Ref: CG-F-4.2.1-4 (Rev. 1) Page 1 of 75 Latest (Rev/Amend) issue : Specification No.

January, 2025 RDSO/CG/S/23002, Rev. 01

INDIAN RAILWAYS

DRAFT

Document Technical Specification Yes

content
Schedule of Technical Requirement Yes
Description AIR SPRING ASSEMBLIES FOR COACHES
of item
Remarks

S. Month/Year of Revision / Page Reason for Amendment/Revision

No. issue Amendment No.
1. June, 2020 - - Revised & merged STR of Air Springs

O April, 2023 nil - Technical changes done, some new clauses

2. added, Section-C added for STR and STR
no. RDSO/2020/CG-01 changed with new
no. i.e. RDSO/CG/S/23002, Rev. nil as per
ISO format.
3. Aug, 2024 01 Added 160.8 Kn Air Spring for VB-2 Coaches
and 160 kN Air Spring for VB-1 &
EMU/MEMU-U/S coaches. Few other
technical upgradations done, some new
clauses added. 0.2 million cycles in deflated
air spring also added with 1 million cycle
endurance tests.

Issued By:
Carriage Directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow - 226011.

Price :

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 2 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

CONTENTS
Description Page
I FOREWORD 3
II AIR SPRING ASSEMBLY (SECTION A)
1. Scope 4
2. Operating Conditions 5
3. Environmental Condition 6
4. Scope of Supply 7
5. Procedure for Vendor Registration 7
6. Technical Requirements 15
7. Submission of Offer 24
8. Guarantee 26
9. Installation, Commissioning, & Maintenance 26
10. Inspection and Testing 27
11. Marking 29
12. Packing 30
13. Maintenance Manual 30
14. General 30
ANNNEXURE - A 31 to 36
ANNNEXURE B 37 to 39
III EMERGENCY RUBBER SPRINGS ( SECTION B)
1. Scope 40
2. Requirements 40
3. Stiffness Characteristics 41
4. Testing of Emergency Rubber Spring 41
5. Bonding Strength Test 42
6. Vertical Load vs Deflection Test (Before Endurance Test) 42
7. Shear Load vs Deflection Test (Before Endurance Test) 43
8. Endurance Test 43
9. Vertical Load vs Deflection Test (After Endurance Test) 45
10. Shear Load vs Deflection Test (After Endurance Test) 45
11. Superimposition of Acquired Data 45
12. Creep Test 45
13. General 46
IV SECTION-C (SCHEDULE OF TECHNICAL REQUIREMENTS) 47 to 53
V ANNEXURE I to IX 54 to 64
DRAWINGS
1. CG Space Envelope (180 KN capacity Air Spring) 65
2. CG 66
3. CG K 4017 Space Envelope (140 KN capacity Air Spring) 67
4. RDSO/CG/DRG/23007, Alt. 01 Space Envelope 160.8 KN AIR SPRING FOR VB- 68
2 COACHES & 160 KN AIR SPRING FOR VB-1 & EMU/MEMU-U/S COACHES
5. CG - 69
6. CG - 70
7. SKETCH- 71
8. CG-18228: Base Plate (140 KN capacity Air Spring for FIAT Bogie) 72
9. RDSO/CG/DRG/23008, Alt. 01, Base Plate 160.8 Kn Air Spring for VB-2 Coaches 73
& 160 kN Air Spring for VB-1 & EMU/MEMU-U/S coaches o

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 3 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

FOREWORD
This specification spells out the technical requirements of following type of Air Springs
assemblies:

1. Air Spring assembly (180 KN Capacity) for higher Capacity Loads used on EMU/DMU/
MEMU Coaches for ICF type Bogies.

2. Higher capacity Air Spring Assembly (160 KN) for LHB Coaches having FIAT Bogie.

3. Air Spring Assembly (140 KN capacity) for Mainline / Rajdhani / MEMU Coaches for
ICF Type Bogies and Mainline/Rajdhani LHB coaches for FIAT type Bogies.

4. Air Spring Assembly (120 KN capacity) for LHB Coaches for FIAT Type Bogies.
5. Air Spring Assembly (160.8 KN capacity) For VB-2 coaches.

6. Air Spring Assembly (160 KN capacity) for VB-1 & EMU/MEMU-U/S coaches

It has been decided to rationalize and ease vendor approval process while keeping
sufficient safeguard for ensuring quality. If a vendor is found capable and competent
to successfully design and manufacture any design / type of air spring for any type of
bogie (FIAT, Vande Bharat or ICF type bogie), service field trial of that type / design of
air spring for that type of bogie has been completed successfully in past, service field
trials of any type / design of air spring for that type of bogie has not been failed /
repeated in past due to complaints regarding poor performance related to quality or
design for any type / design of air springs for that type of bogie, and the vendor has
not been delisted due to poor performance related to quality or design of any type of
air spring in past, design and manufacturing capabilities of the vendor may be relied
upon.

It has been decided to rationalize and simplify the vendor approval process,
while maintaining adequate safeguards to ensure product quality. If a vendor, as
defined in clause 5.5 and 5.6 of section-A, has demonstrated the capability and
competence to successfully design and manufacture any type of air spring for
any bogie (e.g., FIAT, Vande Bharat, or ICF type bogie), and if the field trials for
that air spring design/type have been successfully completed in the past without
any issues related to poor performance, quality, or design, and the vendor has
not been delisted due to quality or design-related issues for any , then the
vendor's design and manufacturing capabilities may be considered [Link]
vendor shall be called as reliable manufacturer.

This specification consists of Section-A, Section-B and Section-C. Section-A is

concerned with the entire Air Spring Assembly whereas the Section-B contains details of the
requirements & tests for the Emergency Springs and Section-C contains infrastructural
requirement.

Note: Specification No. RDSO/CG/S/23002, Rev. nil, had superseded the old no. of this
STR i.e. STR No. RDSO/2020/CG-01.

The specification shall not be altered /modified or reproduced in any form without the
written permission of the Director General (Carriage), RDSO, Lucknow.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 4 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Abbreviations:
IR-Indian Railway OEM-Original Equipment Manufacturer
STR-Schedule of Technical Requirements VB1 coaches - Vande Bharat-1 (Train-18) coaches
Spec.- Specification VB2 coaches - Vande Bharat-2 coaches
LHB-Linke Hofmann Busch (Germany) MEMU-Mainline Electric Multiple Unit
ICF-Integral Coach Factory (Chennai) RDSO-Research Designs and Standards Organization
EMU-Electric Multiple Unit FIAT-Fabric Italina de Automobil Torino (Switzerland)
DEMU-Diesel Electric Multiple Unit dz - Max. Vertical deflection of spring
U/S- Under slung dy - Max. lateral deflection of spring
Sxy Displacement in xy direction Cz - Vertical stiffness Cy - Lateral stiffness
Sz- Displacement in vertical direction LC- Load case
F- Force S- Stiffness f- frequency
fxy- frequency for radial stiffness test Cxy- Radial stiffness
Sxy- Radial displacement Fz- Vertical force

(SECTION - A)

TECHNICAL REQUIREMENTS OF AIR SPRING ASSEMBLIES FOR MAINLINE

COACHES AND EMU/DMU TYPE COACHES

1. SCOPE:

1.1 This schedule lays down the technical requirements for the design and supply of
following types of air spring assemblies:

S. No. Type of Air Spring Assembly Bogie & Stock

1 Air Spring assembly (180 KN Capacity) Conventional ICF type bogies
for higher Capacity Loads used on of EMU / DMU/ MEMU
EMU/DMU/ MEMU Coaches for ICF coaches.
type Bogies.
2 Higher capacity Air Spring Assembly FIAT (Y - frame) Bogie of LHB
(160 KN) for LHB Coaches having FIAT mainline coaches.
Bogie.
3 Air Spring assembly (160.8 KN VB-2 bolster-less Y-Frame
Capacity) for VB-2 coaches. bogie of Vande Bharat
Coaches
4 Air Spring assembly (160 KN Capacity) Y-Frame bogie for Train-18
for Train-18 (VB-1) VB-1 coaches, EMU (VB-1) VB-1 coaches, EMU &
& MEMU-U/S coaches. MEMU-U/S coaches.
5 Air Spring Assembly (140 KN capacity) Conventional ICF type Bogie
for Mainline / Rajdhani / MEMU Coaches and FIAT Bogie for Mainline /
for ICF Type Bogies and Rajdhani / MEMU Coaches.
Mainline/Rajdhani LHB coaches for
FIAT type Bogies.
6 Air Spring Assembly (120 KN capacity) FIAT (Y - frame) Bogie of LHB
for LHB Coaches for FIAT Type Bogies. mainline LHB AC coaches.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 5 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Scope of supply shall generally be as per clause 4 of this specification. However, if the
supplier feels that certain additional items are necessary for improved working
performance of the system, he may quote for the same. In any case, purchaser will
be at liberty to buy all or part material from the offer.

1.2 Control equipment for the air spring assemblies -K407 (Latest
Revision. The air spring assembly should be compatible with the control equipment in
Indian Railways described in the above STR. The purchaser will be at liberty to buy
any part or complete control equipment used in Indian Railways to STR C-K407 (Latest
Revision) and air spring assembly to this specification from different source of supply.

1.3 All the provisions contained in

QO-D-8.1-11 dated 08.05.2019 latest revision -Changes in approved

applicable on the successful vendor/vendors in the contracts floated by Railways to

maintain quality of products supplied to Railways.

