Reasoned document for Amendment to Indian Railway Standard Specification for Fusion Welding of Rails by Alumino-
Thermic Process (IRST-19-2012)
A. Annexure-3: Specification of 3- Pieces Pre-Fabricated Mould Manufactured by A.T. Portion Manufacturers for use
during A.T. Welding of Rails as per IRST-19-2012
S.No. Para/ Existing para
Clause no.
1. Title Annexure-3: Specification of 3-
Pieces Pre-Fabricated Mould
Manufactured by A.T. Portion
Manufacturers for use during
A.T. Welding of Rails as per
IRST-19-1994
2. Para 4.1 4.1 High Silica Sand:
4.1.1 The sand shall be of Gr.
A to IS:1987-2002 in respect of
chemical composition.
4.1.2 The grain fineness of the
sand shall be of Grade 425/212
(See Appendix-I).
4.1.3 The grain shape shall be
mostly of sub angular to rounded
shape.
4.1.4 The manufacturer shall
keep record/inspection certificate
as per IS-1987-2002 with proper
traceability of high silica sand,
being used in the production.
4.1.5 The manufacturer must
also have its own inspection
check on the Silica sand as per
Appendix-I and proper record
shall be maintained with
traceability.
Discussion during
meeting
It was mentioned by
vendors that they decide
the grain fineness
depending upon the
chemistry of portion and it
will not be proper to
define this parameter
uniformly. Accordingly, it
was agreed that the
vendors shall fix the
suitable grade of grain
fineness as per IS 1919-
1966 on their own as per
the chemistry of portion.
The same shall be
mentioned in QAP and
suitable records be made
as per provisions of this
specification.
Revised para Reason of change
Annexure-3: Specification of 3- Pieces Pre- The year of
Fabricated Mould Manufactured by A.T. specification has
Portion Manufacturers for use during A.T. been corrected.
Welding of Rails as per IRST-19-2012
4.1 High Silica Sand: The provision has
been modified in
4.1.1 The silica sand shall be of appropriate accordance with
grade in respect of chemical decision taken during
composition & grain fineness as per IS: the meeting so as not
1987-2002. The grade used as per to have any adverse
requirement of firm shall be indicated in effect on quality of
QAP of firm. The grain shape shall be main product i.e. AT
mostly of sub angular to rounded welding.
shape.
The Para has been
4.1.2 The manufacturer shall keep record/ reworded and
inspection certificate of high silica sand, renumbered for
being used in the production as per IS- better clarity.
1987-2002 with proper traceability. The
manufacturer should also carry out its
own inspection check on the Silica sand
and proper record shall be maintained
with traceability.
3. Para 4.2 4.2 Sodium Silicate:
4.2.1 Sodium silicate used as a
binding agent for pre-
fabricated mould shall be
of Gr.2 to IS:6773-1978
(Reaffirmed 2003).
4.2.2 The manufacturer shall
keep record/inspection
certificate as per Gr.2 to
IS:6773-1978
(Reaffirmed-2003) with
proper traceability of
sodium silicate, being
used in the production.
4.2.3 The manufacturer must
also have its own
inspection check on
sodium silicate batch
wise as per Appendix-III
and proper record shall
be maintained with
traceability.
4. Para 4.4 4.4 Carbon Di-Oxide Gas:
4.4.1 Carbon-di-oxide gas
shall be of commercial
grade to IS:307-66
(Reaffirmed 2006).
4.4.2 The manufacturer shall
keep record/inspection
certificate as per IS-307-
66 (Reaffirmed 2006)
with proper traceability of
Carbon-di-oxide gas,
being used in the
production.
It was mentioned by
vendors that they decide
the properties of sodium
silicate depending upon
the chemistry of portion
and it will not be proper to
define this parameter
uniformly. Accordingly, it
