SCHEDULE OF TECHNICAL REQUIREMENTS FOR FABRICATION OF STEEL

GIRDERS (EXISTING)

1. Scope

This schedule covers the norms for evaluation of both the capability and the
capacity of any firm to manufacture and supply Steel Bridge Girders. Intended
fabricators will be required to fabricate riveted/welded plate girders and
riveted/welded open web girders.

2. Procedure for registration of firms for fabrication of girders.

2.1 The firm will ensure availability of

i) The required infrastructure, machinery & Plant.
ii) Testing and measuring equipments duly calibrated.
iii) Trained technical manpower and Quality Assurance Programme
iv) Equipments meeting the requirements of relevant specifications.
v) Space required for manufacturing, testing and storage viz. manufacturing floor,
godown, store, office and test lab etc.

2.2 In case fabricator is satisfied that the infrastructure available commensurate with
the above stated requirements then firm shall apply for registration ON- LINE on
the RDSO website. All relevant documents like Guidelines for Registration and
Quality Audit of Vendors in Bridge & Structure Directorate, Application Form,
Schedule of Technical Requirement (ŞTR), latest version of relevant specifications
(if applicable), RDSO Vendor Approval Process Guidelines, etc. are available on
the RDSO website. The requisite charges as specified on website are to be
deposited through the means as specified on the RDSO website.

2.2.1 The firm has to submit ONLINE complete application form, self compliance of STR
and all necessary documents in support of self compliance of STR and
documents in support of other important aspects of application. The firm has also
to submit the Undertakings and Documents as mentioned in Doc No. BS- G-4.2.3-1
(latest version) titled “Guidelines for Registration and Quality Audit of Vendors in
Bridge & Structure Directorate.”

2.2.2 For detail procedure for Registration and other related aspects, refer to Doc No.
BS-G-4.2.3-1 (latest version) titled “Guidelines for Registration and Quality Audit
of Vendors in Bridge & Structure Directorate."

3. Norms for Acceptance

3.1 To qualify for riveted steel bridge girders production, the firm must satisfy the
infrastructural requirement as laid down in para 4 to 6.
3.2 To qualify for welded steel girders production, firm must satisfy the requirement
laid down in para 7 in addition to requirement of other para 4 to 6.

3.3 Fabricators who do not have established the workshop for fabrication but do have
required facilities at site as given in para 3.1 & 3.2 above as applicable will also be
considered.

4. General and Infrastructural Requirements for Steel Girders:- Provide Detail

Information on items given below and enclose necessary documents in support as
applicable ONLINE:-

4.1 The fabricator must have adequate organization including supervisors, skilled
workers and adequate manpower to execute the fabrication work in competent
manner. (Enclose list of staff along with Qualification & experience of employees.)

4.2 Various raw materials and consumables etc. required for fabricating steel
girders must be purchased by fabricators and a proper organization must
exist to perform the functions of purchasing of various raw materials and
consumables etc. and maintaining related inspection certificates, test certificates
etc. (Enclose lift of staff along with Qualification & experience of employees).

