Page 1 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev.

INDIAN RAILWAYS STANDARD SPECIFICATION

FOR

THERMOSHRINK JOINTING KIT FOR JOINTING

UNDERGROUND QUAD CABLE

SPECIFICATION NO. IRS: TC 77-2012

Revision 3

TELECOM DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW-226011
Page 2 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

DOCUMENT CONTROL SHEET

NAME ORGANIZATION FUNCTION LEVEL

Director/ Telecom-III RDSO Member Prepare

Executive Director/ RDSO - Approve

Telecom
Page 3 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

DOCUMENT DATA SHEET

Specification Revision

IRS : TC 77-12 3

Title of Document

Indian Railways Standard Specification for

Thermo shrink jointing kit for jointing
underground quad cable

Author

Director/ Telecom-III/ RDSO

Approved by

Executive Director/ Telecom/ RDSO

Abstract

This document specifies technical specifications for Thermo shrink jointing kit for
jointing underground quad cable
Page 4 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

REVISIONS/ VERSION/AMENDMENTS /AMENDMENTS

Version Chapter/ Revision/Version/ Effective

Annexure Amendment Month/Year

IRS:TC 77-2000 - First issue 2000

Version - 0

IRS:TC 77-2006 - Revision - 1 2006

IRS:TC 77-2006 - Amendment - 1 Nov. 2006

IRS:TC 77-2010 - Revision - 2 March 2010

IRS:TC 77-2012 - Revision - 3 Nov. 2012

Page 5 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

0. FOREWORD:-

0.1 This Specification is issued under the fixed serial no. IRS:TC 77, followed by the
year of adoption as standard or in the case of revision, the year of last revision.
Adopted - 2000
First revision - 2006
Second revision - 2010
0.2 This Specification requires reference to the following Indian Railways Standard
(IRS), Telecom Engineering Centre (TEC) and Indian Standard (IS) Specification:-

IRS:TC 30-05 Underground armoured Jelly Filled Quad Cables.

RDSO/SPN/TC/72/07 1.4mm dia. Copper conductor 4/6 quad cable.
IRS: S-23 Electrical Signalling and Interlocking equipment.
IS:9000 Basic climate and mechanical durability test for
Electronic equipments.
G/CJM-01/01/ JUL 92 Thermoshrink Jointing Kits for unpressurised cables.
G/CJM-15/02.Nov 97 Generic Requirements for Discrete Wire
Connectors
IS: 694-1990 PVC insulated cables for working voltages up to
and including 1100 volts- specification.

0.3 In this specification, if any of the above mentioned specification is referred to by

number only without mentioning the year of issue, the latest issue of that specification is
implied.

0.4 The specification is intended chiefly to cover the technical provision and the
provisions relating to supply of materials and does not include all the necessary
provisions of contract.

1. SCOPE:-

This Specification covers the requirements of Thermoshrink Jointing Kits for

Underground 4/6 Quad Jelly Filled Cables and underground 4 quad dry core
cable of conductor dia 0.9 mm and for Underground 4/6 Quad Jelly Filled Cables
of conductor dia 1.4 mm .

2. TERMINOLOGY:-

2.1 For the purpose of this specification the terminology given in IRS S:23 shall be
applied.

2.2 The term referred to in this specification but not covered in IRS S:23 is as under:-

2.2.1 LOT- A lot is constituted by the joints of the same type manufactured in same
factory during the same period using the same process and materials.
Page 6 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

3. KIT CONTENTS FOR QUAD CABLE JOINTS: - Tentative requirements of

various materials in a Kit for Straight through/normal, condenser, Y/derivation, Loading
Coil & Transformer Joints are in Cl. 3.1

3.1 The material (Kit Contents) for Universal Jointing Kit to be used for straight
through joint, condenser joints, Y-(Derivation) joint , Loading Coil Joint, Transformer
Joint.

S.No. Description of For 0.9mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad
Materials cable
Size Quantity Size Quantity
1 Heat Shrink Size 75/15mm – 1 Size 92/25mm – 1
Sleeve Length 850mm Length 910mm
(Reinforced) Dimensions as per Dimensions as per
Annexure I- Annexure I-
2 Stainless Steel Length – 450mm 1 Length – 470mm 1
Channels x 2, (±5mm), Thickness (±5mm), Thickness
0.7mm, ±0.1mm & 0.7mm, ±0.1 &
Underclip (Length = Underclip ( Length
35mm±1mm) & = 35mm±1mm) &
Thickness 0.2mm Thickness 0.2mm
±0.05mm ±0.05mm
3 Aluminium Size = 75mm x 1 Size = 92mm x 1
Cannister Finger length 507mm length 507mm
Coated (Dimension as per (Dimension as per
Annexure-II) Annexure-II)

4 Adhesive Width (25mm 2 Width (25mm 3

P.V.C.Tape ±1mm)x length (10 ±1mm)x length (10
meter/roll meter/roll
Minimum)x Minimum )x
Thickness (0.1 to Thickness (0.1 to
0.13mm) 0.13mm)
5 Adhesive Length 1 Length 2
Aluminium Foil (400mm±4mm) x (400mm±4mm) x
width (100mm± width (100mm±
2mm)x thickness 2mm)x thickness
(0.06 ±0.01mm) (0.06 ±0.01mm)
6 Cleaning Tissue Tissue paper size- 3 Tissue paper size- 3
( Soaked with Length (190mm Length (190mm
5ml min Iso min.) min.)
Propyl Alcohal ) Width- (140mm Width- (140mm
min.) min.)

7 Emery Strip Length (600mm± 2 (Length (600mm± 2

5mm)x width 5mm)x width
(25mm± 1mm)x 60 (25mm± 1mm)x 60
mesh) mesh)
Page 7 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

8 Tinned Copper (length 500mm± 1 (length 500mm± 1

braid 5mm)x width 5mm)x width
(7mm±1mm) with (7mm±1mm) with
heat shrink tubing heat shrink tubing
size 12/4mm (length size 12/4mm
450mm±.5mm). (length
450mm±.5mm).
9 Sealant Tape Length 400mm ±10, 2 Length 400mm 3
width 35mm ±3 x ±10, width 35mm
thickness 3mm ±0.5 ±3 x thickness
3mm ±0.5
10 Protective split Size :– 2 Size :– 2
Aluminium Dia 22mm –0.0mm Dia 30mm –0.0mm
Ring +2mm x +3mm x
width 20mm ±1mm x width 20mm ±1mm
thickness 0.9mm x thickness 0.9mm
±0.1mm ±0.1mm
11 Spring Steel OD-21mm ±1mm 4 OD-21mm ±1mm 4
Roll Width – 16mm Width – 16mm
±1mm, No of rolls ±1mm, No of rolls
Minimum 8, Minimum 8,
thickness of the steel thickness of the
sheet steel sheet
0.2mm±0.02mm 0.2mm±0.02mm
12 PVC Sleeves dia – 30 i) dia – 30 Nos.
(5mm±0.5mm) x (7mm±0.5mm) x
length (50mm±3mm) length
(50mm±3mm)
ii) dia – 10 Nos.
(10mm±0.5mm) x
length
(65mm±3mm)
13 Cleaning Cloth Length 1 Meter 1 Length 1 Meter 1
(1000mm)min. x (1000mm)min. x
Width 0.75 meter Width 0.75 meter
(750mm)min. (750mm)min.
14 Cotton Waste 50 gram (min.) 2 Bags 50 gram (min.) 2 Bags

15 Multi strand Length 2000 mm 1 Length 2000 1

tinned copper ±10 mm, Nominal mm ±10 mm,
conductors Cross sectional area Nominal Cross
insulated cable 4 sq. mm, for sectional area 4
(single core) armour continuity sq. mm, for
armour continuity
16 Transparent length (500mm Min) 1 length 1
polythene sheet: x width (750mmMin) x
(300mmMin), width (750mm
Page 8 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

thickness (0.07 to Min), thickness

0.1mm (0.07 to 0.1mm
17 Jelly filling (300 gm. min.) 2 Pack (300 gm. min.) 2 Pack
Compound
18 Installation 1 1
Instructions
19 Kit Packing Box size length 900mm x 1 size length 950mm 1
140mm height x x 140mm height x
120mm width 140mm width
(Tolerance + 10mm, - (Tolerance +
5mm) 10mm, -5mm)
20 Packing Slip 1 1
21 Cleaning Liquid 200 gm. (min.) 1 Pack 200 gm. (min.) 1 Pack
22 Sheath (1+1+1) indicates (1+1+1) indicates
Connector
(1+1+1) a) 2 Clips Sheath 1 a) 2 Clips Sheath 1
Assembly Connector, length Connector, length
700mm ± 7mm 700mm ± 7mm

b) 1 Clip Sheath
b) 1 Clip Sheath 1 Connector, length 1
Connector, length 300mm ± 3mm
300mm ± 3mm
c) Bridge
c) Bridge connector 1 connector 1
23 Branch Off Clip (Dimensions as per – 1 (Dimensions as per 1
(Medium) Annexure III) – Annexure III)
For Y (Derivation) For Y (Derivation)
Joint & Transformer Joint &
Joint Transformer Joint
24 Cable tie length 1 length 1
(254mm±3mm), (315mm±3mm),
width width
(4.75mm±0.5mm), (4.75mm±0.5mm),
thickness thickness
(1.43mm±0.1mm) (1.56mm±0.1mm)
25 IDC type Jelly IDC type jelly filled 30 Not applicable -
filled discreet butt connector Numbers
wire connectors modules made of
polypropylene for 3
wires (0.4mm to
0.9mm dia.
conductors)
26 IDC type Jelly IDC type jelly filled 6 Numbers Not applicable -
filled discreet connector modules
wire connectors made of
polypropylene for 2
wires bridging type
(0.4mm to 0.9 mm
dia. conductors)
Page 9 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

27 Parallel jaw Parallel jaw plier for One plier Not applicable -
plier crimping the discrete for every
wire connectors. The 20 jointing
dimension of the plier kits for 0.9
shall be compatible mm quad
with the crimping cable or
tool and shall be part
supplied by the thereof.
manufacturer of the Minimum
discrete wire quantity 1
connectors. No.

Note:- 1. The dimensions of kit contents given in the table shall be taken as final in
case of any mismatch with the dimensions mentioned anywhere else in this
specification.
2. Supply of either item at SN.12 or items under SN 25, 26 and 27 shall be
specific to purchaser’s requirement as per clause 12 of the specification. Item
No. 25, 26 and 27 shall only be supplied if IDC type discreet wire connectors
are required by purchaser and in that case item number 12 shall not be supplied.

4.0 DESCRIPTION OF KIT CONTENTS:-

4.1 Heat Shrink Sleeve (Reinforced) :-

4.1.1 The heat shrink sleeves shall be manufactured from cross linked, heat shrinkable,
thermally stabilised polymers consisting of a reinforcing, heat shrinkable fabric
contained in a matrix material. Sleeves shall be of wrap around design furnished
with stainless steel channel and one under clip to make the wrap around sleeve
cylindrical prior to shrinking operation.

The inside surface of the sleeve shall be coated with a hot melt adhesive which
will bond at the temperature attained during the shrinking operation. Outside
surface of the sleeves shall be coated with a temperature indicating paint which
shall change colour when the desired temperature is attained to allow controlled
heating during installation.

4.1.2 The dimensions of heat shrink sleeves (Reinforced) Size shall be as per
Annexure-I.

4.2 Stainless steel channel under clip:-

4.2.1 The stainless steel channel and under clip shall be used to close the heat shrink
sleeves before shrinking.

4.3 Aluminium canister – Finger coated:-

4.3.1 The aluminium canister shall comprise of two performed half shells that can be
hinged and fitted around the cable splice. The aluminium canister shall provide
adequate structural strength to avoid collapsing during installation.
Page 10 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

4.3.2 The dimensions of Aluminium Canister finger coated size shall be as per
Annexure-II.

4.3.3 The fingers shall contain a protective coating of not less than 1 mm thickness for
length of 30 to 40 mm at the finger end.

4.4 Adhesive PVC tape:-

4.4.1 The PVC adhesive tapes shall be used for taping the fingers of Aluminium
canister. Also, it is used to cover the splice bundle.

4.4.2 The size of the tape shall be “Width (25mm ±1mm) x Length (10meter/roll ±
0.1meter) x Thickness (0.1mm to.13mm)”

4.5 Adhesive Aluminium foil:-

4.5.1 The adhesive Aluminium foil shall be used to protect the cable jacket from
damage during shrinking of heat shrink sleeves.

4.5.2 The adhesive Aluminium foil shall be in a strip form with adhesive coating on one
side and protected by a release film.

4.5.3 Dimension of Aluminium foil shall be “Length (400mm ± 4mm) x

Width (100mm ±2mm) x Thickness (0.06mm ± 0.01mm)”

4.6 Cleaning tissue:-

4.6.1 The cleaning tissue shall be supplied in sealed pouches containing Iso Propyl
Alcohal (IPA) conforming to IS: 2631. The size of the tissue paper shall be
“Length 190 mm (min.) x Width 140 mm (min.).”

4.6.2 The quantity of IPA contained in the pouch shall be 5 ml (min.) and the material
of the pouch shall be laminated Aluminum.

4.6.3 The pouch shall be marked as under:

Name of material
Manufacturer’s identity
Batch No.
Precautions regarding handling.

4.7 Emery strip:-

4.7.1 The emery strip shall be used for surface preparation of cable with
PVC/Polyethylene sheath.
Page 11 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

4.7.2 The emery used shall be synthetic or natural emery.

4.7.3 Cloth shall be used as backing material. The cloth shall be drill weave and shall
have a breaking load of not less than 400N/25mm width when tested with a speed
of 50mm/minute.

4.7.4 The emery cloth shall be supplied in the form of strip size “Length (600mm ±
5mm) x Width (25mm ±1mm) x 60 mesh.”

4.8 Sealant tape:-

4.8.1 The sealant tape shall be a butyl rubber based elastic plastic sealing compound,
black in colour which is used for different applications in cable jointing.

