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(For official use only)

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

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SPECIFICATION OF NON-ASBESTOS ‘L’ TYPE COMPOSITION BRAKEBLOCKS FOR BROAD GAUGE DIESEL & ELECTRIC LOCOMOTIVES OF INDIAN

RAILWAYS

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SPECIFICATION NO.MP.0.0100.04 (REV- 07)

JULY - 2008

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y[kuÅ & 226 011 RESEARCH DESIGNS & STANDARDS ORGANISATION

LUCKNOW - 226 011

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CONTENTS

S.N. Description Page No.

1. Scope 1

2.1 Requirement - General 1

2.2 - Friction 1

2.3 Geometrical Characteristics 2

2.4 Mechanical Physical And ChemicalCharacteristics

2

2.5 Marking 3

3. Acceptance Procedure 3

4. Inspection 5

5. Testing Facility 6

6. Criteria For Approval & Upgradation OfThe Firm

7

7. Revision Of Specification / Drawing 7

8. Packing 7

9. Warranty 7

ANNEXURE

I Locomotive Data (WDM2 locomotive) 8

II Friction Curve 9

III Brake Dynamometer Test Programme 10

IV Drawing of Cast Iron Brake Block 11

V Drawing of Composition Brake block 12

VI Sketch of Back Plate strength test 13

VII Sketch of Bending strength test 14

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Specification Of Non-Asbestos ‘L’ Type Composition Brake Blocks For Broad Gauge Diesel &Electric locomotives

1. SCOPE

This specification covers the requirements of non-asbestos ‘L’ typecomposition brake blocks for application on broad gauge diesel andelectric locomotives of Indian Railways.

2. REQUIREMENTS

2.1 GENERAL

2.1.1 The ‘L’ type composition brake blocks shall be freely interchangeablewith cast iron brake blocks to RDSO Drg. No. D/BG-1753 (Annexure-IV) already in use on various BG diesel and electric locomotives. Asample locomotive data for WDM2 locomotive is given in Annexure – I.

2.1.2 The composition of the material and the manufacturing method of seriesproduction of ‘L’ type composition brake blocks must always conform

with that of the block for which approval has been given by RDSO.

2.1.3 The use of asbestos is prohibited.

2.1.4 The use of lead and zinc in the metal state or in the form of compoundsis not allowed. The same applies to all other components if in the formof powder, particles or gas produced during the use of the brake blocks,they may constitute a danger to health or inconvenience to passengers.

2.1.5 The composition of the material constituting the brake block must bechosen to give the best balance between:-

- Braking characteristics.- Wear and service life of blocks.- Wear on the running surface of the wheels.- Effect on adhesion between the rail and wheel.

2.1.6 The characteristics laid down in this specification must be maintainedfor the complete usable thickness of the braking material.

2.17 The life of composition brake blocks should be at least 5 times the life ofcast iron brake blocks presently in use on Indian Railways.

2.2 FRICTION

2.2.1 As far as possible the co-efficient of friction must be independent of theinitial braking speed, the state of bedding-in of the brake block, thespecific pressure as well as the temperature and atmosphericconditions.

2.2.2 The tolerance bands of the instantaneous and mean co-efficient offriction shall be as per Annexure-II of this specification. The definition ofthe coefficients of friction is as per UIC 541-4-OR.

Specification No. MP.0.0100.04 (Rev - 07), July’2008 Page 1 of 14

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2.2.3 In order to minimise the risk of failure of wheel disc on account ofthermal cracks, the following guidelines will be adopted.

i) Minimum 70% of the values should fall within specified band.ii) Maximum 10% of the values should fall above the upper limit of the

band.

2.2.4 During bedding-in, the co-efficient of friction must not vary by more than+15% from the value obtained when bedding-in is complete.

2.2.5 Under the influence of dampness i.e. under wet conditions, the averageco- efficient of friction must not vary by more than +15% in relation tothe value obtained during braking when dry, with the other conditionremaining the same.

2.2.6 After prolonged braking followed by braking to a stop, a particular hightemperature occurs. Even at this temperature (max. 375 0C on the

opposite friction surface i.e. wheel tread) the average co-efficient offriction must not vary with the other conditions remaining the same, bymore than +15% in relation to the value obtained during braking in thecold and dry state.

2.3 GEOMETRICAL CHARACTERISTICS

2.3.1 The controlling dimensions of the brake block shall conform to therequirements given in the RDSO` Drg. No. SK.DP- 3650 Alt.1 placed at Annexure-V.

2.3.2 The constructional features of the brake block must enable it to weardown to a thickness of about 10 mm, including the back plate, withoutthe latter coming into contact with the running surface of the wheel.

