GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
INDIAN RAILWAY
STANDARD SPECIFICATION
FOR
METAL LINERS
FOR USE WITH ELASTIC RAIL CLIPS
Serial.No.T-56-2020
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW – 226 011
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INDIAN RAILWAY STANDARD SPECIFICATION FOR METAL LINERS FOR USE WITH
ELASTIC RAIL CLIPS, Sl. No. T-56-2020
0. FOREWORD:
This specification is framed for facilitating inspection and procurement of metal liners
for use with Elastic Rail Clip on concrete sleepers. This specification was initially
adopted as ‘Provisional Specification 1995’.To make the specification self-explanatory
and to improve quality of the product the specification is revised as first revision and
issued in 2010 with the view to include sources of raw material, hardness test and
marking of Lot No. of the product. Applicability of Freedom from Surface Defect test
has been specified for Pre-acceptance & Acceptance test.
Due to discontinuation in publishing the list of sources of structural steel item in
Vendor Directory by RDSO and non-identification of integrated steel plants by Joint
Plants Committee for procurement, the requirement of steel for rolling of metal liner
bars has been revised in the specification so as to improve the quality & serviceability
of metal liner bars as well as metal liners henceforth on sustained basis.
The specification was revised as Provisional-2013 with a view to cover the
specification & sources for raw material for use by the manufacturer of metal liners and
to exercise checks of the steel being used. The chemical composition & mechanical
properties of the steel was revised to conform to grade designation E250 Quality C as
laid down in Table 1 & Table 2 of IS: 2062-2011 respectively. The chemical
composition and metallurgical properties to be tested on raw material (metal liner bar)
and finished product (metal liner) were defined.
This specification has now been revised and issued in 2020 to cover the corrigendum
issued to this specification till date and to update the latest revision of IS codes.
1.0 SCOPE:
This standard covers the general requirements, inspection and testing procedure for
metal liners, here after referred to as “LINERS”. The metal liner bars used for
manufacture of liners shall be referred to as ‘RAW MATERIAL’.
All the provisions contained RDSO’s ISO Procedures laid down in Document No.
QO-D-8.1-11 dated 22.06.2020 (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.
2.0 REFERENCE DOCUMENTS:
i) IS 228-(Part 1) 1987 (Reaffirmed 2018) - Determination of carbon by Volumetric
method (for carbon 0.05 to 2.50 percent) Third revision
ii) IS-228-(Part 3)-1987 (Reaffirmed 2018)- Determination of phosphorus by alkali
metric method
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iii) IS-228-(Part 8)-1989 (Reaffirmed 2019) - Determination of silicon by gravimetric
method (for silicon 0.05 to 5.00%).
iv) IS-228-(Part 12)-2001 (Reaffirmed 2019) - Determination of manganese by
periodate spectro photometric method in plain carbon, low alloy and high alloy
steels (For manganese 0.01 to 5.0%).
v) IS-228-(Part 20)-2003 (Reaffirmed 2019)-Determination of carbon and sulphur
by infrared absorption method (for carbon 0.005 to 2% and sulphur 0.001 to
0.35%
vi) IS-1153-2000 (Reaffirmed 2016) - Specification for temporary corrosion
preventives, hard film, solvent deposited)
vii) IS-1500-2005 (Reaffirmed 2010)-Method for Brinell hardness test for metallic
materials. (Superseded by IS 1500: Part 1 to Part 4)
viii) IS-1599-1985 (Reaffirmed 2019) Metallic Materials-Bend Test (Fourth revision)
ix) IS-1608-2005-Metalic materials –Tensile testing at ambient temperature.