was agreed that the
vendors shall fix the
suitable grade of sodium
silicate as per IS 6773-
1978 on their own as per
the chemistry of portion.
The same shall be
mentioned in QAP and
suitable records be made
as per provisions of this
specification.
Vendors informed that it
will be difficult to get the
manufacturer test
certificate for carbon
dioxide, as this is being
manufactured by small
units. The provision can
be dispensed with since
the mould will be
subjected to non-
destructive tests and
destructive test as per
para 7.3 of Annexure –III
of IRST-19.
4.2 Sodium Silicate: The provision has
been modified in
4.2.1 Sodium silicate used as a binding accordance with
agent for pre-fabricated mould shall decision taken during
be of appropriate grade as per the meeting so as not
IS:6773-1978 (Reaffirmed 2003). to have any adverse
The grade used as per requirement effect on quality of
of firm shall be indicated in QAP of main product i.e. AT
firm. welding.
4.2.2 The manufacturer shall keep The Para has been
record/inspection certificate of reworded and
sodium silicate, being used in the renumbered for
production as per IS:6773-1978 better clarity.
(Reaffirmed-2003) with proper The appendix
traceability. The manufacturer should number III has been
also have its own inspection check changed to I
on sodium silicate batch wise as per subsequent to
Appendix-I and proper record shall deletion of earlier
be maintained with traceability. Appendix-I.
4.4 Carbon Di-Oxide Gas: As per feedback
during meeting that
4.4.1 Carbon-di-oxide gas shall be of Inspection Certificate
commercial grade to IS:307-66 for CO2gas is not
(Reaffirmed 2006). The available with the
manufacturer shall keep record of traders from where
Carbon-di-oxide gas, being used in the CO2 gas is
the production as per IS-307-66 procured.
(Reaffirmed 2006) with proper , the requirement of
traceability. Inspection certificate
has been deleted.
The Para has been
reworded and
renumbered for
better clarity.
5. Para 4.5 4.5 Mould Wash: AT welding vendors 4.5 Mould Wash: No Change in
informed that it will be Stipulations of Para.
4.5.1 To achieve good finish of difficult to get the 4.5.1 To achieve good finish of the weld
the weld surface, mould manufacturer test surface, mould wash shall be The Para has been
wash shall be used. certificate for Zircon wash. used. It shall be alcohol base Zircon reworded and
It shall be alcohol base It was clarified that this wash Gr. ZA to IS: 10033-92 renumbered for
Zircon wash Gr.ZA to IS: provision is important for (Reaffirmed 2003) (See Appendix- II). better clarity.
10033-92 (Reaffirmed maintaining quality of .
2003) (See Appendix- II). mould, hence, the vendors 4.5.2 The manufacturer shall keep
shall arrange record/inspection certificate of mould
4.5.2 The manufacturer shall manufacturer test wash being used in the production as
keep record/inspection certificate. Alternatively per IS-10033-92 (Reaffirmed 2003)
certificate as per IS- tests may have to be done with proper traceability. The
10033-92 (Reaffirmed in-house for which manufacturer shall also have its own
2003) with proper requisite facilities will have inspection check of mould wash batch
traceability of mould to be developed. The wise as per Appendix -II and proper
wash, being used in the vendors agreed that they record shall be maintained with
production. will impress upon traceability.
manufacturer to provide
4.5.3 The manufacturer must requisite test certificate.
also have its own
inspection check of mould
wash batch wise as per
Appendix -II and proper
record shall be
maintained with
traceability.

