File No.

WR-HQ0ENGG(WBWS)/2/2020-O/o DY CE/BR/CCG/HQ/WR

Headquarter Office,
Engineering Department
Churchgate,
Mumbai-400020.

W 724/5/24 A Computer No. 98177Date: 31/03/2022

CAO/C/WR,DFCCIL,Director/Projects/RVNL,Director/Projects/MRVC,Director/Projects/DM
RC,Director/Projects/MMRCL,Director/Projects/MMRDA,Member/NHAI,Secretary/R&B/Guj
rat,Secretary/R&B/Maharashtra,Secretary /R&B/Madhya
Pradesh,SrDEN/Co./MMCT,BRC,ADI,RTM,RJT,BVP

Sub:Procedure for inspection of steel girders for ROBs being constructed by

construction organization,Railway PSUs, NHAI and other executing agencies in
the Western Railway-Regarding.

Ref:- 1) This office letter of even No. dt.19.08.2020.

2) This office letter No. W 65/1 (Launching WR-HQ0ENGG (WBRR)/4/2019
Dated 16.12.2020.

1.0 All the QAP & WPSS for girder fabrication work of ROBs over WR is required to be
approved by CBE/WR. QAPs submitted by executing agencies for fabrication of steel girders
shall be scrutinized by CWM/BW/SBI and approval granted by CBE/WR for standard span
plate/composite girders. In case of non standard girder & bow string girder the approval of
RDSO is sought through CBE/WR. It is mentioned that the fabrication inspection of girder starts
from the inspection of raw material. Executing agency must process the approval of QAP &
WPSS well in time so that the raw material inspection is also conducted by the inspection
agency without fail.

2.0 In order to streamline and expedite the QAP & WPSS approval & its related
inspections, the following shall be ensured by executing agency seeking inspection and
certification from FIU/Inspecting Agency nominated by Western Railway:

