Effective from Year 1978 Specification no.

IRS: S10-78 Rev 8

Mechanical Signalling And Interlocking Equipment

lR;eso t;rs

INDIAN RAILWAY
STANDARD SPECIFICATION
FOR

MECHANICAL SIGNALLING AND INTERLOCKING

EQUIPMENT

SPECIFICATION NO. IRS: S 10-78

Revision 8

(Number of pages 25)

SIGNAL DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW-226011
Effective from Year 1978 Specification no. IRS: S10-78 Rev 8
Mechanical Signalling And Interlocking Equipment

DOCUMENT DATA SHEET

DESIGNATION Revision

IRS: S 10-78 8
TITLE OF DOCUMENT

Indian Railways Standard Specification for

MECHANICAL SIGNALLING AND

INTERLOCKING EQUIPMENT

Authors

Director/ Signal/ RDSO

Approved by

Sr. Executive Director/ Signal, RDSO

Abstract
This document specifies the technical requirements of Mechanical Signalling And
Interlocking Equipment

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Mechanical Signalling And Interlocking Equipment

DOCUMENT CONTROL SHEET

NAME ORGANIZATION FUNCTION LEVEL

Director/ Signal RDSO Member Prepare

Sr. Executive RDSO -

Director/ Signal Approve

Converted into electronic form on Nov 2008

Prepared By: Vivek Kumar
JE-II/ Signal

Checked By: R. Sahai

Asstt. Design Engineer

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Mechanical Signalling And Interlocking Equipment

AMENDMENTS

Version Chapter/ Amendment Effective date

Annexure

IRS: S 10-1932 FIRST ISSUE 1932

IRS: S 15-1934 Revision 1 1934

IRS: S 15-1937 Revision 2 1937

IRS: S 15-1940 Revision 3 1940

IRS: S 15-1950 Revision 4 1950

IRS: S 15-1953 Revision 5 1953

IRS: S 15-1956 Revision 6 1956

IRS: S 15-1964 Revision 7 1964

IRS: S 15-1978 Revision 8 1978

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Mechanical Signalling And Interlocking Equipment

TABLE OF CONTENTS

S.No. Item Page Number

0.0 FOREWORD 1
1.0 SCOPE 5
2.0 DRAWING AND SPECIFICATIONS 6
3.0 TERMINOLOGY 7
4.0 GENERAL REQUIREMENTS 8

5.0 MATERIALS 8
6.0 DIMENSION, LIMITS AND FITS 10
7.0 MANUFACTURE AND WORKMANSHIP 12
8.0 INSPECTION AND TESTING 13
9.0 MARKING AND IDENTIFICATION 17
10.0 PAINTING 17
11.0 HEAT TREATMENT 17
12.0 VITREOUS ENAMELLING 18
13.0 GALVANISING 19
14.0 WELDING 19
15.0 PROTECTION FROM RUST 19
16.0 PACKING 19
17.0 REJECTION 19
18.0 WARRANTY 20
19.0 IMPORTANT NOTE 20

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Effective from Year 1978 Specification no. IRS: S10-78 Rev 8
Mechanical Signalling And Interlocking Equipment

Government of India

MINISTRY OF RAILWAYS

(Railway Board)

lR;eso t;rs

INDIAN RAILWAY
STANDARD SPECIFICATION

FOR
MECHANICAL SIGNALLING AND INTERLOCKING EQUIPMENT

Serial No. S10 – 78

0. FOREWORD

0.1 This specification is issued under the fixed Serial No. S10, followed
by the year of original adoption as standard, or in the case of
revision, the year of last revision.

Adopted, 1932, Revised 1934, 1937, 1940, 1950, 1953, 1956,

1964 & 1978

0.2 This specification requires reference to the following Indian Railway

Standard (IRS) and Indian Standard (IS) specifications:-

IRS : M2 Steel castings.

IRS : M3 Class I, II, III and IV steel forgings, blooms for

forgings and billets for re-rolling.

IRS : S1 Galvanised solid steel wire for signalling purposes.

IRS : S3 Galvanised steel wire rope for signalling purposes.

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IRS : S5 Point rodding.

IRS : S6 Tubular steel signal poles.

IRS : S7 Roundels and lenses.