4.3 Previous experience of fabricating steel structures capable of with-standing

dynamic loads such as bridge girders, microwave towers, heavy industrial steel
structures etc. is essential.
Note:-
(i) Bridge Girders:- Firm should have fabricated not less than 1 span of 30m
or above Open Web Girder or not less than 3 spans of Plate Girder for
Railway Bridge or ROB’s (Foot Over Bridges, Pipe Line crossings etc.
will not be considered for similar experience purpose).
(ii) Towers:- Fabrication of only those Microwave Tower/Power
Transmission Tower/Chimneys will be considered for which height above
ground level is not less than 30 meters.
(iii) Gantry Girders:- Fabrication of Gantry Girders and/ or columns designed
to cater for EOT crane of capacity not less than 50 tone.
(iv) Heavy Industrial Structure is defined as the work in which firm has
fabricated more than 1000 MT involving built up Section like I-girder of
depth not less than 700 mm or Box section with X-sectional area of Box not
less than 90000 mm2.
(v) Previous experience will be considered only for the works completed
during the last five financial years & upto the date of application in the
current financial year.
(vi) For items (i) to (iv), the applicant has to submit the concerned fabrication
details along with performance certificate from client, explicitly as
supporting documents for this and in absence of these, experience will
 not be considered. Certificate issued by Govt./ Semi Govt./PSU’s will be
accepted for this purpose.
(vii) Performance certificate from Private individuals will not be accepted
except those which are reputed Pvt. Ltd. firm whose turnover is more
than 100 crores per annum and the applicant has to submit necessary
certificate from CA and Audit Reports of CA or Income Tax returns to
prove his point.
(viii) Necessary documents in support of above to be enclosed. If above
conditions are not satisfied, it will be deemed that firm is not having the
desired experience, which in turn is essential & his application will be
closed as per procedure mentioned in Guidelines for Registration/
Renewal of Vendors in Bridge & Structure Directorate.

4.4 A proper procedure for maintenance of records for receipt and consumption of raw
material should be in vogue or developed so as to permit verification by railway’s
representative.

4.5 Adequate power supply should be available through distribution agencies and
adequate backup shall be available through captive generation. (Necessary
documents in support to be enclosed).

4.6 Covered bay area served by EOT cranes or by mechanically operated machines
should be provided to handle day today fabrication of girder components.
(Necessary documents in support to be enclosed).

4.7 Enough area to store raw material, sub assemblies and finished product should
be available. The area provided should be enough to store raw material to
execute the work order for requirement of steel. Suitable material handling
facilities in form of EOT/mobile cranes should be available.

4.8 A separate line for inspection and testing of girders should be provided for final
inspection and testing of bridge girders by railway’s inspecting engineers.

4.9 Covered shed area protected from rain, dust etc. should be provided for surface
preparation/painting/metalizing of steel girders. As no part of the work shall be
painted unless it has been finally passed and cleared by inspecting officer,
adequate space for storing fabricated component awaiting painting shall be
available.

4.10 For full scale layout of drawings to which girders are to be manufactured,
template shop with steel/concrete floor should be available. For symmetrical
girders, central half of the layout may be done and for non-symmetrical girders
full-length layout shall be required. Further, for development of jigs and fixtures
this shop should have in-house jigs manufacturing facilities.
Note: For para 4.6 to 4.10 Applicant has to submit ONLINE neat copy of plan of
works premises & show detail of items given below:-
 (a) Covered bay area with proper handling facilities available to handle
day-to-day fabrication of Steel Bridge Girder.
(b) Area for storing raw material, sub-assemblies & finished products
etc.
(c) Area for separate line for inspection and testing of Girder.
(d) Covered shed area protected from rain, dust etc, available for
surface preparation/painting/metalizing.
(e) Availability of Template floor.

4.11 Sufficient space for trial erection of the girder after manufacture shall be
available. For this purpose, proper handling equipment, stacking space and other
facility shall be available and same should be marked clearly in the factory plan
to be submitted.

4.12 An adequately equipped and staffed drawing office is required for preparation of
fabrication drawings. (Enclose list of staff along with Qualification & experience
of employees).

4.13 Digital Signatures:

It is mandatory for all the vendors to obtain Digital Signature Certificate & get
registered with IREPS at http://www.ireps.gov.in.

4.14 It should be mandatory to inform the RDSO through FAX (followed by

confirmation copy through courier/speed post) as soon as any machinery is
removed from the firm’s premise (even for repair etc.). RDSO should be informed
again, when brought back and made operational.

4.15 Firm should be required to give an undertaking at the time of seeking approval
that if at any time after approval is accorded, some machinery is found deficient
without intimation to RDSO, then it will be presumed that machinery was not
there since beginning and firm’s approval will be withdrawn immediately.