(Superseded by IS 1608:(Part 1:2018) & (Part 3:2018)
x) IS- 2062-2011 (Reaffirmed 2016)- Hot rolled, medium and high tensile structural
steel.
xi) IS-2500 (Part 1)-2000 (Reaffirmed 2016) Sampling Inspection Procedures- Part
1: Attribute Sampling Plans Indexed by Acceptable Quality limit (AQL) for Lot -
by -Lot Inspection.
xii) IS: 4163-2004 (Reaffirmed 2017) Determination of Content of Nonmetallic
Inclusions- Micrographic Method Using Standard Diagrams.
xiii) IS 4748: 2009 (Reaffirmed 2017) : Steels-Micrographic determination of the
apparent grain size
3.0 PROCESS OF MANUFACTURING METAL LINERS:
i) The metal liner manufacturer shall procure metal liner bars from re-rollers
engaged by them.
ii) The desired properties and the chemical composition of the metal liner bars
shall conform to be within the stipulations of IS: 2062:2011 (Grade designation
E250, Quality C).
iii) Such metal liner bars shall be used for manufacture of metal liners by the
process of shearing, punching, grinding etc. which shall conform to the desired
chemical & mechanical properties as contained in this specification.
4.0 PROUREMENT OF RAW MATERIAL (METAL LINER BARS):
i) The Metal Liner bars shall be supplied in hot rolled and normalized heat
treated condition.
ii) The steel used for metal liner should be of killed quality manufactured by any
process of steel making except Bessemer process followed by secondary
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refining. Metal Liner manufacturer shall obtain a certificate for the same from
metal liner bar manufacturer (re-roller approved by them)/ Billet manufacturer
and shall produce this certificate at the time of offering the material for
inspection.
a) The chemical composition of the steel should conform to grade
designation E250 Quality C as laid down in Table 1 of IS: 2062-2011.
TABLE 1: CHEMICAL COMPOSITION
Element % age Permissible variation
(Max.) percent (Max)
Carbon 0.20 0.02
Silicon 0.40 0.03
Manganese 1.50 0.05
Sulphur 0.040 0.005
Phosphorus 0.040 0.005
b) When the steel is killed by silicon alone, the silicon content shall not be
less than 0.1%. When steel is killed by Aluminium alone, the Aluminium
content shall not be less than 0.02%. When the steel is killed by Silicon–
Aluminium, the Silicon content shall not be less than 0.03% and total
Aluminium content shall not be less than 0.01%. Metal liner manufacturer
shall obtain a certificate for the same metal liner bar manufacturer (re-roller
approved by them)/ Billet manufacturer and shall produce this certificate at
the time of offering the material for inspection.
iii) The liner bars after hot rolling shall further be subjected to normalizing heat
treatment by properly soaking in appropriate austenitic state for a suitable
period followed by cooling in still air.
iv) The mechanical properties Tensile strength, Yield strength, % elongation,
bend test & Charpy Impact Test of the liner bars shall conform to grade
designation E250 Quality C as laid down in Table 2 of IS:2062- 2011.
TABLE 2: MECHANICAL PROPERTIES
Ultimate Tensile Strength (Min.) 410 MPa
Yield Strength (Min.) 250 MPa
% age Elongation (Min.) 23%
Hardness (min.) 115 HBW ( BHN/HB/HBS)
Bend test Internal dia. 2t at 180˚(U –Shape)
Charpy Impact Test 27J (Min)
v) The inclusion content of the liner bars shall be in accordance with IS: 4163-
2004 in longitudinal section, inclusion rating shall not be worse than 2.0
A,B,C,D for both thick and thin series when compared to the chart for
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determining the inclusion content of secondary refined steels (Fig. 2) of IS
4163-2004.
vi) The microstructure of the steel should be fine grains ferrite and pearlite with
grain size of ASTM-6 or finer.
vii) The hardness of steel shall be in accordance with IS: 1500-2005 and shall not
be less than 115 BHN.
viii) The chemical and mechanical properties to be tested on metal liner bar shall
be Chemical composition, Hardness, Inclusion content, Microstructure & Grain
size, Tensile strength, Yield strength, % elongation, Bend test & Charpy
Impact Test in accordance to IS: 2062:2011. Metal liner manufacture shall
carryout all these tests at the rate of two samples per 20 metric tonnes of
metal liner bar or per heat whichever is less. Metal liner manufacture shall
also preserve and submit the test pieces of the raw material of metal liner bar
to the inspecting official for verification of chemical and mechanical properties.
ix) The metal liner manufacturer shall be responsible to ensure that only proper
quality of billet is used by re-roller (approved by them) for rolling of metal liner
bars.