IRS : S8 Signal lamp burners.

IRS : S11 Double wire signalling ropes 6X19.

IRS : S13 4 mm signal wire rope for double wire signalling.

IRS : S14 5 mm point wire for double wire signalling.

IRS : S23 Electrical signalling and interlocking equipment

(tentative).

IRS : S27 Signal and point indicator lamps (tentative).

IRS : S40 Nylon insulated joints-nylon components.

IS : 77 Linseed oil, boiled, for paints.

IS : 102 Ready mixed paint, brushing, red lead, non-setting,

priming.

IS : 103 Ready mixed paint, brushing, white lead, for priming

and general purposes.

IS : 104 Ready mixed paint, brushing, zinc chrome, priming.

IS : 123 Ready mixed paint, brushing, finishing, semi-gloss,
for general purposes, to Indian Standard Colours and
red oxide (colour unspecified).

IS : 126 Ready mixed paint, brushing, finishing, exterior semi-

gloss, for general purposes, to Indian Standard colour
No. 671 middle graphite and dark graphite.

IS : 154 Ready mixed paint, brushing, dead black, for use on

metals.

IS : 209 Zinc.

IS : 210 Grey iron casting.

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IS : 226 Structural steel (standard quality).

IS : 292 Brass ingots and castings.

IS : 319 Free-cutting brass bars, rods and sections.

IS : 320 High tensile brass rods and sections.

IS : 410 Rolled brass plate, sheet, strip and foil.

IS : 513 Cold rolled carbon steel sheets.

IS : 549 Split pins.

IS : 696 Code of practice for general engineering drawings.

IS : 808 Rolled steel beam, channel and angle sections.

IS : 887 Animal tallow.

IS : 919 Recommendations for limits and fits for engineering.

IS : 1079 Hot rolled carbon steel sheet and strip.

IS : 1148 Hot rolled steel rivet, bars (upto 40 mm diameter) for

structural purposes.
IS : 1161 Steel tubes for structural purposes.

IS : 1239 Mild steel tubes, tubulars and other wrought steel

fittings.

Part I Mild steel tubes.

Part II Mild steel tubulars and other wrought
steel pipe fittings.

IS : 1363 Black hexagon bolts, nuts and lock nuts (dia 6 to 39

mm) and black hexagon screws (dia 6 to 24 mm).

IS : 1365 Slotted countersunk head and slotted raised

countersunk head screws (dia range 1.6 to 20 mm).

IS : 1366 Slotted cheese head screws (dia 1.6 to 20 mm).

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IS : 1570 Schedules for wrought steels for general engineering

purposes.

IS : 1821 Dimensions for clearance holes for metric bolts.

IS : 1875 Carbon steel billets, blooms, slabs and bars for

forgings.

IS : 1928 Boiler rivets (12 to 48 mm diameter).

IS : 1929 Rivets for general purposes (12 to 48 mm diameter).

IS : 1977 Structural steel (ordinary quality).

IS : 2004 Carbon steel forgings for general engineering

purposes.

IS : 2016 Plain washers.

IS : 2036 Paper base thermosetting synthetic resin bonded

laminated sheets.

IS : 2062 Structural steel (fusion welding quality).

IS : 2073 Carbon steel black bars for production of machined

parts for general engineering purposes.

IS : 2074 Ready mixed paint, red oxide-zinc chrome, priming.

IS : 2107 Whiteheart malleable iron castings.

IS : 2108 Blackheart malleable iron castings.

IS : 2155 Rivets for general purposes (below 12 mm diameter)

IS : 2265 Galvanised steel wire strand for signalling purposes.

IS : 2393 Cylindrical pins.

IS : 2429 Round steel short link chain (electric butt welded)

grade 30.

Part I Non calibrated load chain for lifting

purposes.
Part II Calibrated load chain for pulley blocks
and other lifting appliances.

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IS : 2609 Coach bolts.

IS : 2633 Methods of testing uniformity of coating on zinc

coated articles.

638 Flat split cotters.

IS : 3063 Single coil rectangular section spring washers for

bolts, nuts and screws.
IS : 3469 Tolerances for closed die steel for forgings.

Part I General
Part II Drop and press forgings.
Part III Upset forgings.

IS : 4218 ISO metric screw threads:

Part I Basic and design profiles.