2. OPERATING CONDITIONS:

2.1 Each coach fitted with air spring assemblies would have a feed/MR pipe and one brake
pipe. Normally up to twenty-six coaches form a train. Maximum operating speed and
radius of curve which is negotiated by coaches of IR are as under:

Type of coach Maximum Minimum radius of Maximum

operating curve (negotiated Gross
speed by coaches) load
EMU/DMU/MEMU 110 Kmph 152.4 meter 81.2 t
fitted with ICF Bogie.
Mainline/Rajdhani / MEMU 130 Kmph 152.4 meter 65.0 t
conventional type ICF
coaches fitted with
conventional ICF type Bogie.
LHB coaches fitted with FIAT 160 Kmph 152.4 meter 65.0 t
Bogie.
Vande Bharat VB-2 coaches 160 kmph 152.4 meter 68.0 t
fitted with bolster-less Y-
Frame bogie
Train-18 VB-1 coaches/ EMU 160/ 130 152.4 meter 68.0 t / upto
& MEMU-U/S coaches. kmph 79.639t

2.2 Compressed air supply to the air spring assemblies shall be maintained through a
compressor provided in the Locomotive/ DTC/Motor coach. The Locomotive/
DTC/Motor coach compressor charges the Feed pipe/ MR pipe at 6 Kg/cm² for supply
to air spring. Provision of air-drying does not exist in some of the compressed air supply
system. Pneumatic circuit of air spring assembly system is connected to the Feed/ MR
pipe.

2.3 Each coach shall be fitted with four air spring assemblies (two per bogie) and each air
spring assembly shall be controlled by an independent levelling valve (4-point control
system). Two air springs of the same bogie shall be connected through a duplex check
valve set to act at a pressure differential of 1.5 + 0.12 Kg/cm².

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 6 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

2.4 To maintain continuous supply of compressed air to the air spring assembly system,
an 150-litre or suitable capacity for LHB/ ICF/ MEMU/EMU/DEMU and 75-liters for VB-
1 & VB-2 coaches, auxiliary air reservoir has been provided.

2.5 Track-ballast during train operation may occasionally hit the air spring assembly and
control equipments.

2.6

QO-D-8.1-11, Version No. 2.5 (or latest version -Changes in

applicable on the successful vendor/vendors in the contracts floated by Railways to

2.7

3. ENVIRONMENTAL CONDITIONS:

3.1 Air springs fitted in coaches shall be subjected to following environmental conditions:
Max. Temperature under sun : 60ºC 70ºC.
Ambient temperature : -250C to 50ºC.
Average relative humidity : 70% to 90%, 100% on several days.
Rainfall : Fairly heavy, maximum being more than 200mm
in 24 hours, typical to the coastal areas.
Atmosphere/ Environment : Extremely dusty, humid and salty along with
industrial pollutants for several months of the
year.
Elevation : 2m (MSM) to 3500m (MSM) approx. and
atmospheric pressure upto 0.65 atm approx.
Shock and vibration : Higher than specified in IEC 61373

Note:
i) The equipment Air Spring shall function in accordance with this Specification when
subjected continuously to an atmosphere containing dust in concentrations up to 1.6
mg/m3.

ii) The equipment Air Spring shall function in accordance with this Specification when
subjected continuously to a humid and salt laden atmosphere with maximum pH value
of 8.5, sulphate content of 7 mg per liter, maximum concentration of chlorine 6 mg per
liters and maximum conductivity of 130 micro Siemens/cm.

iii) The equipment Air Spring shall function in accordance with this Specification when
subjected to high wind speed in certain areas, with wind pressure reaching 150 kg/m 2.

iv) Equipment Air Spring shall function in accordance with this Specification when
exposed to solar radiation in the range from 0 kW/m2 to 1 kW/m2.

v) Special care shall be taken to ensure no damage to equipment Air Spring due to
deposition of atmospheric salts and industrial pollutants. Supplier shall enclose the
details of specific measures adopted to ensure the satisfactory working of equipment
Air Spring against the deposition of salts & industrial pollution.
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 7 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

3.2 Air spring assembly system may also come in contact with the following, during coach
maintenance operation:
Chemical products (like cleaning compound of coach cleaning)
Cotton waste smeared with oil and paint etc.
Disinfectants.
Oils & lubricants used in coach bogies.
Organic waste

4. SCOPE OF SUPPLY:

4.1 The scope of supply covers the following items:

i) For each air spring assembly:

S. Item Quantity
1 Air spring (Rubber bellow) 1
2 Top interfacing plate with bolster, with spigot 1
3 Sealing O-rings 2
4 Base plate 1
5 Emergency spring 1
6 Mounting Fasteners 4 sets

ii) Any other item, which in the view of the supplier is considered essential for
operation or enhances the performance of the system, may also be offered.

5. PROCEDURE FOR VENDOR REGISTRATION:

5.1 Vendors willing to supply any particular type of air spring or more than one type of air
spring assemblies (as stipulated in para. 1.1 above) for the use of Indian Railways shall
register themselves with Research Designs and Standards Organization, Ministry of
Railways, Lucknow-226011 (RDSO). A vendor should possess valid ISO certificate for
manufacture of same or similar item at his works address.

5.2 The firm should possess an ISO:9001 certificate for his works address, covering the
items for which he seeks registration with RDSO.

5.3 Vendor should possess a valid IRIS certificate for manufacture of same or similar item
at his works address. However, for existing vendors the IRIS certificate may be
submitted within 6 months of issue of this specification.

5.4 Vendor along with their OEM (if applicable) shall have adequate infrastructure for
design, manufacturing, type testing and quality control requirements for air spring
assemblies - . This will be verified by the
RDSO official at the time of registration of the firm or as per requirement. Facilities
available and type testing shall be witnessed / verified by RDSO officials right from the
stage of fitment on machines and intermittently as decided by RDSO till completion.
Manufacturing of some components may be done at reputed sister/allied/outsourced
concern with approval of RDSO.

5.5 Conditions for established OEM or manufacturers having MOU/Agreement with

any established OEM:
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 8 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

a) Air spring vendors shall be recognized on the basis of the OEM design. An OEM
for this purpose shall be defined as a company having the facilities for designing
the air spring and the necessary infrastructure to carry out detailed type tests at
their own facility. Their air spring designs should have been approved over any
railway systems and been in regular passenger service.

b) Application for registration shall therefore be considered from OEMs or from

companies entering into a valid MOU/Agreement with OEM air spring
manufacturers as defined above. The MOU/Agreement should clearly state that
the OEM undertakes to fulfill the warranty and support obligations with respect to
technology up-gradations as and when required for the air spring assembly, even
in case the MOU/Agreement is rescinded at some later stage.

c) Since air springs are a safety related suspension element, in-service field trials
shall be necessary for OEM design before full clearance is given for supply.

d) OEMs whose air springs have completed five years satisfactory service on other
Railway Systems on at least two hundred fifty coach sets, shall only be considered.
Vendors shall be required to submit verifiable documentary proof of satisfactory
performance of the same. Any vendor can submit one online application of
registration for supply of one or more than one type of air spring assemblies.

e) Only one type/ design of air spring for each type of bogie i.e. VB-2 Y-Frame bogie,
VB-1 Y-Frame Bogie, EMU-US/ MEMU-US (U/S) Y-Frame bogie, FIAT bogie &
ICF type bogie, separately, shall undergo for service field trials for period of 6
months ed in para. 5.5 f), 5.5 5.5 g)
and 5.5 i) of Section A of this specification. For this purpose, trial order for
minimum ten coach sets shall be given to such vendors. For other type/ design of
air springs of the vendor, whose air springs for VB-2 Y-Frame bogie or Train-18
VB1 Y-Frame Bogie or EMU/ MEMU (U/S) Y-Frame bogie, or FIAT bogie and/or
ICF type Bogies covered in this specification have successfully completed service
field trials in past, other type/ design of air springs for the same type of bogie (VB-
2 Y-Frame Bogie or VB-1 Y-Frame Bogie or EMU-US/MEMU-US Y-Frame bogie
or FIAT Bogie or ICF type bogie) for which atleast one type/ design of air spring
has completed the service field trials successfully, will not be required to put under
service field trials before registration in future.

Only one type/design of air spring for each bogie type namely, the VB-2 Y-
Frame bogie, VB-1 Y-Frame bogie, EMU-US/MEMU-US Y-Frame bogie, FIAT
bogie, and ICF-type bogie shall undergo in service field trials for a duration
of 6 months on the Indian Railways system, subject to the conditions
outlined in paras 5.5 f), 5.5 g), and 5.5 i) of Section A of this specification.
For this purpose, a trial order for a minimum of ten coach sets shall be
placed with the respective vendors.

For any other type/design of air springs from a vendor whose air springs
for the VB-2 Y-Frame bogie, VB-1 Y-Frame bogie, EMU/MEMU (U/S) Y-Frame
bogie, FIAT bogie, or ICF-type bogies, as specified in this document, have
previously successfully completed field trials, no further field trials shall be
required for other types/designs of air springs for the same bogie type. This
exemption applies provided that at least one type/design of air spring for
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 9 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

that bogie type (VB-2 Y-Frame bogie, VB-1 Y-Frame bogie, EMU-US/MEMU-
US Y-Frame bogie, FIAT bogie, or ICF-type bogie) has successfully
completed the required field trials trials with a condition that the vendor
should be a Reliable Manufacturers as specified in clause-6 of FOREWORD
above.

f) In case of any failure during service field trials attributable to poor design
/quality/material, the service field trials of that particular type of air spring may be
repeated with upgraded design or material only once. In case of repeated trial,
suppliers should offer the upgraded design of the air spring within 4 months from
the date of communication regarding failure of the trials. Non-compliance within
the time frame will result in closing of the field trail as failed.

g) After completion of service field trial period, both air springs of one bogie shall be
subjected to the tests laid down at paras 10.2.1, 10.2.2 and 10.2.3 of Section A
of this specification. In case the values obtained during these tests are beyond
permissible limits, the air spring design shall be deemed to have failed the service
field trials.

h) Vendors providing a particular OEM design as defined at (a) above shall be given
service field trials on a
minimum of ten coach set air springs for 6 months from date of commissioning . A
Vendor shall be considered eligible for up- for
particular type of air spring on completing successful supply of a minimum of 100
coach sets of that particular type of air spring along with the fulfillment of conditions
- Changes in approved
-D-8.1-11)

i)
spring covered in this specification for poor design /quality/material, and / or
service field trial of one or more type of air spring is failed attributable to poor
design /quality/material and requires retrial, air springs of the vendor will be put
under service field trials before registration in future, until the vendor re-establishes
and proves again its design and manufacturing capabilities by successful service
field trials as per para. 5.4.e 5.5 e) of atleast one type air spring for particular type
of bogie (VB-2 Y-Frame Bogie or VB-1 Y-Frame Bogie or EMU-US/MEMU-US Y-
Frame bogie or FIAT Bogie or ICF type bogie), for which registration is applied.

j) In case any part of the air spring assembly is manufactured outside India, a
certificate of country of origin shall be provided with initial supply clearly
establishing the source of manufacture. Source of manufacture of each
component shall be provided by the vendor at the time of design approval.

k) After type tests, a particular OEM design will be approved by RDSO. Vendors shall
ensure that air springs of that particular design are supplied with components
manufactured from the sources as indicated at the time of design approval and
used for type testing.

l) In case design of critical component i.e. Rubber Bellow, top plate or emergency
spring is changed, fresh type test shall be required. Further, in case of any minor
change/ modification in air spring assembly which will not affect the property and
functionality of air spring, type test may also be exempted by the Carriage

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 10 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Directorate. However, in this regard, reason and technical justification for such
minor change/ modification for convincing the competent authority will be
submitted by the firm.

