SCOPE_Testing of IR type Cantilever at CPRI

Testing Scope:
The total scope of testing of IR type cantilever shall include the followings,

1) Full Scale Test of Cantilever Assemblies,

2) Type Test of Components for IR type cantilevers.

1. Full-Scale Test of IR type Cantilever Assembly:

Various Cantilever configurations as mentioned below for IR type Cantilever Assembly shall be tested in
Full Scale Test, in manner as proposed for testing. The necessary arrangement of the Testing setup and
Assembling of Cantilever shall be done with the support and guidance of CPRI. The required technical
details for assembling of Cantilever e.g. Dimension chart, Tube cutting schedule, Configuration drawings
etc. shall be provided by L&T. The Test Cases are mentioned below:

# Description
1 Open Route / In Run cantilever / Tangent Track / Permanent loads with Construction &
Maintenance load, Reduced Wind (LC E) / pull-off / implantation 4.85 m

2 Yard / Large Span Wire Cantilever / Curved Track / Permanent loads, Wind (LC B) /
implantation 4.00 m

3 Yard / In –Run Turnout-Crossover Cantilever / Curved Track / Permanent loads, Wind

(LCB) / push-off / implantation 4.00 m

4 Open Route / Anti-Creep / Tangent Track / Permanent loads with Construction

Maintenance load, Reduced Wind (LC E) / Pull off / implantation 4.5 m

5 Open Route / Anti-Creep / Curved Track / Permanent loads with Construction &
Maintenance load, Reduced Wind (LC E) / Pull off / implantation 4.5 m

6 Open Route / In Run cantilever / Curved Track / Permanent loads, High Wind (LC B – High Wind)
/ push-off / implantation 4.85 m

7 Open Route / Anti-Creep / Curved Track / Permanent loads with Construction & Maintenance
load, Reduced Wind (LC E) / Pull off / implantation 4.85 m

The test cases mentioned above are individual cases of Cantilever Assemblies having independent
loadings. The associated drawings of the assemblies with direction of loads are provided as Annexure-A
for better understanding.

Few of the above Full-scale test cases shall be performed twice, once internally with L&T representatives
for checking and repeated for witnessing with Engineer and L&T representatives.
Loadings:
There shall be three loadings on Cantilevers Assembly mentioned as follows,

1) Horizontal Load at Catenary wire (Ht)

2) Vertical Load at Catenary wire (Vt)
3) Horizontal load at Contact wire (Hf), wherever applicable.

The load cycles to be followed for the testing of Cantilever Assemblies are described in the Method
Statement.

The magnitude of the Loadings for different Load cases to be tested is attached as Annexure-B.

Displacement Checks:
The displacements of the Catenary point (i.e. at suspension clamp point) & Contact point (i.e. at the drop
bracket point as steady arm is not used in full-scale test) and displacements of Stay, Bracket and Register
tubes for checking of bending shall be measures and recorded.

The point of measurements shall be at every 0.5m along the length of the tubes.

Record of Tests Results:

All the relevant Test Result details in form of Data, Images, Graphs, Videos, Calibration certificates etc.
required shall be recorded and used for compilation of the Test report.

The preparation of the Test report shall be the mutual scope of L&T & CPRI and the report shall be
validated by CPRI.

2. Component Type Test:

The following tests in Component Type testing shall be performed at CPRI.

a) Dimension Check
b) Functional Test
c) Mechanical Load Testing

The necessary Test setups, Rigs, Loading arrangements shall be done in support and guidance of CPRI.

Only Dimension check is required to be performed for the following Tubes,

1) 70x4.3 mm Bracket Tube

2) 33.7x2.65 mm Stay/Register/Strut Tube
3) 33.7x4 mm Register Tube

The Total number of varieties of Component Assemblies to be Type testes shall be 23, out of which 8 nos.
of components require only the Dimension check and for remaining 15 nos. Dimension check, Functional
check and Load testing is required. The further detailing of the Tests to be performed in the type test of
Components is provided below in form of Inspection & Test Plan for better understanding,
 Functional Test Mechanical Load Test
Verification
Drawing No. Description of Clamp
Dimensions Componen
Clamp Component (Slip
t
test)
Galvanized Steel
Tube 33.7x2.65,
RE/33/P/2401
Stay Arm and T - - - -
RE/33/P/2421
Register Arm Tube,
Diagonal strut
Galvanized Steel
RE/33/P/2421 (S) Tube 33.7x4, T - - - -
Register Arm Tube
Galvanized Steel
RE/33/P/2081 (S) Tube 70x4.3, T - - - -
Bracket Arm Tube
ETI/OHE/P/3071-1(S) Mast Hinge Joint T T - T -
Catenary
ETI/OHE/P/2131 (S),
Suspension Bracket T T - T -
2132 (S)
Top & Bottom
RE/33/P/1161 (S) Catenary
T T T T T
Suspension Clamp
RE/33/P/1171 (S) Double Suspension
T T T T T
Clamp
ETI/OHE/P/2402-1
(S1),ETI/OHE/P/2402 Stay Adjuster T T - T -
-1 (S2)
TI/DRG/OHE/FTGFE/
Tubular Stay Sleeve T T - - -
RDSO/00004/03/0
TI/DRG/OHE/2086 Stay Tube Sleeve
T T - - -
(S) 55/33.7 mm
ETI/OHE/P/2390, Steady Arm
T T - T -
2392 (S) Assembly
ETI/OHE/P/2161-2 Large Register Arm
T T - T -
(S1), 2162-2 (S1) Hook
ETI/OHE/P/2422-2 Register Arm Eye
T T - T -
(S1) Piece
ETI/OHE/P/2422-2 Register Arm Eye
T T - T -
(S2) Piece
Drop Bracket
ETI/OHE/P/2360 T T - T -
Assembly
ETI/OHE/P/2161-2 Strut Fitting for Ø70
T T - T -
(S1), 2162-2 (S2) mm Tube
ETI/OHE/P/2161-2 Strut Fitting for
T T - T -
(S2), 2162-2 (S3) Ø33.7 mm Tube
ETI/OHE/P/2422-2 Strut Tube End
T T - T -
(S3), Fitting
Bracket Tube Cap,
ETI/OHE/P/2104-1 T - - - -
55mm (SPL)
Register Arm Tube
ETI/OHE/P/2423-1 T - - - -
Cap, 33.7mm
ETI/OHE/P/2423-1 Register Arm Tube
T - - - -
(S) Cap, 33.7mm (SPL)
ETI/OHE/P/2460,
Register Arm
2277 (S), 2461- T T - T -
Dropper Assembly
1,2471-1
Raised Register
RE/33/P/2432 T T - T -
Arm Adjuster
 Raised Register
ETI/OHE/P/1370-2 T T T T -
Arm Clamp
ETI/OHE/P/2502(S) Wind Stay T - - - -
Eye clip for Wind
ETI/OHE/P/2504(S) T T - - -
Stay
ETI/OHE/P/150, 150
U-bolt T - - - -
(S)
T – Required in Type Test

The drawings for the above components are attached as folder with this scope for better understanding.

The Loadings on the components to be applied during tests is attached as Annexure-C.

Record of Test Results:

All the relevant Test Result details in form of Data, Images, Graphs, Videos, Calibration certificates etc.
required shall be recorded and used for compilation of the Test report.

The preparation of the Test report shall be the mutual scope of L&T & CPRI and the report shall be
validated by CPRI.