6. Para 5.1 The Mould shall be Vendors mentioned that The Mould shall be manufactured by no- No change in Para.
manufactured by no-bake, erroneously “no – bake” bake, sodium silicate process using
sodium silicate process using has been mentioned detachable pattern and shall be suitable for
detachable pattern and shall be which should be “bake”. welding the required rail section.
suitable for welding the It has been clarified by
required rail section. M&C Dte. that CO2mould
preparation is
theoretically known as
“Inorganic no-bake
method’. Some people do
a low temperature
heating only to drive out
 moisture. Therefore, no
change is needed
7. Para 6 The insignia containing firm's It was mentioned by
code allotted (ITC=T, HTI=H, vendors that in this para
OTPL=O, SIRIL=S, RMPL=R, month has been added to
IFA=F as per AT welding be embossed in the
Manual) month and year of mould during
manufacture shall be manufacture, which is in
embossed in the mould during contradiction to para 20
manufacture for identification. at page 28 & 29 of
specification, which
stipulate only year to be
embossed. It will be
difficult to emboss the
month. It was agreed to
modify the para 6.0 as
per stipulation of para 20
of main specification.
8. Para 7.2.5 7.2.5 Record of important It was mentioned by
parameters like moisture vendors that the batch for
content, permeability, PF Moulds has not been
hardness and defined in specifications.
compressive strength M&C Dte. has commented
(As per IS: 11099-1984- that batch for PF moulds
Reaffirmed-2005) of test shall be as per Mulling/
block of 50x50 mm for Mixer batch. The firm has
every batch of to keep the record of
production shall be parameters i.e. non-
maintained. destructive tests observed
9. New Para -------- on each Muller/ Mixing
batch. For inspection of
the finished mould, batch
for PF Moulds shall be
each day’s production
subject to maximum of
batch size for AT portion +
upto 5% (5% taken
considering the normal
wastage). This will be
suitably incorporated in
The insignia containing firm's code allotted As decided during
(ITC=T, HTI=H, OTPL=O, SIRIL=S, meeting, ‘Month’ has
RMPL=R, IFA=F as per AT welding Manual) deleted from the para
and year of manufacture shall be embossed so as to make
in the mould during manufacture for provisions in
identification. conformity to the
provisions at Para 20
on Main
Specification.
7.2.5 Record of important parameters like Batch size, which
moisture content, permeability, was not defined
hardness and compressive strength earlier, has been
(As per IS: 11099-1984- Reaffirmed- specified as Muller/
2005) of test block of 50x50 mm for Mixer batch, as
every batch i.e. Muller/ Mixer batch decided during the
of production shall be maintained. meeting.
7.3.1 For Inspection of finished mould, the New para 7.3.1
Batch size shall be production of each day added in
subject to maximum of batch size of AT specification defining
welding portion of firm+5%, which shall be Batch size for
included in QAP of firm. inspection of finished
mould. Existing Para
7.3.1 renumbered as
Para 7.3.2.
 the specification.
10. Para 7.3.1 7.3.1 The mould should be It was mentioned by 7.3.2 The mould should be sound and it Weld metal
sound and it should not break vendors that provision of should not break during transit under dimensions checking
during transit under normal both para 7.3.1(a) & (e) normal condition. The name of the required execution of
condition. The name of the test are identical and can be test and their frequency, to be large no. of sample
and their frequency, to be carried merged as a single test. carried out on finished mould by the welds as compared
out on finished mould by the This was agreed. manufacturer at their own and by to inspection of
manufacturer at their own and by Regarding 7.3.1 (f), the purchaser or nominated agency shall portion itself, which is
purchaser or nominated agency vendors indicated that be as under: the main product.
shall be as under: for AT Portion batch size S.N. Test Sample Rema Since, Dimensional
a)Visual Examination - 1% of 600, 6 welds shall be size rks check is also
b)Dimensional check - 1% executed only to check 1. Visual 1% of As per required to be
c)Ringing Test - 1% the weld metal Examina Batch size para undertaken on
d)Hardness Test - 1% dimensions from moulds, tion rounded off 7.3.3 moulds, execution of
e)Internal surface of - 1% whereas for portion to next large no. of sample
mould for proper mould wash inspection, only one higher welds is not
f)Weld metal dimensions- 1% weld is to be executed. number considered
This being destructive 2. Dimensi 2% of As per necessary.
The tests shall be carried test, has cost onal Batch size para Accordingly, sample
out at manufacturer's implications. Instead, the check rounded off 7.3.4 size of Weld metal
premises. If any test is non-destructive test of to next dimensions test has
conducted by outside dimension check of higher been made similar to
approved agency, the cost mould can be kept more. number AT welding portion
of the test is to be borne by It was agreed that 3. Ringing 1% of As per inspection and
the manufacturer. provision will be suitably Test Batch size para frequency of non
reviewed. rounded off 7.3.5 destructive
to next Dimensional check
higher has been doubled.
number
4. Hardnes 1% of As per Para no. has been
s Test Batch size para renumbered and
rounded off 7.3.6 descriptive note
to next about procedure of
higher test has been added
number as remarks for better
5. Internal 1% of As per clarity.
surface Batch size para
of mould rounded off 7.3.7
for to next
proper higher
 mould number
wash
6. Weld 1 per As per
metal Batch, to para
dimensi be checked 7.3.8
ons along with
AT welding
Portion
inspection.