Part II Pitch diameter combinations.
Part III Basic dimensions for design profiles.
Part IV Tolerancing system.
Part V Tolerances.
Part VI Limits of sizes for commercial bolts
and nuts (dia range from 1 to 39 mm).

IS : 4820 Vulcanized fibre sheets for electrical purposes.

IS : 4826 Galvanised coatings on round steel wires.

IS : 4855 Bright steel bats for machining.

IS : 5711 Vulcanised fibre rods and tubes for electrical

purposes.

0.3 Wherever reference to any of the above mentioned standard

appears in this specification, it shall be taken as a reference to the
latest version of that standard, unless the year of issue is
specifically stated.

0.4 This specification is intended chiefly to cover the technical

provisions and the provisions relating to supply of the material and
so does not include all the necessary provisions of a contract.

1. SCOPE

1.1 This specification applies to mechanical signalling and interlocking

equipment for Railway signalling. It lays down the general
requirements in regard to the quality of manufacture for ensuring

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that the equipment shall withstand long years of service, under

tropical climatic conditions, without deterioration in performance.

2. DRAWINGS AND SPECIFICATIONS

2.1 The principal object of the drawings is to ensure that items of

equipment developed to the design shall perform the required
function and shall be of uniform standard with inter-changeability of
units or parts consistent with economy in cost.

2.2 The manufacturer shall ensure that the drafting is consistent with
the spirit of the specification and any errors noticed in the drawing
during manufacture or otherwise shall be brought to the notice of
the purchaser or his nominee.

2.3 The manufacturer shall not deviate from the drawings or

specifications without written approval of the purchaser or his
nominee.

2.4 The manufacturer shall be responsible for ensuring that the

provisions of this specification are complied with wherever
applicable in addition to other relevant specifications specified on
the drawings.

2.5 The drawings prepared for purposes of standardization, leave

scope for modifications in designs, materials and manufacturing
and testing, provided the basic objectives of this specification are
maintained.
2.6 Any proposal for deviation from the drawings or specification by
the manufacturer may be considered provided such proposal
results in an improvement in design, reduction in cost or ease in
production consistent with good performance.

2.7 Proposals by the manufacturer for any alternative designs or

equipment of his own design may be considered either by trials of a
prototype or by such data that may be required for proper
consideration of the proposals.

2.8 The proposals envisaged in Clause 2.7 above shall ensure that the
strength, quality, inter-changeability, function of the equipment,
normal life are not impaired in any way and they comply either with
the basic requirements of this specification or that of any other
recognised specification acceptable to purchaser.

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2.9 The manufacturer shall ensure that the equipment supplied by him
conforms to the latest revision of the drawings and specifications to
which such equipment is ordered on him, unless the purchaser
specifically mentions any particular revision to the drawing.

2.10 Information pertaining to alterations and amendments to IRS

drawings and specifications is contained in quarterly notifications
issued from time to time by the Research Designs and Standards
Organisation, Ministry of Railways, Lucknow.

3. TERMINOLOGY

3.1 RDSO’s Drawings – mean those drawings which are initially

prepared for consideration during the various stages of
development of the design in consultation with Railways and firms.

3.2 Advance Drawings – mean the drawings for the design developed
on the basis of the RDSO drawings and are circulated for
manufacture of the equipment for use on railways.

3.3 IRS/S Drawings – mean those drawings which have been finalised
on the basis of the experience gained with the manufacture and
actual extensive usage of the design to the Advance Drawings.

3.4 Investigation Tests – are those which are carried out to determine
that the materials used and the methods of processing adopted are
in conformity with the purchaser’s requirements.

3.5 Type Tests – are those tests which are specified for a particular
equipment in a distinctive manner.

3.6 Performance Tests – are those which are required to prove

satisfactory performance of an equipment under service conditions
and shall include such of those tests as are required to investigate
problems in its installation and maintenance.

3.7 Acceptance Tests – are those which are particularly specified by

the purchaser to be carried out on the equipment at various stages
or on completion and may be any or all the tests concerned with
the equipment before he accepts the delivery.

3.8 Life Tests – are meant to prove that the equipment shall stand
stress and strain of service conditions for a particular period under
particular environments without any sign of disability.