5.0 PRE-ACCEPTANCE TESTS:
5.1 For initial registration /approval, the manufacturer shall manufacture metal liners in
presence of RDSO official. 16 samples shall be drawn randomly from the lot so
produced for initial testing. In addition, the manufacturer shall also furnish 5 Nos.
test specimens each for tensile and bend test for testing.
5.2 Samples manufactured in presence of representative of RDSO shall be tested as
per scheme of testing ‘A’ given in Annexure-I.
6.0 ACCEPTANCE TESTS:
Tests as per Para 6.2 to 6.8 shall be conducted on liners for acceptance of the
material as per scheme of testing ‘B’ given in Annexure I.
6.1 LOT/BATCH FOR TESTING:
For the purpose of inspection, maximum 30,000 liners shall form a lot. Lot no. shall
be punch marked on the liner as per drawing. For identity of material, the firm shall
certify heat number of the above lot. The metal liner manufacturer shall produce
heat-wise complete certificate of chemical analysis of metal liner bar obtained from
metal liner bar manufacturer at the time of inspection of the liners.
6.2 CHEMICAL ANALYSIS:
Three sample liners per lot shall be tested as per stipulations of sub clause 8.1 and
8.2 of IS-2062:2011. Testing shall be done on middle portion of the liner and the
chemical composition shall conform to the following:
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Element Ladle In product analysis max. Variation over
analysis the limit specified for ladle analysis (%)
% (Max.)
C 0.20 0.02
Mn 1.50 0.05
Si 0.40 0.03
S 0.040 0.005
P 0.040 0.005
If the chemical composition does not conform to the specified limit, the lot shall be
rejected.
The chemical analysis shall be done either spectrographically or through wet
analysis as required by inspecting agency.
6.3 DIMENSIONAL CHECK:
6.3.1 Sample size: Sampling plan as per IS–2500 (Part-1):2000 to be followed. For
dimensional check, the sample size and the acceptance & rejection number for
inspection level II and AQL 2.5% shall be as per IS–2500 (Part-1):2000 and is
summarized at Annexure VII of this standard.
6.3.2 TEST:
The sample liners shall be checked for dimensions and shall meet the requirement
of dimensions and tolerances as provided in the drawing of the respective liner.
Checking of the dimensions shall be made by means of approved inspection
gauges to be provided by the supplier.
6.3.3 INSPECTION GAUGES:
Minimum two sets of inspection gauges shall be manufactured by the supplier as
per RDSO approved drawing / manufacturer’s drawing as the case be and shall be
got approved by RDSO before use. Out of these, one set of inspection gauges
shall be used as master gauge and preserved safely by the liner manufacturer. The
second set shall be used by the inspecting officer during inspection. For internal
quality checks the firm should use additional set of gauges as per drawing.
6.4 TENSILE TEST, BEND TEST AND CHARPY IMPACT TEST:
As it is not possible to draw tensile and bend test pieces from finished liners, the
same shall be conducted on specially prepared samples. Three test samples for
these tests shall be prepared by the metal liner manufacturer from same heat of
metal liner bars used for manufacture of liners. The test samples shall be prepared
from rectangular section of raw material for each lot and shall be preserved heat
wise. The test samples shall be produced by the firm for testing at the time of
inspection of liner of respective heat. The chemical composition & mechanical
properties namely Tensile strength, yield strength, % elongation, bend test &
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Charpy Impact Test of the liner bars shall conform to grade designation E250 Quality
C as laid down in Table 2 of IS:2062- 2011.
The test pieces should be prepared as per sketch shown at Annexure-IX. Salient
dimensions of test piece are as under:
S. Description Tensile test piece Bend test piece
No. of test piece
(i) Width 12.5mm 20mm
(ii) Thickness (i) 5mm for liner to (i) 5mm for liner to drawing No RT-
drawing No RT- 3740.
3740. (ii) as available for all other liners
(ii) as available for
all other liners
(iii) Total length 200-300mm Depending on thickness and testing
equipment
Three samples per lot shall be tested for tensile strength, yield strength, %
elongation and bend test as per clause 10 & 11 of IS: 2062-2011 and the test
results shall conform to the following:
Tensile Yield Elongation % Bend test Charpy
strength strength (min.) (Internal dia.) Impact
(min.) MPa (min.) MPa (G.L.=5.65 Test
So)
410 250 23 2t at 180˚ (U-shape) 27 J (Min)
On bending there
should be no
appearance of crack
on outer surface of
the sample viewed
through naked eye
GL =Gauge length, So= Area of cross section, t = Thickness of specimen.
