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I( - m~ Government of India-Minisrry of Railways

'~ifR ~ ~ 'Wf<j; ~ Research Designs & Standards Organisation
~@f~ - 2260ll Lucknow - 226 011
EPBX (0522) 2451200 DID (0622) 2450115
Fax (0522) 2458500 OlD (0522) 2465310

No. CT/SpecificationlT-12 Dated: 27.06.2012.

As per mailing list enclosed.

Sub: Addendum and Corrigendum Slip to Specification for Flat Bottom Rails
-IRS T-12:2009.
~: 'l'I ct1C1crt 3ITUR Ttwit c5 Pcifi~ - ~ 0 3JR'0 1Rf 0 t)- 0 12 : 2 00 9 cil
-R~I

Ref: Railway Board's letter no, Trackl21/2008/0801/7 dated 22.06.2012.

~af: ~ ant c5 'Q'5I' ~ ~/21/2008/0801!7 ~

22/0612012

*******

Please find enclosed herewith Addendum and Corrigendum Slip NO.3 to

Indian Railway Specification for Flat Bottom Rails, IRS T-12:2009.

This has the approval of competent authority.

DA: As above
 ADDENDUM & CORRIGENDUM SLIP NO.3

TO

INDIAN RAILWAYS STANDARD SPECIFICATION FOR FLAT BOTTOM RAIL

IRS T-12:2009 DATED 27.6.2012

The Rails in regard to their quality, manufacturing process, chemical

composition, testing/ retesting, qualifying criteria, etc., shall be complying
Indian Railway Specification IRS-T-12-2009 for Flat Bottom Rail with following
amended clauses.

1. Clause 5.4: Head Hardening Process

For head hardening, rails shall be suitably heat treated to meet the
requirements of the specification. The method of heat treatment adopted by
the manufacturer should be made available to the purchaser. In-line
established deep Head Hardening methods using air quenching process would
be acceptable with the prior approval of the Purchaser. Any other process of
Head Hardening would also be acceptable with the prior approval of the
Purchaser.
2. Clause 7: Grade, Chemical Composition and Mechanical Properties
The steel for the rails shall be of fully killed quality and shall confirm to
chemical composition and mechanical properties given in Table -1. Micro
alloying elements of Cr(0.3% max.) & V (0.01% max.) may also be acceptable,
as it helps in improving mechanical properties. The limits for chemical
composition are applicable both for tests on ladle samples and for check
analysis of finished rails. Ladle and check analysis of steel, will be carried out
by the method specified in the relevant part of IS: 228 or by any other
established instrumental/chemical method of testing with the approval of the
purchaser. In case of any dispute, the procedure given in the relevant part of
IS:228 shall be referred.
3. Clause 8.1: Brand Marks
With the prior approval of purchasers, brand marks of suitable size clearly
legible, shall be rolled in relief on one side of web at 3.0 to 4.0 meters interval.
The brand mark shall include:

a) The rail section.

b) The grade of steel, i.e.
Grade 880 880

'--------- .
 Grade 1080 HH 1080 HH
Grade 1080 Cr 1080 CR
Grade 880 Cu-MO 880 CM
Grade 880 Ni Cr Cu - 880 NC
Grade 880 Vanadium- 880 VN
Grade 880 Niobium - 880 NB

c) Identification mark of the manufacturer

d) Month (using roman numbers) and last two digits of year of manufacture.
e) Process of steel making: -
i) Basic oxygen - 0
ii) Electric E

4. Clause 8.2: Hot Stamping

Each rail shall be identified by a numerical, alphabetical or combined alphabetical
and numerical code which will be distinctly hot stamped at least once every
5.0m on the web in figures and letters of suitable size from which following
information can be obtained:

i) The number of the cast from which the rails has been rolled with
letter 'C'

ii) Number of the strand.

iii) For rails from change over bloom, cast number should be the preceding
cast number with prefix letter'B'.

5. Clause 8.3: Cold Punching

8.3.1 Following should be cold punched on one of end face of each rail

a) Inspecting Agency ID and Group ID

b) Shift No in which product inspected
c) Date of Inspection
To avoid damage to the HH rails, instead of cold punching, any other method of
marking can be adopted, with the prior approval of the Purchaser.
6. Clause 8.4:Colour code
Rails shall be painted as per colour code given in Appendix-IV to distinguish grade,
class, length and other special requirements. Paint of good quality should be used
with the prior approval of the Inspecting Agency. Alternatively, different colour
code may also be decided by the supplier with the prior approval of purchaser.
7. Clause 9.2: Length of Rails
The standard length of rail shall be 13 meters or 25 meters or 26 meters. The
manufacturer shall be entitled to supply in pairs of short lengths up to 10% by
weight of the quantity contracted for or ordered. Shorter lengths shall not be
less than 10.0m in length for 13.0M and shall not be less than 23M in lengths
for 25M and 24 M in lengths of rail for 26M. Short lengths shall be in multiples
of 1.0M. In case of ZU 1-60, 1080 HH grade Rails, length shall be suitable for
turnout design offered/proposed.
Type of Rail Tolerance in length
Prime Quality Rail +20mm -lOmm
IU Grade +30mm -30mm

