No.: WD – 16 – BOXNR – 2010 (Rev.

-1)

INDIAN RAILWAYS

GUIDELINES AND TECHNICAL REQUIREMENTS

FOR UPGRADED REHABILITATION OF BOXN WAGONS TO
BOXNR (WITH STAINLESS STEEL BODY)
FOR
BROAD GAUGE (1676 mm)

S.NO. Month/year of issue Amendment No. Revision No Pages

1. Dec.-2010 01 - 01
2. June 2016 - 01 -
3. January 2017 01 --- 01
4. December 2018 02 --- 01

ISSUED BY

RESEARCH DESIGN AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
MANAK NAGAR, LUCKNOW - 226 011

June, 2016 Price: Rs.

Page 1 of 25
  

Amendment No. 02 to WD –16 – BOXNR–2010(Rev.-1) of December 2018

The following amendment in Section-B is issued with the approval of the competent
authority:

Para /Clause : Amended of Section-B from the existing to

6.0 (xiii) (2) : • “The Stainless steel (IRSM-44) & IS: 2062 E450 as raw material
has to be procured from RDSO approved sources with inspection
by RITES”
shall be read as:
• “Steel will be procured by the contracting firms from the integrated
steel plants from whom Railway Board is procuring these items on
the basis of their Mill’s test certificate. Documentary evidence in
this regard is to be submitted at the time of inspection of wagons”

x-x-x

 
 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

Amendment No. 01 to WD –16 – BOXNR–2010(Rev.-1) of January 2017

The following amendment in Section-A is issued with the approval of the competent authority:

Para /Clause : Amended of Section-A from the existing to

Clause 1.1 : - I Para of the clause shall be read as:
st

“This guideline covers the technical requirements for the rehabilitation and up-gradation
of BOXN wagons to BOXNR for increasing capacity and resistance to corrosion. The
work involves fabrication of new sidewalls, end walls, replacement of floor plate, doors,
damaged under frame members and coupler to WD-70-BD-2010 in place of 48-BD-08.

- In table under Para 4, the following row deleted:

BRAKE SYSTEM
(i) Single pipe graduated release air (i) Twin pipe graduated release air
brake system. brake system.
Clause 2.3 : Deleted
Clause 3.4(iii) : In para 3.4 (iii), the RDSO drg. No WD-07001-S/0 Shall be read as WD-07001-S/04.
Clause 4.5 Deleted
Clause 6.11 : Existing hand brake wheel (Ø 610) drg no. W/BG-6226 is to be replaced with lesser dia
hand wheel (Ø380) as per RDSO drg. no. WD-10087-S-01.

x-x-x
 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

CONTENTS
S.No. Description Page No.

SECTION A
TECHNICAL REQUIREMENTS FOR UPGRADED REHABILITATION OF BOXN
WAGONS TO BOXNR WAGONS IN RAILWAY WORKSHOPS

1.0 Scope 3
2.0 Description of work 5
3.0 Work Details 6
4.0 Details of Materials Required in Workshops 8
5.0 Assembly of Body 9
6.0 Precautions and quality requirements 11
7.0 Handling of Body side wall and end wall 13
8.0 Painting and finishing 13
9.0 Minimum facilities required in workshops 15
10.0 Marking of wagons 15
SECTION B
INFRASTUCTURE AND QUALITY CONTROL REQUIREMENTS FOR MANUFACTURE AND
SUPPLY OF BODY SIDE WALL, END WALL AND FLAP DOOR OF BOXNR WAGONS

1.0 Experience 16
2.0 Manpower Resources at firm’s works 16
3.0 Minimum requirement of M&Ps 17
4.0 Storage and Material Handling Requirements 18
5.0 Testing Facilities 18
6.0 Quality Control Requirements 19
7.0 Other requirements and general guidelines 21
Annexure I : Eyebolt for lifting of Side wall/End wall 22
Annexure II : Parameters of Center Sill that need to be
23
checked/ inspected
Annexure III : Parameters/ Structural Members of BOXN that
24
need to be checked/ inspected,
Annexure IV : Parameters/ Structural Members of Under frame
25
that need to be checked/ inspected,

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

1.0 SCOPE :
This guideline is in two parts. Section-‘A’ deals with the technical requirements of
upgraded rehabilitation of BOXN wagons in Railway Workshops and Section B
deals with the infrastructure and quality control requirements for manufacture and
supply of body side wall, end wall and flap door of BOXNR wagons.

All the provisions contained in RDSO’s ISO 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.

