RDSO/Infra-II/B&S/RG/CG

MODEL QUALITY ASSURANCE PLAN (QAP) FOR FABRICATION OF RDSO STANDARD RAILWAY COMPOSITE GIRDER

PART-A (TOP SHEET)

S.No. Item Details
1 Name of Project
2 Zonal Railway jurisdiction
3 Executing organization of the contract agreement (i.e. Zonal Railway/ Railway
PSU.)
4 Contractor Agency
5 Fabricating Agency
6 Inspecting Agency RDSO
7 QAP No. RDSO/Infra-II/B&S/RG/CG
8 Contract Agreement no. & date
9 LOA No. & date
10 Completion date as per Contract Agreement/LOA
11 Date of MoU Between fabricator and Contractor, if applicable
12 Scope of fabrication (no. of spans x span length in meter) proposed for
fabrication.
13 Scope of fabrication in MT (Only Railway composite Girders)
14. GAD Approved by
15 RDSO Drawing Nos. used.
16 Specifications

Note:- It is certified that fabrication work shall be executed as per RDSO model QAP mentioned above.

Contractor Fabricator Zonal Railway/Railway PSU RDSO

 RDSO/Infra-II/B&S/RG/CG

PART B - MODEL QAP

Sl. Component Characteristic Frequency & Reference Fabricators Inspection Details Type of Acceptance Criteria Remarks
No. / Operations to be checked type of Document Quality Inspecting Extent of record
check Control agency Inspection
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW
MATERIAL
1.1 Steel Plates Identification As per Mill Challan, Mill Verification Zonal Fabricator's 1) Steel Plates: IS 1. Grade and
and other and Co- Test T.C. of reference Railway/ 100% Record 2062:2011 Quality of Steel
Structural relation with Certificate & documents Railway Grade E250 Quality Plates, structural
Steel Mill Test test required PSUs B0 as mentioned in the section to be
Sections Certificate from by Zonal respective approved same as
Supplier. Railway or drawing. mentioned in the
Source/Brand Railway PSU 2) Plates 12mm and respective
of steel to be from above thick are fully approved
decided as per approved killed/normalized or drawings
prevailing Laboratory/ control cooled. 2. For other
instructions Govt. 3) Rolled Sections or details of
issued from approved any other structural structural steel
Railway Board. Laboratory/ steel member: IS plates and
NABL/ 2062:2011 structural section
NABCB. Grade E250 Quality A&C no. 5 of IRS-
B0 as mentioned in the B1: 2000, IS
respective approved 2062-2011 and
drawing. codes referred in
these shall be
complied as
applicable.
3. Raw Material
clearance shall be
done by Zonal
Railway/ Railway
PSUs as per
prevailing
instructions
issued from
Railway Board.
 RDSO/Infra-II/B&S/RG/CG

Physical Visual -- Complete 100% Fabricator's A&C no. 5 of IRS-B1:

Condition i.e.- Visual Record 2000, IS 2062-2011
Pitting, rusting, inspection Zonal and codes referred in
straightness, Railway/ these shall be
rolling defects Railway complied as applicable
etc. PSUs

Mechanical Lab test at - Lab Test Zonal - - Table 2 along with

Test as per IS- approved Report Railway/ notes below and other
2062:2011 laboratory/ Railway relevant clauses of IS-
UTS,YS,%EL,B Govt. PSUs 2062-2011 and codes
end Test approved referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.

Charpy Test at Lab test at - Lab Test Zonal Heat / Cast -

0 ° C for plates approved Report Railway/ no. section
12 mm thick laboratory Railway wise as per
and above Govt. PSUs IS 2062-
approved 2011
Laboratory/
NABL/
NABCB
Chemical Lab test at - Lab Test Zonal Heat / Cast - Table 1 along with
Analysis as approved Report Railway/ no. section notes below and other
per IS 2062- laboratory Railway wise as per relevant clauses of IS-
2011 Govt. PSUs IS 2062- 2062-2011 and codes
approved 2011 referred in it, for quality
Laboratory/ and grade of steel as
NABL/ mentioned in
NABCB respective drawings as
applicable.
 RDSO/Infra-II/B&S/RG/CG

Ultra sonic By ASNT - Lab Test Zonal 100% - IS-4225 or ASTM SA-
test for level- II Report Railway/ 435/435M and codes
12mm and operator Railway referred in it as per
above thick PSUs applicability
plates as per
IS-
4225/ASTM
SA-435/435M

