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0)

Government of India
Ministry of Railways

SCHEDULE OF TECHNICAL REQUIREMENTS FOR INFRASTRUCTURE,

MANUFACTURING, TESTING FACILITIES & QUALITY CONTROL
REQUIREMENTS

FOR

PAINTS BASED ON EPOXY AND POLYURETHANE RESIN

FOR PAINTING OF COACHES, DIESEL AND ELECTRIC
LOCOMOTIVES

STR No. M&C/PCN/040/2020

(Revision 2.0)

2020

Issued By

METALLURGICAL &CHEMICAL DIRECTORATE

RESEARCH DESIGNS & STANDARDS
ORGANISATION LUCKNOW-226 011
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TABLE OF CONTENTS
1. FOREWORD
2. SCOPE
3. APPLICABLE/REFERENCE DOCUMENTS
4. TERMINOLOGY/ABBREVIATIONS
5. GENERAL REQUIREMENTS
6. M&P REQUIREMENTS
7. TESTING FACILITIES
8. QUALITY CONTROL REQUIREMENTS
9. REPAIR/SERVICE CENTRE
MAJOR STEPS INVOLVED IN GETTING THE FIRMS APPROVED/
10. REGISTERED
11. LIST OF PAINTS TO BE APPROVED
12. ANNEXURE-I & II
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Schedule of Technical Requirements

of Epoxy & Polyurethane based Paints
in Two Packs for Painting of Coaches, Diesel & Electric locomotives

1. FOREWORD

1.1 This document has been prepared [(Earlier reference STR

No.M&C/040/2011 (Revision 1)] to lay down the eligibility and capability of
suppliers seeking approval for manufacturing & supply Epoxy/Polyurethane
based Paints in Two Packs for Painting of Coaches, Diesel & Electric
locomotives as per the recommendation of design directorate.

2. SCOPE

2.1 This document covers the infrastructure facilities at works, procurement of

raw materials, manufacturing of paints, quality control etc. These paints will
be used for painting of Coaches, diesel and electric locomotives.

3. APPLICABLE/REFERENCE DOCUMENTS
(i) IS: 101
(ii) ASTM B117
(iii) ASTM D3359
(iv) ASTM G-154
(v) ASTM 4060

4. TERMINOLOGY

STR – Schedule of Technical Requirements

NTH – National Test House
ISO – International Standards Organisation
M&P – Machinery & Plant
NABL – National Accredited Board of Laboratories
NSIC – National Small Industries Corporation Limited
MSME – Micro Small and Medium Enterprises- Testing Centre
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5. General Requirements

5.1 Any firm seeking approval of this organisation:

(i) shall possess valid ISO 9001 : 2015 or latest & ISO: 14000
Environmental maintenance system installation certificate for the
products for which approval is sought.
(ii) shall have minimum manufacturing experience of these paints for 2
years.
(iii) shall procure these resins from national or international sources
and shall produce bill of material.
(iv) shall have valid clearance from Pollution Control Board. (Proposed for
deletion)
(v) Shall have the record of supplying the products to the reputed
national and international organisation like defence, heavy &
earthmover industries like BEML, BHEL, railway and major
automotive industries. (Proposed for deletion)
(vi) Shall have minimum turnover of Rs. 1 Crore per annum for last 2
years. (Proposed for deletion) Proposed for modification as:
Shall have balance sheet for last 2 years.
(vii) Shall have ERP/SAP supported multimodule application software
for managing the important parts of business
(viii) Firm should have their own R&D facilities approved by Govt. Agency or
the firm should have tie up with Govt. R&D Laboratory/Deemed/Govt.
University. Valid certificate with clear date of validity on it should be
available with the firm and same need to be submitted to RDSO/Lucknow.
(Proposed for deletion)
(ix) The firm should have valid capacity certificate issued by NSIC
/Other approved agency for small scale industries.
(x) In case of medium & large scale industries, if capacity certification
is not possible by any approved agency, capacity shall be declared
by the firm itself detailing the points to arrive at the capacity and
subsequently assessing officer will verify the capacity during the
assessment of the firm.
The above information should be furnished by the firm in registration form.

5.2 The firm should have covered area with adequate space for the storage of
raw material, intermediate and finish products like pigments, extenders,
resins, hardeners, varnish, thinners, additives, paints etc. with the firm
which is free from dampness and humidity and all manufacturing facilities
should be available in same campus of factory. One bond room with lock
and key facility for keeping finished products should also be available.