2.4 MECHANICAL PHYSICAL AND CHEMICAL CHARACTERISTICS

2.4.1 The various elements making up the brake blocks must be spreaduniformly in the body of the block. There must be no pitting, flakes orother defects. The material must not attack the opposing frictionsurface or give rise to the formation of metal inclusions.

2.4.2 The blocks must not cause more serious heat damage to the wheels(hot spots, cracks, flaking) than would be caused by cast iron blocksused in similar conditions on the same wheels.

2.4.3 The values of density, hardness, compression modulus, cross breakingstrength, acetone extract, ash content (loss on ignition) and back platepull off strength must be given with the offer.

2.4.4 No method is laid down for fixing the composite material to the backplate. The back plate must be designed to withstand the forces likely tooccur.


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2.4.5 The composition brake block must not unduly affect adhesion betweenwheel and rail obtained on vehicles braked with cast iron blocks.

2.5 MARKING

2.5.1 The marking & colour coding on the brake block shall be as per drawingno. SK.DP- 3650 Alt. 1.placed at Annexure- V.

2.5.2 These marks, preferably be punched, engraved or stamped. Thesemust be applied in such a way so that the block can be identified, evenafter fully worn in service. The marking arrangement shall be gotapproved by RDSO before undertaking supply.

3. ACCEPTANCE PROCEDURE

3.1 Conditions For Vendor Approval

3.1.1 (a) The tenderer seeking to supply brake blocks to Indian Railwaysmust have valid ISO 9001 certification applicable for compositionbrake blocks and a technical collaboration with an foreignmanufacturer who has experience in manufacturing rail road brakeblocks. The foreign collaborator must have existing manufacturingand test facilities including Full Scale dynamometer formanufacturing and testing of brake blocks. The collaborator willhave to give detailed information including type acceptance testdata run as per clause 2.2 and other details in accordance withclause no. 2.4.3. The test on dynamometer will be carried out by

the collaborator as per test scheme given in Annexure – III.

(b) The manufacturer will have to produce adequate evidence from theircollaborator in support of good performance of the collaborator inmanufacturer and supply of composition brake blocks for RailRoad application.

3.1.2 The condition of foreign collaboration is strictly applicable for thosecompanies which are not in the business of manufacturing frictioncomposition materials for industrial use. However, the companies,which are in the business of friction composition materials for industrialuse and have established all the requisite manufacturing and testingfacilities including full scale rail dynamometer conforming to ERRI B–126 / RP-18 specification for indigenous manufacturer of the railwaybrake blocks and are following a quality assurance plan to thesatisfaction of RDSO may be exempted by the RDSO from therequirement of foreign collaboration. Such firm’s should submitdynamometer test results after testing of samples in their owndynamometer.

3.1.3 The information in para 3.1.1, 3.1.2 and 3.2.2 should be presentedtogether with a request for type acceptance test by RDSO.


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3.1.4 The manufacturer will submit six number of brake blocks for typeacceptance test on RDSO's brake dynamometer and samples will betested as per Test scheme given in Annexure III. The testing chargeswill be paid by the manufacturer.

3.1.5 During the tests, the blocks must not reveal any sign of combustion,formation of flaking, sweating of the binding material, permanent gratingor other defects.

3.1.6 The wear should be uniformly distributed over the entire depth of theblock, it should be as low as possible and be largely independent of thetype of brake load application. The specific wear value of each brakeblock found by weighing should not exceed 2.5 cc/ kwh.

3.1.7 The brake blocks tested on the dynamometer must meet therequirements given in para 2.2 of this specification.

3.1.8 On successful completion of the dynamometer testing at RDSO, 1500

nos. brake blocks shall undergo field trials for a period of one year.

The manufacturer shall has to submit QAP as per clause 3.2.2 forapproval before undertaking manufacture of these brake blocks.

The brake blocks will be supplied for field trial only after inspection byMotive Power Directorate of RDSO.