8. Clause 18.3: Macro-Structure Test (For 1080 HH Grade Rails)

One macro-structure test of hardened layer per 1000 meters of heat treated
rails shall be performed. Macro structure of heat affected zone shall confirm to
figure 7.

a,c >
-
IOmm
-
~~~

b
> I5mm
~a", I -
-

I
- -t
Figure -7

Due to specific process of heat treatment being adopted by the manufacturer

e.g. inline air quenching method, Macro-structure of heat affected zone may not
 show distinct zones, as shown above in figure-7, supplier should advise about
the same to the purchaser in advance.
9. Clause 19.2.3: Hardness Distribution Test
The hardness distribution test shall be conducted on transversely cut rail
section as shown in figure-8 . Hardness value at any point shall not exceed
390BHN. The cross sectional hardness distribution of heat treated rails shall
slope towards the inside. No sharp drop in hardness should be present. The
hardness at 10mm below, the rail head shall be 340BHN minimum. The
hardness at 15 mm below the rail head table at centre shall be minimum
315BHN.
10.Clause 21: Determination of Hydrogen Content
Vacuum degassing of liquid steel shall be done to reduce the hydrogen content.
For this purpose, RH degasser or REDA (Revolutional Degassing Activator)
shall be used. In case, any other method of vacuum degassing is adopted, then
the same will require prior approval of the Purchaser. The vacuum levels and
the duration for which liquid steel shall be kept under this level shall be
decided mutually by the purchaser and manufacturer. All measurement of
hydrogen shall be done for the liquid steel in tundish or mould. Any other
method of sampling or determination of hydrogen will require prior approval
of the purchaser.

Clause 21.1 The measurement of hydrogen shall be done by following method:

Clause 21.1 (a) On-Line/Instantaneous Method-

HYDRIS is approved as method of on-line instantaneous measurement. The

method of measurement as prescribed by the manufacturer of HYDRIS system
shall be adopted with approval of the purchaser. Any other alternate method of
determination of hydrogen will require prior approval of the purchaser.

(b) Pin Sample Method-

In case, the manufacturer has not installed the facility for on-line/instantaneous
facility for measurement of hydrogen as described in Para (a) above, this method
may be adopted with prior approval of the purchaser.
•
i,

In this method, sample of liquid steel shall be taken by plunging the sampler
200mm - 300 mm below the molten metal surface in mould and molten slag-metal
interface in tundish. The sample should be held for 2 to 3 seconds and then
quenched in cold water so that sample temperature falls to below 150°C within
5 seconds.

The sample should be removed from cold water and packed in dry ice if
analysis is carried out within 48 hours of sampling or placed in liquid nitrogen if
analysis is to be carried out beyond 48 hours after sampling. Sampling should be
done by 6 mm dia vacuum tube of Pyrex glass with wall of thickness of 1.0mm and
approximately 0.5 mm thick in the fill-end. The tube should have desired vacuum
3
of 10- mm of Hg.

The hydrogen sample can be analysed by inert gas fusion technique in which
sample is to be fused at approximately 1900° C in an induction heating graphite
\ crucible. A nitrogen carrier gas transports the released hydrogen to thermal
conductivity cell. The amplified and integrated output of the cell is to be
calibrated for hydrogen in ppm.

LECO- RH -2 Hydrogen Analyser may be used for Hydrogen determination.

Any other size and material of tube and method of hydrogen determination will
require prior approval of the purchaser.

21.2 The level of hydrogen measured by the method described under Para 21.1 above
shall be 1.6 ppm maximum for acceptance of a heat for production of rail.

11. Clause 26: WARRANTY

As a warranty for supply of rails free from manufacturing defects by rail suppliers,
after initial USFD testing of new rails in rail manufacturing plants , a USFD test
free period of 25% of service life of rails in terms of GMT as given below (Para 302
(1) (d) of IRPWM-2004 as amended from time to time) shall be applicable. This
clause of test free period of 25%of service life of rails shall also be applicable for
all types of 90 UTS (grade 880) and higher grade of rails of this specification. If
any rail fracture due to suspected manufacturing defect is detected within a period
of 25% service life of rail in terms of Gross Million Tonne, then investigation will
be conducted jointly by purchaser and supplier to ascertain the cause of failure".
Rail Section Assessed GMT service life for 90 UTS rails
60 Kg 800
52 Kg 525
90R 375