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3.9 Endurance Tests – are carried out to determine the maximum life
of the equipment under actual service conditions.

3.10 Manufacturing Tests – are those required to be carried out on the

workshop floor at different stages in order to verify the quality and
suitability of the complete product for field operation.

4. GENERAL REQUIREMENTS

4.1 All equipment shall be of substantial design, robust and capable of

withstanding such handling as encountered in service, storage or
transhipment under tropical climatic conditions.

4.2 The construction shall be such that no part or element shall get out
of order or displaced due to vibration or other causes as may be
met in railways usage.

4.3 All parts shall normally be easily accessible for maintenance.

4.4 Where specified sealing and/or locking arrangements shall be

provided for each apparatus to avoid any unauthorised
interference.

4.5 All bearings unless otherwise specified shall be provided with oiling
or greasing arrangements.

4.6 The oil or grease shall be suitable for use in temperature range
between 100 C to 1000 C.

4.7 Oil or grease shall be neutral and free from such materials which
might gum or corrode metals under all specified climatic conditions.

4.8 All mechanical signalling and interlocking equipment shall fail safe.

5. MATERIALS

5.1 The fittings shall be manufactured from the materials specified on

the drawings. Attention is drawn to the following Indian Railway
Standard and Indian Standard specifications to which the materials
must conform unless otherwise specified by the purchaser:-

5.1.1 Steel class I, II, III & IV for forging : IS : 1875

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5.1.2 Structural steel (standard quality) : IS : 226

5.1.3 Structural steel (ordinary quality) : IS : 1977

5.1.4 Structural steel (fusion welding quality) : IS : 2062

5.1.5 Steel for case hardening : IS : 2073 type C14

5.1.6 Bright steel bars for machining : IS : 4855

5.1.7 Hot rolled steel rivet bars (upto 40 mm : IS : 1148

Diameter) for structural purposes.
5.1.8 Steel sheet : IS : 1079 or IS :
513
(grade & type as
specified)

5.1.9 Iron castings : IS : 210 (grade as

specified)

5.10 Steel castings : IRS : M2 Class ‘A’

5.1.11 Malleable iron castings : IS : 2107 for

whiteheart and
IS : 2108 for
Blackheart.
5.1.12 Brass bars : IS : 319 & IS : 320

5.1.13 Rolled brass plate, sheet, strip & foil : IS : 410 (grade as
specified)

5.1.14 Brass castings : IS : 292

5.1.15 Plain washers : IS : 2016

5.1.16 Spring washers : IS : 3063

5.1.17 Steel rivets : IS : 1928, IS : 1929

& IS : 2155
5.1.18 Black hexagon bolts with nuts and : IS : 1363
black hexagon screws.
5.1.19 Coach bolts : IS : 2609

5.1.20 Slotted countersunk head machine : IS : 1365

screws.

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5.1.21 Slooted round and cheese head : IS : 1366

machine screws.

5.1.22 Cylindrical pins : IS : 2393

5.1.23 Flat split cotters : IS : 2638

5.1.24 Split cotter pins : IS : 549

5.1.25 Galvanised solid steel wire for : IRS: S1, S13 & S14
signalling purposes.

5.1.26 Galvanised steel wire strand for : IS : 2265

signalling purposes.
5.1.27 Galvanised steel wire rope for : IRS : S3
signalling purposes.

5.1.28 Round steel short link chain (electric butt: IS : 2429 Part I &
welded) grade 30. Non-calibrated load part II
chain for lifting purposes and calibrated
load chain for pulley blocks other lifting
appliances.
5.1.29 Point rodding : IRS : S5

5.1.30 Tubular steel signal poles : IRS : S6

5.1.31 Roundels and lenses : IRS : S7

5.1.32 Fibre sheet : IS : 4820

5.1.33 Fibre rods and tubes : IS : 5711

5.1.34 Rolled sections : IS : 808
5.1.35 Paper base thermosetting synthetic : IS : 2036
resin bonded laminated sheets.
6. DIMENSIONS, LIMITS AND FITS
6.1 Toleranced dimensions on the drawings are to ensure inter-
changeability and manufacture shall be strictly according to those
tolerances.