4.8.2 The sealant tape shall be supplied in a strip form of uniform dimensions with
release paper on both the side to prevent sticking.

4.8.3 The sealant tape shall be capable of releasing easily from the release paper and
also shall not flow during storage.

4.8.4 The sealant tape shall have a shelf life of not less than two years when stored at
room temperature.

4.8.5 The sealant tape shall have good adhesive to metals and PE without preheat,
medium strength and very good chemical and thermals stability. It shall not cause
corrosion to the metal which comes into contact with it.

4.9 Branch off clip:-

4.9.1 The branch-off clip shall provide high performance cable branching technique and
shall be easy to install.

4.9.2 The branch off clip shall be made of corrosion resistant aluminium alloy
conforming to IS 617 grade 4600 and coated with epoxy.

4.9.3 The design of the branch off clip shall conform to the details given in Annexure-
III and also the dimensions mentioned therein. The branch off clip shall have
three fingers, the middle one coated with hot melt adhesive identical to that on the
Thermoshrink sleeve. The adhesive on the branch off clip shall however, have a
different colour to that of the Thermoshrink sleeve adhesive and thus give a visual
indication to the jointer of correct adhesive flow and scaling of the branch.

4.9.4 The branch off clip shall contain the identification of the manufacturer/supplier on
the metal part.
Page 12 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

4.9.5 Dimension of Branch off clip (Medium size) as per Annexure-III.

4.10 Tinned copper braid:-

4.10.1 Tinned copper braid shall be used for continuity between the aluminium wire
screens.

4.10.2 The tinned copper braid shall be made of copper and shall be free from
dirt/grease.

4.10.3 There shall not be any dark patches on its surface.

4.10.4 “ The width and cross-section area of braid shall be 7mm ± 1mm and 4 sq mm
(min.) respectively. The length of braid shall be 500 mm ± 5mm.”

4.10.5 “ No. of strand/No. of wires in the braid shall be 24/6 or 12/12 or 16/9”.

4.10.6 “ Heat Shrink tubing size 12/4mm – length 450mm ± 5mm.”

4.11 Protective Split Al ring :-

4.11.1 Protective split Aluminium ring shall be used over aluminium wire screen to
prevent loosening of aluminium wire screen from the sheath.

4.11.2 Protective split ring shall be made of Aluminium and shall have no corrosion.

4.11.3 Protective split ring shall have dimensions as under :-

DD

W
Page 13 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Type of cable Internal Diameter Width Thickness

D W T

For 0.9mm dia. 4/6 22mm -0.0mm 20mm ±1mm 0.9mm ± 0.1mm
quad cable +2.0mm

For 1.4mm dia. 4/6 30mm -0.0mm 20mm ±1mm 0.9mm ± 0.1mm
quad cable +2.0mm

4.11.4 Protective split aluminium ring shall be supplied in polybag and with
manufacturer’s identity.

4.12 Stainless Steel Spring:-

4.12.1 Stainless steel spring shall be used to tighten multi strand flexible tinned copper
cable over Aluminium wire screen for providing continuity of Aluminum screen.
Similarly it shall be used to tighten multi strand flexible tinned copper cable over
Steel armour for providing continuity of steel armour.

4.12.2 Stainless steel spring shall be made of stainless steel and its surface shall be free
from oil and grease.

4.12.3 The dimensions of stainless steel spring roll shall be as under :

Page 14 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Outer diameter (D) Width (W) No of Thickness of the steel tape

Complete rolls
(minimum)

21mm ± 1mm 16mm ± 1mm Minimum 8 0.2 mm±0.02 mm

4.12.4 Stainless steel spring roll with manufacturers identity shall be supplied in
polybag

4.13 PVC Sleeve :-

4.13.1 The PVC sleeve shall be used to cover ends of twisted copper conductor pairs.

4.14 Cotton waste:-

4.14.1 Cotton waste shall be used in cleaning of cable joint.

4.14.2 Cotton waste supplied with the jointing kit shall be clean and soft.

4.15 Multi strand tinned copper conductors insulated cable (single core):

4.15.1 It shall be used for providing continuity between the steel armours of the cables
being joined.
4.15.2 It’s length shall be 2000 mm ±10 mm and Nominal Cross sectional area shall be
4 sq. mm.
4.15.3 It shall be flexible multi strand copper conductors single core cable insulated
conforming to IS 690-94

4.16 Filling Compound:-

In joints, the splice bundle shall be filled with filling compound in order to
prevent insulation break down in the event of water entry into the joint.

4.17 Polythene Sheet (TPE Sheet) :-

4.17.1 For quad cable of 0.9mm dia. copper conductor:-

“ The polythene sheet for filling compound shall be provided Length (500mm
± 5mm) x Width (300mm ±3mm) with thickness (0.07mm to 0. 1 mm).”

4.17.2 For quad cable of 1.4mm dia. copper conductor:-

“ The polythene sheet for filling compound shall be provide Length (750mm ±
7mm) x Width (750± 7mm) with thickness 0.07mm to 0.1mm”
Page 15 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

4.18 Sheath Connector Assembly:-

The sheath connector assembly consists of three items, viz an insulated stranded
copper wire with connecting elements on both sides, a small wire of the same
description with connecting elements on one side only and a bridge connector for
jointing the two wires. The connecting element is made of phosphor bronze,
backed by a non-corrosive metal back-plate strongly pressed to it and also
crimped to the connecting wire. The element has an opening provided with
toothed jaws into which the cable sheath can be inserted and crimped using
ordinary pliers. The toothed jaws when crimped bite through the cable sheath to
make a good low-resistance metallic contact with the sheath of the cable. In order
to inter-connect the sheath connector wires in branch joints, the bridge wire
connector is used in conjunction with the single ended connector assembly. The
flexible wire shall be 14 SWG.

4.19 Cable Tie:-

Material:- UL approved Nylon-66,94 V-2
Operating Temperature:- (-)40 degree C to (+) 85 degree C
Colours available:- Natural or Black
Cable tie is an economical and versatile method of cable/wire bunching.
Cable tie has a self-locking one piece construction which ensures fast installation.
It is self-locking and releasable type.

Size For 0.9mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad cable
Length 254 ± 3mm 315mm ± 3mm
Width 4.75 ± 0.5mm 4.75mm ± 0.5mm
Thickness 1.43 ± 0.1mm 1.56mm ± 0.1mm
Tensile Strength 22Kgs (50lbs) min. 22Kgs (50lbs) min.
Kgs (lbs)

4.20 IDC type jelly filled discreet wire connector: It shall be made of Polypropylene
and as per TEC GR No. G/CJM-15/02.Nov 97.
4.20.1 IDC type jelly filled butt connector modules made of polypropylene for 3 wires
(0.4mm to 0.9mm dia conductors) 30 Numbers, to be used for joining two/ three
conductors of conductor diameter varying from 0.4 mm to 0.9 mm.

4.20.2 IDC type jelly filled connector modules made of polypropylene for 2 wires bridging
type (0.4mm to 0.9mm dia conductors) 6 Numbers to be used for making
derivation joint on a quad without cutting conductors.
4.21 Parallel Jaw plier: Parallel jaw plier for crimping the discrete wire connectors. The
dimension of the plier shall be compatible with the discrete wire connector and shall
be supplied by the manufacturer of the discrete wire connectors.

5.0 Tests on Complete Joint Closures:-

Following tests shall be carried out on complete heat shrink joint closures.
Page 16 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

5.1 Tightness Test:-

The tightness of installed closures shall be checked by pressurising to 700m bars

for a period of 15 minutes while immersed in water at room temperature. A
sample shall be considered tight if there is no continuous stream of air bubbles
escaping from it.

One quad will be removed for tightness test (type test) at the times of cable
preparation.

Pressurised air will be applied at one end of the cable & pressure will be
measured at other end of the cable at the time of tightness test.

5.2 Vibration Test:-

A test specimen shall be mounted on a vibration apparatus with the cables rigidly
clamped at distances of 10xD (Minimum 250 mm) from each end of the sleeve. D
being the cable outer diameter.

In case of more than one cable, the outer diameter of the largest cable is used. Its
centre point shall then be subjected to a sinusoidal vibration with a frequency of
100 vibrations per minute and amplitude of 20mm for a period of 2 hours.

5.3 Impact Test:-

Installed specimen shall be placed on a smooth, flat, horizontal surface. The rail
shall be rotated by 90 degree from the point of impact.

A steel load weighing 1 Kg shall be suspended at a height of 2 meters above the

centre of the test specimen. The weight shall be allowed to fall under gravity,
striking the test specimen at the apex of curvature.

After the impact, the samples shall be subjected to the tightness test as described
in clause 5.1.

5.4 Axial Pull Out Test:-

An axial tensile force of D/45 x 1000N, with a maximum of 1000±10N shall be

applied on each individual cable protruding from the splice, where D is the cable
outside diameter in millimeters. Each cable shall be tested individually for 3
hours.

After completing the test, samples shall be subjected to the tightness test as
described in clause 5.1.
Page 17 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

5.5 Torsion Test:-

The specimen shall be clamped rigidly. Extending cables shall be gripped at a

distance of 10xD from sleeve edge. (D is the cable outside diameter). Each cable
shall be tested individually.

A torsion cycle consist of each cable being subjected to a torsional stress of 50

Nm maximum or an angle of 90º maximum in one direction for a duration of .5
minutes. The cable shall be returned to its original position and the same
maximum torsional stress is then applied in the opposite direction for 5 minutes.
The cable shall then be returned to its neutral position. After completing two
torsion cycles per cable, the sample shall be subjected to the tightness test as
described in clause 5.1.

5.6 Bending Test:

The specimen shall be clamped on a smooth, flat, horizontal surface. A being

force of maximum 500N shall be applied at a distance of 10xD (minimum
250mm) from the sleeve edge on each extending cable to deflect the cable to
maximum angle of 45 degree ( or a maximum displacement of 300 mm from the
horizontal) at the point of application of the force. (D is the cable outside
diameter). Each cable shall be tested individually.

A bending cycle shall consist of one excursion of the cable from the neutral
position to the specified limit in one direction, back to the limit specified,
maintained for 5 minutes and returned to the neutral position.

After completing two cycles per cable, samples shall be subjected to the tightness
as described in clause 5.1.

5.7 Temperature Cycling Test:-

Installed samples shall be placed in a water bath and subjected to 30 cycles.

Each cycle requires 12 hours as stated below :-

2± ½ hours – Room temp. to 650C±50C.

6 hours at 650C ± 50C.
2 hours 650± 50C C to room temp.
2 hours at room temp. (minimum).

After completing every 10 cycles, samples shall be subjected to the

tightness test as described in clause 5.1.
Page 18 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

5.8 Thermal Shock Test:-

Installed joint closures shall be immersed in water bath heated to 65 ± 50C so that
they are at least 5 cm below the water surface. After 15 minutes, the samples shall
be suddenly transferred to ice after at 0 ± 50 C for 15 minutes.

After completing ten cycles, samples shall be subjected to the tightness test as
described in clause 5.1.

5.9 Corrosion Test:-

Separate test samples shall be kept immersed in solutions of pH value 4 and 10

for 30 days. After completion of this period, the samples shall be visually
inspected for corrosion of metallic parts and then subjected to the tightness test as
described in clause 5.1.

5.10 Blunt Blade Test:-

The test shall be performed only on glass fibre reinforced sleeve. The installed
sample shall be placed horizontally on a bed of dry sand so that the sample is
supported without movement. A blunt steel blade of 6 Kg shall be allowed to fall
under gravity from a height of 1 meter. The sample shall be positioned so that
impact occurs at 900 from channel. After completing the impact, the sample shall
be subjected to tightness test as described in clause 5.1.

5.11 Spot Heat Test:-

This test is to be conducted on reinforced sleeves.

5.11.1 Immediately after installation of a sleeve according to standard instructions, the

tip of the yellow flame of length approx 330mm with blue position of around
80mmshall be allowed to impinge on area of the sleeve away from the seam, at
the center of splice for 10 seconds. The sleeve shall not split and ooze out any
adhesive during the application or after the withdrawal of the flame.

5.11.2. Application of Flame: The tip of the flame (minimum of 50mm) shall be allowed
to impinge perpendicular to the surface and evenly on the joint so as to ensure
steady contact with the sleeve surface.

5.12 REOPENING:-

One sample shall be reopened and closed five times. After completion, the sample
shall be subjected to Air Tightness Test as per Clause 5.1. Also there shall be no
damage to the cable and other reusable parts.
Page 19 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

5.13 STATIC LOAD TEST

A static load of 1000 ±10N shall be applied on the joint closure 90º from the
seam. The load shall be applied for 5 minutes and then removed. The sample shall
then be turned through 180ºand the load reapplied for an additional five minutes.
After completion the test, the sample shall be subjected to the tightness test as per
Clause 5.1

6.0 TESTS:-

Unless otherwise specified, all tests shall be carried out under prevalent ambient
atmospheric conditions.

6.1 Type Tests on joint closure on Jelly Filled Quad Cable:-

6.1.1 Tests on completed joint closure of Quad cable.

6.1.1.1 All tests on complete closures i.e. given under clause numbers 5.1 to 5.13 shall be
carried out. A minimum of 1 sample of complete joint closures of each type i.e.
straight through, and condenser joint 2 samples of complete joint closures of each
type i.e. loading coil joint and transformer joint shall be made and numbered as 1
to 24. Thus no. of complete joint closure for each type of cable i.e. 4 quad jelly
filled and 6 quad jelly filled shall be 6 each respectively for 0.9mm dia. & 1.4mm
dia 4/6 quad cables. Hence total no. of joints to be made shall be 24.