(i) As per Director CE/B&S Railway Board letter no. 2016/54/CE-III/BR/RDSO Misc.
New Delhi, Dt. 15.07.2019, inspection of steel bridge girders for ROBs are to be
carried out by Fabrication Inspection Unit or Inspecting agency nominated by CBE in
Zonal Railway. Inspection of Steel Bow String Girders for ROBs & that of
nonstandard girders for ROBs shall be carried out by RDSO; until unless specified
otherwise by RDSO.
(ii) The QAP & WPSS for Bow String Girder and Nonstandard girders designated to be
sent to RDSO, must be submitted to CBE-CCG office in 03 copies along with
approved GAD and design drawings. The Preliminary check of the QAP & WPSS is
conducted at CWM/BW/SBI before submission to RDSO.
(iii) Executing agency should submit QAP in standard format as per RDSO BS-130
alongwith WPSS to the office of CBE-CCG’s for scrutiny and approval by the
Competent Authority and an advance copy may be submitted to
 File No.WR-HQ0ENGG(WBWS)/2/2020-O/o
CWM(BW)Sabarmati DY CE/BR/CCG/HQ/WR
office.The QAP & WPSS need to be submitted to FIU/EW/SBI
under CWM/BW/SBI along with WPSS, soft copy of approved GAD, approved
drawings and checklist (issued vide CBE-CCG’s letter No. W65/1 Launching WR-
HQ0ENGG(WBRR)/4/2019 Dt. 16.12.2020) (Copy enclosed) invariably, stating the
various spans involved, standard/non-standard girders and other relevant matters
pertaining to inspection.
(iv) QAP should be duly signed by fabricator, contractor and an officer (not below JAG
grade) of project executing organization for Zonal Railway/ Construction
Organization of Zonal Railway. In case of PSUs like RVNL, DFCCIL etc the
QAP/WPSS should be signed by officer in charge (Not below JAG grade) of the
project for PSUs.
(v) In case only advance copy of QAP, WPSS, GAD and checklist is submitted at
CWM(BW)SBI office then the same is required to be forwarded to CBE-CCG’s office
for nomination of inspecting agency i.e. FIU/EW/SBI or Bridge Line unit of WR etc.
(vi) After approval of QAP & WPSS, FIU/EW/SBI/other nominated inspecting agency will
send the concerned project executing agency, a copy of approved QAP & WPSS,
details for submitting inspection charges and Stage-I inspection call checklist (for
WPQR approval & layout/master plates clearance).
(vii) FIU/EW/SBI or the Inspecting agency nominated by WR will take inspection in
following III stages:
Stage-I :- WPQR and Layout / master plate approval.
Stage-II :- Trial assembly / Component inspection.
Stage-III:- Onsite inspection for test check of assembly and camber.
(viii) For stage-I inspectioncall, checklist (copy enclosed) duly signed by fabricator &
officer of project executing organization, minimum JAG or equivalent rank for Zonal
Railway/ Construction Organization of Zonal Railway and PSU officer in charge of
the project for Railway PSUs like RVNL, DFCCIL etc. shall be submitted to
FIU/EW/SBI / nominated inspecting agency.
(ix) After approval of WPQR and Layout/master plate i.e clearance of stage-I inspection
stage, go ahead clearance will be issued from FIU/EW/SBI / nominated inspecting
agency to start the fabrication work.
(x) As per approved QAP & RDSO BS-130 para 8.6, inspection & approval of raw
material, stud, HSFG bolts and consumables shall be done by junior scale/Senior
scale officer or an officer of equivalent rank or above, from project executing agency
of that project.
(xi) During fabrication, as per approved QAP, stage wise records are to be maintained by
the fabricator which can substantiate that the approved raw material and
consumables, approved welding consumables, approved set of jigs are being used in
fabrication. The representative of Railway/ PSU will check all such records and
necessary signature/ certification should be done by the authorized representative of
Railway/PSU during fabrication at regular intervals. All records related to fabrication
may be verified by FIU/EW/SBI / nominated inspecting authority during their
inspection at any stage.
(xii) Internal inspections shall be done by Railways/PSU to ensure that only approved
welders carry out welding as per approved WPSS, work is as per dimensional
tolerances and other quality standards stated in approved QAP and relevant codes.
They should make sure all compliances of QAP/WPSS and codal provisions before
sending inspection call to FIU/EW/SBI/nominated inspecting agency for Trial
Assembly/Component Inspection.
(xiii) For stage-II inspection call, below mentioned checklist and certificates are required
to be submitted to FIU/EW/SBI / nominated inspecting agency.
a) Checklist (copy enclosed) for trial assembly/components inspection duly signed
by fabricator & officer of project executing organization being minimum railway
JAG or equivalent rank for Zonal Railway / Construction Organization of Zonal
 FileRailway
No.WR-HQ0ENGG(WBWS)/2/2020-O/o DY CE/BR/CCG/HQ/WR
and PSU officer in charge of the project for Railway PSUs like RVNL,
DFCCIL etc.
b) Four point certificate (as per RDSO BS-130 Para 10.0, copy enclosed) duly
signed by fabricator & officer of project executing organization being minimum
railway JAG or equivalent rank for Zonal Railway / Construction Organization of
Zonal Railway and PSU officer in charge of the project for Railway PSUs like
RVNL, DFCCIL etc.
c) Certificate of internal inspection (copy enclosed) duly signed by fabricator’s
Quality Inspector.
(xiv) Metalizing, painting and dispatch is to be carried out by fabricator after receiving
stage-II inspection clearance from FIU/EW/SBI / nominated inspecting agency.
(xv) For onsite stage-III inspection, below mentioned checklist and certificates are
required to be submitted to FIU/EW/SBI / nominated inspecting agency.
a) Checklist (copy enclosed) for test check of assembly / camber duly signed by
fabricator & officer of project executing organization being minimum railway JAG
or equivalent rank for Zonal Railway / Construction Organization of Zonal Railway
and PSU officer in charge of the project for Railway PSUs like RVNL, DFCCIL etc.
b) Four point certificate (as per RDSO BS-130 Para 10.0, copy enclosed) duly
signed by fabricator & officer of project executing organization being minimum
railway JAG or equivalent rank for Zonal Railway / Construction Organization of
Zonal Railway and PSU officer in charge of the project for Railway PSUs like
RVNL, DFCCIL etc.
c) Certificate of internal inspection (copy enclosed) duly signed by fabricator’s
Quality Inspector.
(xvi) Clearance of stage-III inspection will be issued only after submission of inspection
charges for inspection by FIU/EW/SBI/nominated inspecting agency @ 1% of cost of
steel girders.
(xvii) On completion of the work, fabricator should handover the original copy of fabricator
record to the concern Railway / PSU for safe custody.
(xviii) Important reference codes / reports related to fabrication inspection are
IRS B1-2001, IRS WBC-2001, RDSO BS-130, RDSO BS-111, RDSO BS-115.

( ManjulMathur )
Chief Bridge Engineer

Enclosed: 1. Railway Board’s letter Dt. 15.07.2019.