Three samples per lot shall be tested for bend test as per clause 6.2 (b) of IS 1599-
1985.
6.5 FREEDOM FROM SURFACE DEFECTS:
5% liners of sample size as given under clause 6.3.1 or minimum 5 Nos. shall be
checked for freedom from surface defects and should be free from harmful surface
defects within the description given in sub clause 7.1 & 7.2 of IS- 2062: 2011. The
sample liners shall be examined for surface flaws, laminations, rough/ jagged &
imperfect edges etc. and other harmful defects by the macro etching process in hot
acid.
6.6 HARDNESS TEST:
5% liners of sample size as given under clause 6.3.1 or minimum 5 Nos. shall be
tested for hardness on the middle portion of the liner in accordance with IS-1500-
2005 and hardness test values should not be less than 115 HBW (BHN/HB/HBS).
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6.7 INCLUSION CONTENT TEST:
5% liners of sample size as given under clause 6.3.1 or minimum 5 Nos. shall be
checked for inclusion rating in the material of metal liners. The inclusion rating
when determined as per IS: 4163-2004 shall not be worse than 2.0 A, B, C, D both
for thick & thin series when compared to the chart in Fig. 2 of IS: 4163-2004.
6.8 GRAIN SIZE TEST:
5% liners of sample size as given under clause 6.3.1 or minimum 5 Nos. shall be
checked for microstructure of the steel in the material of metal liners. The grain size
when determined as per IS 4748:1988 should be fine grains ferrite and pearlite with
grain size of ASTM-6 or finer.
7.0 RE-TEST:
If any of the sample liner does not conform to the requirements of the tests
stipulated in clause 6 other than chemical analysis and dimension check, twice the
number of samples as stipulated therein shall be drawn at random from the same
lot and tested for that particular test in which the samples are failed. If all the
liners/ test samples so drawn are found to conform to the requirements of that test,
the lot shall be accepted; otherwise the entire lot shall be rejected.
8.0 PROTECTION:
After acceptance by the purchaser or his nominee, liners shall be painted with
temporary corrosion preventive to IS-1153-2000 in such a way that surface of the
liner is covered properly with protective coating.
9.0 MARKING:
All the liners shall be punch marked with Lot No. distinctly along with other
requirements of respective drawing of the liner. The liners shall also be marked
with rail section and GS or NGS as the case be, to indicate use of liner on gauge
face side or non-gauge face side of rail in track. Screen-printing as per drawing
may also make distinction between GS and NGS liner.
In case the purchaser desires to dispense with the screen printing on liners, this
aspect shall have to be specifically mentioned in the purchase order / contract by
the purchasing authority.
10.0 PACKING:
The liner shall be packed in double gunny / plastic bags. Each bag shall contain
not more than 200 liners. Each bag shall be marked distinctly with lot No. followed
by bag No. of that lot i.e. L-1/1 to L-1/200 etc on the bag. The packing shall ensure
that there is no loss or damage to the liners in transit.
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11.0 TEST FACILITIES:
The manufacturer shall install all the essential testing facilities for carrying out
chemical analysis and physical testing along with other accessories required for
inspection in a separate, well lit, clean and properly ventilated laboratory in their
own premises. However, Chemical Analysis test by spectrograph method may be
done at Govt. owned/NABL accredited/RDSO approved lab.
12.0 DISPOSAL OF REJECTED MATERIAL:
The rejected liners shall be cut into two pieces to make it unusable.
13.0 REPORT:
The inspecting officer shall report the test observations in the format given in
Annexure II to VI.
14.0 GENERAL:
14.1 The liner manufacturer shall furnish at his cost the liners/test specimen required for
all tests and shall provide necessary manpower along with required facilities for
carrying out tests at his works.