6.1.1.2(a) 0.9mm dia. 4/6 quad cable straight through joint sample no. 1(4QJ), 7(6QJ) &
condenser joint sample no. 2 (4QJ), 8(6QJ) and loading coil joint sample no.
3,4(4QJ), 9,10(6QJ) and transformer joint sample no. 5,6(4QJ), 11,12 (6QJ) shall
be made.

6.1.1.2(b) 1.4mm dia.4/6 quad cable straight through joint sample no. 13(4QJ), 19(6QJ)
& condenser joint sample no. 14(4QJ), 20(6QJ) and loading coil joint sample no.
15,16(4QJ), 21,22(6QJ) and transformer joint sample no. 17,18(4QJ), 23,24(6QJ)
shall be made.
6.1.1.3 Tightness test as per clause 5.1 shall be carried out on all the 24 samples.

6.1.1.4 Vibration test as per clause 5.2 shall be carried out on sample no. 4,16(4QJ) &
10,22(6QJ) i.e. loading coil joint.

6.1.1.5 Impact test as per clause 5.3 shall be carried out on sample no. 3,15(4QJ) &
9,21(6QJ) i.e. loading coil joint.

6.1.1.6 Axial pull out test as per clause 5.4 shall be carried out on sample no. 6,18(4QJ)
& 12,24(6QJ) i.e. transformer joint.
Page 20 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

6.1.1.7 Torsion clause as per clause 5.5 shall be carried out on sample no. 4,16(4QJ) &
10,22(6QJ) i.e. loading coil joint.

6.1.1.8 Bending test as per clause 5.6 shall be carried out on sample no. 6,18(4QJ) &
12,24(6QJ) i.e. transformer joint.

6.1.1.9 Temperature Cycling test as per clause 5.7 shall be carried out on sample no.
5,17(4QJ) & 11,23(6QJ) i.e. transformer joint.

6.1.1.10 Thermal shock test as per clause 5.8 shall be carried out on sample no.
4,16(4QJ) & 10,22(6QJ) i.e. loading coil joint.

6.1.1.11 Corrosion test as per clause 5.9 shall be carried out on samples no.
1,2,13,,14(4QJ) & 7,8,19,20(6QJ), for pH 4 & pH10 value) i.e. straight through
and condenser joints.

6.1.1.12 Blunt blade test as per clause 5.10 shall be carried out on sample no. 6,18(4QJ)
& 12,24(6QJ) i.e. transformer joint.

6.1.1.13 Spot heating test as per clause 5.11 shall be carried out on sample no. 4,16(4QJ)
& 10,22(6QJ) i.e. loading coil joint.

6.1.1.14 Reopening Test as per Clause 5.12 shall be carried out on sample no. 3,15(4QJ)
& 9,21(6QJ) i.e. loading coil joint.

6.1.1.15 Static load test as per clause 5.13 shall be carried out sample no. 3,15(4QJ) &
9,21(6QJ) i.e. loading coil joint.

6.1.2 Tests on raw material/component of Kit Contents of Quad cable:-

6.1.2.1 One sample each of raw material/components of Kit contents shall be taken for
carrying out tests as per Annexure-IV.
6.1.2.2 Test of raw material/ components shall be done at firm’s premises. If the test
facility for any particular test does not exist with the firm samples of raw
materials for the test shall be sealed by inspecting official and shall be sent to
government approved testing labs for carrying out the tests.
6.1.2.3 Vendors have to use the out sourced raw material/components of the same
manufacturers for which approval was granted. In case vendor decides to
change or to have additional source/ sources of raw material/components which
are procured from out sourced agencies/sub vendors, the vendors have to apply
to RDSO/Lucknow well in advance regarding their proposal with reasons. The
competent authority in RDSO, Lucknow on the merit of the case shall decide
and advice Director/Inspections to conduct tests pertaining to that particular
material/components specified in the specification ( Annexure-IV).For RTSF
Page 21 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

sleeve the tests will be carried out as per clause no. 6.1 also in addition to those
specified in Annexure IV.
6.1.2.4 Main manufacturers/sub vendors manufacturing identity/Trade mark shall be
printed/embossed on each of the items of Kit contents which have to be ensured
by inspecting agencies during test.
Note:- All tests shall be covered regardless of number of specimen samples of complete
joint closures.

6.1.3 All samples shall successfully pass all the tests of the clause 6.1.1 & 6.1.2 for
proving conformity to the specification. Type approval shall be accorded to the
firm after samples pass the above tests.

6.2 Acceptance Tests:-

6.2.1 The following shall constitute acceptance tests :-

The items appearing in Kit contents of Quad Cable i.e. clause 3.1 shall be tested
as per the sampling plan of acceptance tests given below: -

6.2.2 Sampling plan for acceptance tests for Quad cable.

SN Tests Sample size

1. “Dimensions (SN 1 to 3, 5,7 to 2 for lot size 8, 3 for lot size 9-15, 5
13, 16, 19 & 22 to 24 of clause no. 3.1)” for lot size 16-25,8 for lot size 26-50,
13 for lot size of 51 to 90, 20 for lot
size 91-150, 32 for lot size 151-280, 50
for lot size 281-500, 80 for lot size 501-
1200, 125 for lot size 1201-3200 and
200 for lot sizes greater than 3201.
2. Visual Examination (Clause No. 3.1) -do-
3. Manufacturer’s Identity/Trademark Cl. 3.1 -do-
4. Anchorage of PVC Tape (S.N.4 of Cl. 3.1) One sample from the offered lot.
5. Tensile Strength of PVC Tape (SN 4 of Cl. -do-
3.1)
6. Elongation of PVC Tape (SN 4 of Clause -do-
3.1)
7. Adhesion to Steel of PVC Tape (SN 4 of Cl. -do-
3.1)
8. Tensile Strength of Adhesive Aluminium -do-
Foil (SN5 of Cl.3.1)
9. Elongation of Adhesive Aluminium Foil -do-
(SN5 of Cl.3.1)
10. Adhesion to steel of Adhesive Aluminium -do-
Foil (SN 5 of Clause 3.1)
11. Breaking Load of Emery Strip (SN 7 of -do-
Clause 3.1).
Page 22 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

12. Integrity of abrasive bond of Emery Strip -do-

(SN 7 of Clause 3.1)
13. Handling test on Sealant Tape (SN 9 of -do-
Clause 3.1)
14. Shear Strength of Sealant Tape (SN 9 of -do-
Clause 3.1)
15. Softening Point of Sealant Tape (SN 9 of -do-
Clause 3.1)
16. Needle Penetration of Sealant Tape (SN 9 of -do-
Clause 3.1)
17. Colour of Sealant Tape (SN 9 of Clause 3.1)One sample from the offered lot.
18. Weight/Pouch of Jelly Filling Compound 2 for lot size 8, 3 for lot size 9-15, 5 for
(SN 17 of Clause 3.1) lot size 16-25,8 for lot size 26-50, 13
for lot size of 51 to 90, 20 for lot size
91-150, 32 for lot size 151-280, 50 for
lot size 281-500, 80 for lot size 501-
1200, 125 for lot size 1201-3200 and
200 for lot sizes greater than 3201.
19. Cone Penetration of Jelly Filling Compound One sample from the offered lot.
(SN 17 of Clause 3.1)
20. Homogeneity of Jelly Filling Compound (SN -do-
17 of Clause 3.1)
21. Air entrapment of Jelly Filling Compound -do-
(SN 17 of Clause 3.1)
22. Wire Pull Out from connecting element of
Sheath Connector Assembly (SN 22 of
Clause 3.1)
23. Wire Pull Out from Bridge connector of -do-
Sheath Connector Assembly (SN 22 of
Clause 3.1)
24. Quantity & colour of cleaning tissue (SN 6 -do-
of Clause No. 3.1)
25. Colour & Tensile strength of Cable Tie (SN -do-
24 of Clause 3.1)
26. Dimension of Adhesive PVC Tape (SN. 4 of One sample from the offered lot.
Clause 3.1) & Cleaning Tissue (S.N.6 of
Cl.3.1)
27. Peel strength of hot melt adhesive to For these tests (SN 27 to SN 31):– One
polyethylene (SN-1 of clause 3.1) sample of RTSF sleeve from every 100
28. Softening point of hot melt adhesive (SN-1 quantity or part there of shall be taken
of clause 3.1) and tests shall be performed on
29. Colour change of temperature indicating appropriate size of pieces of this
point of RTSF sleeve (SN-1 of clause 3.1) sample. (Example: For quantity less
30. Resistance to split propagation of RTSF than or upto 100, the sample size will
sleeve (SN-1 of clause 3.1) be one and for quantity from 101 to 200
Page 23 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

31. Bursting strength of RTSF sleeve. (SN-1 of the sample size will be two and so on).
clause 3.1)
32. Test for longitudinal sealing of RTSF sleeve. For the tests (SN 32 to SN 33):-
(SN-1 of clause 3.1) One sample of RTSF sleeve from every
33. Longitudinal shrinkage of RTSF sleeve. (SN- 100 quantity or part there of shall be
1 of clause 3.1) taken and tests shall be performed on
this sample. (Example: For quantity
less than upto 100, the sample size will
be one and for quantity from 101 to 200
the sample size will be two and so on).
34 Visual inspection of the Discrete wire 5 samples for each from offered lot
connectors (SN 25 and 26 of clause 3.1)
35 Manufacturer’s marking on Discrete wire 5 samples for each from offered lot
connector (SN 25 and 26 of clause 3.1)
35 Filling compound quantity in Discrete wire 5 samples for each from offered lot
connectors (SN 25 and 26 of clause 3.1)
36 Wire pull out on Discrete wire connectors One sample from offered lot
(SN 25 and 26 of clause 3.1)
37 Contact resistance of Discrete wire One sample from offered lot
connectors (SN 25 and 26 of clause 3.1)
38 Parallel Jaw plier marking and One sample from offered lot
manufacturing identity, model number etc.
(To be supplied one for every 10 jointing kits
or part thereof)
39 Resistance of 2000 mm Multi strand copper One sample from offered lot
conductor single core insulated cable (SN 15
of clause 3.1)
40 Number of strand in 2000 mm Multi strand One sample from offered lot
copper conductor single core insulated cable.
(SN 15 of clause 3.1)
41 Length of Multi strand copper conductor One sample from offered lot
single core insulated cable. (SN 15 of clause
3.1)
42 Marking on Multistrand copper conductor IS One sample from offered lot
Marking (SN 15 of clause 3.1)
43 Marking on the complete jointing kit as per One sample from offered lot
clause 7.2
44 Installation instructions whether in Hindi and One sample from offered lot.
English and in good quality. They are as per
approved instructions or not.

6.2.3 Any other tests as required by the inspecting authority to ensure that equipment is
in conformity with the requirement of specification.
6.2.4 Any failure in the acceptance tests mentioned in clause 6.2.1 shall lead to
rejection of the lot.
Page 24 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

6.3 Routine Tests:-

6.3.1 The following shall constitute routine tests:

6.3.1 All tests given under clause 6.2 acceptance test and any other test as required by
manufacturer shall constitute routine tests.

6.3.2 The manufacturer shall certify that routine test have been successfully carried out
all the jointing kits offered for inspection. He shall produce the test results at the
time of inspection.

7.0 MARKING:-

7.1 “ Following marking to the extent applicable as per marking requirement

of the raw material test under Annexure – IV shall be legibly and
indelibly printed/ engraved on the item of the kit.”
a) Manufacturer’s name and identification mark.
b) Year/ month of manufacture.
c) Specification No.
d) Serial No.
e) Dimensions
f) Batch No.
g) Marking “ For 0.9mm/1.4mm conductor Quad Cable” on RTSF sleeve.

7.2 Following shall be legibly and indelibly marked on the kit packing box :-
a) “Thermoshrink jointing kit for U/G 4/6Q JF cable and 4Q Dry cable of conductor
dia.0.9mm .” or “ Thermoshrink jointing kit for U/G 4/6 quad jelly filled cable of
conductor dia. of 1.4 mm” as applicable
b) Expiry Date ……………………..

Note: The shelf life of all the components of the kit shall be at least 2 years at the time
of Acceptance Testing except for the following components ,the performance of
which may deteriorate by not more than 10% after one year. However these
components shall be perfectly usable till expiry date of the kit. These
components are - Adhesive PVC Tape, Adhesive Aluminium Foil, Sealant
Tape, Jelly Filling Compound & Cleaning tissue.

8.0 INSPECTION:-

8.1 The inspection and test shall be carried out to the satisfaction of the purchaser or
his nominee.

8.2 The purchaser or his nominee shall have the right to be present during all stages
of manufacture and shall be accorded all reasonable/complete facilities to satisfy
himself that the thermoshrink jointing kit contents are being manufactured in
accordance with the terms and conditions of the specification. The purchaser or
Page 25 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

his nominee shall have the right to reject any material that fails to conform to the
specification.

8.3 When inspection is carried out during manufacture, the manufacturer shall supply
the material and samples required for testing free of charge and shall at his own
cost prepare and furnish the necessary test pieces and appliances for such testing
as may be carried out at his premises in accordance with the specification. If
facilities are not available at his own works for conducting the prescribed tests,
manufacturer shall bear the cost of carrying out the tests at an approved test
Laboratory.

9.0 INSTALLATION INSTRUCTIONS:

9.1 Installation instructions shall be supplied with each Thermoshrink Jointing Kits.
The installation instructions shall be given both in Hindi and in English with clear
sketches of stage-wise jointing procedure.

10.0 EXECUTION OF THERMOSHRINK JOINTING AT SITE:

10.1 Cable jointing shall be carried out at site as per the detailed procedure suggested
by the manufacturer only by competent cable jointer having competency
certificate issued by authorized agencies viz IRISET/Secunderabad, zonal training
schools, RDSO approved manufacturers of thermoshrink jointing kit. This is
necessary to ensure quality control over the joints.