4.16 Firm should submit the detail of Equipments/Machinery i.e. covering Quantity,
Make, Model Number, Capacity, Year of manufacture/commissioning, Machine
number etc. preferably in a chart form for the machineries and plants as mentioned
under para-5 and 7.1 to 7.2 given below (Machinery owned by sister concern will
not be accepted).

5. Machinery & Plants:

Following machinery and plants shall be available with the fabricator:

5.1 EOT/Portal/mobile crane of min. 10t capacity or suitable material handling facility
to serve the handling of material for fabrication of girders, unloading of raw
material and loading of finished product.
5.2 Compressors of adequate capacity suitable for riveting and for other
simultaneous applications.

5.3 Oxy-Acetylene gas cutting equipment

a) Profile cutting equipment of adequate size.
b) Self propelled straight cutting equipment preferably consisting of multiple
torches.

5.4 Radial drilling machines of adequate capacity to drill holes of 12 to 50 mm

diameter.

5.5 End milling machine.

5.6 Plate & structural sections straightening machine.

5.7 Pneumatic/hydraulic yoke riveting machine.

5.8 Adequate number of portable pneumatic tools such as grinders, drilling

machines, chipping machines, wrenches etc.

5.9 Dumpy level or theodolite instrument for recording of camber/deflection of trial

erected girder.

5.10 Facilities for surface preparation/painting/metalizing as per IRS B-1 specification.

5.11 A) To test the raw material and girders to conform it for relevant specification,
testing facilities for the following must be provided:-
(a) Elcometer for measuring thickness of paint.
(b) Steel measuring tape duly calibrated

B) Following facilities for testing of material can be In house or may be arranged

from external agencies:
a) Equipments required for testing of mechanical properties, chemical
composition and microstructure etc.
Note:- If facility is in house provide details of Equipment like, Make, Model
Number, Capacity, Year of manufacture/ commissioning and copy of test
certificates issued earlier. If outsourced, submit copy of MOU with NABL
Lab and copy of some previous Test Certificate issued by NABL Lab.
The MOU should have validity of minimum 30 months.
b) Ultrasonic flaw detection testing facilities for checking internal flaws and
thickness of section.
Note:- If facility is in house provide details of Equipment like, Make, Model
Number, Year of manufactured/commissioning, Proficiency Certificate of
minimum level-II of personal conducting UT Test and copy of some test
 certificates issued earlier. If outsourced, submit copy of MOU with NABL
Lab/approved agency, Proficiency Certificate of minimum level-II of
personal conducting UT Test and copy of some previous Test Certificate
issued by NABL Lab/approved agency. The MOU should have validity of
minimum 30 months.

5.12 System of periodical maintenance of M&P must be in vogue and proper records
maintained.

6. Quality Infrastructure:

6.1 Fabricator shall have proper quality infrastructure to ensure the quality product
as required under latest issue of IRS B1 Specification and IRS Welded Bridge
Code as applicable. ISO certified firms would be preferred.

6.2 A system should be in force for analysis of defects noticed during internal and
external inspections of the final product and sub-assemblies. A dynamic
arrangement for a feed back to the source of defects and for rectification should
be in vogue. Necessary performas followed to be enclosed.

6.3 The fabricator should have adequate infrastructure and facilities like checking
gauges, templates etc. during fabrication required from time to time so as to
ensure that the finished product is as per requirement of IRS: B1 and Welded
Bridge Code

6.4 Following specifications/codes commonly referred in connection with fabrication

of riveted steel girders must be available with fabricator.

The latest version of BIS Code/Specifications referred herein including their

amendments issued from time to time are to be followed,

6.5 All equipments must meet the requirements of corresponding BIS or other
international Specifications.

7. Additional general and infrastructural requirements for fabrication of

welded girders.