The tests shall be carried out at

manufacturer's premises. If any test is
conducted by outside approved agency,
the cost of the test is to be borne by the
manufacturer.

11. Annexure- 7.3.1.1 Visual Examination: 1% 7.3.3 Visual Examination: The Para no. has been
III, Para of The prefabricated mould shall prefabricated mould shall be checked changed. Sample
7.3.1.1 be checked visually for any visually for any visible imperfection, such as size already defined
visible imperfection, such as surface condition etc. in para 7.3.2, hence
surface condition etc. deleted in this para.

12. Annexure- 7.3.1.2 Dimensional check:
III, Para Dimensional check shall be
7.3.1.2 carried out on 1% of the moulds
for their conformity to the
respective drawing, fitment with
rail end and in mould shoe.
The weld profile dimension
achieved in AT weld using
developed 3 pieces PF mould
should confirm to the approved
weld profile dimension.
Dimension of 3 pieces PF mould
as width and depth at respective
web, foot and bottom which
affect the weld profile dimension
of AT weld will be standardized
during approval. The location of
weld profile dimension shall be
It was mentioned by
vendors that weld
dimension test as per
para 7.3.1.6 shall be done
at the time of portion
inspection only.
Accordingly, the
dimension check shall be
doubled to 2% from
existing 1%. It was
agreed that provision will
be suitably reviewed.
7.3.4 Dimensional check: Dimensional Para no. has been
check shall be carried out on the moulds for changed. The details
their conformity to the respective drawing, of standardized
fitment with rail end and in mould shoe. dimension to be
The weld profile dimension achieved in AT incorporated in QAP
weld using developed 3 pieces PF mould has been included for
should confirm to the approved weld profile information of
dimension. Dimension of 3 pieces PF mould inspecting official.
as width and depth at respective web, foot Sample size already
and bottom which affect the weld profile included in para 7.3.2
dimension of AT weld will be indicated in has been deleted
QAP of firm and the same shall be from here. Revised
standardized during approval. The location Appendix no. has
of weld profile dimension shall be as per been indicated.
Appendix-III.
 as per Appendix-IV.

13. Annexure- 7.3.1.3 Ringing Test: Ringing 7.3.5 Ringing Test: Ringing Test shall be Para no. has been
III, Para Test shall be carried out by using carried out by using a small and light changed.
7.3.1.3 a small and light hammer made hammer made of 10 mm steel rod for
of 10 mm steel rod for checking checking soundness and degree of ramming
soundness and degree of during manufacture. The mould shall have
ramming during manufacture. characteristic ringing sound and shall not
The mould shall have break.
characteristic ringing sound and
shall not break.

14. Para 7.3.1.4 Hardness Test: 7.3.6 Hardness Test: Hardness Test shall Para no. has been
7.3.1.4 Hardness Test shall be carried be carried out on the plane surface of the changed. Sample
out on the plane surface of the mould using a duly calibrated core hardness size already defined
mould using a duly calibrated tester (scratch type). The min. hardness in para 7.3.2, hence
core hardness tester (scratch value for a silicate carbon-di-oxide hardened deleted from this
type). The min. hardness value mould shall be 70. The hardness test shall para to avoid
for a silicate carbon-di-oxide be carried out as per Cl.26 of IS: 1918-66 duplication.
hardened mould shall be 70. (Reaffirmed 2003).
The hardness test shall be
carried out on 1% mould as per
Cl.26 of IS: 1918-66
(Reaffirmed 2003).

15. Para 7.3.1.5 Internal surface of 7.3.7 Internal surface of mould for proper Para no. has been
7.3.1.5 mould for proper mould mould wash: Surface finish shall be changed. Sample
wash: Surface finish shall be checked on the moulds for uniform and size already defined
checked on 1% of the moulds sufficient coatings as per Cl.7.3 of in para 7.3.2, hence
for uniform and sufficient APPENDIX-II. deleted from this
coatings as per Cl.7.3 of para to avoid
APPENDIX-II. duplication.

16. Para 7.3.1.6 Weld dimensions:
7.3.1.6 Dimensional check shall be
carried out on the finished rail
joints using 1% of the mould
pairs for conformity of the
approved weld profile dimension
of respective AT portion
It was mentioned by 7.3.8 Weld dimensions: Para no. has been
vendors that 1% weld Dimensional check shall be carried out on changed. Sample
dimension check at the the finished rail joints using mould pairs for size already defined
time of manufacturing & conformity of the approved weld profile in para 7.3.2, hence
inspection of mould dimension of respective AT portion deleted from this
result in execution of manufacturer. para to avoid
substantial quality of duplication.
 manufacturer. weld. Accordingly, it was
discussed that weld
dimension test done at
present at the time of
inspection of portion
only. This will be suitably
reviewed.

17. Annexure- 7.3.2 Testing facilities to 7.3.9 All requisite Testing facilities to Both paras have
III, Para Inspectors shall be provided by Inspecting officials shall be provided by the been combined and
7.3.2 the manufacturer at their own manufacturer at their own cost. The reworded for better
cost. Inspecting officials shall have free access at clarity. Para no. has
18. Para 7.3.3 7.3.3 Inspecting officials shall be manufacturer’s works in working hours to been changed.
free to visit manufacturer’s works assess the quality of manufacturing process.
in working hours to assess the
quality of manufacturing process.
19. Annexure- 7.3.4 The manufacturer shall 7.3.10 The manufacturer shall provide test Para no. has been
III, Para provide test results of raw results of raw materials and the batches changed.
7.3.4 materials and the batches offered for inspection to the Inspecting
offered for inspection to the officials.
Inspecting officials.