10.2 The above clause should be suitably reflected in the tender and payment
conditions.

11.0 PACKING:
11.1 The kit content shall be packed so as to permit convenient handling and protect
against loss or damage during transit and storage.

12.0 INFORMATION TO BE GIVEN BY THE PURCHASER.

The purchaser shall clearly specify the conductor dia. of 4/6 quad cable for which
the joints are required. While placing orders for Thermoshrink Jointing Kits, the
purchaser shall quote following description:-

A. “Thermoshrink jointing kits for jointing underground 0.9mm dia. conductor

4/6 quad cable as per specification IRS: TC 77-2012 Rev.3 or latest.”
Or
“Thermoshrink jointing kits for jointing underground 0.9 mm dia. conductor
4/6 quad cable as per specification IRS: TC 77-2012 Rev.3 or latest with IDC
type jelly filled discreet wire connector”

B. “Thermoshrink jointing kits for jointing underground 1.4 mm dia. conductor

4/6 quad cable as per specification IRS: TC 77-2012 Rev.3 or latest.”
Page 26 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3
Page 27 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3
Page 28 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3
Page 29 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

ANNEXURE – IV

RAW MATEIAL TEST OF THERMOSHRINK JOINTING KITS FOR

JOINTING UNDERGROUND QUAD CABLE TO SPECIFICATION
NO. IRS:TC 77-2012

SN TESTS PAGE NO.

1. Thermoshrink Sleeve (Reinforced) and Hot 24 - 35

Melt Adhesive.

2. Thermoshrink Sleeve (Reinforced) Closure 36

Channel and under clip

3. Branch off Clip 37 - 38

4. Aluminium Cannister 39

5. Sheath Connector Assembly 40 - 42

6. Splice Filling Compound 43 - 46

7. Cable Cleaning Liquid 47 - 50

8. Adhesive PVC Tape 51

9. Sealant Tape 52 - 53

10. Emery Strip 54 - 55

11. Cleaning Tissue 56

12. Adhesive Aluminium Foil 57

13. Cable Tie 58

14 Discrete wire connector

15 Multi strand tinned copper conductor flexible

insulated cable (single core)

Page 30 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Note: Either ISO or ASTM or IS test standards are indicated for testing various
properties. Testing by equivalent standards shall be acceptable, (e.g. if a particular ISO
standard is mentioned, then equivalent IS or ASTM standard shall be acceptable and so
on.) provided the value of parameters is same in the equivalent standard as is indicated
in this specification. However, in case of change in parameter value in the equivalent
standard, prior approval of RDSO shall be obtained before initializing process of testing
with equivalent standard.

THERMOSHRINK SLEEVE (REINFORCED) AND HOT MELT ADHESIVE

1. GENERAL

1.1 The heat shrinkable sleeves shall be manufactured from cross-linked, heat
shrinkable, thermally stabilised polymers, or a composite laminate, consisting of a
reinforcing, heat shrinkable fabric contained in a matrix material. The sleeve
shall be of wrap around design furnished with stainless steel channels and one
retaining clip to make the wrap-around sleeve cylindrical prior to the shrinkage
operation.

1.2 The inside surface of the sleeve shall be coated with a hot melt adhesive which
will bond at the temperature attained during the shrinkage operation. The inner
adhesive surface of the sleeve shall be protected by a polythene release paper.
The outside surface of the sleeve shall be coated with a temperature indicating
paint which changes colour when the desired temperature is attained to allow a
controlled heating during installation. The heat shrinkable sleeve and adhesive
shall meet the requirements given in section 2.1, 2.2 and 3 of this specification
respectively when tested in accordance with the associated test methods and test
procedures.

2. HEAT SHRINKABLE MATERIAL REQUIREMENTS

2.1 Heat shrink sleeve manufactured from reinforced heat shrinkable thermally
stabilised materials

Unless otherwise specified, test shall be done on unrecovered, cross linked

uncoated material.
Parameters for full recovery shall be 200 ± 2°C for 5 minutes in an air circulating
oven.
Where test temperature is not indicated, the test shall be carried out at room
temperature.
Page 31 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Section Properties Test methods & conditions Reference Requirements

2.1.1 Bursting Unrecovered material. ISO 3303 Min. 1500 N.
strength Method A
2.1.2 a) Thermal Fresh sleeve aged for 168 ISO 188
ageing hrs. at 150 oC + 2oC .
b) Bursting Min. 1600 N.
strength after
thermal aging
2.1.3 Dielectric Electrodes : 6 mm dia brass ASTM D Min.12KV/mm
strength rods 149
Upper electrode weight: 50
+ 2 gm
Test medium : transformer
oil
Voltage application :
2 KV steps at 20 seconds
intervals
2.1.4 a) Chemical Immersion in the following ISO 175
resistance liquids, one liquid per
sample group.
Na2 SO4 0. IN for 24 hrs.
NaC1 0. IN for 24 hrs.
H2 SO4 0. IN for 24 hrs.
NaOH 0. IN for 24 hrs.
Fuel oil ASTM 396 No.1
for 24 hrs.
Petroleum Jelly 168 hrs. 70
+ 2oC
b) Bursting
Strength after ISO 3303 Min. 1200 N.
the chemical Method A
resistance test
2.1.5 Environmenta Stress Crack initiator 10% ASTM – No cracking
l Stress Igepal CO 630 solution. D 1693
Cracking Immersion time : 48 hrs.
Test Temp : 50 + 2oC
2.1.6 Corrosion Copper mirror test ASTM – No corrosion
effect Test Temp : 120 + 2oC D 2671
Test time : 16 hours. Clause 97.
2.1.7 Colour Suitable length of sleeve
change of containing the paint. Total colour
temperature a) Condition at 260o + 2oC change
indicating for 5 minutes. No colour
paint. b) Condition at 150o+ 2oC change.
for 30 minutes.
Page 32 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Section Properties Test methods & Reference Requirements

conditions
2.1.8 Carbon Heating rate : 20oC per ISO : 11358 Min. 2.5%
content min.
Inert Gas : Nitrogen
Oxidation Gas : Oxygen
2.1.9 Fungus Inoculation : 30oC 85% ASTM – Rating of 1 or
Resistance RH for 28 days G 21 better.
2.1.10 Water 48 hours Immersion Section 2.2.3 0.1% Max.
absorption & ASTM –
D 570
2.1.11 Resistance 15 min. at 200 + 2oC Sec. 2.2.1 No split
to split propagation.
propagation
2.1.12 Longitudina Installed on substrate of Sec. 2.2.2 < 5% shrinkage
l shrinkage min. dia
2.1.13 Test for Recover the sleeve on a Two white
longitudinal mandrel with OD equal lines. Should
sealing to max. dia appear below
the SS channel.
2.1.14 Defects Visual Shall be free
from defects.
2.1.15 Dimensions Measurement As per Ann.-I Shall conform.
& Sl. No. 1 of
Cl. 3.1
2.1.16 Marking Visual - Manufacturer’s
name and
identification
mark, Batch
No., Year of
manufacture,
Dimensions ( as
per SN .1 of
Cl.No. 3.1),
Spec. No. , “For
4/6 quad cable
of 0.9/1.4 mm
dia. conductor”

2.2 TEST PROCEDURE :-

2.2.1 RESISTANCE TO SPLIT PROPAGATION TEST PROCEDURE

The test shall be performed only on fibre glass reinforced sleeve

Page 33 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

A rectangular specimen 50 mm long (in the shrink direction) shall be cut from
material in the unrecovered condition as delivered (preferably uncoated). An
indelible line (unaffected by the recovery process) shall be drawn parallel to and 5
mm from the long edge. A perpendicular cut shall be made approximately half
way along the same edge to just touch the line. The sample shall be clamped at
both ends and held rigidly so that no shrinking may occur during testing. The test
assembly shall be placed in an air-circulation oven at 200 + 2oC for 15 minutes.
After removal from the oven and cooling to room temperature, the sample shall be
examined for cut propagation.

2.2.2 LONGITUDINAL SHRINKAGE TEST PROCEDURE

The test shall be performed only on fibre glass reinforced sleeves.

The minimum length of the sleeve sample as delivered shall be determined to the
nearest millimeter. The sleeve shall then be shrunk onto an aluminium tube with
an outside dia. equivalent to the minimum applicable dia. of the sleeve. The wall
thickness of the aluminium tube shall not exceed 3 mm and its outside surface
shall be treated with a release agent. The minimum length of the sleeve shall be
determined after the sample has cooled to room temperature.

The percentage longitudinal shrinkage shall be calculated as follows –

Min. length as delivered – min. length after shrinking

----------------------------------------------------------------- x 100
Min. Length as delivered

2.2.3 WATER ABSORPTION

The test shall be done as per ASTM D.570. However, to prevent entry of water
into the sample, the edges of the sample shall be sealed with Microcrystalline
wax.

3.0 HOT MELT ADHESIVE

3.1 REQUIREMENT

Whenever test temperature is not indicated, the test shall be carried out at room
temperature.

Section Properties Test methods & Ref. Requirements

conditions
3.1.1 Peel Strength - Polyethylene Sec. 3.2 Min. 100N/25m
- Lead Min. 100N/25m
3.1.2 Environmental Stress crack initiator : ASTM D No cracking
Page 34 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

stress cracking 10% 1693

Igepal CO 630
solution
Immersion time : 48
hrs.
Test temp : 50 + 2oC
3.1.3 Corrosive effect Copper mirror test ASTM D No corrosion
Test temp. 120 + 2oC 2671
Test time : 16 hrs. Clause 97
3.1.4 (a)Chemical Immersion in the ISO 175
Resistance following liquids, one
liquid per sample
group
Na2 SO4 0. IN for
24 hrs.
NaC1 0. IN for 24
hrs.
H2 SO4 0. IN for 24
hrs.
NaOH 0. IN for 24
hrs.
Fuel oil ASTM D 396
No.: 1 for 24 hrs.
Petroleum Jelly 168
hrs. 70 + 2oC

(b)Peel Strength - Polyethylene Sec. 3.2 Min. 80N/25m

after chemical - Lead Min. 80N/25m
resistance test.
3.1.5 Shear strength Test Speed : Sec. 3.3 Min. 1300 N
50 mm / min.
3.1.6 Fungus Inoculation : 30oC ASTM Rating of 1 or
Resistance 85 RH% for 28 days G21 better
3.1.7 Softening point Ring & Ball method ASTM 100 +10oC
E-28
3.18 Water 48 hours immersion ASTM 0.5% max.
absorption at RT D570
3.1.9 Colour Visual Amber

3.2 TEST PROCEDURE FOR PEEL STRENGTH\

3.2.1 PROCEDURE

The adhesive peel strength shall be determined by the rolling drum peel test
method. The test samples shall consist of uncoated heat shrinkable tubing or
Page 35 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

equivalent sleeves of appropriate size and a sheet of adhesive under test, installed
on straight cylindrical substrates in the form of polyethylene cable jackets. The
sheet of adhesive shall be approximately 1 mm thick.

The specimen shall remain at room temperature for one day before cutting the
samples into 25 mm wide. Exposure to any specified medium shall be done at
this stage.

The specimen shall be placed in a tensile testing machine, with the specimen
around the positioning mandrel and the free end of the specimen inserted into the
tensile testing machine jaw. The holding fixture shall be constructed so that the
yoke is free to rotate during testing. Testing shall be with a jaw separation speed
of 50 mm per minute. Readings of peel strength shall be taken at every 12.5 mm
of jaw separation after an initial separation of 25 mm. The average of five
readings shall define peel strength.

3.2.2 SAMPLE PREPARATION

The mandrel specimen shall be 450 mm (approximate) length of lead or

polyethylene sheath telephone cable. The diameter of the cable shall be
approximately twice that of the free recovered equivalent diameter of the heat
shrinkable product and shall be at least 30 mm.

Polyethylene
Clean cable mandrel with cleaning tissue.
Lightly abrade the cable mandrel with 60 mesh emery strip.
Wipe particles from abrasion off the cable mandrel with a clean, dry cloth.

Flame brush the cable mandrel for 15 seconds by passing a yellow flame lightly
over the entire specimen (not to a glossy finish)

Assemble the adhesive and then tube or sleeve over the cable mandrel.
Completely recover the tube or sleeve over the cable mandrel.
Post-heat the specimen assembly for 30 seconds after complete recovery.

Metal
The sample preparation shall be as described for polyethylene, except for the
flame brushing which shall be replaced by a preheating of the mandrel to
approximately 60oC and the abrasion which must remove all oxide from the metal
surface. It is preferable to use a flat file to remove the oxide coating.

3.3 TEST PROCEDURE FOR SHEAR STRENGTH

3.3.1 TEST METHOD

The method shall be in accordance with ISO 4587.

Page 36 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

The adhesive bonds shall be pulled in a suitable tensile testing machine at a jaw
separation rate of 50 mm per minute. The initial jaw separation shall be between
100 mm and 150 mm. The mean of five breaking loads shall be recorded as the
shear strength, which shall be reported in Newton.

3.3.2 SAMPLE PREPARATION

Adhesive bonds shall be prepared using test pieces of 25 + 1 mm wide and 1.0 +
0.1 mm thick aluminium alloy sheeth approximately 100 mm long. They shall be
free of burrs and the surfaces shall not be scratched or roughened.

To prepare the etching solution, dissolve 25 gms. of sodium metasilicate (Na2 Sio3
9H20) in 1000 ml of distilled water. Add 2.5 gms. of non ionic detergent (e.g.
10% IGEPAL C0 630 solution). Heat the solution to 70oC.

At least a 25 mm length of each test piece shall be etched in the metasillicate

solution for 5 minutes. The aluminium shall then be washed well with distilled
water and air-dried. Test joints shall be formed not more than three hours after
the etching process.