2. CBE-CCG letter Dt. 16.12.2020.
3. Stage- I, II & III checklist.
4. Four point certificate.
5. Certificate of internal inspection.
225236/2020/0lo CBE/CCG/HQWR
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)

No. 2016/54/CE-IVBR/RDSO Misc New Delhi, dt 15.07.19

24
Instruction No._2019
Principal Chief Engineers Chief Administrative Officers (Cons)
All Indian Railwayys. All Indian Railways.

Sub: Fabrication, Supply and Inspection of Steel Girders for ROBs.

Ref: i) RDSO's letter no. CBS/G/Reg dt. 24.05.19
ii) Board's letters of even no. dt. 29.05.19 and 02.07.19

The following provisions have been approved for the Fabrication, Supply and Inspection of
Steel Girders for ROBs:
1.0 Fabrication and Supply: For all type of Steel Girders of ROBs, of Zonal Railways,
Railway PSUs, NHAI and other executing agencies, the tendering firm shall be from RDSO
approved list of firms for Steel Bridge Girder; in case the tendering firm is not in the list of RDSO
approved firms for Steel Bridge Girder, then he will have to get the Steel Girder manufactured
through an RDSO approved firm in the RDSO approved premises only. Further subject too
condition that tendering firm fulfills other Technical and Financial eligibility criteria, as prescribed
by the Railways in the tender and the Steel Girder to be manufactured in the RDSO approved
premises only.

2.0 Inspection:

2.1 Inspecti n of Composite Steel Plate Girders for ROBs:

Railways may carry out fabrication inspection on its own by Open Line Bridge
Organization or may engage specialized third party (RITES, WRI or any other expert Public
Sector Undertaking e.g. CEIL etc.) for fabrication inspection of girders to ensure the quality of
fabrication. The respective procuring entity shall be responsible for nominating/selecting third
party to ensure quality.
i. A fabrication inspection unitto be set up in each Zonal Railway headed by an officer not
below JA Grade under CBE of that Railway.
i. RDSO to impart training to Railway Officers/Staff in inspection fabrication of Steel Girders.
iv. For ensuring quality fabrication, QAP to be prepared by fabricating agency and approved
by the Inspection Agency.

2.2 Inspection of Steel Bow String Girders for ROBs shall only be done by RDso (both at
workshop and site). This shall be reviewed after one year.

2.3 Inspection of Non-standard Girders for ROBs (in rare cases) shall be done by RDSO only.

(O. N. Sharma)
Director CE/ B&S
Railway Board
Email: [email protected]
Copy, for information and necessary action to:
1. CBEs/AIl Indian
Railways
2. ED/B&S, RDSO, Lucknow
3. MDs/CMDs RITES, IRCON, KRCL, RVNL, DFCCIL
2s9% 22-12:
.12 INDIAN RECD. EY E-DAKON..
. 12.2
Headquarter Office,
Churchgate, Mumbai-20
ufoeiaICT
Western Railway

No. W65/1(Launching Date: 16.12.2020

WR-HQOENGG(WBRR)/4/2019
CAOICWR, ED/WDIDFCCIL, Director/Projects/RVNL, Director/Projects/MRVC,
Director/Projects/DMRC, Director/Projects/MMRCL, Director/Projects/MMRDA,
Member/NHAI, Secretary/R&B/Gujarat, Secretary/R&B/Maharashtra,
Secretary/R&B/Madhya Pradesh
Sub: Inspection of steel girders for ROBs being constructed by Construction
Organization, Railway PUs, NHAI and other executing agencies in the
Western Railway-Regarding

Ref: This office letter of even No. dt.19.8.2020

**k *

With reference to the above letter, vide para 2.0 it was stated that all QAPs
submitted by executing agencies for fabrication of steel girders shall be scrutinized
and approved by CwM(EW)SBI. in order to streamline and expedite the Inspections
following shall be ensured:

) QAP/WPSS must be submitted to the office of CBE and an advance copy

may be submitted to CWM/BW/SBI.
(i) The executing agencies submitting the QAPWPSS must send copies of
approved GAD and design drawing with a checklist invariably stating the
various spans involved, standard/ non standard girder adopted for each
span and other relevant matters pertaining to inspection of girder etc along
with QAP, WPQR and WPSS.
(ii) The agency executing work should also mention the RDSO approved
fabricator's name, address contact no etc. While the fabrication should be
started only after the approval of QAP and related documents, however,
and the stage at which the girder is in presently namely material being
procured; cutting of material, setting of jigs and fixtures etc may also be
advised.