Dimension Measurement Challan Measurem 100% Fabricator's IS 2062: 2011 or other

ent of Record & relevant codes
dimension Zonal referred in it as
Railway applicable
Record

1.2 HSFG Bolts Dimensions Visual / Challan and Verification Zonal As per BS- Fabricator's As per BS – 111 Procure from
with DTI Measurement Manufacturer's of Railway/ 111(Latest Record (Latest revision) RDSO approved
washers Test Certificate reference Railway revision) Vendor only.
Documents PSUs

Mechanical & T.C. And Manufacturer Verification Zonal

Chemical tests Test Certificate of Railway/
properties required from reference Railway
Govt./NABL/ Documents PSUs
NABCB
approved lab
As per BS –
111 (Latest
revision)
 RDSO/Infra-II/B&S/RG/CG

1.3 Paints and Verification Visual Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS: 5666 Test at the
Primers of Manufacture's of Railway/ er's Test IS: 51, IS: 104, IS: approved
Manufactur Test Certificate Reference Railway Certificate 2339 and applicable laboratory
er's Test Documents PSUs codes referred in these suitable for the
Certificate, codes therein. purpose shall be
Inspection done as per the
Certificate, instruction of the
Challan Zonal Railway/
Tests as Lab test at Challan , Verification Random Lab Test Railway PSU.
per approved Manufacture's of Report
specificatio laboratory Test Certificate Reference
n Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.4 Aluminium Properties Review of Challan , Verification Zonal Each Batch Manufactur IRS B1-2001, IS:2590 Test at the
wire of reference Manufacture's of Railway/ e's Test and applicable codes approved
Aluminium documents Test Certificate Reference Railway Certificate referred in these codes laboratory
wire such with material Documents PSUs suitable for the
as Dia, purpose shall be
class and done as per the
purity as instruction of the
mentioned Zonal Railway/
in Railway PSU.
appendix-
VII of IRS
B1-2001
Tests as Lab test at Challan , Verification Random Lab Test
per approved Manufacture's of Report
specificatio laboratory Test Certificate Reference
n Govt. Documents
approved
Laboratory/
NABL/
NABCB
1.5 Welding As Per Any Test as Challan & Verification Zonal As per Fabricator's IRS Welded Bridge As per
Consumables Specificatio required Manufacturer's of Railway/ requiremen record Code 2001, IRS M28, specification and
n and Test Certificate reference Railway t IRS M39, IRS M46 WPSS.
approved Documents PSUs and other applicable
WPSS codes referred in these
 RDSO/Infra-II/B&S/RG/CG

codes and
specifications

1.6 Stud Visual Test as Approved 100 % Zonal 100% Test Approved Fabrication
Inspection , mentioned in Fabrication Visual Railway/ Reports & Drawing, IS 9595-96,
dimensions BS 115 Drawings and inspection Railway Fabricator IRSB1-2001 and
inspection (Latest WPSS & PSUs report codes as applicable
Revision) verification instructions issued by
of Railway Board also to
dimension be followed.
by gauge
and test
record
2.0 Manufacturing
Process

2.1 Layout Dimension Measurement Approved Measurem RDSO 100% Inspection Approved fabrication
with Drawings ent of Report of Drawings and relevant
calibrated dimensions Inspection IS/IRS codes.
steel Tape officials
2.2 Master Plates Dimension, Measurement Approved Measurem RDSO 100% Record for Approved fabrication
intersection with Drawings ent of Master drawings, IRS B1-
line, pitch, calibrated dimensions Plates on 2001 and BS-110
gauge, Dia. steel Tape & proforma (Latest Revision)
of holes & gauges. same as of
No. of Appendix
holes. I(1)
proforma
given in
IRS B1-
2001
 RDSO/Infra-II/B&S/RG/CG

2.3 Preparatory Dimension Visual / Inspection Visual & 100% Inspection Approved fabrication --
work such as , freedom Measurement Report of Measurem Report of drawings, IRS B1-
Cutting, from with master Inspection ent of Inspection 2001, IS- 1852-85 and
Straightening,
defects plates and officials & dimensions officials & codes referred in these
EdgePreparatio Zonal
n,Marking,Drillin
templates fabricator's fabricator's codes as applicable
record Railway/ record
g, Fit up,Pre- Railway
assembly, End
PSUs
finishing