The adhesive under test shall be applied to one treated surface of each test piece
so that an even, continuous film is formed. Test surfaces assembled to form joints
shall overlap by 12.5 + 0.5 mm. The joints shall be placed under a pressure of 1
Kg. in an oven at 180oC for 10 minutes; subsequently they shall be held at room
temperature for one day before testing.
Page 37 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

THERMOSHRINK SLEEVE ( REINFORCE) CLOSURE CHANNEL AND

UNDER CLIP

1.0 GENERAL

1.1 The thermoshrink sleeve closure channel and under clip are required in close the
thermoshrink sleeve before shrinking.

1.2 The closure channel and clip are same for RTSF sleeves.

1.3 The dimensions of closure channel and under clip shall be as per drawings as per
clauses 3.1 Serial No. 2 of this specification.

1.4 The under clip is positioned under the closure channels for reinforced sleeve.

2.0 REQUIREMENT

Sr. No. Property Requirement Test Method

2.1 Material Stainless steel Chemical analysis
conforming to IS –
6911 04 Cr 18 Ni 10
or
AISI-304 or equivalent
2.2 Dimensions: Measurement

Closure Channel As per SN 2 of Cl. 3.1

Under clip

2.3 Visual Absence of burrs and Visual

sharp edges and any
other defect.
2.4 Fittings Correct fitting over the Installation.
rail portion should
neither be too tight not
too loose. Should not
cause scratches over
the thermoshrink
sleeve. Sleeve should
not pull out while
shrinking.
2.5 Marking Manufacturer’s identity Visual
Page 38 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

BRANCH OFF CLIP

1 GENERAL

The branch –off clip shall provide high performance cable branching technique,
easy to install.

2. MATERIAL

The branch off clips shall be manufactured from corrosion resistant aluminium
alloy conforming to IS 617 grade 4600 and coated with epoxy.

3. DESIGN

The design of the branch off clip shall conform to the details given in Annexure –
III and also have dimensions mentioned therein. The branch off clip shall have
three fingers, the middle one coated with hot melt adhesive identical to that on the
thermoshrink sleeve. The adhesive on the branch off clip shall, however, have a
different colour to that of the thermo shrink sleeve adhesive and thus give a visual
indication to the jointer of correct adhesive flow and sealing of the branch.

There shall be two types of Branch off clips, small, medium. Each type of Branch
of clip shall be used for particular size of Thermo shrink sleeves as specified
Annexure – III as per clauses no. 3.1 serial no. 23 of this specification.

4. COMPATIBILITY

The branch -off clip shall be compatible with the jointing system and should show
no failure at the branch when tested for tightness on a complete joint.

5. CORROSION RESISTANCE

The clip shall show no traces of corrosion when subjected to salt spray test as per
ASTM D 117 for 72 hours.

6. MARKING

The branch off clip shall contain the identification of the manufacturer / supplier
on the metal part in order to identify the source of supply of the item when
required.
Page 39 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

7. REQUIREMENT

Sr. No. Property Test Method Requirement

7.1 Appearance Visual Shall be free from burrs, sharp
edges, holes, cracks, and shall
be finished smooth shall be
given black epoxy coating.
7.2 Dimensions Measurement As per Annexure – III
7.3 Material conformity Chemical analysis Aluminium alloy conforming
to IS:617 Grade - 4600
7.4 Corrosion resistance Salt spray as per No corrosion
ASTM D117 for
72 hrs.
7.5 Thickness of corrosion As per IS : 101 80 microns, min.
resistance epoxy
coating
7.6 Marking Visual Manufacturer’s identity on
metal part
7.7 Compatibility with Visual Sample joints made using the
sleeve BOC’s shall meet the installed
product requirements.
7.8 Softening point of Ring & ball 100 +10oC
adhesive method
(ASTM E 28)
Page 40 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

ALUMINIUM CANNISTER

1.0 GENERAL

The aluminium Canister shall comprise of two performed half shells that can be
hinged and fitted around a cable splice. Finger –like formation shall be provided
at the ends of the Canister such that, when bent, it will give a smooth transition
over the cable. The Aluminium canister shall provide adequate structural strength
to avoid collapse during installation. The aluminium cannister shall conform to
the dimensions given as per Annexure – II of Clauses 3.1 serial no. 3 of this
specification and satisfy the requirements given in Section 2. The fingers of
Cannisters supplied in kits containing reinforced sleeves shall contain a protective
coating of not less than 1.0 mm thickness for length of 30 to 40 mm at the finger
end.

2.0 REQUIREMENT

Sr. No. Property Requirement Test Method

2.1 Material As per IS – 737 of I.S. 504
grade 40800 or its I.S. 1816
equivalent I.S. 737
2.2 Dimensions As per Annexure – II Measurement

2.3 Visual Absence of burrs and Visual

sharp edges and any
other defect.
2.4 Cleanliness Free from oil, dust dirt, Visual
(Degreasing by
chemical treatment
desirable)
2.5 Marking Manufacturer’s identity Visual
2.6 Packing Shall be enclosed in a Visual
poly bag of correct
size. The fingers shall
be protected from
damage during transit.
2.7 Tensile Strength 8 Kgf / Sq. mm Measurement
minimum
2.8 Bend Test No cracks IS : 737 & IS : 1599
Page 41 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

SHEATH CONNECTOR ASSEMBLY

1.0 GENERAL

The sheath connector assembly consists of three items, viz. an insulated stranded
copper wire with connecting elements on both sides, a small wire of the same
description with connecting element on one side only and a bridge connector for
jointing the two wires. The connecting element is made of phosphor bronze,
hacked by a non-corrosive metal back-plate strongly pressed to it and also
crimped to the connecting wire. The element has an opening provided with
toothed jaws into which the cable sheath can be inserted and crimped using
ordinary pliers. The toothed jaws when cripped, bite through the cable sheath to
make a good low-resistance metallic contact with the sheath of the cable. In order
to inter-connect the sheath connector wires in branch joints, the bridge wire
connector is used in conjunction with the single ended connector assembly. The
flexible wire shall be 14 SWG.

2.0 REQUIREMENTS

The sheath connector assembly shall conform to the following requirements when
tested as per details given in section-3 of this specification.

Sr. No. Property Requirements Test Method

2.1 Connection resistance Less than 3 milli ohms Sec. 3.1
2.2 Vibration at 100 vibrations/ Change in CR less than Sec. 3.2
min. for 2 hrs. at an 1 milli ohm
amplitude of + 10 mm
2.3 Wire pull out of connecting More than 150 N Sec. 3.3
element (sheath wire
connector)
2.4 Wire pull out of Bridge More than 75 N Sec. 3.4
wire connector
2.5 Salt fog Exposure No corrosion. Sec. 3.5
Change in CR not more
than 1 milli ohm
2.6 Marking Manufacturer’s Identity Visual
2.7 Material conformity Copper wire (Grade Chemical analysis
Cu-FRHC) as per IS-
191 & clip elements
(Grade 1 ) as per IS-
7814.
Page 42 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

3 TESTING PROCEDURE FOR SHEATH CONNECTORS

3.1 MEASUREMENT OF CONNECTION RESISTANCE

Cut a length of 300 mm of any size of cable with aluminium moisture barrier.
Mark at 75 mm from the ends and remove the sheath at both ends up to mark.
Clean the polyethylene coating over the aluminium moisture barrier using a knife.
Measure the D.C. resistance of this piece (R.1) making connections at the flaps
using a sensitive measuring instrument.

Similarly, measure the resistance of the sheath connector assembly (R.2) using the
same instrument.

Cut the sheath connector wire approximately in the middle and expose the wire
for about 20 mm for making connection. Install the sheath connector halves on
the already prepared flaps of the samples. Measure the resistance of the sample at
the connector ends (R.3)

The contact resistance is calculated by using the formula:

R3 - ( R1 + R2 )
2
This value should not be more than 3 milliohms.

3.2 VIBRATION TEST

The test sample is prepared as described in Sec. 3.1 and is rigidly mounted on a
vibration table. The sample is vibrated at 100 vibrations per minute with an
amplitude of + 10 mm for 2 hrs. During this process the sheath connector wires
are connected in series to an electrical circuit and continuity is monitored. There
should be no discontinuity during the vibration test. On completion of the test the
contact resistance variation is measured which should not be more than 1 milli
ohm.

3.3 WIRE PULL OUT TEST ON SHEATH WIRE CONNECTOR

Cut the sheath connector wire in the middle. From the cut end remove insulation
for about 100 mm. Hold the connector element on the jig and place the assembly
in a tensile machine. Measure the pull out strength at a speed of 50 mm jaw
separation per minute. The pull out strength should not be less than 150 N.
Page 43 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

3.4 WIRE PULL OUT TEST ON BRIDGE WIRE CONNECTOR

Join two connector wires together using a bridge wire connector. Connect wires
to the upper and lower jaws of the tensile testing machine and measure the pull
out strength at a speed of 50 mm per minute. The value obtained should not be
less than 75 N.

3.5 SALT FOG EXPOSURE TEST (ASTM D 117-73/79)

Prepare the test sample as described in Section 3.1. Expose the sample to salt fog
as per ASTM D 117-73/79 for 72 hours. The sheath connectors are checked for
corrosion after the test. There shall be no corrosion. Measure the variation in
connector resistance. The variation shall not be more than 1 milli ohm.
Page 44 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

SPLICE FILLING COMPOUND

1.0 GENERAL

1.1 The splice filling compound shall be used for RTSF joints.

1.2 The splice bundle is filled with splice filling compound in order to prevent
insulation break down in the event of water entry into the joint.

2.0 REQUIREMENT

The splice filling compound shall conform to the following requirements when
tested as detailed in Section 3 of this specification.

Sr. No. Parameter Requirement Test Method

2.1 Water Penetration No dripping of water or Section 3.1
oil
2.2 Homogeneity No un dissolved Section 3.2
particles
2.3 Air Entrapment No bubble formation Section 3.3
2.4 Dry heat aging No crack of drying Section 3.4
after over ageing at
70+2oC for 7 days
2.5 Stability No separation of the Section 3.5
constituents of filling
compound after 120
hrs. at 65+2oC
2.6 Cone Penetration 200 to 300 Section 3.6
2.7 Volume resistivity Not less than 1010 ohm Section 3.7
cm.
2.8 Water absorption The volume resistivity Section 3.8
shall not be less than
1010 ohm cm.
2.9 PE Stress cracking No cracks after ageing Section 3.9
for 7 days at 70+2oC
2.10 Connector stress cracking No cracking after Section 3.10
ageing in filling
compound at 70+2oC
for 7 days
2.11 Copper corrosion No pitting or Section 3.11
blackening of bare
copper conductors after
7 days ageing at
70+2oC in filling
compound.
Page 45 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

2.12 Colour The compound shall Section 3.9

not obscure the
identification of
colours of the
insulation after ageing
in filling compound for
7 days at 70+2oC
2.13 Handling The splice filling The supplier shall
compound shall be free produce a certificate
from unpleasant odor from a recognized
and shall have no toxic Laboratory to this
or dermatitis hazard. effect.
2.14 Packing 300 gm. in sealed PE Measurement
pouches (transparent)
2.15 Marking Identity of the Visual
manufacturer, Batch
No., Month and Year
of manufacture.

3.0 TEST PROCEDURE FOR SPLICE FILLING COMPOUND

3.1 WATER PENETRATION

A joint is made using cleaned jelly filled cable and filled with adequate quantity
of filling compound and wrapped tightly with 2 layers of PVC tape. One end of
the cable is connected to a water column of one meter for 14 days. The cable on
either side of the joint should be restricted to 150 to 200 mm. Dripping of oil or
water shall be construed as a failure.

3.2 HOMOGENEITY

Place a small sample of splice filling compound between two glass slides and
squeeze together to form a thin film. There shall be no un dissolved particles /
lumps, when observed visually.

3.3 AIR ENTRAPMENT

Fill a glass beaker evenly with filling compound. Place the beaker in an oven at
65+2oC for two hours. Remove the beaker from the oven and observe. There
shall be no bubble formation on the surface of the filling compound.
Page 46 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

3.4 DRY HEAT AGEING

Fill three plastic cups 37.5 mm. In dia, and 25 mm deep with splice filling
compound such that no air pockets are formed. Scrape off the excess material
place the cups in an oven at 70+2oC for 7 days. The compound shall show no
signs of cracking or drying.

3.5 STABILITY

About 5 grams of splice filling compound is filled in a glass container with both
ends open and held with the axis of the container in a horizontal place. The outer
surface of the glass tube is covered with a copper wire mesh to ensure uniform
temperature and prevent local hot spots.

This container is suspended vertically in a test tube so that it hangs freely. The
temperature of the compound is measured by a thermometer. The test tube is now
placed in a constant temperature bath maintained at 65+2oC for 5 days. There
shall be no dripping of the filling compound and consequent disintegration of its
constituents.

3.6 CONE PENETRATION

Place an empty grease worker cup and an appropriate amount of the sample of
splice filling compound in a metal container in water or air bath maintained at
25oC for sufficient time to bring the temperature of the sample and the worker cup
to 25+2oC. Transfer the sample, preferably in one lump, to overfill the cup of the
grease worker. Shake the cup to drive out trapped air and pack the grease with a
stapula with as little manipulation as possible to obtain a cupful without air
pockets. Scrape off the excess compound extending above the using a stapula.
Place the cup on the penetrometer table and set the mechanism to hold the cone in
zero position, adjusting the apparatus so that the tip of the cone just touches the
surface of the sample. Release the cone shaft rapidly and allow it to drop for 5
seconds. Gently depress the indicator shaft until stopped by the cone shaft and
read the penetration from the indicator. The reading obtained shall not be less
than 200 and not more than 300.