20. Para 9.2 9.2 A pair of such packed Vendors mentioned that 9.2 A pair of such packed moulds shall AT portion
moulds shall again be packed in proper nylon strip bailing again be packed in carton paper boxes manufacturers
carton paper boxes confirming to can damage the mould. confirming to IS:2771(Second Revision). advised that Nylon
IS:2771 (Second Revision). Instead of this, the Proper sealing shall be done on each carton. strip bailing may
Proper Nylon strip bailing shall cartoon paper boxes can damage the mould.
be done on each carton. be sealed by proper Accordingly, Nylon
BOPP tape. It was strip bailing is being
discussed and decided substituted with
that provision will be proper sealing.
reviewed and para shall
be suitably modified.
 B. Indian Railway Standard Specification for Fusion Welding of Rails by Alumino-Thermic Process : Main
Specification
S.No. Para/ Existing para
Clause no.
1. Para 4 4. ACCEPTANCE TEST:
Two portion shall be
randomly selected per batch and
weight of each portion shall be
within + 0.25% of the approved
weight of the portion which shall
be recorded by the inspector.
One portion shall be
utilized for execution of test weld
as per approved parameters for
AT Welding technique. While
executing the test joint,
characteristics of the alumino-
thermic reaction, i.e. whether it is
quiet, normal or boiling shall be
observed and if the reaction is
found to be boiling, the batch
shall be rejected. The reaction
and tapping shall be within 20+ 3
seconds for manual tapping.
Following tests shall be
conducted for assessing the
quality of portion :
a) Ultrasonic test on test
weld as per Annexure-1.
b) Checking of weld metal
dimensions of test weld
with approved weld metal
dimensions of that
particular AT Welding
Discussion during
meeting
It was mentioned that para
does not provide for auto
thimble, which is required
as the same is under
development. It was
agreed that this para shall
be suitably modified.
Revised para Reason of change
4. ACCEPTANCE TEST:
Provision for
Two portion shall be randomly checking of tapping
selected per batch and weight of each time range for AT
portion shall be within + 0.25% of the welding techniques
approved weight of the portion which shall be with Auto-tapping
recorded by the inspector. thimble / One shot
crucible has been
One portion shall be utilized for made in para to
execution of test weld as per approved cover these welding
parameters for AT Welding technique. While techniques.
executing the test joint, characteristics of the
aluminothermic reaction, i.e. whether it is
quiet, normal or boiling shall be observed
and if the reaction is found to be boiling, the
batch shall be rejected. The reaction and
tapping shall be within 20+ 3 seconds for
manual tapping.
In case of A.T. welding technique
with Auto tapping thimble/ One shot crucible,
the reaction and tapping time shall conform
to the tapping time range approved for the
particular AT welding technique, as indicated
in approval certificate and QAP of Firm.
Following tests shall be conducted
for assessing the quality of portion :
a) Ultrasonic test on test weld as
per Annexure-1.
b) Checking of weld metal
dimensions of test weld with
approved weld metal dimensions
of that particular AT Welding
technique.
 technique. c) Mechanical and metallurgical
c) Mechanical and test as per Para 4.2.
metallurgical test as per d) Weld metal chemistry test as per
Para 4.2. Para 4.1.”
d) Weld metal chemistry test
as per Para 4.1.”

2. Para 12.5.1 “12.5.1 (ii) Twelve tests weld “12.5.1 (ii) Twelve tests weld joints shall be The para has been
joints shall be made as per made as per clause 4.2.2. modified so as to
While executing the test joints, make stipulations in
clause 4.2.2. The joints shall characteristics of the aluminothermic line with Para 4 and
be subjected to following reaction, i.e. whether it is quiet, normal or to cover new welding
tests:” boiling shall be observed and if the reaction techniques of auto
is found to be boiling, the technique shall be thimble.
rejected. The reaction and tapping shall be
within 20+ 3 seconds for manual tapping.

The reaction and Tapping time for A.T.

welding technique with Auto tapping thimble/
One shot crucible, shall conform to the
tapping time range indicated in respective
QAP..
The joints shall be subjected to following
tests:”

3. Para 6.2 The manufacturer shall dispatch It was mentioned that in The manufacturer shall dispatch the The provision has
the accepted portions to the view of the latest accepted portions immediately to the been modified in line
consignee preferably within 60 instruction about validity of consignee so as to reach consignee within of ISO guidelines of
days from the date of IC for one month, this para 30 days from the date of issue of Inspection RDSO for validity of
acceptance. shall be deleted. It was Certificate . IC as 30 days.
agreed that this para will
be modified suitably.