Notwithstanding above However, on the basis of reasons for change and extent
of modification, service field trials can be conducted afresh as per discretion of
Carriage Directorate / RDSO, if any service field trials of the vendor repeated /
failed in past or vendor has been delisted for poor performance of any type of air
spring in past. Status of approved vendor will not be changed if, there is any design
up-gradation / improvement in approved design/drawing of air spring assembly to
meet the upgraded requirements of Indian Railways, with the approval of
Competent Authority.

Notwithstanding the above, service field trials may be conducted afresh at

the discretion of the Carriage Directorate or RDSO, based on the reasons for
the change and the extent of the modification. This may apply in cases where
the vendor's previous field trials were repeated or failed, or if the vendor has
been delisted due to poor performance of any type of air spring in the past.
The status of an approved vendor will not be affected in the event of a design
upgrade or improvement to the approved air spring assembly
design/drawing, provided such changes are made to meet the upgraded
requirements of Indian Railways, and have received approval from the
Competent Authority.

m) In case the source of any critical component of air spring assembly is changed or
any additional new source is introduced, fresh type tests shall be required.
However, the OEM/vendor should provide the detailed information of the source
changed/ additional source introduced for critical as well as non-critical
components both along with the documentary evidence for the record of this office.
OEM shall validate the source in all respects i.e. material, manufacturing process,
quality control and inspection & testing etc. to conform to originally approved
design and process. Compliance with all obligations including
guarantee/warrantee (As per Para 8/Section - A) shall remain the responsibility of
OEM.

n) Vendor in MOU/ agreement with OEM (as mentioned in para. 5.4.b 5.5 b above)
must undertake manufacturing of minimum one of three critical/major components
of Air Spring assembly i.e. either Air Bellow or Emergency Spring or Top Plate
assembly in-house or at allied/sister concern. Facilities and process of
manufacturing (indigenous) shall be validated by OEM. At this stage a fresh type
test shall be essential. The sample air spring assembly shall be picked up by
RDSO. The vendor shall arrange the detailed type testing of sample air spring
ities.
The vendor has to submit the fresh drawing and modified QAP for approval
before undertaking in-house manufacture of these components.
Essential documents as per clause 5.4.b 5.5 c /Section A of specification shall
be submitted for review.

o) Condition for dispensation of vendor items for prototype testing / service field trials
/ upgradation approval for Vande Bharat-ver. 1.0 or Vande Bharat-ver. 2.0 or EMU-
US / MEMU-US Rolling Stock.`
i) Prototype Testing:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 11 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

For prototype testing / type testing of Air Spring for Vande Bharat-ver.1.0 or
Vande Bharat-ver.2.0 or EMU-US/MEMU-US, if prototype / type testing of air
spring design of any vendor has been conducted & accepted under any earlier
contract of Indian Railways, type / prototype testing shall not be repeated and
earlier type / prototype test report shall be accepted. However, if any testing
parameters mentioned in this RDSO specifications were not covered in earlier
above-mentioned type / Prototype test report and source of any critical
component is changed, the necessary compliance as per the specification
shall be completed at the time of fresh registration.

ii) Service Field Trials:

For service field trials of Air spring, for Vande Bharat-ver.1.0 or Vande Bharat-
ver.2.0 or EMU-US/MEMU-US, if any vendor has already supplied number of
air springs for respective bogie designs (Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US/MEMU-US) more than the minimum quantity for
service field trials under any earlier contract of Indian Railways and the same
air springs have been in served in service for more than the service field trials
period as specified in specifications, service field trials of air spring design of
such vendors for respective type of bogie i.e. Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US / MEMU-US, shall not be repeated.

iii) Upgradation:
For upgradation of any firm for Air Spring for Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US/MEMU-US, if any vendor has supplied number of
air springs of particular design against earlier IR contract, more than minimum
required quantity as specified in this specification for upgradation from
developmental vendor to approved vendor. The same shall be considered for
upgradation.

5.6 Conditions for completely indigenous manufacturers without MOU/ agreement

with any established OEM:
a) Supplier should have adequate in-house facilities for design, manufacture and Type
testing of Air Spring. Facilities available and type testing shall be witnessed / verified
by RDSO officials right from the stage of fitment on machines and intermittently as
decided by RDSO till completion. Manufacturing of some components may be
done at reputed sister/allied/outsourced concern with approval of RDSO.

b) Only one type/ design of air spring for each type of bogie i.e VB-2 Y-Frame bogie,
VB-1 Y-Frame Bogie, EMU-US/ MEMU-US (U/S) Y-Frame bogie, FIAT bogie &
ICF type bogie, separately, shall undergo for service field trials for period of one
6.c), 5.6. d), 5.6.e),
5.6.f) and 5.6.h) of Section A of this specification. For this purpose, trial order
for minimum ten coach sets shall be given to such vendors. For other type/ design
of air springs of the vendor, whose air springs for VB-2 Y-Frame bogie or Train-
18 VB1 Y-Frame Bogie or EMU/ MEMU (U/S) Y-Frame bogie, or FIAT bogie
and/or ICF type Bogies covered in this specification have successfully completed
service field trials in past, other type/ design of air springs for the same type of
bogie (VB-2 Y-Frame Bogie or VB-1 Y-Frame Bogie or EMU-US/MEMU-US Y-
Frame bogie or FIAT Bogie or ICF type bogie) for which atleast one type/ design
of air spring has completed the service field trials successfully, will not be required
to put under service field trials before registration in future.
Only one type/design of air spring for each bogie type namely, the VB-2 Y-

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 12 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Frame bogie, VB-1 Y-Frame bogie, EMU-US/MEMU-US Y-Frame bogie, FIAT

bogie, and ICF-type bogie shall undergo in service field trials for a duration
of one year on the Indian Railways system, subject to the conditions
outlined in paras 5.6 c), 5.6 d), 5.6 e), and 5.6 f) of Section A of this
specification. For this purpose, a trial order for a minimum of ten coach sets
shall be placed with the respective vendors.

For any other type/design of air springs from a vendor whose air springs
for the VB-2 Y-Frame bogie, VB-1 Y-Frame bogie, EMU/MEMU (U/S) Y-Frame
bogie, FIAT bogie, or ICF-type bogies, as specified in this document, have
previously successfully completed field trials, no further field trials shall be
required for other types/designs of air springs for the same bogie type. This
exemption applies provided that at least one type/design of air spring for
that bogie type (VB-2 Y-Frame bogie, VB-1 Y-Frame bogie, EMU-US/MEMU-
US Y-Frame bogie, FIAT bogie, or ICF-type bogie) has successfully
completed the required field trials trials with a condition that the vedor
should be a Reliable Manufacturers as specified in clause-6 of FOREWORD
above.

c) After complete type testing of air spring followed by satisfactory test results, firm
will supply minimum 10 coach set air springs only to IR for service field trials,
which shall be preferably fitted in coaches like Power Car, SLR, Motor Coach etc.
where passenger occupancy is relatively lesser.

d) Field performance of minimum 10 coach set air springs shall be monitored for six
months and after six months of service, characteristics of 04 air springs i.e. leak
test, Pressure vs Load test of air spring assembly and load vs deflection test of
emergency spring of in-service air spring
If results of above tests are found within beyond the specified limit then trials of
min. 10 coach sets shall be continued for 6 more months considered failed. The
similar exercise shall also be conducted after 12 months.

e) In case of any failure during service field trials attributable to poor design
/quality/material, the service field trials of that particular type of air spring may be
repeated with upgraded design or material only once. In case of repeated trial,
suppliers should offer the upgraded design of the air spring within 4 months from
the date of communication regarding failure of the trials. Non-compliance within
the time frame will result in closing of the field trail as failed.

f) After successful trial reports from Zonal Railways for one year of service (06
months + 06 months) followed by satisfactory characteristic testing results of two
04 nos. sample in-service air springs at firm s premises as per para. 10.2.1, 10.2.2
and 10.2.3 of Section A of this specification, vendor shall be allowed for regular
supply of air springs as a developmental vendor.

g) A Vendor shall be considered eligible for up-

particular type of air spring on completing successful supply of a minimum of 100
coach sets of that particular type of air spring along with the fulfillment of
- Changes
-D-8.1-11)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 13 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

h)
spring covered in this specification for poor design /quality/material, and / or
service field trial of one or more type of air spring is failed attributable to poor
design /quality/material and requires retrial, air springs of the vendor will be put
under service field trials before registration in future, until the vendor re-
establishes and proves again its design and manufacturing capabilities by
successful service field trials as per para. 5.6.c, 5.6.d, 5.6.e and 5.6.f of atleast
one type air spring for particular type of bogie (VB-2 Y-Frame Bogie or VB-1 Y-
Frame Bogie or EMU-US/MEMU-US Y-Frame bogie or FIAT Bogie or ICF type
bogie), for which registration is applied. Not required in view of the modification
in clause b above. Once the vendor has failed the field trail and or delisted,
his each type of air spring shall be sent to field trail for safety purpose. (for
understanding only deleted after discussion)

i) Source of manufacture of each component of air spring assembly shall be

provided by the vendor at the time of design approval. Sources of critical
components shall be verified by RDSO.

j) After type tests, a particular vendor design will be approved by RDSO, vendors
shall ensure that air springs to that particular design are supplied with components
manufactured from the sources as indicated at the time of design approval and
used for type testing.

k) In case design of critical component i.e. Rubber Bellow, top plate or emergency
spring is changed, fresh type test shall be required. Further, in case of any minor
change/ modification in air spring assembly which will not affect the property and
functionality of air spring, type test may also be exempted by the Carriage
Directorate. However, in this regard, reason and technical justification for such
minor change/ modification for convincing the competent authority will be
submitted by the firm.