6.2 Open dimensions on the drawings can be varied by agreement

between manufacturer and the purchaser or his representative
provided that the strength and functioning of the equipment are not
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Mechanical Signalling And Interlocking Equipment

impaired. The limits of open dimensions shall be those as given

below depending upon related dimensions unless other limits are
agreed upon:-
Dimensions Limits
a) Cast surfaces and cored holes
(spacing and dia) in sand casting.

i) Upto and including 150 mm : ±1 mm

ii) Over 150 mm : ±1.5 mm

b) Forgings : IS : 3469 (Part I to II)

c) Machined surfaces : ±0.5 mm
d) Spacing of drilled holes : ±0.5 mm

e) Diameter of drilled holes : IS : 1821

f) On angular dimensions : ±1/20

6.3 The limits and fits shall be on unilateral holes basic in accordance
with IS : 919* unless otherwise specified, the combinations of hole
and shaft shall be as given below:-

a) Fro clearance (loose running) fit : H8 – d9

b) For clearance (extra loose running) fit : H11 – C9

c) For interference (press) fit : H8 – S7

d) For interference (light press) fit : H7 – Y6

6.4 Since the metric limits and fits are shown to the third place of
decimal in IS : 919*, they should be rounded off to the second
place on the following basis:-

To the next higher number in the second place when the third place
is above 2, otherwise, the third place of decimal is ignored.
6.5 The tolerances on screw threads shall be in accordance with
IS : 4218** (Parts I to VI).
_______________________________________________________________________________________________
* Recommendations for limits and fits for engineering.
** ISO metric screw threads.

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6.6 Unless otherwise specified on the drawings, the symbols for

machining and surface finishes shall be in accordance with
IS : 696*.

7. MANUFACTURE AND WORKMANSHIP

7.1 The workmanship throughout shall be of best quality and shall be in

accordance with the best current engineering practice.

7.2 All parts shall be manufactured strictly in accordance with the

drawings and/or specifications as approved by the purchaser.

7.3 All parts shall be free from liability to destruction likely to affect their
operation under severe service conditions, storage or
transhipment.

7.4 All like parts shall be interchangeable.

7.5 The fittings of the parts during assembly shall be first class in all
respects and shall not cause any obstruction to moving parts and
no part shall show any sign of erratic behaviour in service.

7.6 All cranks, balance levers, joints, adjusting screws, lock bar clips
and like parts shall be forged from solid unless otherwise specified.

7.7 Signal and point indicator lamps – The lamps shall comply with
IRS : S27**

7.8 Burner – The burner shall comply with IRS : S8***, unless
otherwise specified by the purchaser.

7.9 Signal Arm

7.9.1 The signal arms shall be made of steel sheet to IS : 1079.#

7.9.2 The arm must be so formed that it can be bolted on to the

semaphore spectacles.

7.9.3 Unless otherwise specified by the purchaser, signal arms shall be

vitreous enamelled and furnished with fastening and pads to fit the
semaphore spectacles. For details of enamelling process, see
Clause 12.

________________________________________________________________

* Code of practice for general engineering drawings.

** Signal and point indicator lamps.
*** Signal lamp burner.
# Hot rolled carbon steel sheet and strip.
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7.10 TESTING OF SIGNAL ARMS

7.10.1 The signal arms shall be tested to the satisfaction of the Inspecting
Officer, in the following manner, for strength to resist wind
pressure.
7.10..1.1 Attach the signal arm to a semaphore spectacles held rigidly with
the arm as a cantilever, and its surfaces horizontal. Apply a load of
122 Kg. per sq.m. at the geometric centre of that portion of the arm
projecting beyond the spectacle. The table sown below is for IRS
arms:-
Type Load Distance of application of load
from free end
A1 28 Kg. 495 mm
A2 26 Kg. 530 mm
B1 24 Kg. 425 mm
B2 22 Kg. 460 mm
C1 15 Kg. 285 mm

7.10.2 The test shall be made first on the front and then on the back of the
arm.
7.10.3 During either of the above tests, the arm shall not take a permanent
set.
8. INSPECTION AND TESTING
8.1 Inspection and tests shall be carried out to ensure that all the
requirements of this specification and those of IRS : S23* where
applicable are complied with.
8.2 General
8.2.1 Testing Facilities – The manufacturer must have an organised
system of manufacturing tests for the equipment and materials and
also system of floor inspection to control the quality of the
equipment in the factory while the equipment is being
manufactured from stage to stage. Manufacturing tests may
include tests other than specified by the purchaser.
8.2.2 Semi-finished Materials – the manufacturer shall ensure that
finished or semi-finished materials received from other sources
used for manufacture are in accordance with the approval current
specification unless otherwise indicated, and with the details as on
the drawings, if any. These may be subjected to tests at any stage
of manufacture to verify their correctness at a laboratory approved
by the purchaser or his nominee.
____________________________________________________
* Electrical signalling and interlocking equipment.