5.3 Approval of a firm will be given as per laid down procedure given in ISO apex
document only after Inspection of the factory premises to assess the
capacity/capability of the firm and samples of paints drawn during inspection
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(comprising of a full system of painting) meets the norms and requirements

of the relevant RDSO specifications on testing at RDSO. The initial approval
shall be given in “List of RDSO Vendors for developmental orders” and
further upgradation to “List of approved vendors” will be given after meeting
the requirement given in ISO apex document and supply of minimum 20,000
litres after initial approval.
5.4 The firm should submit the Brand Names of the applied products.

5.5 The Approval to the firm will be given for full paint system . The list of paint
items is furnished at Clause 11.0

5.6 The firms approved as “List of RDSO Vendors for developmental

orders”/“List of approved vendors” shall submit statement of supplies
during the duration between two periodic quality audits to RDSO, about
the details of the supplies of the relevant paint systems to Zonal
Railways/PUs and Wagon Builders in the format as Annexure-II.

6. Manufacturing Machines & Plants

Firm should possess the following minimum machines and plants for
manufacture paints based on Epoxy & Polyurethane resins with valid
calibration certificates of balances at S.No.7 & 8.

Table-I
Sl. Equipments Quantity
No. (min.)
1. High Speed Disburser/Pug mixer, min. capacity 500 kgs 3 Nos.
-3 nos. or the total capacity shall be 1500 Kgs/day min.
may be considered irrespective of no. of machines.

2. Sand Mill/LMZ Sand mill,(min.chamber capacity 10 lts.) 2 Nos.

( in case of higher capacity of the mill , total capacity
shall be 2000 ltrs./day irrespective of kind of machine
and no. of machines)

3. Bead Mill/ Dyno mill/ LMZ Sand mill,(min. 3 Nos.

capacity1000 lts./day), (total capacity of the mill shall
be 3000 ltrs./day irrespective of no.of machines)
4. Paint Mixer, min. capacity 2 K ltr.( in case of higher 5 Nos.
capacity of the mill ,total capacity shall be 10000
ltrs./day irrespective of no.of machines)
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5. Thinning Pump 6 Nos.

6. Automatic Filling Machine 3 Nos.
7. Weighing Machine, 300 Kg., Least count 0.100 Kg. 2 Nos.
Weighing Machine, 60 Kg., Least count 0.050 Kg. 2 Nos.
Weighing Machine, 10 Kg., Least count 25.00 gm 2 Nos.
8. Electronic Balance, 1.00 Kg., Least count 10.00 gm. 3 Nos.
9. Industrial Vibrator or agitator 3 Nos.
10. Solvent Pump 3 Nos.
11. Unloading Pump 5 Nos.
12. Slow Speed Premixer and High Speed Premixer / 3 Nos.
variable speed premixer with gear design each
13. Resin Transfer Pump 2 Nos.
14. Diesel Generator of adequate capacity 1 Nos.
15. Hoist 2 ton / suitable plant design to fulfil the 2 Nos.
requirement
16. Filter press with variable mesh size filter 2 Nos.

7. Testing facilities

7.1 The firm should have proper air conditioned laboratory to maintain lab test
conditions at 27 ± 2°C and 65 ± 5% relative humidity, for which suitable
indicating/measuring instruments will be available in the lab.

7.2 There should be full testing facilities with equipments which are covered as per
requirements of IS: 101 latest version or as per ASTM. Other equipments not
covered in IS /ASTM shall be of reputed make and these should have valid
calibration certificate. It is mandatory for a firm seeking approval of RDSO to
have equipments listed in table –II at their end.
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Table-II
Sl Name of the Equipment Quantity (min.)
No.
1. Humidity Chamber as per IS : 101 1 No.
2. Salt Fog Test Cabinet as per ASTM B117 or equivalent 1 No.
3. Gas Liquid Chromatograph 1 No.
4. Cross cut adhesion tester as per ASTM D3359 1 No.
5. Sagging index as per IS : 101 1 No.
6. Gloss-O-Meter of 600 angle of incidence as per IS : 101
1 No.
7. Abel’s Flash Point Apparatus as per IS : 101 1 No.
8. Cryptometer or Black & White Charts as per IS : 101 1 No. or Black and
White Charts in
adequate quantity
9. Flexibility & Adhesion Apparatus as per IS : 101 1 No.
10. Scratch Hardness Tester as per IS : 101 1 No.
11. Flow Cup (Ford Cup No. 4) as per IS : 101 1 No.
12. Stormer/Brooke Field Viscometer as per IS : 101 1 No.
13. Weight/10 Litre Cup as per IS : 101 1 No.
14. Hegman Gauge as per IS : 101 1 No.
15. Centrifuge as per IS : 101 1 No.
16. Dry Film Thickness Measuring Equipment as per IS :101 1 No.