14.2 Purchaser/Inspecting officer or his representative shall have free access to the
works of manufacturer at all reasonable times and shall be at liberty to inspect the
manufacture at any stage including calling for records pertaining to raw material,
manufacturing process, quality control etc. which shall be made available to him
within reasonable time.
14.3 The material shall be offered for inspection as per letter of offer given at Annexure–
VIII.
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ANNEXURE-I
(IRS specification of T-56-2020)
A: SCHEME OF TESTING FOR PRE-ACCEPTANCE TEST FOR METAL LINERS
S. Property No. of Criteria value No. of samples to
No. samples to for acceptance/ be drawn
be tested rejection
1. Chemical analysis 3 Each sample must 3
clear the test
2. Tensile strength* 3 -do- 5
3. Bend Test* 3 -do- 5
4. Surface Defects 5 -do- 5
5. Hardness 3 -do- Test shall be conducted on samples
drawn for Surface Defects test
6. Inclusion content 3 -do- Test shall be conducted on samples
drawn for Surface Defects test
7. Grain size 3 -do- Test shall be conducted on samples
drawn for Surface Defects test
8. Dimensions 8 -do- 8
Note: Total number of samples of the metal liners shall be 16 along with 5 No. test specimens each
of tensile and bend test.
*The tests to be conducted on specially prepared test specimens.
B: SCHEME OF TESTING FOR ACCEPTANCE TEST FOR METAL LINERS
S. Property No. of samples Criteria value for No. of samples
No. to be tested acceptance/ to be drawn
rejection
1. Chemical analysis 3 Each sample 3
must clear the
test
2. Tensile strength* 3 -do- 3
3. Bend Test* 3 -do- 3
4 Surface Defects As per clause 6.5 -do- As per clause 6.5
5 Hardness As per clause 6.6 -do- Test shall be conducted on
samples drawn for Surface
Defects test
6. Inclusion content As per clause 6.7 -do- Test shall be conducted on
samples drawn for Surface
Defects test
7. Grain size As per clause 6.8 -do- Test shall be conducted on
samples drawn for Surface
Defects test
8. Dimensions As per IS -2500 -do- As per IS -2500 (Part-1): 2000
(Part-1): 2000
Note: The samples for tensile and bend test shall be made from the raw material of the same lot at
the time of manufacture of liner and preserved lot wise by the firm. An undertaking shall be
given by manufacturer to inspecting official in this regard.
*The tests to be conducted on specially prepared test specimens.
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ANNEXURE-II
(IRS specification of T-56-2020)
TEST RESULTS - CHEMICAL ANALYSIS
1. Name of firm: M/s
2. Firm’s offer letter no. :
3 Liner to Drg. no. :
4. Qty. on order:
5. .……….. Rly. P.O. no. :
*Chemical analysis (%)
/
Quantity(Nos.)
Not Accepted
Sample size
Grain Size
Accepted
Heat No.
Inclusion
Lot No.
Rating
S. No.
Mn
Si
C
*Remark: Variation over and above ladle analysis shall be as per clause 6.2 of the
specification.
Signature of inspecting authority Signature of Firm’s representative
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ANNEXURE-III
(IRS specification of T-56-2020)
TEST RESULTS - DIMENSIONS
1. Name of firm: M/s.
2. Firm’s offer letter no. :
3. Liner to Drg. no.:
4. Qty. on order:
5. ….. Rly. P.O. no.:
S. Heat Lot Quantity Sampl Dimension as per approved Total No. of Accepted/
No. No. No. (Nos.) e size gauges defectives Not
Failing in Failing in Accepted
assembly GO/NO GO
gauge dimensions
Signature of inspecting authority Signature of Firm’s representative
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S. No.
5.
4.
2.
1.
1.
Heat No.
Lot No.
Quantity (Nos.)
Sample size
Qty. on order:
Width (mm)
bell
Liner to Drg. No.:
Name of firm: M/s.
. …. Rly. P.O. No:
Thickness (mm)
Firm’s offer letter no.:
Area (.mm Sq.)
Size of dumb
Signature of inspecting authority
Yield load (N)
Ultimate load (N)
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Gauge length (mm)
Elongated length (mm)
Tensile strength (410 MPa)
Min.
