INDIAN RAILWAYS

SPECIFICATION
for
DESIGN, DEVELOPMENT AND SUPPLY
of
PREMIUM ELASTOMERIC PADS
for
BROAD GAUGE FREIGHT BOGIES

NO. WD-37-MISC-2004
(REVISION-1)

ISSUED BY

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
MANAK NAGAR, LUCKNOW – 226 011

November - 2019
 WD-37-MISC-2004(Rev-1)

INDEX
S.No. DESCRIPTION Page
No.
1.0 INTRODUCTION 3

2.0 SCOPE 3

3.0 MATERIAL 3
3.1 MATERIAL OF COMPOUND – 3
3.2 MATERIAL OF METAL PLATES – 4

4.0 PHYSICAL PROPERTIES 4

4.1 RUBBER COMPOUND 4
4.2 FOR OTHER COMPOUND 4
4.3 ACCELERATED AGEING 4

5.0 FUNCTIONAL PROPERTIES AND TEST REQUIREMENTS 5

5.1 COMPRESSIVE LOAD DEFLECTION CHARACTERISTICS: 5
5.2 LATERAL SHEAR LOAD DEFLECTION CHARACTERISTICS: 6
5.3 LONGITUDINAL SHEAR LOAD DEFLECTION CHARACTERISTICS 6
5.4 SHEAR BOND STRENGTH 7
5.5 FATIGUE TEST 7

6.0 DIMENSIONS AND TOLERANCES: 8

6.1 CONSTRUCTION, FINISH AND MOULDING PROCESS 8

7.0 INFRASTRUCTURE REQUIREMENTS AND PROCEDURE FOR 9

APPROVAL

8.0 PURCHASE INSPECTION 10

9.0 GUARANTEE 10

10.0 MARKING 11

11.0 PAINTING 11

12.0 PACKING 11
13.0 STORAGE 11

2
 WD-37-MISC-2004(Rev-1)

SPECIFICATION FOR DESIGN, DEVELOPMENT AND SUPPLY

of
PREMIUM ELASTOMERIC PADS
for
BROAD GAUGE FREIGHT BOGIES
(UPTO 25t AXLE LOAD)

1.0 INTRODUCTION

Indian Railways is currently using Elastomeric Pads between the roller bearing adapter and
bogie side frame of the bogies as an anti- vibration component. This rubber to metal bonded
elastomeric pads fitted is as per RDSO Specification No. WD-20-MISC-95 and drawing No
WD-95005-S/1. The life of these elastomeric pads is assessed as 30 months; however,
premature failures have been reported from field.
The objective of this specification is to develop elastomeric pads, which should have
enhanced life of at least 6 years, equivalent to 1.5 million km.

2.0 SCOPE

2.1 This standard specifies the evaluation of physical and functional properties, laboratory
testing and field performance requirements for elastomeric pads to space envelope Drawing
No. WX-98/606. These elastomeric pads shall be used in CASNUB type freight bogies of
Indian railways including LCCF & LWLH25 bogies ranging from 20.32t axle load to 25t
axle loads.

2.2 The elastomeric pad placed between bogie side frame and adapter is subjected to
compressive load and shear forces in dynamic mode of the order of 15 and 3.5 tons (each
elastomeric pad) respectively with a frequency range of 1 Hz to 3 Hz. The lateral shear force
and longitudinal shear force acting on these elastomeric pads generally have maximum
values 3.5 tons. The elastomeric pad shall be capable of withstanding wide climatic variation
prevailing in India (temperature range of –50C to +500C) without physical deterioration and
any marked change of its characteristics, over service life.

3.0 MATERIAL-

3.1 MATERIAL OF COMPOUND –

a) Natural rubber or elastomer or a blend thereof suitably compounded is to be used for

the in manufacturing of elastomeric pads.

b) Any other compound with reputed global associate may also be used with prior
approval of RDSO to conform to the requirements stipulated in this specification. For
this vendor shall obtain the raw material and manufacturing technology/process from
reputed firms. The vendor shall submit a copy of memorandum of
understanding/agreement in this regard to Wagon Directorate, RDSO, and Lucknow at
the time of application.

3
 WD-37-MISC-2004(Rev-1)

3.2
MATERIAL OF METAL PLATES –

Metal plates presently used in EP to RDSO drawing WD-95005-S/1 are as per IS: 2062-
2006 grade E250A. Equivalent or better physical properties material, rolled or forged
can be used in elastomeric pads as per requirement.