SECTION A

TECHNICAL REQUIREMENTS FOR UPGRADED REHABILITATION OF

BOXN WAGONS TO BOXNR WAGONS IN RAILWAY WORKSHOPS

1.1 This guideline covers the technical requirements for the rehabilitation and
upgradation of BOXN wagons to BOXNR for increasing capacity and resistance
to corrosion. The work involves fabrication of new sidewalls, end walls,
replacement of floor plate, doors, damaged under frame members, fitment of
feed pipe (to convert the wagon from single pipe to twin pipe) and coupler to
WD-70-BD-2010 in place of 48-BD-08.
Preferably BOXN wagons in age group 12-18 years should be taken up for this
upgraded rehabilitation. Rehabilitation using RDSO Specification WD-12-
BOXN(Rehab.)-2006 Rev-1 may be done for wagons in age group of 18-22
years on condition basis.
Rehabilitation of wagon to be taken up only if centre sill of wagon found to be in
sound condition and meeting the parameters laid down in check sheet at
Annexure-II.
After the rehabilitation and upgradation, the wagon shall be marked as BOXNR
in place of BOXN. The major differences in constructional features of BOXN &
BOXNR are as under:
SIDE WALL

BOXN BOXNR

(i) Material mild steel (i) Material stainless steel(IRS:M44) and

Micro alloyed steel (IS :2062 E 450)

(ii) Provided with 6 Nos. of side (ii) Provided with 9 Nos. of side
stanchions with 8mm thick hat stanchions with 6mm thick CRF hat
section ( on one side) section (on one side)

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

(iii) Side sheets of 5mm (iii) Side sheets of 3 mm thickness.

thickness

(vi) Inside height of side wall is (iv) Inside height is 2127mm from floor
1950mm from floor level. level.

(v) Two Nos. middle coping (v) Middle copings are not provided in
provided in sidewall. side walls, except at corner side
panels.

(vi) Top coping provided with (vi) Top coping provided with press
ISMC-100 section of BOX 100x100x6mm thick.

(vii) Side stanchion riveted with (vii) Side stanchion Lock bolted with sole
sole bar with two rows rivets. bar with single row.

DOOR PLATE

(i) Door Plate provided with (i) Door plate to be provided as per door
Mild Steel for 5 mm thickness drawing

END WALL

(i) Made with mild steel. (i) Made with stainless steel (IRS:M44)
and Micro alloyed steel (IS :2062 E
450)

(ii) Each End wall provided with (ii) End wall provided Two side stanchion
4 Nos. of End stanchions of in three pieces and two middle coping
ISMC-150mm. of Hat section 6 mm thickness.

(iii) End top coping provided (iii) End top coping provided with
with ISMC-150 channel. CRF section of BOX
100x100x6mm thickness

(iv) End Sheet provided with 5 (iv) End Sheet provided with 3 mm thick
mm thick

FLOOR PLATE

(i) Floor Plate provided with (i) Floor plate provided with stainless
Mild Steel for 6 mm thickness steel of 4 mm thickness.

BRAKE SYSTEM

(i) Single pipe graduated release (i) Twin pipe graduated release air brake
air brake system system

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

COUPLER & DRAFT GEAR

(i) High Tensile Non-Transition (i) High Tensile Non-Transition coupler to

coupler to 48-BD-08 & Draft WD-70-BD-2010 & Draft gear to 49-
gear to 49-BD-08 BD-08

2.0 DESCRIPTION OF WORK:

The rehabilitation of BOXN wagon body by using of CRF section (to RDSO’s
specification no. WD – 01 – CRF – 12 (latest revision) and stainless steel (IRS:M
44: 97 latest revision)/ Micro alloyed steel (IS :2062 E 450) will provide additional
strength to body and reduce corrosion. The volume will also increase to fully
utilize the capacity upto 22.9 Tonne axle load for coal.
List of construction drawings of BOXNR is as under:

Drawing No. Latest Alteration Description

as on June 2016

WD-07001-S/01 3 Index

WD-07001-S/02 9 Diagram

WD-07001-S/03 8 General Arrangement

WD-07001-S/04 3 Under frame Arrangement

WD-07001-S/05 6 Under frame Details sheet-1

WD-07001-S/06 2 Under frame Details sheet-2

WD-07001-S/07 2 Under frame Details sheet-3

WD-07001-S/08 10 Body side Arrangement

WD-07001-S/09 5 Body side stanchion

WD-07001-S/10 9 Body End Arrangement

WD-07001-S/11 6 Attachment of End to Head stock

WD-07001-S/12 7 Marking Diagram

WD-07064-S/01 9 Cold Rolled Formed Sections

WD-09034-S-07 7 Flap door Arrangement

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

WD-80007-S-12(Sheet-1 of 2) Nil Fitment of Graduated release Air

brake equipment and Twin pipe
WD-80007-S-12(Sheet-2 of 2) 14 layout

2.1 The wagon underframe needs to be strengthened and additional cross members
(cross ties) are to be provided to make integrated structure of body and
under frame, as shown in drawing no-WD-07001-S/04.
2.2 As nos. of stanchions on side wall has been increased to 9 from 6, the location
of holes for fitment has been changed. Hence, sole bar is to be strengthened
to take additional load to compensate for the loss of strength due to
additional holes, as per drawing no- WD-07001-S/05. In case sole bar needs
replacement with new one, proper fitment with cross members to be ensured.
2.3 Wagons provided with single pipe shall be converted into Twin pipe Air brake
system to RDSO drawing no-WD-80007-S-12 (Sheet 1of 2) & WD-80007-S-12
(Sheet 2 of 2)
2.4 High Tensile Non-Transition coupler to RDSO specification no 48-BD-2008 shall
be one time replaced with coupler to RDSO specification no WD-70-BD-2010
and the serviceable components of the removed coupler may be given to
Division for further use. Attention to components like bogie, draft gear etc. should
be given as per extent instruction of Railway Board and RDSO on the subject.
2.5 Railway Workshops nominated to carryout upgradation may purchase side walls,
end walls and flap doors from RDSO approved vendors listed in vendor directory.