However, on the basis of reasons for change and extent of modification, service
field trials can be conducted afresh as per discretion of Carriage Directorate /
RDSO, if any service field trials of the vendor repeated / failed in past or vendor
has been delisted for poor performance of any type of air spring in past.
Notwithstanding the above, service field trials may be conducted afresh at
the discretion of the Carriage Directorate or RDSO, based on the reasons for
the change and the extent of the modification. This may apply in cases where
the vendor's previous field trials were repeated or failed, or if the vendor has
been delisted due to poor performance of any type of air spring in the past.
The status of an approved vendor will not be affected in the event of a
design upgrade or improvement to the approved air spring assembly
design/drawing, provided such changes are made to meet the upgraded
requirements of Indian Railways, and have received approval from the
Competent Authority.
l) In case, source of any critical component of air spring assembly is changed or any
additional new source is introduced, fresh type tests shall be required. The vendor
should provide the detail information of the source changed/ additional source
introduced for critical as well as non-critical components both along with the
documentary evidences for the record of this office. Vendor shall validate the
source in all respects i.e. material, manufacturing process, quality control and
inspection & testing etc. to conform to originally approved design and process.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 14 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Compliance to all obligations including guarantee/warrantee (As per Para

8/Section - A) shall remain the responsibility of Vendor.

m) A vendor must undertake manufacturing of minimum two of three critical/major

components of Air Spring assembly i.e. Air Bellow, and either Emergency Spring
or Top Plate assembly in-house or at allied/sister concern.

n) Condition for dispensation of vendor items for prototype testing / service

field trials / upgradation approval for Vande Bharat-ver. 1.0 or Vande Bharat-
ver. 2.0 or EMU-US / MEMU-US Rolling Stock.

i) Prototype Testing:
For prototype testing / type testing of Air Spring for Vande Bharat-ver.1.0 or
Vande Bharat-ver.2.0 or EMU-US/MEMU-US, if prototype / type testing of air
spring design of any vendor has been conducted & accepted under any earlier
contract of Indian Railways, type / prototype testing shall not be repeated and
earlier type / prototype test report shall be accepted. However, if any testing
parameters mentioned in this RDSO specifications were not covered in earlier
above-mentioned type / Prototype test report and source of any critical
component is changed, the necessary compliance as per the specification
shall be completed at the time of fresh registration.

ii) Service Field Trials:

For service field trials of Air spring, for Vande Bharat-ver.1.0 or Vande Bharat-
ver.2.0 or EMU-US/MEMU-US, if any vendor has already supplied number of
air springs for respective bogie designs (Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US/MEMU-US) more than the minimum quantity for
service field trials under any earlier contract of Indian Railways and the same
air springs have been in served in service for more than the service field trials
period as specified in specifications, service field trials of air spring design of
such vendors for respective type of bogie i.e. Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US / MEMU-US, shall not be repeated.

iii) Upgradation:
For upgradation of any firm for Air Spring for Vande Bharat-ver.1.0 or Vande
Bharat-ver.2.0 or EMU-US/MEMU-US, if any vendor has supplied number of
air springs of particular design against earlier IR contract, more than minimum
required quantity as specified in this specification for upgradation from
developmental vendor to approved vendor. The same shall be considered for
upgradation.

5.7 Capability and capacity assessment of vendors:

Verification of STR and QAP along with assessment of capacity and capability of
manufacturer of Air Spring shall be undertaken by authorized representative of RDSO
at the premises of firm. In case of the firm having their sub assembly manufacturers
located at different locations, the facilities at the location of manufacturing of critical
components i.e. Air Bellow, Top Plate assembly and or Emergency Spring will be
verified along with witnessing of assembly of air spring and Type Testing of Air spring
assembly.

5.8 Prototype Inspection:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 15 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

5.8.1 Vendor shall offer at least two nos. prototype air springs assemblies of particular type,
for which they are seeking registration in RDSO, for necessary inspection and testing
as per paras. 10.2.1, 10.2.2 and 10.2.3 of Section A and other relevant para of this
Specification.

5.8.2 The prototype inspection of air spring assemblies shall be carried out by Carriage
Directorate of RDSO or their nominee at manufacturing premises of firm. The
manufacturer shall provide material, tool and any other assistance without any extra
charges which may consider necessary for any test / examination and dimensional
test.
5.9 Service Field trials quantity:
As per the requirement of Indian Railways, RDSO at its discretion with approval of
competent authority can increase the trial quantity of air springs of particular vendor
based on the satisfactory performance of air springs supplied earlier against
developmental orders for service field trials.

6. TECHNICAL REQURIEMENTS:

6.1 Static load & pressure per air spring assembly:

6.1.1 The air spring assembly shall be capable of withstanding following range of static
vertical loads by using compressed air with a limiting pressure value of 6 Kg/cm².
S. No. Type of air spring Load
Minimum/ Tare Maximum/
load Full load
i) 180 KN capacity 50 KN 180 KN
ii) 160 KN capacity for LHB 50 KN 160 KN
iii) 160.8 KN capacity for VB-2 50 76.6 KN 160.8 KN
iv) 160 kN for VB-1, EMU/MEMU 50 70 KN 160 KN
(U/S)
v) 140 KN capacity 50 KN 140 KN
vi) 120 KN capacity 60 50 KN 120 KN
* For VB-2 coaches and ** for Train-18 VB-1, EMU & MEMU (U/S) coaches

Further, the air spring assembly for FIAT and ICF bogies should be capable of meeting
the maximum vertical load at an air pressure of 5.5-5.8 Kg/cm2 to allow for minor
pressure drops along the train length during run. However, for VB-2/VB-1/EMU-
US/MEMU-US Y- frame bogies, marginal tolerance on air pressure above 6.0 Kg/cm2
may also be allowed marginally due to availability of air pressure more than 6.0 Kg/cm2
through MR pipeline.
6.1.2 It shall be possible to inflate the proposed air spring assembly from its deflated
condition when pre-loaded with a static vertical full load mentioned in above table,
simply by supply of compressed air through levelling valve without any other external
assistance.
6.1.3 The air gap between top plate and emergency spring at tare load should be
minimum 25±3 mm for VB-2, VB-1, EMU-US & MEMU-US coaches. The air gap
between top plate and emergency spring in air springs (120 kN/140 kN/160 kN/180
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 16 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

kN) of FIAT and ICF type bogies, preferably also should be same. Top plates of air
spring assemblies for VB-2 coaches shall be made of Aluminum & for VB-1, EMU-US
& MEMU-US coaches shall be made of Aluminum/ Corrosion resistant Steel and
capable to withstand the maximum dynamic load of coaches (upto max. axle load) on
IR condition and to withstand the max. burst pressure upto 30 kg/cm² during the type
test.

6.2 Deflection characteristics of air spring assembly:-

During dynamic (running) condition of coaches, the air springs shall be subjected to
the following deflections at frequencies of upto 3Hz. The design of the spring should
be able to cater for the same:
S. Type of air spring Deflection
Max. Vertical deflection Max. Lateral deflection
No.
of spring (dz.) of spring (dy.)
i) 180 KN capacity ± 30 mm ± 60 mm
ii) 160 KN capacity for LHB ± 30 mm ± 80 mm
iii) 160.8 KN capacity for VB-2 ± 30 mm ± 128 mm
iv) 160 kN for VB-1, ± 30 mm ± 125 mm ±128 mm
EMU/MEMU (U/S) ±125mm
v) 140 KN capacity ± 30 mm ± 60 mm (ICF Bogie)
& +80 mm (FIAT
bogie)
vi 120 KN capacity ± 30 mm ± 80 mm
* For VB-2 coaches and ** for VB-1, EMU/MEMU-U/S coaches.