Welding
3.0
3.1 WPSS Approval of Verification IS 9595-96, Verification RDSO 100% Fabricator's Approved Welding to
WPSS IRS B1-2001, Reference Record fabrication be performed
IRS WBC- Documents Drawings, IS following the
2001 and 9595-96, IRS different
codes B1-2001, IRS specification
referred in WBC-2001 and and
these codes codes referred parameters
as applicable in these codes mentioned in
as applicable WPSS
approved by
RDSO
3.2 WPQR 1. Witnessing of Visual DT As per Codal Verification RDSO 100% WPQR IS 7307 (Part-1), Only RDSO
established and NDT at Requirement of Reference Sheet to be IS 7310 (Part-1), certified
WPSS. 2. approved Documents recorded in IRS B1-2001, welders to be
Witnessing of laboratory/ presence of IRS WBC-2001 engaged in
Welder Govt. RDSO. and codes the job
Qualification approved referred in these
test Laboratory/ codes as
NABL/ applicable
NABCB
 RDSO/Infra-II/B&S/RG/CG

3.3 Preheating Measurement Visual with Approved Verification Zonal Random Inspection IS 9595-96, IRS --
of Temperature thermal WPSS of Reference Railway/ Report of B1-2001, IRS
Chalk or Documents Railway Inspection WBC-2001 and
Infrared PSUs officials & codes referred
Thermometer fabricator's in these codes
record as applicable

3.4 Baking of To have Visual check As per Verification Zonal 100% Inspection IRS B1-2001 --
Electrode, flux moisture free of Electrodes Manufacture' of Reference Railway/ Report of and other
electrode and and heating s Documents Railway Inspection applicable
flux Recommend PSUs officials & codes.
ation fabricator's
record
3.5 Selection of Reference to Visual As per Verification Zonal 100% Inspection IRS Welded As per WPSS
Correct WPSS. Approved of Reference Railway/ Report of Bridge Code and other
Electrodes & WPSS Documents Railway Inspection 2001, IRS M28, codes
flux PSUs officials & IRS M39, IRS applicable.
fabricator's M46 and other
record applicable
codes referred
in these codes
and
specifications
3.7 Current Measurement Visual with As per Verification Zonal Random Inspection IS 9595-96, IRS As per WPSS
Condition of Amp./Voltage Ammeter and Approved of Reference Railway/ Report of B1-2001, IRS and other
Voltmeter WPSS Documents Railway Inspection WBC-2001 and codes
PSUs officials & codes referred applicable.
fabricator's in these codes
record as applicable

3.8 Sequence of Controlling Visual As per Verification Zonal Random Inspection IS 9595-96, IRS --
Welding Distortion Approved Reference Railway/ Report of B1-2001, IRS
WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/CG

3.9 Provision of To avoid crater Visual As per Verification Zonal 100% Inspection IS 9595-96, IRS --
Run-on and defects Approved Reference Railway/ Report of B1-2001, IRS
Run-off Plates WPSS Documents Railway Inspection WBC-2001 and
PSUs officials & codes referred
fabricator's in these codes
record as applicable
 RDSO/Infra-II/B&S/RG/CG

Sl. Componen Characteristic Frequency Reference Fabricators Inspection Details Type of Acceptance Remarks
No. t/ to be checked & type of Document Quality Inspecting Extent of record Criteria
Operation check Control agency Inspection
s
1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection For Fillet Visual, Approved Visual RDSO 100% Fabricator's Approved It is to be
of Welded Welds - Visual, Gauge and fabrication Inspection & Record fabrication ensured
componen D.P. Test, Fillet Macro Drawings & Verification Drawings, IRS during
ts Size, etching WPSS of Dimension B1-2001, IRS fabrication
Penetration, Leg by Gauge WBC-2001 and process that
length, Throat codes referred fabrication
thickness etc. in these codes has been
as applicable done as per
the WPSS
approved by
RDSO and
Welders
approved by
RDSO. This is
to be ensured
n by Zonal
Railway/
Railway PSUs
and certificate
to this effect
(By Minimum
JAG officer)
shall be given
in the form of
four point
certification
along with
inspection call
raised to
RDSO.
 RDSO/Infra-II/B&S/RG/CG