4.0 PHYSICAL PROPERTIES

4.1 RUBBER COMPOUND (Finished product)

Physical properties of rubber compound carried out from the finished product shall
be as under-

PROPERTIES Permissible limit

(i) Tensile strength (Kg/cm2) 225 (Minimum)
(ii) Elongation at break (%) 400 % (Minimum)
0
(iii) Compression set (%) at 70+1 C after 24 hours 20 % (Maximum)
(iv) Hardness (shore “A”) 67 + 5
(v) Ash content not to exceed 5%
(vi) Specific gravity not to exceed 1.22
Variation in hardness on entire surface and at core shall not be more than 20 shore A.

To achieve desired fatigue life, resistance to ozone cracking test has to be carried out
as per method ‘A’ of IS: 3400-1994 Part 20.

Wherever it is not possible to cut the Elastomeric Pad for rubber sample, required
number of sample pads without the application of adhesive to the metal plates may
be moulded and then the rubber sample cut from it for tests.

Tests shall be carried out as per relevant part of IS: 3400.

Deviations from above specified values, if any, required for achieving deflection
characteristics [compressive, shear (longitudinal) & shear (lateral)] mentioned in the
4.2 specification is permissible provided prior approval from RDSO is obtained.

FOR OTHER COMPOUND

For material other than rubber, firm with reputed associate shall give values of
physical properties of compound used for elastomeric pad as per parameters given in
4.3 clause 4.1. Other properties relevant to material may be included in the list.

ACCELERATED AGEING

Tests shall be as per IS: 3400 (Part-4) and shall be carried out from the finished
product. Wherever it is not possible to cut the Elastomeric Pad for rubber/compound
sample, required number of sample pads without the application of adhesive to the
steel plates may be moulded and then the sample cut from it for tests.
4
 WD-37-MISC-2004(Rev-1)

After ageing at 70+ 1 degree Celsius in an air oven for 72 +0/-2 hours, the hardness,
tensile strength and elongation at break (%) shall not vary from the values obtained
with the unaged specimens for rubber by more than the following:

(i) Hardness (Shore “A”) +5

-0
(ii) Tensile strength + 20%
(iii) Elongation at break +10%
-30%

It shall be the responsibility of the manufacturer to carry out Accelerated ageing tests
as above. The manufacturer shall carry out these tests on test pieces prepared out of 4
pads for every 1000 pads manufactured. Records of this testing shall be put up to
Inspecting Officer along with every lot offered for inspection. Apart from inspection
of these records, inspecting officer shall also carry out accelerated ageing tests during
purchase inspection for confirmatory purpose.

For compound other than rubber, firm shall provide in QAP the variation in
properties after aging with respect to properties of unaged final product. Aging tests
as described above shall be carried out accordingly.

5.0 FUNCTIONAL PROPERTIES AND TEST REQUIREMENTS

5.1 COMPRESSIVE LOAD DEFLECTION CHARACTERISTICS:

The elastomeric pad shall have compression load deflection characteristics as under-

Load in tons Deflection range in mm

7.5 1.90-2.80
15.0 2.80-4.00
22.5 3.5-4.8

TEST PROCEDURE AND OTHER REQUIREMENTS-

The test shall be carried out at temperature of 25+20C and a machine speed of 10+2.5
mm/minute

The elastomeric pad shall be subjected to three successive loadings from 0 to 22.5 tons.
After third cycle, load of 50 kg is to be applied on pads and deflection readout reading
to be set at zero. The deflection readings are to be recorded at loads on 7.5, 15 and 22.5
tons with the help of digital readout. The load-deflection values shall be within the
specified range as given in Table. The digital readout should be suitable to read a
minimum variation of 10 kg.

5
 WD-37-MISC-2004(Rev-1)

5.2 LATERAL SHEAR LOAD DEFLECTION CHARACTERISTICS:

The elastomeric pad shall have following load deflection characteristics in lateral shear
mode-

Load on 2 pads in tons Deflection range (in mm)

1.4 2.0 – 3.0
2.3 3.2 – 4.8
4.5 4.8 – 7.2
7.0 7.6 – 9.5

TEST PROCEDURE AND OTHER REQUIREMENTS-

This test shall be carried out with combination of two elastomeric pads in a fixture
conceptualize in RDSO Sketch No.WD2-7561-S/1 (Copy enclosed). The elastomeric
pads shall be subjected to a compressive load of 12 tons three times at a ram speed rate of
10+ 2.5 mm/ minute in the fixture. During the fourth compression, the pad shall be held
at compressive load of 12 tons. This assembly then shall be subjected to shear force in
the lateral direction. The load shall be applied to the wooden block and the end plates of
pads, three times successively up to 7.0 tons. Deflection values as per table up to 7.0 tons
shall be recorded during the fourth cycle.