6.3 Air Spring assembly shall be designed for use with an additional air reservoir of
following capacity (volume) permanently connected to air spring:

S. No. Type of air spring Additional Volume

i) 180 KN capacity 20 or 40 dm3
ii) 160 KN capacity for LHB 60 dm3
iii) 160.8 KN capacity for VB-2 50 dm3
iv) 160 kN for VB-1, EMU/MEMU (U/S) 50 dm3
v) 140 KN capacity 20 or 40 or 60 dm3
vi) 120 KN capacity 60 dm3
* For VB-2 coaches and ** for VB-1, EMU/MEMU-U/S coaches

6.4 Vertical stiffness of air spring assembly:

6.4.1 Minimum air cushion provided under minimum/tare load condition shall be 25 mm,
with following installed heights:

S. No. Type of air spring Installed / Design Height

i) 180 KN capacity 255+5-0 mm
ii) 160 KN capacity for LHB 294+0-5 mm
iii) 160.8 KN capacity for VB-2 300+5-0 mm
iv) 160 kN for VB-1, EMU/MEMU (U/S) 300+5-0 mm
+0
v) 140 KN capacity 255 -5 mm (for ICF Bogie)
294+0-5 mm (for FIAT Bogie)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 17 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

vi) 120 KN capacity 294+0-5 mm

* For VB-2 coaches and ** for VB-1, EMU/MEMU-U/S coaches

6.4.2 At dz + 20 mm for S. No. i), ii), v) & vi) and + 10 mm for S. No. iii) & iv) at constant
speed of 5 mm/sec, the vertical stiffness (Cz) shall be as under:

S. Type of air Vertical Stiffness under load

No. spring
i) 180 KN
capacity Load in Vertical stiffness (Cz)
KN Additional Additional volume
(Static) Volume 20dm3 40dm3
50 600±100 N/mm 550±100N/mm
165 1200±200N/mm 1000±200N/mm
180 1350±200N/mm 1150±200N/mm

ii) 160 KN
capacity Load in KN Vertical stiffness (Cz)
(Static) (With Additional Volume 60dm3)
50 Informative
60 285 + 20 N/mm
90 360 + 25 N/mm
120 430 + 30 N/mm
160 530 + 40 N/mm

iii) 160.8 KN
capacity (For Load in KN Vertical stiffness (Cz)
VB-2 coaches) (Static) (With Additional Volume 50dm3)
60 Informative
76.6 395 + 7% 10% N/mm
111.8 545 + 7% 10% N/mm
122.7 597 + 7% 10% N/mm
160.8 805+ 7% 10% N/mm

iv) 160 KN
capacity (for Load in KN Vertical stiffness (Cz)
VB-1, (Static) (With Additional Volume 50dm3)
EMU/MEMU- 50 287+ 7% 10% N/mm
U/S coaches)
70 344 + 7% 10% N/mm
100 427 + 7% 10% N/mm
160 597 + 7% 10% N/mm

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 18 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

v) 140 KN
capacity Load in KN Vertical stiffness (Cz)
(Static) Additional Additional volume
Volume 20dm3 40dm3
50 550±50 N/mm 400±50N/mm
115 875±75N/mm 625±75N/mm
140 1000±100N/mm 700±100N/mm

vi) 120 KN
capacity Load in KN Vertical stiffness (Cz)
(Static) (With Additional Volume 60dm3)
50 Informative
60 350±25 N/mm
90 400±50N/mm
120 500±75N/mm

6.5 Lateral spring stiffness of air spring assembly:

At dy +20 mm for S. No. i), ii), v) & vi) and + 10 mm for S. No. iii) & iv) at constant
speed of 5 mm/sec, the lateral stiffness (Cy) shall be as under:
S. Type of air spring Lateral Stiffness under load
No.
i) 180 KN capacity
Load in KN (Static) Lateral stiffness (Cy)

50 250 ±50 N/mm

165 450±100 N/mm
180 500±100 N/mm
ii) 160 KN capacity
Load in KN (Static) Lateral stiffness (Cy)
60 130 + 20 N/mm
90 165 + 25 N/mm
120 200 + 30 N/mm
160 250 + 40 N/mm

iii) 160.8 KN capacity

(For VB-2 Load in KN (Static) Lateral stiffness (Cy)
coaches)
Note: This test also
60 Informative
to be done at dy +10 76.6 101 + 15% N/mm
mm at constant 111.8 111.9 115 + 15% N/mm
speed of 5 mm/sec 122.7 120 + 15% N/mm
160.8 140 + 15% N/mm

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 19 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

iv) 160 KN capacity

(for VB-1, Load in KN (Static) Lateral stiffness (Cy)
EMU/MEMU-U/S 50 111 + 15% N/mm
coaches)
Note: This test also 70 110 + 15% N/mm
to be done at dy +10 100 129 + 15% N/mm
mm at constant 160 164 + 15% N/mm
speed of 5 mm/sec
v) 140 KN capacity
Load in KN (Static) Lateral stiffness (Cy)

50 150 ±25 N/mm

115 175±25 N/mm
140 200±25 N/mm
vi 120 KN capacity
Load in KN (Static) Lateral stiffness (Cy)

60 175±30 N/mm
90
120

6.6 Special characteristic tests & parameters for 160.8 kN & 160 kN air spring for VB-2
& VB-1, EMU/MEMU-U/S coaches
6.6.1 Load v/s Pressure:
S. No. For VB-2 Coaches For VB-1, EMU/MEMU-U/S
Load in KN Pressure (bar) Load in KN Pressure (bar)
1. 76.6 KN *2.90 + 5% 50 *1.9+ 5%
2. 111.8 111.9 KN *4.20+ 5% 70 *2.6+ 5%
3. 122.7 KN *4.60+ 5% 100 *3.65+ 5%
4. 160.8 KN *6.00+ 5% 160 *5.75+ 5%
Variation of +/- 2% in *mean values shall be permissible.

6.6.2 Vertical Stiffness of Emergency Spring:

S. For VB-2 Coaches For VB-1, EMU/MEMU-U/S
No. Load in KN Stiffness (N/mm) Load in KN Stiffness (N/mm)
1. 76.6 KN 2175+ 15% N/mm 50 1575+ 15% N/mm
2. 111.8 111.9 KN 3325+ 15% N/mm 70 2000+ 15% N/mm
3. 122.7 KN 3700+ 15% N/mm 100 2800+ 15% N/mm
4. 160.8 KN Informative 160 5050+ 15% N/mm

6.6.3 Lateral Stiffness of Emergency Spring for VB-1, EMU/MEMU-U/S coaches:

S. No. For VB-2 Coaches For VB-1, EMU/MEMU-U/S
Load in KN Stiffness (N/mm) Load in KN Stiffness (N/mm)
1. 76.6 KN Informative 50 242+ 15% N/mm
2. 111.8 111.9 KN Informative 70 261+ 15% N/mm
3. 122.7 KN Informative 100 291+ 15% N/mm
4. 160.8 KN Informative 160 370+ 15% N/mm

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 20 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

6.6.4 Stability and Inflatability test of air spring for VB-2, VB-1, EMU/MEMU-U/S
coaches:
The air spring system must be inflatable without additional measures in all operational
states. This should be checked by inflation at tare load in combination with maximum
lateral deformation.
For stability test -deflection hysteresis must be stable in the meaning

However, for Stability and Inflatability test of air springs for VB-2, VB-1, EMU/MEMU-
U/S coaches, following load cases mentioned in para [Link] may be applied:
I) For Inflatability test : Load cases LC1- LC4 LC0- LC4
II) For Stability test : Load cases LC50- LC72
Load Cases for Stability and Inflatability test of air springs for VB-2, VB-1, EMU/MEMU-
U/S coaches:
Load Deformation Fz [kN] Description
Condition
case z-z [°] Sxy [mm] Sz [mm]
LC0 Deflate -- 0 0 160.8 Deflated Service
t>15 min with subsequent
inflatability
LC1 Inflated 7,0 128 0 76,6 Depot curve
LC2 Inflated 7,0 128 -Z0 76,6+20 Depot curve + dynamic;
LC3 Inflated 5,0 92 0 122,7 Service curve
LC4 Inflated 5,0 92 -Z1 160,8 Service curve + dynamic;
LC1 Deflate 7,0 128 0 76,6 Deflated Depot
LC2 Deflate 5,0 92 0 122,7 Deflated Service
LC3 Deflate 5,0 92 0 160,8 Deflated Service
LC4 Deflated 7,0 128 0 76,6
inflatability test
LC50 Inflated 7,0 0 ± 128 0 76,6 Stability Depot
LC51 Inflated -- 0 ± 128 -30 76,6 Stability Depot
LC52 Inflated -- 0 ± 128 +20 76,6 Stability Depot
LC60 Inflated 5,0 0 ± 92 0 122,7 Stability Service
LC61 Inflated -- 0 ± 92 -30 122,7 Stability Service
LC62 Inflated -- 0 ± 92 +20 122,7 Stability Service
LC70 Inflated 5,0 0 ± 92 0 160,8 Stability Service
LC71 Inflated -- 0 ± 92 -30 160,8 Stability Service
LC72 Inflated -- 0 ± 92 +20 160,8 Stability Service
Note: For VB-1/EMU/MEMU-U/S coaches, deformation shall be limited to 125mm in place of 128 mm.
[Link] Load Cases for Stability and Inflatability test of air springs for VB-1/EMU-U/S/MEMU-
U/S coaches
Load case movement
No. Condition z-z [°] x [mm] y [mm] z [mm] Fz [kN]
LC1 inflated 5.4 0 100 0 70
LC2 inflated + dyn. 5.4 0 100 -X 70+14
LC3 inflated 3.5 0 65 0 160
LC4 inflated + dyn. 3.5 0 65 -X 160 + 32
LC5 deflated - 0 100 0 70
LC6 deflated - 0 65 0 160
LC7 deflated - 0 100 0 70

[Link] Stability test of air spring for VB-2, VB-1, EMU/MEMU-U/S coaches
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 21 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

(To be conducted before & after fatigue tests):

Test Condition Specified Value
i) Load Cases LC1 to LC9
Stable in all load cases & functionally ok

[Link] Inflatability test of air spring for VB-2, VB-1, EMU/MEMU-U/S coaches:
Test Condition Specified Value
i) Inflatability after max. deformations
for load cases LC5, LC6 & LC7 Inflatable in either load case
ii) Inflatability after max. deformation
and time t = 8 h; for LC8

6.6.5 Dynamic Stiffness of air spring for VB-2 coaches:

S. Description Test Condition Specified Value
No. of tests
1. Dynamic Fz = 76,6 / 111,9 / 122,7 / 160,8 kN Cxy0,dyn (76,6 kN) = Informative
Radial Sxy = 0 ± 10 mm Cxy1,dyn (111,9 kN) = Informative
Stiffness fxy = 1 Hz Cxy2,dyn (122,7 kN) = Informative
Cxy3, dyn (160,8 kN) = Informative
2. Dynamic Fz = 76,6 / 111,9 / 122,7 / 160,8 kN Cz0,dyn (76,6 kN) = Informative
Axial Sz = 0 ± 10 mm Cz1,dyn (111,9 kN) = Informative
Stiffness fz = 1 Hz Cz2,dyn (122,7 kN) = Informative
Vaux = 50 dm³ Cz3,dyn (160,8 kN) = Informative
#Note: However, amplitude may be restricted to ensure maximum load equal to or less
than 240 kN.
6.6.6 Dynamic Stiffness of air spring for VB-1, EMU/MEMU-U/S coaches:
S. Description Test Condition Specified Value
No. of tests
1. Dynamic Fz = 70 / 90 / 100/ 160 kN Cxy0,dyn (70 kN) = Informative
Radial Sxy = 0 ± 10 mm Cxy1,dyn (90 kN) = Informative
Stiffness fxy = 1 Hz Cxy2,dyn (100 kN) = Informative
Cxy3, dyn (160 kN) = Informative
2. Dynamic Fz = 70 / 90 / 100/ 160 kN Cz0,dyn (70 kN) = Informative
Axial Sz = 0 ± 10 mm Cz1,dyn (90 kN) = Informative
Stiffness fz = 1 Hz Cz2,dyn (100 kN) = Informative
Vaux = 50 dm³ Cz3,dyn (160 kN) = Informative

6.6.7 Torsional Stiffness of air spring for VB-2, VB-1, EMU/MEMU-U/S coaches:
S. Description Test Condition for VB-2 Test Condition for VB-1, Specified
No. of tests coaches EMU/MEMU-U/S Value
coaches
1. Torsional Fz = 76,6 / 111,9 / 122,7 Fz = 70 / 90 / 100 /160kN Informative
stiffness / 160,8 kN.