Yield stress min. (250 MPa)
mint
% Elongation with min. gauge
length= 5.65 So ( 23%
Min.)
Tensile Test OK / NOT OK
Bend Test OK / NOT OK
TEST RESULTS - TENSILE TEST, BEND TEST& Charpy Impact test
Charpy Impact test OK/NOT
OK
Accepted / Not Accepted
ANNEXURE-IV
(IRS specification of T-56-2020)
Signature of Firm’s representative
ANNEXURE-V
(IRS specification of T-56-2020)
TEST RESULTS – FREEDOM FROM SURFACE DEFECTS
1. Name of firm: M/s
2. Firm’s offer letter no :
3. Liner to Drg. no. :
4. Qty. on order:
5. ……. Rly. P.O. no. :
S. Hea Lot Quantity Sample Freedom from No. of Accepted /
No. t No. (Nos.) size surface defects defectives Not
No. OK / Not OK Accepted
Signature of inspecting authority Signature of Firm’s representative
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ANNEXURE-VI
(IRS specification of T-56-2020)
TEST RESULTS – HARDNESS TEST
1. Name of firm: M/s
2. Firm’s offer letter no. :
3. Liner to Drg. no. :
4. Qty. on order:
5. …….. Rly. P.O. no. :
S. Hea Lot Quantity Sample Hardness value No. of Accepted /
No. t No. (Nos.) size (115 HBW Min.) defective Not
No. s Accepted
Signature of inspecting authority Signature of Firm’s representative
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ANNEXURE-VII
(IRS specification of T-56-2020)
DOUBLE SAMPLING PLAN
General Inspection Level-II
(Refer: Table I & 3A of IS 2500 Part I – 2000)
Lot size Sample size Sample Sample Cumulative Accepted quality level
code letter size sample Percent defectives-2.5
Acceptance Rejection
No. (a) No. (r)
281-500 H First 32 32 1 3
Second 32 64 4 5
501-1200 J First 50 50 2 5
Second 50 100 6 7
1201-3200 K First 80 80 3 6
Second 80 160 9 10
3201-10000 L First 125 125 5 9
Second 125 250 12 13
10,001-35,000 M First 200 200 7 11
Second 200 400 18 19
Notes:
(ii) For any other lot size less than 281, reference may be made to table I & 3-A of IS-
2500 (Part I)-2000 for sample size, acceptance and rejection numbers.
(iii) In the first sample if the number of failed pieces is equal to the acceptance number (a),
the lot shall be accepted. If number of failed pieces is equal to or more than rejection
number (r), the lot shall be rejected.
(iv) If the failed pieces exceeds the acceptance number (a), but less than the rejection
number (r), the second sample should be considered.
(v) If the cumulative failed pieces equal or exceed the rejection number (r), the lot shall be
rejected. The cumulative failed pieces are the total number of failed pieces in the first
and second samples.
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ANNEXURE-VIII
(IRS specification of T-56-2020)
LETTER OF OFFER FROM THE FIRM
To,
(Address of inspecting agency)
Sub: Call letter for inspection of metal liner to drg. no. RDSO/T-
Ref … Railway’s/ Railway Board’s P.O. No. …….………. dated ….. for
metal
liner to drg. no. RDSO/T-…….
The metal liners as per following details are offered for inspection in terms of the
above referred purchase order. These liners have been internally checked and found
satisfactory as per drawing no. RDSO/ T- …… and relevant IRS specification. All burrs
on liners are also properly removed. Copy of internal test result is enclosed.
1. Installment No.
2. Quantity on order
a) Against original order
b) Against extension
3. Quantity previously inspected and passed.
4. Quantity now offered for inspection
a) Against original order
b) Against extension
5. Batch /Lot Nos.
6. Corresponding cast/heat no. of raw material
and its source of procurement
7. Rate per liner.
8. Marking on liners
9. Delivery period
a) Original
b) Extended
c) Letter no. (for extension)
10. Consignee
11. Consignee letter of authority no.
12. Packing
13. Test certificate No. of raw material
14. Rolled section of Metal liner bar supplied by
Yours faithfully
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ANNEXURE-IX
(IRS specification T-56-2020)
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