Lateral and longitudinal shear load deflection tests can also be carried out on dual axis
machine of appropriate capacity if available with the firm. For this, suitable fixtures have
to be used.

5.3 LONGITUDINAL SHEAR LOAD DEFLECTION CHARACTERISTICS

The elastomeric pad shall have following load deflection characteristics in longitudinal
shear mode-
Load on 2 pads in tons Deflection range (in mm)
1.4 2.1-3.2
2.3 3.6-5.4
4.5 6.2-8.9
7.0 8.4-11.2

The test is similar lateral shear deflection test and the same assembly is to be used. The
only difference is that the shear load application is in longitudinal mode.
The fixture given in RDSO’s sketch number WD2-7561-S/1 has to be modified to suit
for elastomeric pad and direction of loading. The elastomeric pads shall be subjected
three times to a compressive load of 12 tons at a rate of 10+2.5 mm/minute machine
speed in the modified fixture. During the fourth compression, the elastomeric pad shall
be held at a compressive force of 12 tons. This assembly then shall be subjected to shear
force in the longitudinal direction. The load shall be applied to the wooden block for
three times successively up to 7.0 tons deflection values as per table up to 7.0 tons shall
be recorded during the fourth cycle.

6
 WD-37-MISC-2004(Rev-1)

5.4 SHEAR BOND STRENGTH

The shear bond strength between metal plates and rubber of elastomeric pad shall be
minimum 50.0 kg/cm2. To assess the bond strength, method ‘B’ as given in IS: 3400 -
1984 (part 14) (Reaffirmed in 2013) shall be followed. All the precautions taken for
metal preparation and bonding for preparing test piece shall also be followed for batch
production. The unvulcanised rubber disc for preparing the test piece shall be taken from
the rubber compound prepared for batch production. Record of batch number & test
results should be maintained by the manufacturer and in case of any doubt the Inspecting
officer shall also get a fresh test piece prepared and tested in his presence.

5.5 FATIGUE TEST

This test shall be carried out in the supplier’s premises, for which necessary testing
infrastructure shall be available with the firm. Following infrastructure for fatigue testing
should be available.

i. Fatigue test machine with appropriate capacity to apply load as per RDSO Drg.
No WX-04100F should be available.
ii. The loading cycle should be semi- sinusoidal/trapezoidal.
iii. It should be possible to digital read out of load applied, deflection obtained as
well as number of cycles directly on the machine.
iv. The test fixtures to place elastomeirc pad and load application in such a direction
that shear component of the force applied should be as described in drawing No
WX-04100F.
v. The elastomeric pad shall be fatigue tested at an ambient temperature at 25+20C.
Different pad for vertical-lateral and vertical-longitudinal mode is to be used.
Suitable arrangement for this should be available.

a) VERTICAL AND LATERAL SHEAR MODE

Fixture and load application for vertical & lateral shear mode of fatigue test shall be as
per RDSO drawing WX-04100F. The value of load to be applied on the elastomeric pad
for vertical & lateral shear mode of fatigue testing shall be such as to provide lateral
deflection of elastomeric pad of 5 + 0.2 mm.
Test shall be conducted for 6 (six) lakhs cycles at 2Hz frequency in two stages. After
completion of two lakhs cycles, the elastomeric pad shall be aged at 70+ 20 C for 24
hours. Again, the elastomeric pad shall be fatigue tested for four lakhs cycles at 2 Hz.
The dynamic load should not be allowed to relax during fatigue testing and should be re-
adjusted using shims if necessary to ensure lateral deflection of 5+ 0.2 mm.

b) VERTICAL AND LONGITUDINAL SHEAR MODE

Fixture and load application shall be as given in RDSO drawing WX-04100F for vertical
& longitudinal shear mode of fatigue test. The value of vertical load to be applied for this
purpose on the elastomeric pad shall be such as to provide longitudinal deflection of
elastomeric pad of 7 + 0.3mm.
Test shall be conducted for a total of 6 (six) lakhs cycles at 2Hz frequency in two stages.
After completion of two lakhs cycles, the elastomeric pad shall be aged at 70+ 20 C for
24 hours. Again, the elastomeric pad shall be fatigue tested for four lakhs cycles at 2 Hz.
7
 WD-37-MISC-2004(Rev-1)