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8.2.3 Access to Inspection – The purchaser or his nominee shall have

free access to the works of the manufacturer at all reasonable
times and shall be given facilities by the manufacturer to inspect
the manufacture of the equipment at any stage of manufacture. He
may reject in whole or part any work or materials that does not
conform to the terms of this Specn: or any other Specn: or
requirement applicable and may order the same to be removed,
replaced or altered at the expense of the manufacturer. All
gauges, templates and other fixtures considered necessary by the
inspecting officer for the inspection of the equipment must be
supplied by the manufacturer free of cost.
8.2.4 Materials and Appliances for Inspection and Testing –
The manufacturer, when required shall supply free of charge, the
material required for test, and shall, at his own cost, furnish and
prepare the necessary test pieces and supply labour and
appliances for such testing as may be carried out in his premises in
accordance with this specification. Failing the existence of facilities
at his own works for making the prescribed tests, the manufacturer
shall bear the cost of carrying out the tests in a laboratory,
workshop or test house, approved by the purchaser.
8.2.5 Tests Requiring Long Periods – In case some of the tests require
long testing periods, the purchaser may demand a warranty for
working of the equipment for at least 3 years in the field without any
deterioration in performance and of materials used in the
equipment.
8.2.6 Approval of Sample by Purchaser.

8.2.6.1 For drawings marked as ‘Advance’ the contractor shall first prepare
a sample for approval of the purchaser or his nominee. Bulk
manufacture, shall be undertaken only after the sample has been
approved in writing by the purchaser or his nominee.
8.2.6.2 Before bulk manufacture is undertaken, the manufacturer shall also
undertake to carry out such modifications as may be considered
necessary by the purchaser in order to ensure the suitability of the
product of the purpose it is required, without any claim of additional
charges.
8.2.7 Test Results – The inspecting officer may, at his discretion check
test results obtained by the manufacturer at his works by
independent tests at Government Test House or in a laboratory or
workshop approved by the purchaser, and should the material so
tested be found to be unsatisfactory, the cost of such test will be
borne by the manufacturer. Should the manufacture’s testing
facilities be found in the inspecting officer’s opinion unreliable, he is
empowered to cancel any tests already carried out with these
facilities and have these tests carried out at the manufacturer’s

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expense at the Government Test House or in a laboratory or

workshop approved by the purchaser.
8.3 Visual Inspection

8.3.1 General
8.3.1.1 Visual inspection shall be carried out to ensure:-

a) that the equipment is of sound construction and that reasonable

precautions have been taken to prevent the ingress of foreign
bodies,

b) that adequate protection is provided for all components against

possible damage due to laying the equipment on any face during
maintenance,
c) that the base of equipment rests squarely on the four corners while
on flat surface,
d) that general arrangement of assembly is in accordance with
specified description and drawings,
e) that no part is damaged or cracked

f) that no metal filings are present,

g) that mating surfaces mate squarely,

h) that parallel faces are in parallelism and true to the eye,

i) that all nuts are tight and locking washers are turned up correctly,

j) that split pins are opened out,

k) that dowel pins are provided wherever required,

l) that adjustments have been correctly made,

m) that working strokes are correct, and

n) that the surface finish is to the satisfaction of the purchaser.

8.3.2 Sealing and locking – It shall be checked that the equipment is

provided with sealing and or locking arrangements as required.

8.3.3 Painting – Visual inspection shall be made to ensure that painting

is as specified and does not affect the working part.

8.3.4 Greasing and Oiling – Visual inspection for greasing and oiling
shall be made to ensure:-
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a) that greasing and oiling arrangements are correct, and

b) that right quality of grease or oil has been used.