3.0 WORK DETAILS:

3.1 Identification of Repairs:

Every incoming wagon to a workshop should undergo a comprehensive incoming
examination that should identify the repairs that need to be carried out before the
wagon is turnout. Format for the same is placed at Annexure-III

3.2 Stripping:
The stripping of wagon’s body structure (Side & End Panels, Door etc.) shall be
carried out as per following:
 Stripping: Detach the doors of wagons by removing its cotter pins and
other attachments to the body structure.
 Trim the Side and End top copings and disconnect the side and end
panels joined at corner stanchion at top.
 Trim off the side and end panels from the crib angles.

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

 Cut all the rivets of corner stanchions, side and end stanchions by gas or
other suitable mechanical means.
 Lower the body structure by means of crane or other suitable means
and placed on the floor.
 Trim off the crib angles from the side and head stock.
 Remove the floor plate from the underframe.
3.2 Cleaning of Underframe:
Cleaning of the underframe can be carried out by placing the underframe on
trestles. Both cleaning and de-rusting can be carried out simultaneously. The
members are to be made rust free by scrapping and hammering so that it can
be checked if any member is heavily corroded or deformed requiring rectification.
Surface cleaning shall be to St3 as per IS 9954:1981(or latest)

3.3 Repair of Underframe:

Please refer to “Maintenance Manual for Wagons” (latest).

Before taking up the repair work, the underframe is to be inspected in respect to
the following:-
(i) Cracks (ii) Alignment and (iii) Replacement of members.

(i) Cracks: If any crack is found in the member of the underframe, the
same should be rectified as below:-
(a) In case of horizontal crack, it is to be drilled out at both ends and
cracked portion gouged out and welded properly.
(b) In case of vertical cracks, strengthen the cracked portion by
patching.
(ii) Alignment: The under frame is to be inspected for its proper
alignment and any deflection of its member either in form of sagging
or buckling should be rectified as per “Maintenance Manual For
Wagons”( latest) .
(iii) Replacement: If any member of underframe is found beyond repair
except centre sill, it should be replaced with new one.
A check sheet detailing measured/observed parameters of the underframe
members is enclosed as Annexure-IV

3.4 Repair of Head stock and Cross Bars:

i) Slightly bent members or portion as the case may be , are heated in

position and straightened by means of straightening device or by

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

applying blows with sledge hammer. To carry out this repair, the CBC
assembly is to be stripped off.
ii) Strip the heavily bent members and sent to Smith Shop for alignment. The
members are to be straightened.
iii) If any defect is noticed in sole bar of the underframe, then it should be
rectified as below:-
Cracks at web/flange to be given proper repairs by electric arc welding Cracks on
flange extended up to web should be duly supported with plain or flanged patch,
as the case may be.
In case there are more than two joints, the complete sole bar should be replaced.
Slightly bent sole bars should be repaired by local heating and straightening. If
flanges are only bent, the same are straightening by a jawed crow bar.
In addition to above repair work, the underframe should be modified and
strengthened (Solebar etc.) to RDSO drg. No WD-07001-S/0, WD-07001-S/05
with latest alteration.

4.0 DETAIL OF MATERIAL REQUIRED IN WORKSHOPS:

The following materials should be available at the time of rehabilitation work:
4.1 Body Side, End Wall & Flap Door assemblies to drg. No WD-07001-S/08,
WD-07001-S/10 and WD-09034-S-07 respectively.

4.2 4 mm thick floor plate to Specification. IRS:M 44 (RDSO drg. No

WD-07001- S/04) floor plates are to be welded at suitable locations so as
to provide backing of underframe members just below the weld seam.

4.3 Lock bolts of sizes ½”, ¾” and 7/8” are to be provided as per Clause 5.1
& 5.2. Availability of proper tooling required for application of these bolts is
to be ensured

4.4 Adequate number of cross bars, should be available before hand to drg.
No WD-80007-S/15 so that these can be changed as and when required.
In addition to this, adequate No. of C.P Top & C.P Bottom should be
available so that on condition basis these can be changed.

4.5 Feed pipe & other equipment’s to RDSO drawing no WD-80007-S-12

(Sheet 1of 2) & WD-80007-S-12 (Sheet 2of 2) for converting the single
pipe graduated release air brake system into twin pipe graduated release
air brake system.

4.6 High Tensile Non-Transition coupler to RDSO specification no WD-70-BD-

2010 to replace existing coupler to RDSO specification no 48-BD-08.