The dynamic load should not be allowed to relax during fatigue testing and should be re-
adjusted using shims if necessary to ensure lateral deflection of 7+ 0.3 mm.

c) FATIGUE TEST CRITERIA-

The Composite Elastomeric Pads should be inspected for following after fatigue testing:
i) There should not be any crack/failure indication in metal plates, crushing/perishing of
rubber or other compound of elastomeric pad.
ii) There should be no visual crack or de-bonding of more than 20mm long at any
surface of the rubber/other compound.
iii) Rubber of the elastomeric pad should not take a permanent set exceeding 1.5 mm
from the nominal value at any location.

6.0 DIMENSIONS AND TOLERANCES:

The elastomeric pads shall be manufactured as per firms approved drawing by RDSO.
Firm shall provide dimensions with tolerances on drawing sufficient for quality inspection
of components and elastomeric pad assembly.

6.1 CONSTRUCTION, FINISH AND MOULDING PROCESS

For rubber and its compound, elastomeric pads shall be manufactured by injection
moulding process.

The metal plates shall be degreased, shot/grit blasted to Sa 2.5 and chemically cleaned
with tri chloroethylene, benzene, toulene or naphtha before bonding with rubber. The
shots/grits shall be as per IS: 9139-G-M30. The metal plates must be degreased before
mechanical cleaning as well as after mechanical cleaning. It has to be ensured before
bonding that the metal surface is free from dust, rust, moisture, metal oxide, oily
contaminants and other foreign matter. Chemlok primer shall be applied on dry plates
within one hour of last chemical cleaning. The process adopted for bonding of rubber to
metal plate shall be a proven one using “Chemlok” as primer and bonding agent to
achieve the required durable bond strength. Any other bonding agent can be used only
with prior approval of Director General (Wagon), RDSO, Lucknow.

The rubber (after injection moulding) shall be smooth and free from pinholes, blisters and
any other visual flaws. All sharp edges and burrs shall be removed from the steel plates.
Before applying primer coat for achieving the required bond strength between metal
plates and rubber, the metal plates, which are ready for use, should be stored suitably to
avoid contamination of the metal surface. The metal to rubber bonding shall be uniform
and to the standard laid down later in this specification.

The temperature and moulding time of Injection moulding process shall be optimized for
proper curing of rubber. Rheometer shall be used for this optimization.

For other than rubber/rubber compound, firm shall provide all relevant information
regarding dimension with tolerances, construction process and finish on the drawing and
QAP of the product.

8
 WD-37-MISC-2004(Rev-1)

7.0 INFRASTRUCTURE REQUIREMENTS AND APPROVAL PROCEDURE-

The procedure to be followed for approving vendors for premium Elastomeric Pad to this
specification is given below.

7.1 Firm willing to develop and register for premium elastomeirc pad shall apply to Wagon
Directorate, RDSO, Lucknow along with list of M&P, drawing, MOUs attained, QAP and
copy of complied orders of elastomeric pads (if any) for last three years.

7.2 For existing EP vendors and other firms producing metal to rubber bonded products shall
have all the facilities including steel fabrication shot/grit blasting facilities, cleaning
facilities, injection moulding facilities, rubber testing facilities and fatigue testing machine
in-house as per STR QMS: 05 (latest).

7.3 For firms using raw material other than rubber/rubber compound shall have all facilities for
steel fabrication. In addition, the firm shall have all facilities for processing of compound
used. The infrastructure should have PLC controlled mixer with mass flow meters and
timers to ensure accurate proportion of components in the cast mixture. Pre/Post curing
Ovens of adequate size with temperature control shall also be available.

7.4 The firms for other than rubber/rubber compound shall have to purchase the suitable grade
of raw material from reputed manufactures/technology providers. The supplier shall submit
a copy of memorandum of understanding/agreement in this regard with the application. The
firm shall have trained work force to produce quality product.

7.5 Scrutiny of documents submitted shall be done for the compliance of STR/ product
processing M&P, QAP of the firm and internal test results submitted by firm as per para
4&5. On ascertaining the compliance, RDSO official shall be deputed for infrastructure
verification and sample testing at firm’s premise. Minimum 20samples of elastomeric pads
shall be offered for dimensional measurements and testing as per para 4&5.

7.6 On successful completion of infrastructure verification and sample testing as given in para
7.4, firm shall be permitted to supply 1500 Nos premium elastomeric pad for service trials
on CASNUB 22HS, LCCF and LWLH bogies fitted wagons for a period of 24months.
During field performance, failure of premium elastomeric pads must not be more than 4% of
pads fitted during trail of 24months.