8.3.5 Gears – Visual inspection shall be made to ensure:-

a) that gears do not show any tight spot when manually operated,

b) that there is no unusual back lash in the gearing arrangement, and

c) that profiled are correct and properly finished.

8.3.6 Marking and Labelling – It shall be ensured that marking and

labelling are in accordance with purchaser’s requirement and
correspond with the equipment.

8.3.7 Packing and Transhipment – it shall be ensured:-

a) that necessary precautions have been taken to avoid damage of

moving parts in transit, and

b) that packing is of a size to permit convenient handling and is fit to

stand shock, dropping or bumping in transhipment and storage.
8.4 Tests –
8.4.1 Type Tests – All type tests must be carried out in accordance with
approved specification as specified by the purchaser.
8.4.2 Performance Test –
8.4.2.1 The equipment shall work correctly for the purpose intended and
shall show no signs of jamming anywhere or erratic behaviour
under all possible simulated conditions or environments visualised
as being met with under actual service conditions.
8.4.2.2 Test may also be carried out on actual installations to make sure
that the equipment shall correctly perform the required function.
8.5 Investigation Tests –
8.5.1 General – Investigation tests shall be carried out to examine the
suitability of materials and methods of processing in fabrication and
investigate other requirements the apparatus may have to comply
with according to environmental conditions, and shall be carried out
on the first sample. It may also be performed on samples
subsequently made, or if required by the purchaser, on the sample
drawn out at random from the assembly line.

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8.5.2 Life Test – The equipment shall be operated for a number of times
as specified by the purchaser, at the specified rate continuously
and no part of it shall show any sign of erratic behaviour, and after
this shall pass the initial performance test.
8.5.3 Endurance Test –
8.5.3.1 The equipment shall be operated for a maximum number of times
at specified rate continuously till the equipment or parts thereof
begin to show signs of erratic behaviour and fail to pass the
performance test.
8.5.3.2 The above test shall be made in the same manner as the life test
and thereby show the factor of safety available for the equipment
between its maximum tested useful life and its service life
expectancy.
8.6 Acceptance Tests – Purchaser shall specify those tests which are
required to be carried out on a sample or samples from each lot
and on each equipment before accepting the delivery.
9. MARKING AND IDENTIFICATION
9.1 When the size of the part permits, all metal parts shall have the
letters ‘IRS’ and the part number shown on the drawing, stamped
or cast thereon, in letters and figures of suitable size. Cast or
malleable iron parts shall have, in addition to the above,
manufacturer’s name or initials or Trade Mark cast thereon.
9.2 Wherever possible, an engraved name plate giving manufacture’s
name, the IRS No. if nay, Serial No. and year of manufacture shall
be attached on the outside of the apparatus in a conspicuous
position.
10. PAINTING
10.1 Unfinished parts (except parts galvanised) shall be thoroughly
cleaned from rust, scale and dust with steel brushes before
applying a priming coat of red lead paint to IS : 102* or red oxide
paint to IS : 123** or zinc chrome to IS : 104*** or of boiled linseed
oil (cold) to IS : 77**** as specified by the purchaser.
11. HEAT TREATMENT
11.1 Heat treatment, where specified, shall perform to IS : 1570# unless
otherwise indicated.
_______________________________________________________________________________
* Ready mixed paint, brushing, red lead, non-setting, priming.
** Ready mixed paint, brushing, finishing, semi-gloss, for
general purposes, to Indian Standard Colours and red oxide
(colour unspecified).
*** Ready mixed paint, brushing, zinc chrome, priming.
**** Linseed oil, boiled for paints.
# Schedules for wrought steels for general engineering purposes.
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Effective from Year 1978 Specification no. IRS: S10-78 Rev 8
Mechanical Signalling And Interlocking Equipment

12. VITREOUS ENAMELLING

12.1 Prior to the application of the porcelain enamel coatings the metal
shall be thoroughly cleaned to free it from all foreign substances,
such as dirt, scale and grease, by immersion in an acid bath
followed by proper washing and neutralisation.

12.2 All corrugating, slotting drilling etc. shall be carried out before
enamelling and due allowance made for the enamel coatings so
that the finished piece shall be correct to the dimension specified.
All burrs and rough edges shall be removed from the piece before
enamelling is commenced.