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

4.7 Sufficient No. of electrodes for welding of bi-metal (IRS:M44 to

IS:2062) should be available as prescribed in RDSO specification
no. G -72 Rev.3. (latest amendment)

4.8 Welders qualified for welding of stainless steel to stainless steel and
stainless steel to mild steel/micro-alloyed steel should be deputed to
work for this upgradation work

5.0 ASSEMBLY OF BODY:

The assembly of body structure should be carried out as detailed below:-

(a) Manufacture body side wall, end wall and flap door assemblies to drg. No.
WD-07001-S/08, WD-07001-S/10 and WD-09034-S-07 respectively.
(b) Make sure that holes for lock bolting are made at strengthened solebar
location and headstock location to drg. No. WD-07001-S/05 and WD-07001-
S/11 respectively.
(c) Put the side wall assembly and end wall assembly on underframe and be
sure that holes of side and end stanchions coincide with the holes of
sole bar and head stock. After ensuring it, fix the side and end
stanchion temporarily by means of nut and bolt then tag weld the side
wall and end wall with the corner stanchion.
(d) Check all the controlling dimensions of side wall and end wall, if found
satisfactory or within the limit, weld the side and end wall sheets to corner
stanchion and lock bolt the side stanchions with the sole bar after
replacing the nut and bolt.
(e) Weld the four corner stanchions underframe to drg. No. WD-07001-S/10.
(f) After completing the body assembly, provide top corner gusseting as per
RDSO Drg. No. WD-07001-S/10. The tolerance on inside dimensions of
wagon and on other dimensions shall be as per Appendix – I of G-72
(Revision 3) or latest.
(g) Modified doors of IRSM-44 to be fitted and ensure for proper opening and
locking of the doors.
5.1 Lock Bolting:
Entire lock bolting is to be done with zinc plated/galvanized lock bolts (conforming
to RDSO “guidelines for Product/ Vendor development of Lock bolts & Collars
used on freight stock on IR” (Drawing No. WD-11036-S-01& WD-11036-S-02) .
A list of lock bolts required for the work of upgradation is as under:

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

S. Locations Existing Proposed Qty./ Grip Grip Drawing Nos.

Dia. Of Dia. Of Wagon range
No
Rivet lock bolt (App.)

1. Side stanchion 12 ½” (12.7) 180 23 19.05-25.4 WD-07001-S-09

with sole bar
outer

2. Standard plate 10 ½” (12.7) 4 28 25.4-31.75 W/ML-7 & 14

with sole bar

3. Door hinge foot 16 5/8” (15.9) 48 37.15 31.75-38.1 WD-09034-S-07

with sole bar
WD-07001-S-05

4. End stanchion 20 ½” (12.7) 32 19 19.05-25.4 WD-07001-S-11

with head stock

5. Corner 20 ¾” (19.1 ) 12 19 19.05-25.4 WD-07001-S-11

stanchion with
sole bar

6. Corner 20 ¾” (19.1 ) 12 23 19.05-25.4 WD-07001-S-11

stanchion with
head stock

7. Door check 20 ¾” (19.1 ) 16 36.15 31.75-38.1 W/DW-305A

spring with sole
WD-07001-S-05
bar

8. Centre Pivot top 22 7/8”(22.2) 8 56 50.8-57.15 WD-92058-S-6

with Under (30%)
frame
57.15-63.5
(70%)

Summary : 1/2” Size : 216 Nos.

3/4" Size : 40 Nos.

7/8” Size : 08 Nos.

5/8” Size 48 Nos

Total : 312 Nos.

Add 5% in each category as Grand : 328 Nos.

contingency Total

Note: The lock bolts on sole bar are tabulated taking into account 8 mm plate stiffeners

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

5.2 Proper Installation of lock bolts:-

It should be ensured that:
(i) The collars of lock bolts are completely swaged. The collar of lock bolt fasteners
not completely swaged may be causes of improper tool operation or worn anvil in
nose.
(ii) The pintail of fastener break without fail. The pintail of fastener fails to break due to
improper installation/incorrect fasteners.
(iii) After breaking of pintail, the extruded/projected portion of lock bolt should be in the
range of 2.00 to 10 mm and collar should always be on annular groove of lock bolt.
(iv) Mismatch of holes to be reamed properly to align and gas cutting to match holes is
strictly prohibited.

6.0 PRECAUTIONS AND QUALITY REQUIREMENTS

The following points are to be considered before and after assembly of the
wagons:-

6.1 Ensure that underframe is well cleaned and rust free.

6.2 Repair of underframe should be carried out as per Clause 3.3 of this
Specification)

6.3 After repairing the underframe, its alignment, squareness and tolerances
should be checked and maintained as described in Specification G-
72 Rev.-3 (Latest Amendment).

6.4 Ensure that consumable items used for different combinations of

welded materials should be as detailed in G-72, Rev. 3 (latest
Amendment).

6.5 All the welds shall be visually inspected. Any cracks, porosity, blow
holes shall be repaired.

6.6 Precautions must be taken by welder to control moisture content, where

high humidity exists. The electrodes shall be taken out from the
drying oven as per the requirement of work ,i.e. electrodes should
not be taken out for work in bulk.