7.1 The following facilities should be available for fabrication of welded girders.

a) Welding transformers/rectifier for Manual Metal Arc Welding (MMAW)

b) Inert gas (Carbon Dioxide) welding equipment sets.
c) Automatic sub-merged arc welding equipment.
d) Suitable welding manipulators.
e) Macroetching /Dye Penetrant or Magnetic Particle testing facilities.
f) Arrangement for radiographic test either in house or from external agency.
 Note:- If facility is in house provide details of Equipment like, Make, Model
Number and Year of manufacture/commissioning and provide copy of
proficiency Certificate of minimum level-II of personal conducting RT Test
and copy of Test Certificates issued earlier. If outsourced, submit copy of
MOU with approved Agency by BARC/Atomic Energy Regulatory Board
and copy of Proficiency Certificate (preferable which should be minimum
level-II) of person trained for Radiography Testing and copy of previous
Test Certificates issued earlier by approved agency. The MOU should
have validity of minimum 30 months.
g) Tongue tester for measuring current and voltage.
h) Gauges for checking weld size, throat thickness and edge preparation etc.

7.2 Machine for edge preparation before welding.

7.3 Fabricators must ensure that welding and gas cutting equipment/accessories
meet BIS or other international standard requirements, It will be fabricators
responsibility to satisfy the inspecting engineer that all the welding
equipment/accessories conform to the BIS standard or any other standard in the
absence of proper marking on such equipment/accessories.

7.4 Only trained and qualified Welders shall be deployed for welding. The welders
must be trained in accordance with the provisions of IS: 817. They must be
trained either from recognized welding institutes or by in-house training, if proper
facilities exist. The welders must be tested as per requirements of IS: 7310 and
proper records maintained. Applicant to submit copy of some welding procedures
and Welders Qualification followed at their works.

7.5 All welding shall be carried out under the overall supervision of a qualified
welding supervisor who has been trained in Welding Technology from any
recognized welding institute. Submit details of staff & their Qualification and
experience.

7.6 Welding instructions shall be prominently displayed on the shop floor.

Requirement of the job in hand must be clearly explained to the welder before he
is permitted to work.

7.7 Following specifications/codes commonly referred in connection with fabrication

of welded steel girders must be available with fabricator.

The latest version of BIS Code/Specifications referred herein including their

amendments issued from time to time are to be followed. Wherever to the
standards mentioned above appears in the specification it shall be taken as a
reference to the latest version of the standard.

7.8 Quality Audit of the Registered Vendors will be done every three years for which
following are the requirements:
 (a) The firm should continue to maintain the facilities as required at the time of
initial approval.
(b) The firm should have participated in at least one of the tender of Railway
Bridge Girder Fabrication.
OR
The firm should have carried out any one work satisfying criteria 4.3 of this
STR during the last five financial years & upto validity of current financial
year at the time of Quality Audit.
(c) The firm should not have any adverse report from any of the Railways.

7.8.1 For Quality Audit, firm will be inspected for facilities provided under para 5 to 7 of
this STR, which in turn will be verified alter inspection by the RDSO team.
Regarding para 4 of STR, the firm should give undertaking that organizational
and infrastructural requirement mentioned in para 4 of STR have been
maintained as existing at the time of initial approval.

7.8.2 It the firm does not satisfy either of the criteria given in para 7.8(b), its name will
be removed from list and firm shall have to apply afresh.

8.0 RESPONSIBILITY AND AUTHORITY:

The following table indicate responsibility related to this document:-

Activity Responsible Approver Supporting Consulted Informed

Creation, DBS/T&I ED/B&S DD Insp., - Through

maintenance of this AE/Insp. and intranet/ soft
document Staff of copy.
DD/Insp.
Compliance of DD/B&S/Insp. DBS/T&I Directorate
Directive contained staff
in this document
Requirement of DBS/T&I ED/B&S DD/Insp., Through
Deviation from AE/Insp. intranet/soft
Directive copy

9.0 ABBREVIATION:
ED = Executive Director/B&S
DBS = Director/Joint Director(B&S)/Insp.
DD/Insp. = Deputy Director/Inspection
AE = Assistant Engineer/Insp.
SE = Section Engineer/inspection