3.1.9 Four samples out of 1500 initial brake blocks shall be picked up by theRDSO to under take full scale dynamometer test. The manufacturershall arrange this testing of blocks on his own/with collaborator. Alternatively the manufacturer may send the brake block for testing atRDSO at his own cost. This test will be carried out as per Test schemegiven in Annexure III

3.2 Conditions For Approved Vendor

3.2.1 Manufacturer should have valid ISO 9001 certification specificallyapplicable for composition brake blocks.

3.2.2 The manufacturer shall get his Quality Assurance Plan approved byRDSO before undertaking manufacture of the brake block. The Quality Assurance Plan must contain the details of process of manufacture,

process controls and quality records maintained as well as the drawingshowing dimensions. The QAP must also contain the acceptablereadings of the following parameters along with the method of testing.In case of (d),(e) and (f) acceptable limits should be within ± 15% ofnominal values.

a) Compression modulus (Max.)b) Cross breaking strength (Min.)c) Acetone extract (max.)d) Ash content (loss on ignition)e) Hardness

f) Density


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g) Back plate pull off strengthh) Back plate strength (As per annexure VI)i) Bending Strength (As per annexure VII) j) Any other test

3.2.3 The approved vendor shall undertake full scale dynamometer test asper Annexure- III and submit the result to RDSO/ MP on the basis of20,000 brake blocks supplied to railways or after three monthswhichever is earlier, In case there is no production for three months ormore, dynamometer testing will get suspended till production isresumed. To audit the quality control RDSO at their discretion may pickup samples for confirmatory dynamometer testing at RDSO, Lucknow.

4. INSPECTION

4.1 The inspection of the brake blocks shall be carried out by DirectorGeneral / RDSO or his authorised representative at the premises of themanufacturer. During development stage, inspection authority will be

Motive Power Directorate of RDSO and during series production stageinspection authority will be QA - I Directorate of RDSO.

4.2 The inspection will be carried out as per the following procedure:-i) Manufacturer to submit pre-inspection report for the lots offered

for inspection as per the approved QAP of the firm.

ii) Manufacturer to ensure traceability of each block to its parentmix batch number & heat number.

iii) The inspector shall inspect the quality records maintained bymanufacturer for the entire lot.

iv) Each lot offered for inspection shall consist of 1000 brake blocksor part thereof. The lot No. shall represent the mix batchnumbers and heat No. out of which these brake blocks havebeen manufactured.

v) 2% of every offered lot of 1000 no. brake blocks will be selectedat random and checked for dimensional accuracy, duringdevelopmental stage. Once the manufacturer is approved forregular supply of brake blocks this sample size of 2% will getreduced to 1%. Dimensions are to be checked as per approved

drawing of manufacturer. However it is to be ensured that blocksfrom different mix batches will be taken up for inspection.

(A) One brake block selected at random from the above lot shall betested for the following :

a) Compression modulusb) Cross braking strengthc) Acetone extractd) Ash contents (loss on ignition)e) Hardnessf) Density


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The brake block shall be accepted based on acceptable readingsgiven in the RDSO approved QAP of the manufacturer. Themethod of testing shall be as given in UIC -541-4 OR or as perthe method of testing followed by manufacturer indicated in their

approved QAP.

(B) One brake block selected at random from the same lot to betested for back plate pull off strength and accepted based onacceptance values specified in approved QAP of the firm.

(C) One brake block selected at random from the same lot to betested for back plate strength (As per annexure VI).

(D) One brake block selected at random from the same lot to be

tested for bending strength given in annexure- VII.

(E) One brake block selected at random will be subjected to anyother test to be included in the QAP of the firm as decided bythe manufacturer and RDSO.

4.2.1 The brake block shall confirm to the requirements mentioned in theQAP of the firm and approved by RDSO. If any of the samples selectedas per para 4.2 fail to meet the requirements of any of the requirements,double the quantity of samples stipulated in clause 4.2 shall be selectedfor tests. If during re testing any of the brake blocks fail to meet therequirements of any of the tests the entire lot of brake blocks offered forinspection shall be rejected and brake blocks shall be renderedunserviceable.

4.2.2 The rejected lot shall be destroyed.

5. TESTING FACILITIES:

i) Manufacturer shall have adequate facilities for checking of brakeblock according to dimensional tolerances shown on the drawing.

ii) Manufacturer shall have adequate facilities for determining thecharacteristics as laid down in para 4.2(v).

iii) The manufacturer shall have in house full scale dynamometerfacilities conforming to ERRI B–126 / RP-18 specification to testthe brake blocks as per test scheme laid down in Annexure III.


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6. CRITERIA FOR APPROVAL AND UPGRADATION OF THE FIRM

i) Based on the technical evaluation after field trial of indigenouslot, any firm which meets the requirement as given in thespecification will be enlisted as Part - II source.

ii) For Upgradation To Part – I

a) The firm should meet minimum quantity requirement of40,000 nos., minimum period of supply and other conditions,as laid down in “Guidelines for Vendor Approval No. MPG0002 (Rev. 00) June, 2006” .

b) The quantity and period of supply of brake blocks supplied forfield trials will be counted towards the stipulated qualifyingtime & quantity.

c) Periodical renewal of registration will be done as laid down in“Guidelines for Vendor Approval No. MPG 0002 (Rev. 00)June, 2006”.