6.7 All the welding operations should be down hand welding operations.

6.8 The existing holes of rivets at head stock location should be

plugged before drilling the new one for end stanchions.

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6.9 Ensure that painting of underframe is carried out as explained in

para 11.2 of G-72, Rev.-3 (latest Amendment )

6.10 Ensure that brake rigging , including hand brake, and empty load
device are according to Clause 7.2 & 7.5 of RDSO Specification no.
WD – 11 – BOXN - 2001

6.11 Existing hand brake wheel (Ø 610) drg no. W/BG-6226 is to be replaced
with lesser dia hand wheel (Ø356) as per drg. no. W/BG-1100.The
(Ø356) hand wheel slot to be increased accordingly to match existing
spindle for hand brake.

6.12 Maintain the “A” and “E” dimension in brake rigging arrangement to
Clause 7.4 of RDSO Specification no. WD – 11 – BOXN - 2001

6.13 Ensure that the gap between the wheel flange to brake block is as
per standard practice as specified in Clause 7.4 of RDSO Specification
no. WD – 11 – BOXN - 2001

6.14 After assembly brake rigging shall be checked as per RDSO drawing
no. WD-80007-S-09.

6.15 A central database of Rehab wagons is required to be created in FMM

and WISE. Till such time FMM and FOIS database are ready ,Rehab
information shall be updated on current wagon master .FOIS will be
customized by adding more fields to ensure updation of maintenance
history by workshops.
Any maintenance activity on the rehab wagons should be taken up after
perusing the past rehab/maintenance details and the maintenance input
provided should be fed into the database.

6.16 In order to identify the workshop that did the work of upgraded
rehabilitation on a particular wagon for times to come, an oval shaped
Rehab plate to RDSO drawing no WD-07001-S-06 (similar to the one
used by wagon builders after new manufacture of wagon) must be
rivetted/welded to the sole bar at suitable location as mentioned in
marking diagram drawing no WD-07001-S-12 identifying the name of the
workshop (UST Code allotted to the workshop may be used), month and
year of upgraded rehabilitation of the wagon into BOXNR.

6.17 Rehab wagon needs to give trouble free residual service, over their
stipulated codal life. Any major repairs/ NPOH marking, in rehab wagons,
needs, be reported to the shop which had undertaken the rehab and
these repairs also reporting to CRIS to include this in FMM and WISE.
Till such time FMM is fully functional, these repairs reports send to
rebuilding Workshop and RDSO.

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7.0 HANDLING OF BODY SIDE WALL, END WALL AND FLAP DOOR:

For handling, following precautions are to be taken during packing of body

side wall, end wall and flap door:-

7.1 Drill 1” (25 mm) dia holes on each end on top coping of side wall and
end wall on top face middle and use eye bolts as per IS:4190 along with
solid threaded block for lifting purpose as per Annexure I. Each side,
end wall requires two solid threaded block with eye bolt for lifting each
assembly.

7.2 To prevent damage to corners of walls, all the four corners of

Side and End walls during handling should be well covered by
100 x 10 x 25mm thick wooden pieces before lifting of walls.

7.3 As the overall length of side/end stanchion is larger than the

vertical height of side/end wall, the bottom portion of stanchion, to be
joined shall always be projecting beyond end/side walls. During
handling of end wall/ side wall, care must be taken to avoid any
damage to bottom portion of side stanchion to be joined with
sole bar, by covering with gunny bag filled with suitable cushioning
material.

7.4 If walls are stacked one on other or side by side, be sure that suitable
packings are provided to avoid tilting, damage etc.

7.5 Side wall and end walls should not be stacked together.

8.0 PAINTING AND FINISHING:

8.1 Body (IRSM-44) & Underframe:

(i) Degrease with petroleum hydrocarbon solvent to IS:1745-78 (or latest),

low aromatic grade 145/205 or any other degreaser (suitable for
IS:2062/IRSM-44).
(ii) Surface preparation:- Clean the parts to achieve surface finish to
Min. St3 as per IS 9954:1981(or latest) and clean the surface by using
compressed air or any other suitable means like brush etc. Apply one coat
of Etch primer to IS: 5666-70 (or latest) to minimum DFT of 10 microns and
air dry.
(iii) Apply two coats of R/M Red Oxide Zinc Chromate primer to IS: 2074-92 (or
latest) to a minimum DFT of 25 microns per coat.