12.3 After the piece has been properly pickled, a primary or ground coat
shall be applied by spraying. This coast shall be applied to all parts
of the piece front, back, sides and edges. When fused, the ground
coat shall present a lustrous continuous surface of porcelain
enamel all over the piece, of uniform thickness and free from
blisters, copper-heads or other defects which would expose the
steel to atmospheric effects.

12.4 Following the ground coat, the front and sides of the piece shall
have applied, three coats of porcelain enamel of colours as
specified, each coat to be separately applied and fused. The
primary coating shall be fired at the maximum temperature,
subsequent coasts being fired at progressively lower temperatures,
but the final cost shall be fired at not lower than 8000C.

12.5 Great care must be exercised to prevent the formation of heavy

enamel in the openings in the piece. All holes shall be carefully
wiped for a distance of 3 mm round the edge of the hole in order to
ensure a uniform diameter and to prevent the accumulation of
enamel round the hole edges.

12.6 The enamel application shall be as thin as practicable to ensure a

strong, tenacious covering. The colours, surface and enamelling of
the piece shall be guaranteed unaffected by Indian atmospheric
and climatic conditions and not to crack, craze, fish scale or chip
nor shall it be impaired in any way by free acids contained in the
commoner grades of soap and washing compounds used for
cleaning purposes.

12.7 The enamelling shall be carried out so that no firing marks are
evident on surface of the piece. Plates shall be free from warpage.

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Effective from Year 1978 Specification no. IRS: S10-78 Rev 8
Mechanical Signalling And Interlocking Equipment

13. GALVANISING
13.1 Materials specified to be galvanised shall be hot galvanised with
spelter complying with grade ZN 98.5 of IS : 209*. The coating
shall be clean, free from defects and generally to the satisfaction of
the purchaser or the inspecting officer. The quality of the finished
coating of all galvanised materials shall be such that it meets the
requirements specified in IS : 4826** and IS : 2633*** in so far as
they apply.
14. WELDING

14.1 Electric arc welding of parts shall be in accordance with IRS code
of practice for electric care welding for mild steel structure.
14.2 In all cases where welds are permitted by flash butt welding
method by a machine specially meant for this purpose, the test for
welding shall be carried out as specified by the purchaser.

15. PROTECTION FROM RUST

15.1 Machine finished surfaces shall be coated with a mixture of white
lead and tallow to IS : 103# and IS : 887+ respectively or other
approved preparation which will not melt readily in tropical climate.
15.2 Working parts shall be oiled before being assembled.
15.3 When necessary, screwed holes shall be effectively protected.
15.4 Black bolts and nuts shall be dipped in good quality non-drying
heavy lubricating oil before being packed.
16 PACKING
16.1 Fittings shall be packed in wooden packing cases or crates of a
size and strength suitable for handling and transit, as required by
the purchaser, or the inspecting officer.
16.2 Detailed list of loose components etc. shall be furnished for each
consignment.
17. REJECTION
17.1 Any material which does not comply with the requirements of this
specification may be rejected.
________________________________________________________________________________
* Zinc.
** Galvanised coating on round steel wires.
*** Methods of testing uniformity of coating on zinc coated
articles.
# Ready mixed paint, brushing, white lead for priming and
general purposes.
+ Animal tallow.

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Effective from Year 1978 Specification no. IRS: S10-78 Rev 8
Mechanical Signalling And Interlocking Equipment

18. WARRANTY
18.1 the contractor shall warrant the material covered by this
specification to be free from defects in design, materials and
workmanship under ordinary use and service, his obligation under
this warranty being limited to replace free of cost, those parts which
shall be found defective within one year after delivery to the
purchaser. This warranty shall not apply to any apparatus which
shall have been repaired or altered in anyway by anyone other than
the manufacturer thereof, so as to affect, in the contractor’s
judgement, its proper functioning or reliability, or which has been
subjected to misuse, negligence or accident.
19. IMPORTANT NOTE
19.1 In the event of any requirement, information or specification
applicable to any apparatus or equipment being omitted from this
general specification, the manufacturer shall at once obtain from
the purchaser or his nominee required information, specification or
drawing that may be necessary before proceeding with the
manufacture.

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