7. REVISION OF SPECIFICATION / DRAWING

i) RDSO reserves right to change / revise any part of thespecification.

ii) In case any revision of the specification / drawing takes placewithin the period of approval, suitable time period shall be givento the firm depending upon the nature of the changes toimplement the revised specification & the drawing of the product.

iii) Subsequent to the revision of the specification, testing of thebrake blocks if required, shall be carried out on Full scaledynamometer at RDSO and the testing charges in such casesare not to be levied for approved manufacturer, if the samplesare submitted within the stipulated time. However, if samples failand re-testing is carried out, the same shall be charged.

8. PACKING

The brake block shall be securely packed in cardboard boxes so thatthere is no damage to brake block during transit & handling. It should beensured that QAP submitted for approval by RDSO includes packingdetails.

9. WARRANTYThe warranty shall be 18 months from the date of placing in service orthe duty life cycle i.e. time taken in reaching the wear limit of brakeblock whichever is earlier.


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Annexure-I

Locomotive Data (WDM2 locomotive)

S.No. Particulars

1. Max. axle load 18.8 t

2. No. of axles/loco 6

3. Wheel dia.

– New 1092 mm – Condemning 1016 mm

4. No. of brake blocks per wheel 2

5. Locomotive weight 112.8 t

6. Total brake force 85.806 t

7. Efficiency 100 %

8. Max. speed (kmph) 120

9. Type of brake system Dual/Air brake

10. Condemning thickness of brake block 10 mm


http://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.doc

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Annexure-II


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Annexure III

PROGRAMME OF TEST FOR ‘L’ TYPE COMPOSIOTION BRAKEBLOCKS ON BRAKE DYNAMOMETER FOR DIESEL & ELECTRIC

LOCOS

Diameter of wheel 1092mm

No. of brake blocks /wheel 2

Axle load 18.8 t *

Brake force /wheel 7150.5 Kgs *

* These data are for WDM2 loco. For other locos parameters may vary.

Speed from 40 kmph to a maximum of 140 kmph. Increase in steps of 20

kmph from 40 to 100 kmph and then in steps of 10 kmph from 100 to 140kmph.

The following parameters shall be recorded /measured during the tests.These parameters are to be recorded after testing brake blocks upto 100, 120,130 and 140 kmph.

1. Wheel tread diameter before and after the tests.

2. Weight of brake block before and after the test to observe the specificwear rate of the brake block.

3. Surface condition of brake blocks after test specifically in respect ofgrooving metallic inclusions, burning, non-uniform wear, overheatingetc. and surface condition of wheel tyre in respect of polishing, pittingflaking, cracking and other defects after every test.

4. Initial and maximum temperature reached on brake block and wheeltread for each test during brake application.

5. General observations i.e. physical condition deterioration, smoke, smell,sparks and noise during tests.

6. Five applications at each speed may be recorded under dry and wet

conditions.

7. Mean co-efficient of friction in dry and wet conditions:

a) Dry conditionb) Wet condition

8. The drag test with 2400 kg/brake block for 20 minutes immediatelyfollowed by braking to stop under warm conditions.

9. Simultaneous testing of the two samples of brake blocks may be undertaken on the same wheel.


http://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.dochttp://c/Documents%20and%20Settings/Dirbk/Composition%20Brake%20Block/Specification/L-TYPE%20(BG)/Rev-07/MP-0-01-00-04%20Rev-2%20Nov%202001.doc

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Annexure- IV


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Annexure-V


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Annexure - VI

TEST OF BACK PLATE STRENGTH

Test Conditions:

Test Load F

F = 15 k N

Performance

The test is to be carried out as shown in figure. A new brake block is to be used for

the test. This is determined by means of the wedge lug.

Test load F is to be applied evenly in the direction of the circumferential load when

braking and increased to the maximum load of 15 k N within 4 second and

maintained constantly for two minutes.


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Annexure - VII

TEST OF BENDING STRENGTH

Test Conditions:

Test Force Fb

Fb =33 k N

Support Width L

Ls1 = 270 mm

Ls2 = 110 mm

Flexion ∆ h

∆ h1 = 2 mm

∆ h2 = 1 mmPerformance

For both tests, new brake blocks are used.

The test force is applied evenly at a speed of 30 mm / min. to the given maximum

value of the test force or to the given maximum value of the flexion ∆ h, and held

constant for 2 minutes.

5 tests must be performed per series.

The base for the support must have a radius of R = 5 mm.