6.6.8 Friction Coefficient:

Test Condition Specified value

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 22 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Fz = 76,6 kN
test speed v = 20 mm/s
test amplitude = 0 ± 40 mm
Lubricant: With lubricant (Silicon grease
SOB1316 or equivalent)

6.7 The new designs of air springs should be belted design and able to withstand an
occasional 50% dynamic augment over the maximum static load. Existing designs
without belt would also be acceptable if performance is found to be satisfactory. For
verification, characteristics test, shear load calculation, type tests & creep test of
emergency spring is also done at 150% of vertical designed load as specified in para 6,
7, 8 & 12 of Section-B of this specification.

6.8 Bursting strength of the air spring:

Air spring shall be capable of withstanding a minimum bursting pressure of 30 Kg/cm².

Test procedure for check bursting strength of air spring should be as follows.
This test shall be performed with water at an ambient temperature above or around
200C.
- Install the air spring assembly that was subjected to one million cycles
endurance test at design height.
- Inflate the air spring assembly with minimum 30 kg/cm 2 internal pressure and
hold the air spring assembly at this pressure for a minimum of 5 minutes.
- Observe if there is any damage or visible crack.

6.9 In case of accidental deflation of the air spring assembly during dynamic condition of the
coach due to reasons other than leakage/bursting/puncture etc. of the air spring, when
the coach sits on emergency springs (Clause 6.9.3 6.10.3), there shall be no damage
to air spring assembly under normal operating conditions.

6.10 Emergency spring:

6.10.1 During train operation, deflation of an air spring due to depletion of pneumatic pressure
either on account of leakage or disruption in air supply cannot be ruled out.
6.10.2 To counter such situations, an emergency rubber spring shall be required to be
installed in the air spring assembly, which shall act as suspension element during such
happenings.

6.10.3 This spring shall be capable of safely carrying the affected vehicle as above (either
fully or partially loaded) upto distance of 4500 km at speed of at least 60 kmph in
mainline coaches/ EMU/DEMU/MEMU/VB-2/VB-1/EMU-US/MEMU-US coaches fitted
with air springs of 160 KN capacity / 140 KN capacity / 120 KN/ 160.8 KN/ 160KN
capacity and upto destination at speed of at least 60 kmph in EMU / DMU / MEMU
type coaches fitted with air spring of 180 KN capacity under normal operating
conditions without suffering any self-damage or any further damage to the air spring
which will make them unfit for further use. This situation is likely to arise occasionally
in the service life of the air spring. Operational speed in the range of 100 Kmph or
above in deflated conditions shall be preferable.

6.6 Space Constraints:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 23 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Air spring assembly consisting of top plate with spigot (for air connection), air spring
bellow, rim, external / internal emergency rubber spring, base plate etc. in inflated
condition (at 6.0 kg/cm2 bellow pressure) shall be within the space envelope shown in
RDSO Drawings. Some of the leading parameters of air spring assembly and drawing
no. in inflated condition are enclosed as Annexure - VIII (enclosed). Profile & overall
dimensions of inflated air spring assembly in extreme lateral, vertical & torsional load/
force to be prepared during the type test as per para 6.4.3 of EN 13597:2003 and shall
be submitted to RDSO.

6.7 Mounting arrangement:

The material of the base plate shall be stainless steel or corrosion resistant steel or
equivalent even if this arrangement is an integral part of the emergency spring to avoid
inter-metallic corrosion. The base plate shall be provided with 04 nos. mounting
fasteners. Details of base plate and mounting fasteners are specified in Annexure
VIII (enclosed)
6.8 Pneumatic supply connection:

Air inlet connection point to the air spring shall be located at the centre of top plate
through a spigot made air tight by using minimum two rubber O-rings. The dimension
of spigot for all type of Air Springs shall be as under as per Annexure IX:

i) = Ø 85-0.036-0.071 mm.
Outer diameter of spigot
ii) Height of spigot = 35 + 0.5 mm- for LHB & ICF coaches
& 45 mm for VB-2/VB-1/EMU-US/MEMU-US
coaches
iii) Cross section diameter = 5.7 + 0.1 mm.
over spigot

Detailed dimensions of Spigot and O-ring over spigot are given in Annexure IX
(enclosed).
6.9 Other Details:

6.9.1 The fasteners shall be zinc/ flake coated as mention in Annexure - VIII. All exposed
metal parts of the air spring assembly shall be of Aluminum/stainless steel or corrosion
resistant steel or equivalent. Salt spray test, for assessment of corrosion resistance of
metal should be carried out according to ISO 9227. The specimen should not have any

per ISO 9227 and also part of type test report. Moreover, as quality control measure,
salt spray test should also be repeated by the firm at every 3 years for any one type of
air spring assembly and report along with clear photographs (before and after) of the
same also to be submitted to RDSO. The testing time should be a minimum of 720
1000 Hrs. All exposed metal parts should be painted as follows:

S. No. Type of air spring Colour and shade

i) 180 KN capacity for EMU/DMU/ MEMU Grey (RAL no. 7042)
Coaches with ICF type bogie
ii) 160 KN capacity for LHB Coaches Sky Blue (RAL no. 5012)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 24 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

iii) 140 KN capacity for mainline ICF & Red (RAL no. 3024/3020)
LHB coaches
iv) 120 KN capacity for LHB Coaches Light Green (RAL no. 6037)
v) 160.8 KN capacity for VB2 Grey (RAL no. 7042 7012)
vi) 160 KN capacity for VB-1/EMU- Red (RAL no. 3024/3020/3001)
US/MEMU-US coaches

6.9.2 Any alternate material for manufacturing of emergency spring and metal parts of air
spring assembly, which fulfills the functional and technical requirement of metal
parts/emergency spring can also be considered provided that it is proven and
established globally, which is to be demonstrated by firm, subject to clearance by
RDSO.

6.10 Physical tests of air spring bellow:

specification shall form a part of the type test report.

7. SUBMISSION OF OFFER:

7.1 Vendors desirous of seeking approval from RDSO for supply of material as per this
Specification, should submit their proposal accompanied by the documents containing
the following information to RDSO: -
1. FEA/ FKM calculation and design validation of Air spring assembly and it's critical
components (i.e. Rubber Bellow, top plate or emergency spring) for preliminary
examination of the adequacy of design.

2. Dimensional drawing of air spring assembly.

3. Min. height of air spring under full load with no air and without spigot (mm)
4. Inner volume, effective area and effective diameter of springs.

5. Self-damping characteristic of air spring assembly in inflated condition at 1 Hz to

3 Hz frequency.

6. Self-damping characteristic of emergency spring at 1 Hz to 3 Hz frequency.

7. Diameter of air bellow at 6 Kg/cm2 under design height.

8. Vertical and lateral stiffness of emergency spring under tare, gross and
intermediate loads as specified in Specification.
9. Data for particular type of air spring as mention in Annexure - X (enclosed). Same
details shall be required for modeling of air spring system of particular vendor in
simulation software.

10. Weight of one air spring assembly.

11. Whether proposed air spring is being used by any other rail-road system? If yes,
details regarding quantity, type of stock, max. operating speed and type of service
shall be furnished.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 25 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

12. Details of deviation from the Specification.

13. Content of indigenous and imported items in offered air spring assembly.
14. Expected life cycle in operating and environmental conditions enumerated in
clause 2 & 3.
15. MOU / Agreement with the OEM permitting supply/manufacture of the offered
springs. (For proposals from other than OEMS).
16. A write-up giving broadly the maintenance requirements on a time/distance basis
along with the facilities that would be needed for proper maintenance/upkeep of
the offered air spring assembly. It may be noted that maintenance schedules
recommended for air spring assemblies should coincide with the specified various
maintenance schedules of the respective coach.
17. A detailed write-up giving the details of "Quality Assurance System" being followed
for manufacture of the offered items; and
18. Details of manufacturing and testing facilities available with the manufacturer.

7.2 Vendor applying for registration shall submit strength calculation & simulation for top
plate, bottom plate and rubber components of the air spring assembly during the
submission of offer.

7.3 The information received above shall be used for preliminary evaluation of the firm's
capability in meeting with the requirements of this Specification.

7.4 The firm shall be required to submit a Type Test Report of a proposed design after the
preliminary evaluation carried out as per para 7.3 is found satisfactory. Type Test
Specification.