3.7 VOLUME RESISTIVITY

Prepare electrode assembly using two plates of 1 cm2 cross section. Place the
assembly into the filling compound. The other ends of the wires shall be
connected to a mega ohm meter set to 500 volts. Measure the insulation
resistance. The value obtained should not be less than 1010 ohms cm.
Page 47 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

3.8 WATER ABSORPTION

A container is formed by solvent welding a polycarbonate pipe of I.D. 25 mm into

a polycarbonate plate of 6 mm thick. Two copper electrodes O.D. 2 mm
approximately are installed through the bottom plate spaced 12.5 mm apart to a
height of 1 cm. The compound to be tested encapsulate the two electrodes upto a
height of approximately 2.5 mm above the top of electrodes. Measure the volume
resistivity. A 25 mm water is then applied over the compound surface. After 48
hours, the insulation resistance is measured again using a mega ohm meter. The
reading obtained shall not be less than 1010 ohm cm. and there shall be no change
between the initial and final readings.

3.9 POLYETHYLENE STRESS CRACKING

Prepare 150 mm long PE insulated conductors of all colours at the rte of 5

samples for each colour and immerse them in the splice filling compound.
Condition it in an oven for 24 hours at 70oC. Remove the conductors and wipe
them clean. Wrap the conductors around its own diameter for a minimum of ten
continuous turns over a length of 2 cms. of insulated conductor. Then suspend
them in an air circulating over maintained at 70+2oC for 7 days. At the ends of
the period, remove the samples from the oven and observe for cracks. There shall
be no cracks. Also there shall be no change of colours.

3.10 CONNECTOR STRESS CRACKING

Fill a 250 ml beaker with the splice filling compound immerse approved wire
connectors completely in the compound and place in an air circulating oven at
70+2oC for 7 days. Wipe off the connectors with a tissue, and inspect for sign of
cracking. There shall be no cracking.

3.11 COPPER CORROSION

Remove bare copper conductors from cables, wipe them clean using a solvent and
cotton wool and immerse them in a beaker containing the splice filling compound.
Place the container in an oven maintained at 70+2oC for 7 days. The condition
the sample for 4 hours at R.T. Remove the conductors from the filling compound
and thoroughly clean them using a solvent and wipe them clean using cotton
wool, examine the copper conductors carefully. The samples should show no
pitting or blackening.
Page 48 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

CABLE CLEANING LIQUID

1.0 GENERAL

1.1 The cleaning liquid shall effectively dissolve and remove the different cable
filling compounds used in the manufacture of Quad cable.

1.2 The cleaning liquid shall be non-flammable at room temperature.

1.3 The cleaning liquid shall be safe to handle and shall not cause any dermatic
hazard or toxic effect or respiratory problems. (The manufacturer / supplier shall
produce a test certificate to this effect from a recognized laboratory).

1.4 The cleaning liquid shall be compatible with the insulation of cable conductors
and shall not cause corrosion to the metal parts of the conductors and sheath of
the cable with which it is likely to come into contact.

1.5 The cleaning liquid shall have a shelf life of not less than two years and during
this period the properties of cleaning liquid shall not change under normal storage
conditions.

1.6 The cleaning liquid shall be packed in water-tight containers so that the loss of the
liquid shall be negligible.

2.0 REQUIREMENT

The cleaning liquid shall comply with the following requirements when tested in
accordance with the test method shown against each.

Sr. Property Requirement Test Method

No.
2.1 Cleaning of cable Good cleaning to be As per Section 4
jelly from conductors ensured. There shall be no
discoloring of conductor
insulation.
2.2 Flash Point > 50oC ASTM D 92
2.3 Boiling Point Not less than 100oC Measurement
2.4 Corrosion No Corrosion Immerse copper
conductors & an
Al. strip into the
cleaning liquid
for 24 hrs. wipe
& age at 65+2oC
for 7 days.
Page 49 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Sr. Property Requirement Test Method

No.
2.5 Connector stress No crack should be Immerse
crack observed when viewed connectors of
through an optical device. various makes
into the cleaning
liquid for 24
hours & age in an
oven at 65+2oC
for 7 days.
2.6 Compatibility with No crack or colour fading. Section 3
PE Insulation The retention of average
tensile strength shall not be
less than 85% elongation
shall not be less than 70%
of the reference sample.
2.7 Storage Stability Weight less shall not Sealed container
exceed 2% with cleaning
liquid shall be
aged at 65+2oC
for 7 days.
2.8 ESCR test No failure when tested on As per ASTM D
cable sheath grade P.E. 1693 @ 50o+2o C
in 10% Igepal
Co-630 after
conditioning in
the cleaning
liquid for one
hour. Test
duration 48 hours.
2.9 Marking Manufacturer’s Identity, Visual
Batch No., Month & Year
of manufacture, caution
level.

3.0 TEST METHOD FOR DETERMINING COMPATIBILITY OF THE

CLEANING LIQUID WITH PE INSULATION

3.1 Immerse 100 to 250 mm length of insulated conductors, 5 samples per color, into
the cable cleaning liquid for 24 hours. Then remove them and wipe them clean
and allow them to dry. Twist the wires over their own diameters 10 close turns
continuously. Suspend the samples in an air circulating oven at 70+2oC for 14
days. After this period remove them and condition at RT for 6 hours. Visually
Page 50 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

examine the samples for cracks or colour fading. There shall be no cracks or
fading of the colours.

3.2 Elongation and Tensile Strength:-

10 long lengths of insulation shall be carefully removed from the conductors and
made into 2 sets of 10 half lengths. The tensile strength and elongation of the 1st
set (reference samples) shall be measured and their average value shall be noted.
The 2nd set shall be immersed into the cleaning liquid for 24 hours and then wiped
clean and dry. Then they will be aged at 70+2oC for 14 days and conditioned at
RT for 6 hours. The tensile and elongation of the aged samples shall be measured
and their average value shall be calculated. The tensile strength of the aged
samples should not be less than 85% of the reference samples and the elongation
shall not be less than 70% of the reference samples.

4.0 CLEANING PROCEDURE

This procedure is applicable only in locations, where the free ends of the cables
are available. (Wherever cleaning is required on a through cable joint, soak
cotton waste in the cleaning liquid and then clean the conductors of the through
cable with the cotton waste.

4.1 Open the sheath of the cable up to one and half times the recommended splice
opening.

4.2 Separate the units and complete the unit binder ties.

4.3 Tie the free end of the cable core with a wire.

4.4 Pour the entire quantity of cleaning liquid into the pouch supplied in the Kit.

4.5 Insert the cable core into the pouch such that the end is about 50 mm above the
liquid level.

4.6 Starting from the free end squeeze the pouch and remove the entrapped air inside
the pouch. Tie the pouch over the sheath tightly close to the sheath opening.

4.7 Work the pouch by hand for 15 minutes for cables up to 200 pairs and 10 mts.
For cables of larger sizes so that the cleaning liquid comes into contact with all
conductors.

4.8 Leave the end free for about 5 minutes so that the cleaning liquid drains to the
bottom at the pouch.
Page 51 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

4.9 Release the pouch with the liquid carefully by untying the PVC tape over the
sheath.

4.10 Repeat the procedure for Quad cable in the joint.

4.11 Now the cable is cleaned and ready for commencing the jointing work.

4.12 Bury the used up material and containers at site and do not reuse them for any
other purpose.
Page 52 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

ADHESIVE PVC TAPE

1.0 GENERAL

1.1 PVC Tapes are required for taping the splice bundle and the fingers of the
aluminium Cannister in case of RTSF joints.

2.0 REQUIREMENT

The PVC adhesive tape shall bear the ISI mark or shall be from TEC approved
source and meet the following requirements when tested in accordance with the
test methods shown against each.

Sr. Property Requirement Test Method

No.
2.1 Length / Roll 10meter/roll ± 0.1meter. Measurement

2.2 Width 25 mm + 1mm Measurement

2.3 Thickness 0.1 mm to 0.13 mm Measurement
2.4 Breaking > 5 Kgf / 25 mm width IS - 3676
Strength
2.5 Elongation > 100% IS - 3676
2.6 Adhesion to > 400 gm. / 25 mm width IS - 3676
Steel
2.7 Durability test > 350 gm. / 25 mm width IS - 3676
at 65+2oC for 7
days, 80% RH
followed by
adhesion
2.8 Anchorage No transfer of adhesive IS - 8402
2.9 Water No decrease in adhesion IS – 3676
immersion
followed by
adhesion
2.10 Marking Manufacturer’s identity. Visual
Batch No., Mfg. date.
Page 53 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

SEALANT TAPE

1.0 GENERAL

1.1 The sealed tape shall be butyl rubber based elastic-plastic sealing compound,
black in colour which is used for different applications in cable jointing.

1.2 The sealant shall be supplied in strip form of uniform dimensions as indicated in
the specifications of respective jointing kits protected on both sides by release
papers to prevent sticking. It will not cause swelling of the release paper.

1.3 The sealant tape shall be capable of releasing easily from the release paper and
also shall not flow during storage.

1.4 The sealant shall not phase separate during storage or drastically change its
properties.

1.5 The sealant shall have a shelf life of not less than two years when stored at room
temperature.

1.6 The sealant shall have good adhesion to metals and PE without preheat, medium
strength and very good chemical and thermal stability and shall not puddle on
bottom of the sleeve. It shall not also cause corrosion to the metals which come
into contact with it.

1.7 The sealant shall be compatible with the cable and other jointing materials and
shall not cause deterioration to the electrical properties of the cable.

1.8 The sealant shall be safe to handle and shall be free from biological attack.

2.0 REQUIREMENT

The sealant tape shall conform to the following requirements, when tested in
accordance with the methods, shown against each.

Sr. No. Property Requirement Test Method

2.1 Water absorption Less than 0.5% Immersion at RT for
24 hours.
2.2 Corrosion No corrosion ASTM D 2671
24 hours at 120oC
method B
2.3 Fungus & Bacteria Rating of 1 or better ASTM G 21
resistance
2.4 Solvent resistance Weight change not ASTM D 543
more than 1%
Page 54 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

2.5 Volume resistivity More than 1010 ohms Section 3.1

cm.
2.6 Shear Strength 2 N / cm2 (min.) Section 3.2
2.7 Softening Point Not less than 100oC ASTM E 28 Ring &
Ball method
2.8 Brittleness Temp. Less than (-) 30oC ASTM 2137
2.9 Heat Ageing No flow, stratification ISO 188
or cracks after 120+2oC
for 7 days
2.10 Needle Penetration 70 to 130 units per 10 ASTM D 5
seconds
2.11 Colour Black Visual
2.12 Marking Manufacturer’s Visual
identity, Batch No.
Mfg. date.
2.13 Dimensions Length : 400 + 10 mm Measurement
Width : 35 + 3 mm
Thickness : 3 + 0.5 mm

3.0 TEST METHOD

3.1 PROCEDURE FOR TESTING VOLUME RESISTIVITY

The test sample is sandwiched between two copper (disc) electrodes and placed
centrally inside a guard ring (1) of copper. The outer electrode (2) is connected to
one terminal of the million ohm meter. The guard ring and the outer electrode (2)
are strapped together and the inner electrode connected to the other terminal of
the meter. The resistance is recorded and the volume resistivity arrived as follows

Volume Resistivity in ohms cm = Rx x A/H

Rx = Volume Resistance in ohms.

A = Effective area of inner electrode in cm2

H = Average thickness of the test specimen in cm.

3.2 PROCEDURE FOR TESTING SHEAR STRENGTH

Take two metal strips 100 mm x 50 mm x 2 mm. Clean the surface for 50 mm x
50 mm at one end of both the plates. Cut a piece of 25 mm length of sealant tape
and sandwich the same between the cleaned surfaces of the metal plates. Keep a
weight of 1 Kg. for about one minute over the plates to press the sealant between
them. Release the weight and carefully fix the plates in a tensile machine such
that the plates are lulled in opposite direction at a speed of 50 mm / min.
Calculate the shear strength per square cm. of area.
Page 55 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

EMERY STRIP FOR CABLE JOINTS

1.0 GENERAL

The Emery strip covered under this specification shall be used for surface
preparation of cables with lead or polyethylene sheath.

2.0 MATERIAL REQUIREMENTS

2.1 EMERY

The emery used shall be synthetic or natural emery and shall not have less than
55% aluminium oxide and also shall not have less than 15% or more than 35%
combined oxide by mass. Other properties shall be as follows:

Specific gravity 3.6 minimum

Hardness 8.0 on mhos. Scale

2.2 ADHESIVE

Adhesive used shall be of good quality glue or any other adhesive suitable for the
purpose and shall satisfy the requirements given in Sec. 6.0. The adhesive shall
be properly treated to resist attack by fungi or micro organism.

2.3 BACKING

Cloth shall be used as backing material. The cloth shall be of drill weave and
shall have a breaking load of not less than 400 N / 25 mm width when tested with
a speed of 50 mm / minute.

3.0 WORKMANSHIP

Finished product shall be free from any imperfection that may affect the
serviceability.

4.0 FORM AND DIMENSIONS

The emery cloth shall be supplied in the form of strips conforming to dimensions
given in the respective Kit content chart.

5.0 COATING

The material shall be supplied in CLOSED COAT, in which the abrasive grains
completely cover the surface of backing.
Page 56 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

6.0 ADHESIVE STRENGTH OF ABRASIVE

The strip shall be tested by rubbing abrasive side against the abrasive side of the
sheet with the same grit in a to and fro motion. The criterion of acceptability shall
be that the grains shall not disintegrate from the base in 20 strokes when tested in
accordance with IS 715 Part – I.

7.0 MARKING

Each strip shall be marked with the following:

A) Grill number
B) Manufacturer’s name and trade mark
C) Batch number or manufacturing code

8.0 PACKING

The emery strips shall be packed in PE pouches.

9.0 REQUIREMENT

The emery strip shall conform to the following requirements when tested in
accordance with the methods.