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

(iv) Apply two coats of R/M Red Oxide (ISC: 446), brushing, finishing, glossy to
RDSO specification No. M&C/PCN/122/2006 (or latest) to a minimum DFT
of 35 microns per coat.
8.2 The painting of bogies, couplers and air brake equipments shall be as given in
para 11.2.5 & 11.2.6 of G 72, Rev.3 (latest amendment )

8.3 Precautions before and after painting shall be observed as detailed in para
11.2.2, 11.2.3 and 11.2.4 & 11.2.6 of G 72, Rev. 3 (latest Amendment )

8.4 General Guidelines for ensuring quality during upgradation using Stainless
Steel Body (IRS: M 44 – 97)
i) Steps to be taken in work area while dealing with IRS: 44 – 97

1. It should not be contaminated by contact with mild steel or alloy steel during
the fabrication process.
2. All sources of carbon contamination should be eliminated e.g. varnish, paint,
wax marking pencils, etc.
3. Identification markings, usually written on the plate, must be removed from
the weld area.
4. When carbon steel lifting lugs are used for handling heavy components,
IRS:M44 pads should be used between the lugs and the component. (This
prevents dilution of the IRS:M44 and carbon pick up, both of which cause
deterioration in the mechanical and corrosion properties of the steel)
5. Oil or greases deposits on, or near a weld joint should be removed using
suitable degreasing agents as otherwise they can cause weld related
problems.
6. Prevent carry over of mild steel grinding swarf onto IRS:M 44 as otherwise it
can cause significant discolouration and under some conditions, loss of
corrosion resistance.
7. Before using guillotines, bending brakes etc, the equipment should be wiped
clean of any adhering mild steel particles.

Most of these potential contamination problems can be avoided if separate work

areas for IRS:M 44 exist that is remote from those used for mild steel.

ii) Precautions to be taken in storage of IRS: M 44 steels

a) IRS:M 44 should be stored in a dry area, separate from carbon steels.
b) The storage racks used should be made of IRS:M 44 or wood.
c) Prevent accumulation of dirt, dust and greasy deposits on the IRS:M 44’s
surface as otherwise it will prevent oxygen from ensuring the integrity of the

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protective film beneath the deposit and localized staining can take place after
lengthy shielding from the air.
d) Grinding tools, stainless steel wire brushes and other tools and equipments
used for IRS:M 44 should be stored separately to avoid mild steel
contamination. Marking inks free of chlorides, lead and sulphur should only be
used.

9.0 MINIMUM FACILITIES REQUIRED IN RAILWAY WORKSHOPS:

The workshop should have infrastructure capability to upgrade BOXN wagon to

BOXNR wagon (stainless steel).

9.1 In case the workshop intends to get side wall, end walls & flap doors
fabricated from outside agencies, then following additional facilities
should be available in Workshops:

 Complete tooling, power units and lock bolts required for

assembly of side, end wall & flap door with solebar/head stock.

 Manipulator/Suitable means for assembly of under frame with body

side wall, end wall & flap door.

 Other detailed facilities required for repair /replacement and welding

of underframe members, facilities for stripping, cleaning and painting
of wagons.

9.2 In case, side wall, end walls & flap door are to be fabricated by the
workshop itself, the minimum facilities mentioned under Section B
should be available

10.0 MARKING OF WAGONS:

The marking of the wagon shall be done as per RDSO Drg. No. WD- 07001-S/12
and wagon old number to be retained thereon.

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SECTION B

INFRASTUCTURE AND QUALITY CONTROL REQUIREMENTS FOR

MANUFACTURE AND SUPPLY OF BODY SIDE WALL, END WALL AND FLAP
DOOR OF BOXNR WAGONS

1.0 Experience: Only firms having minimum experience of one year in

fabricating stainless steel sub-assemblies shall be considered. The firm
should have experience in fabricating stainless steel sub-assemblies
weighing a minimum of 1000 kg. The minimum annual output of the firm in
any of the last three financial years should be 200 Tonnes of steel. A
documentary proof for above shall be submitted by the firm.

2.0 Manpower resources at firm’s Works:

At the contractor’s works place, there should be following personnel:
a) Plant Manager: He shall be a Graduate Engineer in
mechanical/production/industrial engineering (with minimum 3 years
experience) or diploma holder in mechanical/production/industrial etc. (with
minimum 8 years experience) and shall be responsible for overall production
and implementation of QAP (Quality Assurance Plan) during manufacturing of
components.
Name and qualification of such person shall be displayed at place of work
suitably.

b) Shop Floor Managers: Minimum two nos of diploma holder engineers with
minimum 3 years experience should be deployed on shop floor for ensuring
proper quality during manufacture. One of the diploma holder engineers
should be exclusively responsible for welding. He should have been
trained in welding of stainless steel sub-assemblies. Documentary proof to be
shown.
Name and qualification of such persons shall be displayed at place of work
suitably.

c) Skilled Artisans: Trained welders should be available who are either ITI
passed (in welding trade) with minimum 2 years’ experience in welding or
Have a minimum of 5 year’s experience in welding and trained in welding of
steel.
Welders should be certified as per IS: 7310 Part – I (1974 or latest) for steel
welding by well recognized certifying agencies like Indian Institute of Welding
or it’s certified agencies/Welding Research Institute etc. and the validity of
their certification should be current. Only welders who meet these criteria
shall be engaged in fabrication of side walls, end walls & flap door. The firm
should provide documentary evidence for the same.

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d) All managerial and supervisory personnel and at least 75% of the total
Welders used for this work should be regular employee of the firm & should
be covered by PF rules. The firm should provide documentary evidence for
the same.