7.5 The premises of the firm shall be visited by RDSO's officials for on-the-spot
assessment of the firm's capability.

7.6 RDSO reserves complete right in granting approval or otherwise to a firm.

8. GUARANTEE:

8.1 Complete air spring assembly including emergency spring shall be guaranteed for
satisfactory performance for a minimum period of 60 months from the date of actual
commission in bogies or 72 months from the date of supply whichever is earlier.
Satisfactory performance for this purpose means that complete air spring assembly or
any of its part shall neither show any kind of deterioration which is likely to render it
unserviceable nor lose its characteristics as stipulated in this Specification, during the
guarantee period for reasons attributable to manufacturing/design defects.
8.2 In the event of 'non-satisfactory performance' of any of the items as indicated above,
supplier will have to replace the same with new Air spring assembly at his own
expense without levying any cost involved in transportation, handling and replacement
of such items on the Purchaser.

9 INSTALLATION, COMMISSIONING & MAINTENANCE:

9.1 On placement of order, supplier whose equipment will be purchased for the "First
Time" for installation on the coaches, shall have to depute his representative at his
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 26 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

own expense to associate with the purchaser in installation and commissioning of the
equipment on the first five coaches. He shall also depute to his representative during
maintenance schedules undertaken on his equipment as per maintenance booklet
supplied by him.

9.2 With every order for supply of the air spring assembly, the supplier shall have to supply
maintenance instructions in the form of a booklet (hard copy / soft copy).

9.3 Maintenance booklet supplied by the supplier shall cover the following aspects in
detail:
1) Specification of the air spring assembly.
2) Drawing and specification of gauge for measuring spring height in installed
condition in coach.
3) Drawing and specification of other gauges required for maintenance.
4) Working principle based on the actual construction.
5) Constructional details giving sketches, drawings and photographs etc. identifying
various items and their part numbers etc. for easy identification.
6) Procedure for dismantling using sequential steps with the help of sketches.
7) Procedure for assembly, using sequential steps with the help of sketches.
8) Jigs, tools, other materials and details of special set-ups etc., necessary for item
6 & 7 above.
9) Testing procedures and facilities required along with their details.
10) Comprehensive details containing legible sectional views of defects normally
observed or may happen on air spring and emergency spring with clear remarks
whether the defect is rejectable or non-rejectable.
11) List of other defects and their remedies.
12) Periodicity for various maintenance activities on time and distance basis.
13) Do's and Don'ts for maintenance officials.
14) It may be ensured that maintenance schedules recommended for air spring
assemblies coincide with the specified various maintenance schedules of the
respective coach.

10 INSPECTION AND TESTING:

10.1 General requirements:

During initial approval of a firm by RDSO (Clause 7) and later on when approval has
been granted, RDSO for purpose of ensuring quality of purchased product may carry
out periodic quality audit, inspection and testing of the equipment at the premises of
the manufacturer. Purchase inspection shall be done at the premises of the
manufacturer by a representative of the Research Designs and Standards
Organization or an agency authorized by RDSO. The supplier shall have to arrange
for the following and associate with the same:

1. Access to all records considered relevant for such activity by inspecting officials.
2. Questioning of relevant personnel engaged in production, testing and quality
checking activities etc. or related issues.
3. Testing of few samples of items already produced by the firm to ascertain the
technical characteristics given in this Specification.
4. Any other check considered necessary by the inspecting party.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 27 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

5. The inspecting official will carry out purchase inspection as per updated checklist
approved by RDSO. The general format of inspection checklist is attached at
Specification.

10.2 Inspection and testing of air spring assembly (air bellow and emergency spring):

10.2.1 Dimensional check:

ITEM REFERENCE DOCUMENTS

Air spring Top Plate with spigot,
Diameter of air bellow at 6 Kg/cm2
under design height. by RDSO & technical requirements of
clause 6 of this Specification.
Base plate

10.2.2 Leak test of air spring bellow:

Leak test of air spring assembly shall be carried out as follows-
- Install the air spring assembly at design height.
- Gradually raise the air pressure to 9 kg/cm 2 and disconnect the air supply.
- Air spring assembly shall be checked for pressure drop at the following
pressure and time intervals.
a) After one hour at internal pressure 9.0 kg/cm2.
b) After 15 minutes at internal pressure 6.0 kg/cm 2. The above tests shall be
conducted with the air supply and drain system of the test device turned off.
Drop of pressure at the completion of test shall be measured. The pressure
drop is required to be within 1% of the test pressure i.e. 9.0 kg/cm 2 or 6.0 kg/cm2
as applicable.
10.2.3 Characteristics tests:
[Link] Air bellow spring assembly:
Pressure vs load test of air spring assembly:
Air spring assembly at fixed installation height (para. 6.4.1/ Section - A) and with
additional volume (para. 6.3 / Section - A) shall be tested at pressure starting from 1,
2, 3, 4, 5 and upto 6 kg/cm2. The recordings shall be done as given below: -

S.N. Pressure Specified Observed Vertical Load in kN

in Kg/cm2 Vertical Load
in kN Spg. No. Spg No. [Link]. [Link].

The Pressure v/s Load relationship of air spring assembly shall be same as given in
type test report / QAP/drawing approved by RDSO.

[Link] Emergency spring:

Vertical load vs. deflection characteristics measured at vertical loads on Emergency

spring given in type test report / QAP/drawing approved by RDSO.

10.2.4 Periodical tests of Air Spring Assemblies, as a quality control measure to ensure
quality of this critical suspension element:
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 28 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

To ensure consistency in quality of rubber components of this critical suspension

component (Air Springs), following tests shall be done periodically. Tests shall be
conducted by the vendors & reports along with photographs shall be submitted to
RDSO. The plan & schedule of these tests shall be communicated to RDSO & RDSO
might depute its personnel to witness the tests by suitable means including video call.
S. Description of test Sample qty Periodicity of tests from
No date of issue of this
specification
1. Salt spray test of all exposed metal 01 no. Every 3 years or supply
parts of air springs of every 500
coach sets, whichever is
later
2. Lateral load v/s deflection test of 05 Nos. Yearly/ After supply of
Air spring assembly upto deflection 500 coach sets of
mentioned in para 6.2 of Section-A particular type of air
of RDSO Specification No. spring, whichever is later.
RDSO/CG/S/23002, Rev. nil 01
3. Lateral load vs. deflection of 05 Nos. Yearly/ After supply of
Emergency spring as per para 4.1 500 coach sets of
of Section-B of RDSO Specification particular type of air
No. RDSO/CG/S/23002, Rev. nil 01 spring, whichever is later.
4. Lateral stiffness of air spring 05 Nos. Yearly/ After supply of
assemblies as per para 6.5 of 500 coach sets of
Section-A of RDSO Specification particular type of air
No. RDSO/CG/S/23002, Rev. nil 01 spring, whichever is later.
5. Vertical stiffness of air spring 05 Nos. Yearly/ After supply of
assemblies as per para 6.4 of 500 coach sets of
Section-A of RDSO Specification particular type of air
No. RDSO/CG/S/23002, Rev. nil 01 spring, whichever is later.
6. Fatigue test of air spring assemblies 01 no. of each Every 5 years
(All the tests of para 8 & 9) of type of air
Annexure-A of RDSO Specification spring assembly
no. RDSO/CG/S/23002, Rev. nil 01 approved by
to be done. RDSO (i.e. 120
kN, 140 kN, 160
kN, 160.8 kN &
180 kN
capacity).

10.3 10% samples of the lot or a minimum 10 samples whichever is maximum shall be
picked up randomly for dimensional test as given in clause 10.2.1/ Section -A of this
Specification.
10.4 For other specified inspections as given in clause 10.2.2 / Section - A and 10.2.3 /
Section - A of this Specification, samples shall be picked up randomly as under:

Lot size upto 10 25 50 75 100

No of samples 2 3 4 5 6

For lot sizes more than 100, 6% of the samples shall be picked up randomly for the
above inspections.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 29 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

10.5 In case any picked up sample fails, manufacturer/supplier shall re-offer, rectifying the
defects. However, in such cases, double the quantity of samples shall be picked up
and shall be checked for dimension and other specified tests. In case anyone sample
fails again; the entire lot shall be rejected.

11 MARKING:

Marking on air spring assembly shall be legibly marked to indicate the following:

S. Detail of item of Particulars to be marked

No. air spring
assembly
1. Every item of the air
1) Manufacturer's initials (Vendor code/OEM Name).
spring assembly
2) Month and year of manufacture (MM/YYYY).
(Top plate, Bottom3) Identification marks, i.e. Part Number, Batch
plate, Air bellow & Number, Serial Number etc.
Emergency spring) 4) Capacity of air spring (180 KN/ 160.8 kN/160 KN/
140 KN/ 120 KN)
2. Base plate of air (180 KN / 160 KN/ 160.8 kN / 140
spring assembly KN / 120 KN)
3. Identification plate 1) Type of Stock (ICF Coaches/LHB Coaches/MEMU
of air spring Coaches/EMU type coaches)/VB-2 Coaches/ VB-1
assembly. Coaches/ EMU-US coaches/MEMU-US Coaches
2) Capacity of air spring (180 KN/ 160 KN/160.8
kN/140 KN/ 120 KN)
3) Installed height (255 mm / 294 mm/300 mm)
4) Name of Vendor.
5) Month & year of manufacturer (MM/YY)
Marking on air spring assembly should be lasting. Marking on metal plates shall be
done with engraved/ punched continuous letters with font height 12 mm and 0.5 mm
deep.

12 PACKING:
The air spring assembly shall be suitably packed along with its loose parts and
exposed threaded portion, to protect against any damage that may occur during transit
and handling. The opening of the spigot of the spring shall be suitably covered with a
plastic/rubber cap to prevent ingress of dust or foreign material in the air spring.

13 MAINTENANCE MANUAL:

The supplier shall provide at least one copy of the maintenance manual, free of cost
with each consignment, for maintenance and overhaul purpose.

14 GENERAL:

14.1 RDSO may draw samples for quality check to test any property mentioned in this

reputed outside laboratory as decided between RDSO and the vendor. The testing
charges should be borne by the vendor.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 30 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

14.2 RDSO reserve the right to modify any clause of this Specification as per requirement
of Indian Railways.

14.3 Additional information if required may be obtained from the office of the Director
General (Carriage), RDSO, Manak Nagar, Lucknow 226011.