Sr. No. Property Requirement Test Method

9.1 Defects No burrs / sharp edges free from Visual
defects, moisture and fungus,
abrasive intact.
9.2 Marking Manufacturer’s identity, Batch No., Visual
Grit size (60 mesh)
9.3 Packing Should be enclosed in a PE pouch / Visual
sheet.
9.4 Integrity of abrasive No disintegration of abrasive Rub test, IS - 715
bond material

9.5 Breaking Load Not less than 400 N / 25 mm width Tensile test
9.6 Dimension Length (600mm ± 5mm) x Measurement
Width (25mm ±1mm) x 60 mesh.
Page 57 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

CLEANING TISSUE

1.0 GENERAL

The cleaning tissue shall be supplied in sealed pouches containing IPA

conforming to IS 2631. The supplier shall produce a certificate to this effect from
a recognized laboratory. The size of the tissue paper shall be Length (190 mm
min.) x Width (140mm min.).

2.0 PACKING

The quantity of IPA contained in the pouch shall be 5 ml (min.). and the material
of the pouch shall be laminated aluminium.

3.0 INTEGRITY OF SEALING

The sealed pouches shall be kept in an air-circulating oven at 50 ± 2oC for seven
days and the weight loss is calculated. The weight loss shall not exceed 2%.

4.0 MARKING
Name of material
Manufacturers identify
Batch No.
Precautions regarding handling

5.0 REQUIREMENT

The cleaning tissue shall conform the following requirements:

Sr. No. Property Requirement Test Method

5.1 Packing No breakage, leakage or spilling Visual
5.2 Marking Manufacturer’s identity, Caution Visual
level, Batch No.
5.3 Tissue / cloth The tissue / non-woven cloth should Visual
not get softened or dissolved in the
solvent due to reaction with the
solvent. It shall be intact and
useable.
5.4 Quantity of IPA 5 ml (min.) conforming to IS-2631. Measurement

5.5 Colour Clear or colourless Visual

5.6 Integrity of sealingThe weight loss shall not exceed Air-circulating oven
2%. at 50o±2oC for 7 days.
5.7 Dimension of Tissue Length: 190 mm (min.)Width: Visual
paper 140mm (min.)
Page 58 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

ADHESIVE ALUMINIUM FOIL

1.0 GENERAL

The adhesive aluminium is used to protect the cable jacket from damage during
shrinkage of thermo-shrink sleeve.

2.0 REQUIREMENT

The adhesive aluminium foil shall be in a strip form with adhesive coating on one
side and protected by a release film.

Sr. No. Property Requirement Test Method

2.1 Dimension (400mm ± 4mm) x (100mm Measurement

± 2mm) x (0.06mm ±
0.01mm)

2.2 Tensile Strength > 7.5 Kgf / 25 mm (width) IS – 7809 Part - II

2.3 Elongation > 4% IS – 7809 Part - II

2.4 Peel Strength > 400 gms. / 25 mm (width) IS – 7809 Part - II

2.5 Marking Manufacturer’s identity, Visual

Batch No.
Page 59 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

CABLE TIE

1.0 GENERAL

The Cable Tie is used to bunch cable / wires.

2.0 REQUIREMENTS

The Cable Tie shall conform to the following requirements.

Sr. No. Property Requirement Test Method

1 Colour Natural or Black Visual

2 Dimensions For 0.9mm dia.4/6 quad cable:- Measurement

Length: 254mm ± 3mm
Width: 4.75mm ± 0.5mm,
Thickness: 1.43mm ± 0.1mm.

For 1.4mm dia.4/6 quad cable:

Length: 315mm ± 3mm
Width: 4.75mm ± 0.5mm
Thickness: 1.56mm ± 0.1mm.

3 Tensile Strength 22Kgs (50lbs) min. Tensile Machine

4 Marking Manufacturer’s identity. Visual

Page 60 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Discrete Wire Connectors

1.0 GENERAL

Discrete wire connectors shall be used to join individual conductors while making
straight joint or derivation joints of 0.9 mm dia. conductor quad cable.

2.0 REQUIREMENTS

The discrete wire connector shall be made of Polypropylene plastic material and
shall be filled with Moisture resistant compound. The Discrete wire connectors shall
conform to the TEC GR No. G/CJM-15/02. Nov 97.

2.1 The following two types of Discrete wire joint shall be part of the jointing
kit content for 0.9 mm dia. conductor quad cable.
2.1.1 IDC type jelly filled butt connector modules made of polypropylene for 3
wires (0.4mm to 0.9mm dia. conductors) 30 Numbers
2.1.2 IDC type jelly filled connector modules made of polypropylene for 2
wires bridging type (0.4mm to 0.9mm dia. conductors) 6 Numbers
2.2 All the tests as required under clause 6.1 of the TEC GR shall be carried
out for type approval.
Page 61 of 61 Effective from : 01.11.2012 IRS: TC 77-2012 Rev. 3

Multi strand tinned copper conductor flexible insulated cable (single core)

1.0 General: The single core insulated cable conforming to IS: 694:1990 shall
consist of multi strands of flexible tinned annealed copper conductors
2.0 Requirements:
2.1 The nominal Cross sectional area of the single core shall be 4 mm2
2.2 The nominal thickness of the insulation shall be 0.8 mm
2.3 The minimum number of strands shall be 53.
2.3 It shall be supplied in nominal length of 2000 mm
2.4 The resistance of 2000 mm long wire shall be 9.9 milliohms (maximum) at 20°C.
 'I1ffil ~ - ~ ~

~lTele : 2492 XXX ~~ 3if~ 3ffi ~ Wra1 AN ISO 9001

2493 XXX ~ - 226 011 CERTIFIED
Government of India-Ministry of Railways
~/Fax: 91-0522-2458500
Research Designs & Standards Organisation
ORGANISATION
Lucknow - 226 011

~; STT/RE/CJ/368 Rci1icp: 08/11/2013

~~l!Ci~3~, 1 Chief Signal & Telecom Engineer

-;m.~ Tcvm, ~ ~.m.:r.ir.I i Central Rly, Mumbai CST-400 001
~'i:Id1 Tcvm, ~ cJ'rc, ~ I ii western Rly, Churchgate,Mumbai-400020
~~, q,<!l "2<:41 -c#R:r, c5J C1cpl('!l I iii Eastern Rly, Fairlie Place, Kolkata
700 001
~ ~ Tcvm, ~ -fur, qj) C1CPl('lI I iv South Eastern Rly. , Garden Reach,
Kolkata - 700 043
3""ITR:" Tcvm, ~ 6[:Rl, ~~ I v Northern Rly. , Baroda House, New Delhi-
110 001
l!. cifm "l Tcvm, Jil"2~~F I vi Northeastern Rly. , Gorakhpur 273 012
l!.cifm"2 "2:fl CH1Cii.i ~, CHIC'11JIiCl, '?JCl161tl vii North Frontier Rly. , Maligaon, Guwahati
781 011
~~, ~ CJ",3Gf, ~ I viii Southern Rly. , Park Town, Chennai -600
003
<IT~ d'n'.~ ~, R:1CP~I<SlIG I ix South Central Rly, Rail Nilayam,
Secunderabad-500 371
~ <ff~~ ~, 616rl~"2 I x East Central Railway, Hazipur 844101
3""ITR:" ~'i:Id1 ~, ~ I xi North Western Railway, Jaipur-300206
wf ~ Tcvm, ~ fu&R Wt.-gr.U. ~ Xii East Coast Railway, Rail Vihar, BDA,
CPlc•.il<>fl, ~~~"2~"2, ~~CR:"I Rental Colony, Chandrashekherpur,
Bhubneshwar -751023
~ -;m.~~, ~ irs, $C1161<SlIG I xiii North Central Railway, HQ's office (S&T
Branch) , Ganga Parisar, Subedarganj,
Allahabad-211033.
<IT~ ~'i:Id1 ~, ~ CPI<!lfC1<!l, ~ xiv South Western Railway, Headquarter
Office, Hubli.
~'i:Id1 <ff~~ Tcvm, sIT OlRTo-gr 0 CPI<!lfC1<!l, xv West Central Railway, OSD Office,
61<SlC1~" Jabalpur.-482004
<IT~ ~~ Tcvm, 31RO~O ~ xvi South East Central Railway, R. E. Office
cpl d'Q di cr"i, fulC1Rl~"21 Complex, Bilaspur-495004
CH61!>l<SlticP/ ~ tiq ~"":t!:iql'<,~ , ~ 2 The General Manager (S&T) , CORE, Nawab
~ iT5 fufuc;r ~ $C1lgldlIG I Yusuf Road, civil Lines, Allahabad-
211001
CH61!>1
<Sll.'.fcp/ ~ tiq ~a:jql"2, cf'rir ~, 3 The General Manager (S&T) , Metro
33/1, ~ ;!m, cfil C1cp('ll I Railway, 33/1, Chowringhee Road,
Kolkata.
"Q"~T1"fucp .3ff'~, wfl L!CH"& The CAO, IRPMU, Shivaji Bridge, Behind
~ ~31 4
~~ lNur, ~~ ~ ~ 11m, Shanker Market, New Delhi -110 001. '
~~ I
~~TCP /~, R:ICb6t:I<SlIG I 5 Director/IRISET/Lalaguda/Secunderabad.
CH61!>1csia<P (~ ), ~,~ 3lTQ5 6 General Manager(Projects)/RAILTEL/Bank
~ fulfC;5JI, ~~ I of Baroda, Building, Parliament Street/
New Delhi.

2/-
 -2-

~: Amendment 1to the Specification No. IRS:TC-

77/2012, Rev.3 for Thermo Shrink Jointing Kit
for Jointing underground quad cable.
*****
The amendment 1 to the Specification for Thermo
Shrink Jointing Kit for Jointing underground quad cable has
been issued. The copy of the same is enclosed. The same
is also availabl~ on RDSO website.

In the Amendment certain parameters of IDe type

connectors are modified. The Amendment will be effective
from 01.04.201

""Copy to :-

1. Executive Director (Telecom) , Railway Board, Rail Bhawan,

New Delhi.

2. ED/QA/S&T, 4th floor, Annexe-II, RDSO, Lucknow

. ~
 Amendment 1 to IRS-TC 77/2012 Rev 3

Clause 3.1

Existing Clause

S.No. Description of For 0.9mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad
Materials cable
Size Quantity Size Quantity
26 IDC type Jelly IDC type jelly filled 6 Not applicable -
filled discreet connector modules Numbers
wire made of
connectors
polypropylene for 2
wires bridging type
(0.4mm to 0.9 mm
dia. conductors)

Amended Clause

S.No. Description of For 0.9mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad cable
Materials
Size Quantity Size Quantity

26 IDC type Jelly IDC type jelly filled 6 Not applicable -

filled discreet connector modules Numbers
wire made of
connectors
polypropylene for 2
wires for Tap type
joint (0.4mm to 0.9
mm dia.
conductors)

Clause Existing Clause Amended Clause

Number
4.15.3 It shall be flexible multi strand copper It shall be flexible multi
conductors single core cable insulated strand copper conductors
conforming to IS 690-94 single core cable insulated
conforming to IS 694.
4.20 IDC type jelly filled discreet wire IDC type jelly filled discreet
connector: It shall be made of wire connector: It shall be
Polypropylene and as per TEC GR No. made of Polypropylene.
G/CJM-15/02.Nov 97.

Amendment 1 to IRS-TC 77/2012 Rev 3 Page 1 of 4

Clause Existing Clause Amended Clause
Number
4.20.2 IDC type jelly filled connector modules IDC type jelly filled
made of polypropylene for 2 wires connector modules made of
bridging type (0.4mm to 0.9mm dia. polypropylene for 2 wires tap
conductors): 6 Numbers to be used for type (0.4mm to 0.9 mm dia.
making derivation joint on a quad conductors) : 6 Numbers to
without cutting conductors. be used for making derivation
joint on a quad without
cutting conductors.

ANNEXURE – IV

RAW MATEIAL TEST OF THERMOSHRINK JOINTING KITS FOR JOINTING

UNDERGROUND QUAD CABLE TO SPECIFICATION

NO. IRS:TC 77-2012 Rev 3

Discrete Wire Connectors (Page 60)

2.0 REQUIREMENTS

Existing Clause:

The discrete wire connector shall be made of Polypropylene plastic material and shall be
filled with Moisture resistant compound. The Discrete wire connectors shall conform to the TEC
GR No. G/CJM-15/02. Nov 97

Amended Clause

A. The discrete wire connector shall be made of Polypropylene plastic material and
shall be filled with Moisture resistant compound. The Discrete wire connectors shall
comply following parameters.

SN Parameter Value
1 Contact Resistance ≤ 5 mΩ
2 Stress Relaxation The increase in contact resistance ≤ 2
mΩ
3 Temperature Cycle with High The increase in contact resistance ≤ 2
Humidity mΩ
4 Vibration The increase in contact resistance ≤ 2
mΩ
5 Dielectric Strength 1.0 KV AC

Amendment 1 to IRS-TC 77/2012 Rev 3 Page 2 of 4

 SN Parameter Value
6 Insulation Resistance
i Water Immersion Better than 108 Ω
ii Temperature Cycle with High
Humidity Better than 108 Ω
7 Tensile Strength for various conductors of various diameters.
Copper Conductor Dia. In mm Minimum breaking load (Kgf)
i 0.40 2.4
ii 0.50 3.6
iii 0.63 4.5
iv 0.90 11.5
8 Wire Torsion No wire breakage or slipping of contact
for 5 Cycles
9 Wire Bending No wire breakage or slipping of contact
for 5 Cycles
10 Thermal Shock (Heat & Cold) The increase in contact resistance ≤ 2
mΩ
11 OIT for Plastic cover ≥ 30 Minutes

B. The filling compound shall comply the following:

i. The Connector shall be filled with compound to prevent ingress of moisture.

ii. The quantity of filling compound should be such that when crimped with
insulated conductors of 0.4 mm diameter, the filling compound would appear level with
the open ended of the connector.

iii. The filling compound shall not cause cracking, swelling, softening or any other
degradation of the moulding as well as of the PE insulation of the conductor when
connectors are aged for 1000 hrs at 70±2°C. Also it shall not corrode the crimping
element.

iv. The filling compound shall have a drop point of not less than 70°C when tested as
per IS:1448.

v. The compound shall be non toxic. The compound shall not have any
dermatological effect.