17. Dean & Stark Apparatus as per IS : 101 / Carl Fischer 1 No.
apparatus
18. Lovibond Tintometer as per IS : 101 1 No.
19. Accelerated Weathering Tester viz QUV to ASTM G-53 1 No.
20. Taber Abrasion tester as per ASTM D 4060 1 No.
21. Color Spectrophotometer as per IS:101/ASTM 1 No.
22. Chemical Balance upto 4 decimal places (in gms.) 1 No.
23. Physical Balance upto 2 decimal places (in gms.) 1 No.
24. Hot Air Electric Oven 1 No.
25. Distillation Plant 1 No.
26. Hydrometer of different ranges 1No.of each range
27. Hygrometer 1 No.
28. Drying time recorder as per ASTM D 5895 1 No
29. Air & Air less spray gun 1 No each
30. Hot Plates 3 Nos.
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31. Set of Sieves, Thermometers, Glass Wares, Crucibles, In adequate

Reagents & Chemicals for Testing of Raw Materials,
Intermediate and Finished Products as per relevant Qty./Nos.
specifications

32. Heating Mantles 3 Nos.

33. Water Bath 2Nos.
34. Muffle Furnace 1 No.
35. Mild Steel, Tinned and Glass Panels and Test Racks In adequate
number

8. Quality Control Requirements

8.1 There should be a well-designed system for traceability and

identification of the materials from raw material, intermediate and
finished product stages.
8.2 The quality manual of the firm for ISO should clearly indicate at any
stage the quality control over procurements of raw materials,
manufacturing of intermediate and finished products by
computerized process control technique.
8.3 The technical supervisors/managers responsible for production &
quality control activities related to manufacturing of subject paint item
should have the minimum qualification of B.E. / B.Tech (Paint
/Polymer Technology/Chemical Engg.) with a minimum of 3 years
experience or M.Sc. (Chemistry) with a minimum of 7 years
experience in relevant fields to look after the production, quality
control and testing activities and should have knowledge of paint
manufacturing, testing of raw materials etc. They should be able to
take corrective steps in case of difficulties in maintaining quality
control.
8.4 The firm should ensure that proper analysis is being done on monthly
basis to study the rejection at various levels and it is documented.
Process capability should also be studied.
8.5 The firms should ensure that all the relevant RDSO/BIS/ASTM and
other specifications, standards, manuals etc. are available with them.
8.6 If the firm intends to obtain approval for paints based on epoxy as
well as polyurethane resins they should possess test certificates for
both, one primer and one finishing paint based on epoxy or
polyurethane resins issued by approved test houses viz NTH/MSME/
HBTI/ Shri Ram Test House/National Laboratories under CSIR.
(Proposed for deletion)
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8.7 A periodical/Need basis Quality Audit check may be carried out of

the firm to check the quality of paint and other infrastructure and
testing facilities mentioned in the STR .
8.8 The firm should prepare and submit Quality Assurance Plan for products,
which they intend to supply to Indian Railway and Production Units as per
Guidelines of ISO Document no. QM-RF-8.1-3 (Latest version) detailing
various aspects:

• Organisation chart
• Write up on manufacturing process of paints
• Process flow chart for paints
• Traceability of various products.
• Inspection and testing plan for all the products starting from raw
materials, in process and final product.
• Details of non-conformity
• Details of customer complaints and warranty failures/In service failures.
• M&P/T&P as per specification/STR/IS

9. Repair / Service Centre

The firm should have 24X7 customer complaint registration & redressal
mechanism through website.

10. Major steps involved in getting the firms approval / registration as per
latest ISO apex documents:
10.1 The firm shall apply online for vendor registration on RDSO website.

10.2 The application form and other relevant documents shall be scrutinized at M&C
Dte and if any deficiencies are found, the firm shall be asked to comply the
deficiencies as per latest ISO apex guidelines.

10.3 After all deficiencies are complied by the firm, the capacity, capability and STR
verification of the firm shall be assessed by nominated official. Samples shall
also be drawn from the firms premises after satisfactory compliance of STR
and shall be tested at RDSO/National Test House (Lab which is accredited by
an accrediting agency which meets the criteria laid down in QO-D-8.1-11
{Latest version}) and if test facility for any of parameter is not available either at
RDSO/NTH/as specified in QO-D-8.1-11 then it may be referred to Govt
lab/University/any other NABL accredited lab, where it exist.
10.4 If all the test results are satisfactory and all other requirements are
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fulfilled, the firm shall be approved for “List of RDSO Vendors

for developmental orders”.