In case the QAP and WPSS are designated to be sent to RDSO as per
policies, then the QAP and WPSS must be submitted in three copies to the office of
CBE along with approved GAD & Design drawings.

(Manjul Mathur)

10.12
)FiU23/2/2- Chief Bridge Engineer
 Checklist

Details to be submitted along with QAP & WPSS

Reference to Approved GAD enclosing a copy
Set of approved Designdrawings and Fabrication drawings
3 Span ofgirder
Whether the span is Standard (Type design of RDSO)/Non-Standard girder
Skew Degree
6 IFabricator: RDSO approved vendor with name, address,Plate
contact detailsBow String
ype of girder: Open web girder (Through/Under slung)/ girder/
girder
 STAGE-I Inspection call (as per BS 130)
Name of Work:

(Ref codes: -IRS Welded Bridge Code., IRS: B1-2001, RDSO Report No. BS:110,
RDSO Report No. BS:111, IS:1852, BS 130)
Offering status
Inspection of Layout/Master plates & WPQR. from agency Remarks, if any
(Yes/No)
Welder approval i.e. WPQR
Readiness of sample pieces for welding in
1.
presence of inspecting authority
WPQR documents availability
2. Offering of layout/master plates for approval
Material offered are placed properly for
3.
inspection i.e. WPQR samples, Master plates etc.

It is certified that:
 Work is done as per approved QAP.
 Internal inspection is done by quality inspector of agency & Sectional authority as per approved QAP
and no significant defect is left over.

Agency Sectional Authority

 STAGE-II Inspection call
Name of work:

(Ref codes: -IRS Welded Bridge Code., IRS: B1-2001, RDSO Report No. BS:110,
RDSO Report No. BS:111, IS:1852, BS 130)
(Further inspection will be done after completing activities mentioned in stage-I.)
Offering status
Inspection of trial assembly from agency Remarks, if any
(Yes/No)
Documents to be submitted
Fabricator record
1
Welding Procedure Data Register
Weld inspection report (DPT & Etching)
Trial Assembly
Before offering the girder for trial assembly inspection all
finishing operations such as final run of GMAW, holes for
2
bearings, removal of tack weld, surface finish, drag lines,
spatter, drill burr, finishing of notch mark etc. to be
ensured by fabricator.
Readiness for measurement of camber. (Girders must be
3
supported at end points only for camber measurement.)
4. Material offered are placed properly for inspection.
Note: During fabrication, it is to be ensured that work is as per approved QAP, only approved welders
carry out welding as per approved WPSS, work is as per dimensional tolerance and other quality aspects
and should satisfy itself before sending inspection call to FIU/EW/SBI for trial assembly.

It is certified that:
 Work is done as per approved QAP.
 Internal inspection is done by quality inspector of agency & Sectional authority as per approved QAP
and no significant defect is left over.

Agency Sectional Authority

 STAGE-III Inspection call
Name of Work:

(Ref codes: -IRS Welded Bridge Code., IRS: B1-2001, RDSO Report No. BS: 110, RDSO Report No. BS:111,
IS:1852, BS 130)
(Further inspection will be done after completing activities mentioned in stage-II.)
Offering status
Inspection of assembly at site from agency Remarks, if any
(Yes/No)
1 Submission of inspection charges
2 HSFG Bolt fitment inspection
Torque wrench calibration certificate
Competency certificate of bolt tightening personnel.
3 Camber verification of I-Section after HSFG bolt fitment
4 Material offered are placed properly for inspection.
(Note: Stage-III inspection call should be raised only after payment of inspection charges.)

It is certified that:
 Work is done as per approved QAP.
 Internal inspection is done by quality inspector of agency & Sectional authority as per approved QAP
and no significant defect is left over.

Agency Sectional Authority

 Four Point Certificate

Name of Work:

Ref:

It is certified that,
(i) Steel used for welded Bridge Girders components is of weldable quality is IS: 2062 Gr.
B0 fully killed and fully normalized, which has been inspected & approved by the
Railways.
(ii) Fabrication has been done with the help of CNC machines.
(iii) Entire welding was done by approved welders using approved welding procedures
(WPSS) and welding consumables.
(iv) Fabrication work has been inspected by our internal quality control/ inspection
organization including the welding. All significant defects have been rectified and final
dimensions are within tolerances.

Sectional Authority
 Certificate of internal inspection
Name of work:………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………..
Ref.:…………………………………………………………………………………………………………………………………......
***
This is to certify that, we have inspected all components of above subjected work for
weld and dimension. Weld and dimension are found as per approved drawing, QAP & WPSS.

Agency Quality Inspector

Name: