager (QC) of the firm
Page | 56 of 67
ANNEXURE – VI
PROFORMA FOR DIMENSIONAL INSPECTION OF CAST MANGANESE

STEEL CROSSING
1 Cast on serial number

2 Type and section with drawing number
3 Date of inspection
4 Heat number
5 Items to be inspected
5.1 Position of Crossing (Running surfaceup)
5.1.1 End fitments (both toe and heel end)

5.1.2 Alignment at the fish-plated joint
matching etc.
5.1.3 Length
5.1.4 Wheel tread
5.1.5 Top edge contour
5.1.6 Offset (both toe end and heel end)
5.1.7 Flange well depth (including surface
condition of flange well)
5.1.8 Flange way clearance
5.1.9 Overall alignment (including local

misalignment)
5.1.10 Throat clearance Top surface level
5.1.11 Top surface level
5.1.12 Concavity/convexity/twist. If any
5.1.13 Wing rails

5.1.14 Nose thickness
5.1.15 Nose depression
5.1.16 Height at different locations
5.1.17 Fish bolt holes
5.1.18 Fishing plane
5.1.19 Bond holes
continued…
Page | 57 of 67
5.2 Position of crossing (Bottom up)
5.2.1 Bottom surface

5.2.2 Web thickness
5.2.3 Tie (thickness, width etc.)
5.2.4 Bottom width
5.2.5 Flange thickness (including thickness
atrecesses)
5.2.6 Roof thickness (i.e. below flange well,
Vee portion etc.)
5.2.7 Condition of end section – faces (both
heel and toe end)
5.3 Other items, if any
Manager (QC) of the Firm Inspecting official
Note: 1. Defect, if any, be marked on a sketch at Annexure-IV.
2. Marking of certain locations with chalk to be done on the crossing as

desired by inspecting official to expedite inspection with the help of
gauges/templates.
Page | 58 of 67
ANNEXURE – VII
SCHEMATIC DIAGRAM FOR IMPACT BEND TEST
continued…
Page | 59 of 67
ARRANGEMENT FOR IMPACT BEND TEST
Page | 60 of 67
ANNEXURE – VIII
SKETCH SHOWING DIFFERENT CATEGORIES OF LOCATION TO BE

CONSIDERED FOR REPAIR BY WELDING
Page | 61 of 67
ANNEXURE – IX
SCHEMES FOR FILM ARRANGEMENT
Page | 62 of 67
ANNEXURE – X
DYE PENETRATION TEST LOCATIONS FOR CROSSING
Page | 63 of 67
ANNEXURE - XI
FORMAT FOR DIMENSION RECORD FOR WELDING JOINT
Firm‟s Name
Contract./P.O no. & date
WCMS Crossing No.
Date of Inspection
1 meter straight edge 10 cm straight edge Remarks

Rail Rail Rail Rail Rail Rail
head top head head head head head
table side LH side RH top side LH side RH
table
Welding
Joint 1
Welding
Joint 2
Welding
Joint 3
Welding
Joint 4
Signature of the Inspector Signature of the firm‟s Rep.
Page | 64 of 67
ANNEXURE – XII
SAMPLE WELDING GRAPH
Page | 65 of 67
ANNEXURE – XIII
SECTION SKETCH FOR MACROGRAPHIC TEST
Page | 66 of 67
ANNEXURE – XIV
SECTION SKETCH FOR MICROGRAPHIC TEST
Page | 67 of 67

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IRS : T–29 (Revised – 2023)

SERIAL NO. IRS: T-29 (REVISED-2023)

RESEARCH DESIGNS AND STANDARDS ORGANISATION

Clause No. Item Page No.

PART – A : CAST MANGANESE STEEL (CMS) CROSSINGS

PART – B : WELDABLE CAST MANGANESE STEEL (WCMS) CROSSINGS

ANNEXURE FOR BOTH PART – A & PART – B

V Proforma for Showing Metallurgical Defects of CMS/WCMS 56

0.2 This specification was revised in 2016 to incorporate the requirements of

SPECIFICATION FOR CAST MANGANESE STEEL (CMS) CROSSINGS

1.2 Reference specifications

1 IS: 2 – 2011 Rules for round off numerical values

2 IS: 210 – 2010 Specification for Grey Iron Castings

3 IS: 228 – 1987 Methods of chemical analysis of steels (plain

4 IS: 12308 – 1991 Methods of chemical analysis of cast iron and

5 IS: 13607 – 1992 Ready mixed paint, Finishing, for general

6 IS: 104 -1979 Ready mixed paint, brushing, zinc chrome,

7 IS: 12117 -1996 Norms for classification of steel foundries for

9 IS: 1599 -1985 Method of bend test

11 IS: 2062 – 2011 Hot Rolled Medium and High Tensile

12 IS: 3063-1994 Fasteners - Single coil rectangular section

13 IS: 7318-1974 Approval Test for Welders When Welding

14 IS: 7739 (Part-V) - Code of practice for preparation of

15 IS:276-2000 Austenitic-Manganese Steel Castings

16 IS:4748:2009 Steels – Micrographic determination of the

17 IS:3658-1999 Code of practice for liquid penetrant flaw

18 IS:11732-1975 Acceptance standards for liquid penetrant

19 IS:6601 Permissible deviations in chemical composition

1 IRS: T-12-2009 or latest version Flat bottom railway rails

1.4 Inspecting authority shall mean RDSO/RITES or any other agency

1.5 Inspecting official shall mean authorized representative of inspecting

2.0 QUALITY ASSURANCE PROGRAMME

a) Type of scrap to be used.

u) Machine finishing of bottom, fishing planes, top gauge face radius,

3.0 STEEL MAKING

4.0 CHEMICAL COMPOSITION

The ratio of Manganese to Carbon should be minimum 10:1. In case of any

4.3 Calibration of Spectrometer

Spectrometer should be calibrated at pre-designated intervals based on

Wide variation for CMS Crossings will mean :

For Mn 5% of certified value or 0.5 actual variation

For C and Si 5% of certified value or 0.05 actual variation

For P and S 5% of certified value or 0.005 actual variation

5.0 INTERNAL DEVELOPMENT

5.1 In view of the sophisticated nature of work involved in casting CMS

5.2 As a part of internal development, the manufacturers should cast a few

soundness of the cut sections, dimensional accuracy, records of non-

5.3 During internal development, inspection procedure detailed at Clause 6

6.1 Manufacturing of Prototype

6.1.1 On receipt of permission for casting of prototypes, the manufacturer shall

6.1.2 Various stages of manufacture for bulk production as detailed in Clause 8

6.2.1 Surface inspection

However, all such defects have to be in a location which is at least 300 mm

6.2.2 Solidity Tests

10% of the prototype castings subject to a minimum of one casting of each

6.2.3 Radiographic Examination

Flange portion of the crossing shall be radiographically examined.

6.3 Approval of Prototypes

2. Properties of above sand