11. The list of paints based on epoxy and polyurethane resins which may be used for
painting, coaches, diesel and electric locomotives as per RDSO Specn.
M&C/PCN/100/2018 etc. in Indian Railways and Production Units is furnished
below:

(i) Epoxy Zinc Phosphate Primer to M&C/PCN/100/2018 (Chapter II)

(ii) Unsaturated Polyester Putty to M&C/PCN/100/2018 (Chapter III)
for coaches only.
(iii) PU Surfacer to M&C/PCN/100/2018 (Chapter IV) for coaches .
(iv) Polyurethane finishing paint to M&C/PCN/100/2018 (Chapter V) for
coaches.
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ANNEXURE –I

SN Description of Machine Capacity Total No. of Operation to Capacity of Year & Present
/Equipment/ Manpower Make
requirement/ requirement Machines be performed available of Status—
by Machine/
Qualification available Equipment Machine Machine Working/
Under
Commencing
/Not working

1 2 3 4 5 6 7 8 9
1 Highspeed Disburser/ 500 kg. 3 Nos.
Pug Mixer
2 Sand Mill/LMZ Sand 2000 lit. /day 2Nos.
Mill(chambercap.10lit.)
3 Bead/Dyno Mill/LMZ Sand 3000 lit. /day 3 Nos.
Mill
4 Paint Mixer 2K lit.each 5 Nos.
5 Thinning Pump 6 Nos.
6 Automatic Filling Machine 3No.
7 WeighingMachine,LC=0.1 300 kg 2 Nos.
00 kg
8 WeighingMachine 60 kg 2 Nos.
LC=0.050 kg
9 WeighingMachine 10 kg 2 Nos.
LC=25.0 gm
10 Electronic Balance 1.0 kg 3 Nos.
LC=10.0 gm
11 Industrial Vibrator or 3 Nos.
Agitator
12 Solvent Pump 3 Nos.
13 Unloading Pump 5 Nos.
14 Slow /High/Variable speed 3 Nos.
premixer each
Resin Transfer Pump 2 Nos.
15

16 Hoist 2 ton 2 Nos.

17 Diesel Generator Adequate 1 Nos.
18 Filter Press 2 Nos.
19 Humidity Chamber 2 Nos.
20 Gas Chromatograph 1No.
21 Salt Fog Test Cabinet as 1No.
per ASTM B117 or
equivalent
22 Cross cut adhesion as per 1No.
ASTMD3359
23 Sagging Index 1No.
24 Glossometer 60° Angle 1No.
25 Abel’s Flash point 1No.
Apparatus
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26 Cryptometer/Black & White 1No.

Charts
27 Flexibility & Adhesion 1No.
Apparatus
28 Scratch Hardness Tester 1 No.
29 Ford Cup no.4 1No.
30 Stromer/ Brookefield 1No.
Viscometer
31 Weight/10 lit Cup 1No.
32 Hegman Gauge 1No.
33 Centrifuge 1No.
34 Dry FilmThickness 1No.
MeasuringApparatus
35 Dean & Stark Apparatus 1 No.
36 Lovibond Tintometer 1 No.
37 Accelerated Weathering 1 No.
Tester
38 Taber Abraser 1 No.
39 Colour Spectrometer 1 No.
40 Chemical Balance,upto 4 1 No.
decimal place
41 Physical Balance,upto 2 1 No.
decimal place
42 Hot Air Oven 1 No.
43 Muffle Furnace 1 No.
44 Distillation Plant 1 No.
45 Hydrometer 1 No.
each
46 Hygrometer 1 No.
47 Drying time Recorder 1 No.
48 Air & Airless Spray Gun 1 No.
each
49 Set of Sieves, Adequate
Thermometers, Glassware, qty.
Crucible, Reagents &
Chemicals for testing of Raw
materials, Intermediate &
finished products as per
relevant specifications.
50 Hot Plates 3 No.
51 Heating Mantles 3 No.
52 Water Bath 2 No.
53 Mild Steel, Tinned & Glass Adequate
panels & test Racks
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1 2 3 4 5 6 7 8 9
54 Manpower— The 1 No.
technical supervisors/ each
managers responsible for
for production & quality Product
control activities related ion &
to manufacturing of Quality
subject paint item Control
should have the respect
minimum qualification ively.
of B.E. / B.Tech (Paint
/Polymer
Technology/Chemical
Engg.) with a minimum
of 3 years experience
or M.Sc. (Chemistry)
with a minimum of 7
years experience in
relevant fields to look
after the production,
quality control and
testing activities and
should have knowledge
of paint manufacturing,
testing of raw materials
etc.

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

column 5 to 9 shall be furnished by vendor.
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ANNEXURE –II

Statement of supplies during the duration between two periodic quality audits
as per QO-D- 8.1-13 (Latest version)
Name of the Vendor:

S.No. Period Full Item Supplied to P.O No. Quan Inspecting Performance Whether Any
detail with Zonal Rly/ and date tity Agency Report of supplied other
specification PU/ Inspecting within information
Wagon Builder Agency D.P or
extension
of
D.P
Taken
(Informa
tion to
be given
in detail)