3.0 Minimum Requirement of M&Ps:

(i) Firm should have at least one shearing machine of sufficient capacity
so as to cut IRS M-44 sheet of thickness up to 8 mm.

(ii) Firm should have minimum 5 nos. of plasma cutting machine with
minimum 12 mm thick plate cutting capacity or minimum 2 nos. CNC
plasma cutting machine with minimum 12 mm thick plate cutting
capacity.

(iii) Firm should have adequate number of drilling machines and grinders
for ensuring smooth working.

(iv) Firm should have at least one EOT crane of at least 3 ton capacity so
as to transfer side wall/end wall assembly from one place ( or
stocking yard) to another.

(v) One Fork Lift truck/ mobile crane of at least 3 ton capacity should be
available for transportation of metal sheets from one place or stock
yard to another.

(vi) The firm shall have at least one straightening machine for straightening
of Steel sheets.

(vii) One compressor (Min. 300 cfm) for Plasma Cutting machine

(viii) Minimum 20 nos. MIG/MAG welding plants of minimum 400 Amps

capacity should be available. Electrode welding (Manual Metal Arc
Welding) is not to be resorted to while fabricating end wall/side wall/flap
door. In case, robotic welding is used for such fabrication, the minimum
requirement of standalone MIG/MAG welding plants will not be insisted
upon.

(ix) Firm should have adequate number of jigs and fixtures for
manufacturing of end wall, side wall & flap doors. Power
Fixtures/Modular Fixtures/Hydraulic Fixtures shall be preferred.

(x) Firm should have adequate space under cover for fabrication and
packing of panels. Fabrication and packing in open space is not
permitted.

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4.0 Storage and Material Handling Requirements:

1. Covered area with adequate space underneath for storage of raw material
e.g. sheets, plates, pipes and bars etc. should be available.
2. The covered area should have display board showing different colour codes
nominated to different grades of steel to avoid mix up of materials.
3. Arrangement of painting the plates, pipes, etc. with particular paint code
previously nominated according to the grade of steel should be available.
4. The finished product (side wall, end wall & flap door) should be stored in
covered area which should have displayed boards showing different products.

5.0 Testing Facilities:

(i) Chemical Lab: The firm should either have a spectrometer or should have
permanent arrangement with a NABL certified Lab or a reputed steel making
company for arranging the spectro analysis of the raw material on a regular
basis.
.
(ii) The firm shall have in-house facilities/arrangement with outside agencies for
conducting non-destructive testing for welding as per requirement of the
purchaser.

(iii) Other Testing Facilities: The firm shall possess the following:

1. Adequate number of fine punches for stamping marking particulars on

finished components.
2. Adequate numbers of measuring instruments such as:
 Digital Vernier Calipers of range 0 mm to 300 mm.
 Screw Digital Gauges for checking thickness of plates
 Measuring scales and other working and measuring tools required
from time to time.

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6.0 Quality Control Requirements:

(i) There should be a system to ensure the trace-ability of the product from
raw material stage to finished product stage. This system should also
facilitate identification the raw material composition from the finish product
stage. The system should ensure that proper documentation such as
purchase orders, inspection certificate, test certificate etc. is available.
Side Walls, End Walls and Flap Doors should be punched for
manufacturer’s identification details, month and year of manufacture at the
upper left corner of the assembly so that traceability of the firm is ensure
even during the running of the wagons.
For manufacturer’s identification, alphabetical code that shall be issued
after vendor registration by RDSO may be used.

(ii) A system shall exist to ensure control of receipt and issue of stainless
steel material (as per IRS: M 44–97 & IS:2062 E450) with detailed records
e.g. Original copy of P.O. placed, Bill/Challan form as a proof of purchase
from authorized vendor of stainless steel etc., to facilitate traceability of
raw material used.

(iii) Down hand welding for side wall / end wall / flap door should be ensured.

(iv) Suitable procedure for accountal of receipt, storage & consumption of all
materials should be available

(v) A system to monitor the items required to be purchased from RDSO

approved sources shall be available and proper control is exercised in
ensuring that it is updated regularly

(vi) The manufacturing should be done using modern production planning

techniques

(vii) All welding equipment and accessories should meet the requirements of
the corresponding Indian Standard Specification (or International
Specifications where IS Specifications do not exist).The firm shall be
responsible for satisfying the Inspecting Officer that all welding equipment
and accessories being used to meet these requirements

(viii) Post weld cleaning should be done through a suitable process.

(ix) The firm shall comply with G 72, Rev. 3 (with latest Amendment)
regarding selection of welding consumables like filler wire for MIG/MAG
welding

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(x) The firm shall ensure that all the relevant Specifications of
IS standard/RDSO Specifications are available with them.

(xi) It has to be ensured that there is a QAP for the product detailing various
aspects:-
a) QA Organizational Chart
b) Flow Process Charts
c) Stage inspection details
d) Various quality parameters and to checks to ensure control over them

(xii) Firm having valid ISO: 9001 series certification with scope of certification
including fabrication of stainless steel items shall only be considered. The
firm should provide documentary evidence for the same.