4.1 Stud Visual Test as Approved 100 % Visual Zonal Railway/ 100% Test Reports Approved
Welding Inspection, mentioned Fabrication inspection & Railway PSUs & Fabricator Fabrication
dimensions in BS 115 Drawings and verification of report Drawings 9595-
inspection, ring (Latest WPSS dimension by 96, IRSB1-2001
test and bend revision) gauge and and codes as
test etc. As test record applicable
applicable, for instructions
good issued by
penetration & Railway Board
crack free weld. also to be
followed.
5.0 Inspection a) Overall length Visual & Approved Complete RDSO First span Inspection IRS B1-2001, 1. RDSO
of first b) Bearing Dimensiona Drawings Dimensional Report of IRS WBC-2001 inspection call
span in centres l Check of Inspection and applicable to be raised
assembled c) Height Assembly officials & codes referred by Zonal
condition d) Girder fabricator's in these codes. Railway/
Centres record Railway PSUs
e) Squareness in the form
f) Verticality of 4 point
g) Camber on certification
Jack after
h) Dead Load
satisfactory
deflection
(Camber without quality
Jack) checks. 2.
i) Dimension Assembly
j) Fairness of shall be done
Holes in Workshop
k) Temporary of fabricator
fasteners only.
l) Any Fabricator
Infringement shall ensure
m) Butting of that sufficient
compression space is
members available in
workshop for
assembly
before
finalizing the
order of
fabrication for
a particular
 RDSO/Infra-II/B&S/RG/CG

span.
6.0 Inspection i) Overall Visual, Stage clearance Verification RDSO 100% Inspection IRS B1-2001, 1. All spans are
of length ii) Dimensiona Record of Stage Report of IRS WBC-2001 to be checked in
Componen Bearing l& clearance Inspection and applicable leaf assembled
nd
ts of 2 centres Structural Record officials & codes referred condition.
span fabricator's in these codes. 2. RDSO
iii) Height
onwards record inspection call to
iv) Girder be raised by
Centres Zonal Railway/
v) Squareness Railway PSUs
vi) Verticality in the form of 4
vii) Camber point
viii) Dimension certification
ix) Fairness of after
Holes satisfactory
x) Butting of quality checks.
compression
flanges
 RDSO/Infra-II/B&S/RG/CG

7.0 Surface Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's IRS B1-2001 1. Clearance
Preparatio condition after checking Fabrication of Stage Railway PSUs fabricator & Record Appendix- VII shall be given
n by blasting with Drawing & IRS - clearance Random by IS: 6586, by Zonal
Blasting & reference B1-2001 and Record Zonal IS:5905 , Railway/
Metalizing to surface codes referred Railway/ IS:2590 and Railway PSUs
preparation in these Railway codes referred
PSUs in these codes
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's
after metalizing checking Fabrication of Stage Railway PSUs fabricator & Record
Drawing & IRS - clearance Random by
B1-2001 and Record Zonal
codes referred Railway/
in these Railway
PSUs
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of Stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and Record
codes referred
in these
 RDSO/Infra-II/B&S/RG/CG

8.0 Cleaning & Surface Visual Approved Verification Zonal Railway/ 100% by Fabricator's Clause 39.2.1
Painting condition before checking Fabrication of stage Railway PSUs fabricator & Record and appendix
painting with Drawing & IRS - clearance Random by VII of IRS B1-
reference B1-2001 and records Zonal 2001, IS: 5666,
to surface codes referred Railway IS:51, IS:104,
preparation in these IS: 2339 and
Surface finish Visual Approved Verification Zonal Railway/ 100% by Fabricator's applicable
after painting checking Fabrication of stage Railway PSUs fabricator & Record codes referred
Drawing & IRS - clearance Random by in these codes
B1-2001 and records Zonal
codes referred Railway
in these
DFT checking Measureme Approved Verification Zonal Railway/ Minimum one Measuremen
nt Fabrication of stage Railway PSUs reading per t Record
Drawing & IRS - clearance square meter
B1-2001 and records
codes referred
in these
9.0 Final 1. Shipping Visual Fabricator's Zonal Railway/ Random Approved Approved Site Painting is
Dispatch Mark on all Record Railway PSUs Fabrication Fabrication to be done after
including Components as Drawing& Drawing & assembly and
packing, per Approved Fabricator's Clause 42, 43 erection of
Shipping Fabrication record and 44 of IRS - girder on site as
mark and drawings B1-2001 and per IRS B1-
loading 2. Fixing of codes referred 2001
etc. Inscription Plate in these
3. Packing
4. Loading

Note: During fabrication, internal inspection are to be done by Zonal Railway/ Railway PSU to ensure that only RDSO approved welders carry out welding as per
approved WPSS, work is as per dimensional tolerances & other quality aspects. Zonal Railway/ Railway PSU to satisfy itself before sending Inspection call to
RDSO for Assembly or components inspection etc.