7.7 Wheel and flange wear shall also be monitored during field trial and compared with the
comparator wagon.

7.8 After successful field trial, firm shall be registered as ‘approved vendor for developmental
orders’. Final approval shall be accorded as per existing procedure prevailing at that time.
Those firms, not successful in field performance as per criteria given above may be given one
more opportunity subject to analysing the cause of failures with corrective action taken by
firm and accepted by competent authority.

9
 WD-37-MISC-2004(Rev-1)

8.0 PURCHASE INSPECTION

a) Maximum lot size to offer of elastomeric pads for inspection shall be 2000nos.
b) Material shall be offered for inspection within two months of its manufacture.
c) Visual inspection of 100% pads in general for defects and records of elastomeric pads
produced shall be checked before proceeding further.
d) Out of offered lot 20nos pads shall be drawn randomly by inspecting Officer for
following various checks/tests-

i) Dimensioning as per drawing 20 Nos.

ii) Physical properties tests 02 Nos.
iii) Compressive load deflection test 10Nos.
iv) Shear load deflection (Lateral & longitudinal) 10Nos
v) Shear bond test 01 No.
vi) Shear fatigue test 02 Nos

Note: The same pads will be subjected to compressive load deflection test, shear bond and
shear load deflection tests, as far as possible.
e) Material offered for inspection shall not be withdrawn during the course of inspection.
Any move to withdraw the material or interfere with the inspection in any way shall
render the entire lot being rejected.
f) If the samples fail in one or more of the criteria in para 4.2, “double” the samples will
be drawn and tested against the criteria in which the failure had occurred. If the
“double” samples pass, the lot shall be accepted. Failure of the “double” sample will,
however, result in the rejection of the lot. No further inspection shall be carried out
until the firm has investigated and come up with satisfactory reason for the failure as
well as the remedial action to improve the quality of raw material and/or improved
process and implemented the same.
g) Improvements in raw material quality and/or improved process shall be put to
competent authority for approval before undertaking inspection again.
h) In the event of rejection, the entire lot offered for inspection shall be made unusable
for Railway application destroyed/defaced in the presence of the inspecting authority.
i) Each pad, which has been passed by the Inspecting official, shall be stamped.

9.0 GUARANTEE

9.1 The firm shall stand guarantee of premium elastomeric pad for service period of 60 (sixty)
months from the month and year of manufacturing. In case of any premature failure of pads,
firm will be liable to make free replacement within reasonable time to the depot where
failure has been reported. Whenever repeated failures are reported, firm shall investigate and
come up with satisfactory reasons for failure and take remedial action to improve the
quality.
10
 WD-37-MISC-2004(Rev-1)

9.2 The Zonal Railways will send the information in the following format while claiming
guarantee replacement. Following shall be treated as failures for warrantee replacement.

i) Any crack/failure in metal plate/s, crushing/perishing of rubber or other compound.

ii) Visual crack of more than 12mm or de-bonding of more than 40x25mm at any
surface of the rubber/other compound. However, miner surface crack/s in rubber/
other compound should be ignored.
iii) Permanent set of elastomeric pad of more than 4mm from the nominal value of
elastomeric pad.

manufacture
Elastomeric
Wagon No.

ROH/POH

Causes of
Month of
Make Of

Date of
failure

failure
S. No

date

pad
 Bond failure
 Rubber/other compound crushed
 Rubber/other compound perished
 Rubber/other compound crack
 Permanent set
 Any other defect (please specify)

10.0 MARKING

10.1 Top plate and flange of the Elastomeric Pad shall be punched with the information as given
below: -
 Manufacturer’s name (initials /trade mark).
 Month and year of Manufacture.

10.2 The markings shall be of size and the location as shown in the drawing/approved drawing.

11.0 PAINTING

Each Elastomeric Pad shall be painted with two coats of beach brown enamel to IS: 8662
No.490 on the steel plates only after application of two coats of primer red oxide zinc
chromate to IS: 2074. Powder coating on plates may be permitted.

12.0 PACKING

12.1 The elastomeric pads shall be dusted with French chalk and suitably protected against
damage during transit and storage.

12.2 In the event of sublet orders from bogie manufacturers, packing shall be as agreed to
between purchaser and the supplier.

13.0 STORAGE

These elastomeric pads shall be stored in a cool and dry place.

11