Amendment 1 to IRS-TC 77/2012 Rev 3 Page 3 of 4

 Clause Existing Clause Amended Clause
Number
2.1.2 IDC type jelly filled connector IDC type jelly filled connector
modules made of modules made of polypropylene
polypropylene for 2 wires for 2 wires Tap joint type (0.4mm
bridging type (0.4mm to 0.9mm to 0.9mm dia. conductors): 6
dia. conductors) 6 Numbers. Numbers

2.2 All the tests as required under The compliance to the

clause 6.1 of the TEC GR shall requirements given in clauses 2.0
be carried out for type approval. A and B of Annexure IV for
Discrete wire connectors shall be
verified during type approval. For
testing of parameters of clause
2.0A, test methods of TEC GR No.
G/CJM-15/02. Nov 97 shall be
followed. For compliance of 2.0 B
iv and v, filling compound
manufactures certificates and
Material Safety Data Sheet
(M.S.D.S) shall be submitted.

Multi strand tinned copper conductor flexible insulated cable (single core) (Page 61)

Clause Existing Clause Amended Clause

Number
1.0 General: The single core General: The single core
insulated cable conforming to IS: insulated cable conforming to IS:
694:1990 shall consist of multi 694 shall consist of multi strands
strands of flexible tinned of flexible tinned annealed copper
annealed copper conductors conductors

***************End*****************

Amendment 1 to IRS-TC 77/2012 Rev 3 Page 4 of 4

 Amendment 2 to IRS-TC 77/2012 Rev 3

The amended clauses to IRS TC 77/2012 Rev. 3 , amend. 1 shall be as given below:

Clause 3.1

S.No. Description of For 0.9 mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad
Materials cable

Size Quantity Size Quantity

4 Adhesive PVC Width (25 mm Total Width (25 mm Total

tape min.) x Length Length of min.) x Length Length of
(Min. 5 meter/ roll) tape shall (Min. 5 meter/ tape shall
x Thickness (0.1 to be roll) x Thickness be
0.13 mm) minimum (0.1 to 0.13 mm) minimum
20 meters. 30 meters.

5 Adhesive Length (400 1 Length (400 2

Aluminium mm min.) x Width mm min.) x
foil (100 mm min.) x Width (100 mm
Thickness (0.06 min.) x Thickness
mm±0.01 mm) (0.06 mm ±0.01
mm)

7 Emery strip Length (600 2 Length (600 2

mm min.) x Width mm min.) x
(25 mm min.) x 60 Width (25 mm
(mesh) min.) x 60 (mesh)

9 Sealant tape Length (400 2 Length (400 3

mm min.) x Width mm min.) x
(35 mm min.) x Width (35 mm
Thickness 3 min.) x Thickness
mm±0.5mm 3 mm±0.5mm

15 Multi-strand Length 2000 1 Length 2000 1

tinned copper mm+50 mm, mm+50 mm,
conductors Nominal cross Nominal cross
insulated cable
section area 4 sq. section area 4 sq.
(single core)
mm, for armour mm, for armour

Amendment 2 to IRS-TC 77/2012 Rev 3 Amend 1

Page 1 of 4
S.No. Description of For 0.9 mm dia. 4/6 quad cable For 1.4mm dia. 4/6 quad
Materials cable

Size Quantity Size Quantity

continuity. continuity.

26 IDC type Jelly IDC type jelly filled Nil (item Not applicable -
filled discreet connector modules deleted)
wire made of
connectors
polypropylene for 2
wires for Tap type
joint (0.4mm to 0.9
mm dia.
conductors)

27 Parallel jaw Parallel jaw plier One plier Not applicable -

plier for crimping the for every
discrete wire 16jointing
connectors. The kits for
dimension of the 0.9 mm
plier shall be quad cable
compatible with the or part
crimping tool and thereof.
shall be supplied by Minimum
the manufacturer of quantity 1
the discrete wire No.
connectors.

4.4.2 The size of the tape shall be “Width (25 mm min.) x Length (Min. 5 meter/ roll) x
Thickness (0.1 to 0.13 mm)”

4.5.3 Dimension of Aluminium foil shall be “Length (400 mm min.) x Width (100 mm min.) x
Thickness (0.06 mm ±0.01 mm)”

4.7.4 The emery cloth shall be supplied in the form of strip size “Length (600 mm
min.) x Width (25 mm min.) x 60 (mesh).”

4.15.2 It’s length shall be 2000 mm +50 mm and Nominal Cross sectional area shall be 4 sq.
mm.

4.20.2 Deleted

Amendment 2 to IRS-TC 77/2012 Rev 3 Amend 1

Page 2 of 4
Clause 6.2.2 Sampling plan for acceptance tests for Quad cable:

SN Tests Sample size

38 Parallel Jaw plier marking and One sample from offered lot
manufacturing identity, model number etc.
(To be supplied one for every 16 jointing kits
or part thereof)

Adhesive PVC tape (Page 52 of Specification)

2.0 REQUIREMENT

Sr. No. Property Requirement Test Method

2.1 Length / Roll 5 meter/ roll minimum. Measurement

2.2 Width 25 mm minimum Measurement

Sealant Tape (Page 53 of Specification)

2.0 REQUIREMENT

Sr. No. Property Requirement Test Method

2.13 Dimensions Length : 400 minimum Measurement
Width : 35 minimum
Thickness : 3 ± 0.5 mm

Emery Strip for cable joints (Page 55 of the specification)

9.0 REQUIREMENT

Sr. No. Property Requirement Test Method

9.6 Dimension Length (600mm min) x Measurement
Width (25mm min) x 60
mesh.

Amendment 2 to IRS-TC 77/2012 Rev 3 Amend 1

Page 3 of 4
Adhesive Aluminium foil (Page 58 of the specification)

9.0 REQUIREMENT

Sr. No. Property Requirement Test Method

2.1 Dimension (400mm min) x Measurement
(100mm min) x
(0.06mm  0.01mm)

Discrete wire connectors (Page 60 of the specification)

2.0 REQUIREMENT

2.1.2 Deleted

***************End*****************

Amendment 2 to IRS-TC 77/2012 Rev 3 Amend 1

Page 4 of 4
 'If«' B~

I
m<f,TI -

~lTeIe • 2492 XXX ~ ~ 3ft< l!Rifi Wr;;;t A!\ ISO 9001

. 2493 XXX ~-226011 CERTIFIED
Governmenf oIlnd1a· •••inislty 01 Railwa~s
~fFax: 91-0522·2456500 OR(a\ISATIO~
Research DesIgns & Standards Organisation
Ludlnow· 226 011

No.: STTlRE/CJ/368 Dated: 17-10-2016

1. The CSTE, CSTEIConst.: ~.tm.it,~., lfi.~.it,~~" :

-- '"

(i) Central Rly., Mumbai, CST -400001 ~ ~, ~.~,;!!,-400 001

00 Western Rly, Churchgate, Murnbai - 400020 ~, ~, ~-400 020
OH) Eastern Rly., Fairlie Place, Kolkata 700001 ~, ~, ~-700 001
Ov) South Eastern Rly., Garden Reach, Kolkata ~~Ul~a4, ~, ~-700 043
(v) Northern Rly. Baroda House, New Delhi- 110001 ~,~, Of{~-110001
(vQ North Eastern Rly., Gorakhpur- 273012 ~,~-273012
(vii) North East Frontier RIy., Maligaon, GlfNahati 'tiI«mll'l;ffla4, ~. ~-781 011
(viiQ Southern Rly. ParkTown, Chennai - 600003 ~. ~, ~-600 003
Ox) South Central Rly., Secunderabad 500371 ~ 'f&I ~. ff\i&'G<iG(i~-500371
(x) East Central Railway, Hajipur t!f 'ltlf ~. ~

(xi) East Coast Railway, Rail Vihar BOA Rental ~ ~, ~.it.~. 't~"'ictl41, «:ihil<!J<,~-751023
Colony, Chandrasekharpur, Bhubneshwar
(xii) North Central Railway, Hastings Road, \!«R'f&I~.~, ~
Allahabad.
(xiii) North Western Railway. Jaipur 300206 \3tt1<<ftq'l'ta4,
~-300206
(xiv) South Western Railway, Club Road, Keshavpur, ~~"l41~'1"{cli\,
~. ~, ~-23
Hubli-23.
(xv) West Central Railway, Annex Building, llf./qq ~ ~. ~ 'I!QiI'. ~

Opp Indira Market, Jaba!pur-482068

(xvi) South East Central Railway, R.E. Office ~ ~ m. ~o{(J \Jl1!ii;{l1li""-'liRi.

~-495004
Complex, Bilaspur - 495004
2. The CSTE, Metro Railway, 23-A, Jawaharlal ~.tm.itJ.~, m. ~-71
23~. "1qiiHclicl~i5""
Nehru Road, Kolkata - 700071
3. The CSTE, CORE, Nawab Yusuf A1i Road, Civil ~.~.it,t./ <iiR, ~~. faf4clcli~'i1,
~-211001
Unes, Allahabad
4. The Director, IRISET, Tarnaka Road, Lallaguda ~~uw:/Ri'li<::<i<li~-500017
(P.O.), Secunderabad-500 017

5. CAOIlRPMU IRCOT Building, Behind Shanker ~.~.-m. /~<q;fcI4RSli/~

A1!It.\!lR.1lt.\R.'L- ~ -Qt6~
Market, New Delhi.
6. MD, RailTel Corporation of India Ltd., 10m Floor, ~ f.fuTq;, 1cl~cl"'iift'll'1;Jjiq;~f.s'URifqls,
100 ~, ~i'6<l~~i'li'1'1.
Bank pf Baroda Building, Parfiarnent Street, New qi~<1iq.,..({lc,
~
Delhi

Page 1 of3
-----------_._---_.
~.

Sub.: Amendment NO.3 to ROSa specification No.IRS;TC-77/2012, Revision-3

(Amendment -1&2) of "Thermoshrink Jointing Kitsfor Jointing Underground Quad Cable".
"'''''''''''''

In compliance to the VigilancelRDSO Letter No. 13Nig/Policy dated 26.07.2016

& 08.09.2016, Amendment No.3 to the. Specification No. IRS;TC-77/2012, Revision-3
(Amendment -1&2) of "Thermoshrink Jointing Kitsfor Jointing Underground Quad Cable"
IIis hereby issued with approval of competant authority for information &implementation.
This Amentment No.3 is effective from 17 .10.2016.

Encl: Copy of Amendment No.3 of Specification

No. IRS;TC-77/2012, Revision-3 (Amendment -1&2)

For Director General/Telecom

COPY to:

1 Executive DirectorlQAlS&T.'RDSOILKO /1UlqffilJll~qlfl13t03l0lID~. ~ I

2 DirectorlQA/S&TIRDSO, 1st Floor, IRCOT ~ / ~UlqroIJlRqltl1/ftrr;R;f I{cj'i~'tiill(3!03IolID'tiO.

Bldg., ShivajiBridge, NewDelhi-ll0 001 f.I<bCii~q;k ~i<b~ql<Scc5 'Ifu).~ ~110 001

3 Director/QA/S&TIRDSO, 1st floor, New ~/~olqct1l31l~qlfl1/~i 1(<i'k~'tiill'!O

3!03I0lID'tio.
~. ~ 1{;)cffi'tfi\~II.
~. q~>R('I~. ~.400 020
Annexe Bldg., W. Railway, Churchgate,
Mumbai-400 020
4 Director/QA/S&TIRDSO, Ground Floor, ~ /~ /~ I{<i'iffiill'l.3!03!Ol!lJ'tio.
~. -flO3rnO~JjO~ •• ~ 560 013
DRM Office, Bangalore-560 023
5 Director/QA/S&TIRDSO, 4th Floor, 17 N.S. ~ /TTqmlJll~c;i'«1/~ 1{<i'i'l'tiill'!O
3!03I0lID'tio.

1 Road, West Wing, Fairlie Place, Kolkata-700

~. 17 IR~. -m. ~.~IHd'lt<OI'(j. ~
700001
001
6 Director/QAlS&TIRDSO,Hasanpura Road, ~ /'10j(1i'i1iJjl~qlfl1/~ I{ci1'.Hiili{
In Front of Railway Hospital 3!03I0l!lO'tio.~ ~- 302006
JAIPUR-302006
7 Mis Western Cablex Engineering Pvt. Ltd,Office: ~ cmat 'hIi<4 Cffi $"i'lf.l~~dl ~~.
202,Universal Industrial Estate,J.P .Road,Andheri ~:m,~qfl(>l $5~~(>I mc,~.q'r.~~
West,Mumbai-400058 clR:,~-400058

8 Mis General Auto Electric Corporation,Office:D- ~ ~ :ffic)- $JI~Cf> Cf>1'(4)l~lif.

207, Ansa Industrial Estate.Saki Vihar Road, Saki ~:D-207, 3rrm $~~(>I mc.'f14>1~e;F{.~
Naka,Andheri(E)Mumbai-400072
il<tlT ~ Fe. ¢400072

Encl: Copy of Amendment No.3 of Specification

No. IRS;TC-77/2012, Revision-3 (Amendment -1&2)
IAn~G~ -
Directo~
For Director General/Telecom

Page 2 of3
 Amendment No.3
to
Rosa specification no. IRS;TC-77/2012, Revision-3 (Amendment -1&2)
of "Thermoshrink jointing Kits for Jointing Underground Quad Cable".

Following Clause is added to the Specification No. IRS;TC-77/2012, Revision-3

(Amendment -1&2)

Clause No. 13.

"All the provisions contained in RDSO's ISO procedures laid down in Document No. 00-D-7.1-11
dated 19.07.2016 (titled "Vender-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".

End of Amendment No.3

Page 3 of3