(xiii) Inspection:
1. The contractor shall submit details of the purchase documents, and
test certificate of materials which will be used for fabrication.
2. The Stainless steel (IRSM-44) & IS: 2062 E450 as raw material has
to be procured from RDSO approved sources with inspection by
RITES.
3. CRF sections used for the manufacture of side walls and end walls
for this work must be procured to RDSO’s specification no.WD-01-
CRF-12 (Rev-1) or latest. These CRF sections must be inspected/
got inspected as per extant instructions of Railway Board and RDSO
on the subject.
4. The RDSO approved class of filler wire for MIG/MAG welding for the
relevant applications have to be procured.
5. Sources for CRF Section and filler wire are available in the latest
RDSO Vendor directory which is available for free download at
RDSO’s website www.rdso.gov.in
6. The inspecting agency can check composition of material any time in
the premises of manufacturer using the in house facilities of
spectrometer or send samples to the NABL approved spectro lab
with which the firm has a contractual agreement. Samples can also
be sent to any other NABL approved spectro lab in case the need is
felt by the inspection agency.
7. Stage and final inspection of the side wall assembly, end wall
assembly and flap door assembly may be inspected by the
representative of consignee (as per RDSO’s approved and verified
QAP for the vendor).

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7.0 Other requirements and General Guidelines:

(i) The general guidelines mentioned in the RDSO Pamphlet entitled

“Guidelines for Fabrication of Stainless Steel wagons” of October 2007
dealing with Cutting, Forming, Welding may be used as per need.

(ii) The manufacturer must have a copy of Indian Railways Condition of Stores
Contract (latest) and General Condition of Works Contract on Indian
Railways (latest).

*****

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 No.: WD – 16 – BOXNR – 2010 (Rev.-1)

Annexure-II

Parameters of Center Sill that need to be checked/ inspected & condition

recorded before BOXN wagons are marked for being taken-up for Rehab to
BOXNR

1. Should not be cracked at any portion.

2. Should not be patched/ repaired at any portion.

3. Should not be bent/ hogged/ permanently distorted in any portion/ part. The
camber should not be less than 2 mm for considering the wagon for upgradation.

4. The Draft Gear portion should be inspected & those wagons should not be
marked for Rehab that have hole/ pockets cut in the center sill & the same are
covered/repaired/ patched using cover/ patch plate.

5. Wagons wherein any bulging is noticed at the draft gear location (owing to lateral
hitting of the draft gear) or section thinning of center sill at the draft gear locations
is noticed, should not be selected for Rehab.

6. The Thickness should not have reduced below 7mm.

7. Weld Joints of the Two Z section should be intact & satisfactory.

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Annexure-III

Parameters/ Structural Members of BOXN that need to be checked/ inspected,

Condition recorded & the required repairs identified
Part Of Wagon Incoming Condition Warranted Repairs
End Body
End Body Buldging
Body End Stanchion
End Body Corner Angle
Corner Top Gusset
Ladder
Side Body
Side Body Buldging - Both Side
Body Side Stanchion
Body Side Middle Coping
Door Way Crossbar Pressing
CBC
CBC with Yoke Pin
Knuckle with Pin & APD
Back Stop
Wear Plate (Striker casting)
Yoke Pin Support Plate
Yoke Support Plate
Uncoupling Rod Arrangement
Under Frame
Central Brake Rigging including SAB
Centre Pivot Top
Center Sill
Sole Bar - Pillar to Pillar
Sole Bar/Head Stock Patch
L/E Change - over arrangement
Main Transom/ Bolsters
Hand Brake Wheel
Hand Brake Gear with Gear Box
Head Stock
Head Stock & Sole Bar – Joint
DOOR
Door Check Spring
Door Patch (Full Length)
Door Locking Pin
Door Hinge Long/ Short
Door Hinge Foot
Doorway Buldge (Both side)
Door Gravity Catch/Chainless cotter
Floor
Crib angle & End angle
Floor Sheet/Floor Patch

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Annexure-IV

Parameters/ Structural Members of Under frame that need to be checked/

inspected, condition recorded & the required repairs identified

1. Overall Condition (corrosion/ damaged/bent members) of Underframe.

2. Twist/ Permanent Distortion in Underframe.

3. Camber of Underframe (Should not be less than 2 mm)

4. Condition of Center Sill (Pls refer Annexure-II)

5. Draft Gear Pocket Condition.

6. Center Sill at Back Stopper location.

7. Bolster-Top Plate/ Bottom Plate Condition & Joints with Sole Bar & Center Sill.

8. Sole Bar Condition

9. Cross Bar Joints with Sole Bar & Center Sill.

10. Condition of Stingers. These need to be added/ replaced/ repaired as per drgs of
BOXN/BOXNR.

11. CP Top Castings & Bolster Gusset Plates condition.

12. Head Stock Condition & Joints with Sole Bar

13. Brake Gear Support Brackets Condition.

14. Striker Casting Condition

15. Brake Gear (including Hand Brake) & its components should be inspected
separately & the warranted repairs recorded

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