*****************

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 31 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure A

REQUIREMENTS OF TYPE TEST REPORT

The type test report of air spring assembly shall consist of the following, clearly
represented by graphs as well as in tabulation forms, with detailed test procedures and their
results -
measured and verified during the type test: -

1) Lateral characteristics measurement at speed V= 5 mm/sec, using triangular wave form

of vibrations in lateral direction with following conditions:

S. Type of air Conditions at which characteristics shall be measured

No. spring Vertical Load Stroke (dy) Additional
Volume
i) 180 KN capacity 50, 115, 165 & ±10, ±20, ±30, ±40, ±50, ±60 20 lit.
180 KN mm
ii) 160 KN capacity 50, 60, 90, ±10, ±20, ±30, ±40, ±50, 60 lit.
120 & 160 KN ±60, ±70 & ±80 mm
iii) 140 KN capacity 50, 70, 115 & ±10, ±20, ±30, ±40, ±50, ±60 40 lit.
140 KN mm, +80mm (FIAT bogie)
iv) 120 KN capacity 60, 90 & 120 ±10, ±20, ±30, ±40, ±50, 60 lit.
KN ±60, ±70 & ±80 mm
v) 160.8 KN 60, 76.6,111.8, ±10, ±20, ±30, ±40, ±50, ±60, 50 lit.
capacity (VB-2) 122.7&160.8 KN ±70, ±80 & ±120 100 mm
vi) 160 KN capacity 50, 70, 100 & ±10, ±20, ±30, ±40, ±50, 50 lit.
(VB-1, 160 KN ±60,±70, ±80 & ±100 mm
EMU/MEMU-US)
2) Vertical characteristics measurement at speed V= 5 mm/sec, using triangular wave form
of vibrations in vertical direction with following conditions:

S. Type of air Conditions at which characteristics shall be measured

No. spring Vertical Load Stroke (dz) Additional
Volume
i) 180 KN capacity 50, 115, 165 & ±10, ±20, ±30 mm 20, 30 & 40 lit.
180 KN
ii) 160 KN capacity 50, 60, 90, 120 ±10, ±20, ±30 mm 40, 60 & 80 lit.
& 160 KN
iii) 140 KN capacity 50, 70, 115 & ±10, ±20, ±30 mm 20, 30, 40 & 60 lit.
140 KN
iv) 120 KN capacity 60, 90 & 120 KN ±10, ±20, ±30 mm 40, 60 & 80 lit.
v) 160.8 KN 60, 76.6, 111.8, ±10, ±20, ±30 mm 20, 40, 50 & 60 lit.
capacity (VB-2) 122.7 & 160.8 KN
vi) 160 KN capacity 50, 70, 100 & 160 ±10, ±20, ±30 mm 20, 40, 50 & 60 lit.
(VB-1, KN
EMU/MEMU-US)
Note: Characteristic test shall be conducted at +10 & + 20 mm at all loads. However,
at +30mm, characteristic shall be tested at max. capacity of air spring.
3) Rotational stiffness of air spring assembly*
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 32 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

A) The rotational stiffness at constant velocity, shall be tested and mentioned in the type test
report as per para [Link] & [Link].4 of EN 13597:2003 (E), for tare to full load conditions
for each type of air spring assemblies i.e. 120 kn, 140 kn, 160 kn, 160.8 & 180 kn
capacities at respective installation heights.

B) The rotational stiffness under sinusoidal motion, shall be tested and mentioned in the type
test report as per para [Link] & [Link].4 of EN 13597:2003 (E) for tare to full load
conditions for each type of air spring assemblies i.e. 120 kn, 140 kn, 160 kn, 160.8 & 180
kn capacities at respective installation heights.
*Similar tests as per applicable alternate standards shall also be acceptable.

4) Vertical force versus internal pressure characteristic measurements of air spring.

5) Effective area versus deflection curve of air bellow.

6) Salt spray test of metal part as per para. 6.13 6.14.1 / Section A of Specification.

7) PHYSICAL TESTS

a) For Air Spring Bellow:

(i) Abrasion test as per para. 6.2.5 of EN 13597 : 2003 (E) or latest.
(ii)
(iii) Adherences between plies as per para. 7.3.3 of EN 13597 : 2003 (E).
(iv) Resistant to ozone test as per para. 6.2.2 of EN 13597 : 2003 (E).

(iiv) Low temperature test as per para. 6.2.1 of EN 13597 : 2003 (E).

b) For Emergency Spring:

(i) Abrasion test as per para. 7.2.7 of EN 13913 : 2003 (E).

(ii)

(iii) Heat ageing test as per para. [Link] of EN 13913 : 2003 (E).
(iv) Resistant to ozone test as per para. 7.2.4 of EN 13913 : 2003 (E).
v) Low temperature test as per para. 6.2.1 of EN 13597: 2003 (E)
8) Durability test at 6 Kg/cm² internal pressure (Endurance Test) of air bellow as follows.

ENDURANCE TEST OF AIR SPRING ASSEMBLY:

a) The endurance test is conducted to access suitability of the air spring assembly
provided at secondary stage suspension in coach bogie by simulating service/ field
conditions in the laboratory.
b) The test on air spring assembly shall be conducted only when the results of load
deflection characteristics are obtained and found satisfactory.
c) The test shall be conducted in vertical and horizontal directions.

(i) Vertical Endurance Test:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 33 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

a) The air spring shall be installed on an endurance testing machine by maintaining the
installed height of air spring as mention in para. 6.4.1/ Section - A and pressure 6
kg/cm2. Vertical load shall be measured at this stage. Value of load should not be less
than gross static vertical load as specified in para 4.1(Section- B).
b) The above air spring assembly is subjected to vertical oscillation at sinusoidal
frequency of 1.0 Hz or more and deflection of + 30 mm.
c) Endurance test shall be conducted for a total 1 million cycles in inflated and 0.2 million
cycles in deflated condition at a stretch with conditions stipulated in para (a) and (b)
above.
d) At the end of 1 million cycles in inflated and 0.2 million cycles in deflated condition
following measurements/ observations shall be recorded after 30 minutes from load
release.

S. No. Parameters Result

1 Adhesion anomalies
2 Obvious sign of failure
3 Excessive wear or abrasion
4 Any visible crack or rupture

(ii) Shear Endurance Test:

a) The base plate of air spring assembly is clamped rigidly on a fixed horizontal table.
b) Air spring shall be installed on an endurance testing machine by maintaining the
installed height of air spring as mention in para. 6.4.1/ Section - A and pressure
mentioned below. Vertical load shall be measured at this stage.
c) The above air spring assembly is subjected to lateral displacement of + 30 mm & + 56
mm as per the table mentioned below at a sinusoidal frequency of 1.0 Hz or more in
lateral direction.
Sequence Number of cycles Pressure Offset Amplitude
2
1 800000 cycles 6.0 Kg/Cm + 25 mm + 30 mm
2 50000 cycles 5.8 Kg/Cm2 0 + 56 mm
2
3 50000 cycles 5.2 Kg/Cm 0 + 56 mm
4 50000 cycles 5.8 Kg/Cm2 + 25 mm + 56 mm
2
5 50000 cycles 5.2 Kg/Cm + 25 mm + 56 mm

Sequence Number of cycles Pressure Offset Amplitude

1 3,50,000 cycles 6.0 Kg/Cm2 25 mm ± 30 mm
2 6,50,000 6.0 Kg/Cm2 40 mm ± 56 mm
4,50,000 cycles
3@ 2,00,000 cycles 6.0 Kg/Cm2 40 mm ± 56 mm
4 2,00,000 cycles Full design load 40 mm ± 56 mm

d) Endurance test shall be conducted for a total 1 million cycles in inflated and 0.2 million
cycles in deflated condition at a stretch with conditions stipulated in para (a) and (b)
above. Shear Endurance Test with lateral offset of 25 mm & 40 mm between top and
bottom plate of air spring assembly shall be conducted as per the provision of BS EN
13597: 2003 E (Annexure - C) and fixture/ test setup also to be made as per Figure
C.2 of the Annexure - C of the same.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 34 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

The test specified under para 8 (i) and para 8 (ii) above shall be carried out on the
same air spring assembly and it shall not exhibit deterioration such as tearing, wear,
cracks etc. upto 800000 cycles during shear endurance test. Minor surface cracks on
bellow may be permitted during & after sequence 2-5 3@ mentioned in the above table
of shear endurance test. After test, the same air spring assembly shall be subjected to
Burst Resistance Test as per para. 6.7 6.8 of Section A of this Specification and leak
test as per para. 10.2.2 of Section - A of this Specification subsequent of completion
of endurance testing as above and results reported.

e) At the end of 1 million cycles in inflated and 0.2 million cycles in deflated condition
following measurements/ observations shall be recorded after 30 minutes from load
release.

S. No. Parameters Result

1 Adhesion anomalies
2 Obvious sign of failure
3 Excessive wear or abrasion
4 Any visible crack or rupture

9) Stability & Inflatability test:

The air spring system must be inflatable without additional measures in all operational
states. This should be checked by inflation at tare load in combination with maximum
lateral deformation.
For stability test force-deflection hysteresis must be stable in the meaning of

Load cases for Air Springs for FIAT & ICF type bogies:
Load movement Description
case Condition Fz [kN]
Sxy (mm) Sz (mm)
No.
LC0 Deflated -- 0 120 kN for 120 kN Deflated Service
140 kN for 140 kN
160 kN for 160 kN subsequent
180 kN for 180 kN inflatability
LC1 Deflated 80(LHB) 0 60 kN Deflated Depot
60(ICF)
LC2 Deflated 75(LHB) 0 90 kN for 120 kN Deflated Service
55(ICF) 115 kN for 140 kN
120 kN for 160 kN
165 kN for 180 kN
LC3 Deflated 60(LHB) 0 120 kN for 120 kN Deflated Service
50(ICF) 140 kN for 140 kN
160 kN for 160 kN
180 kN for 180 kN
LC4 Deflated 80(LHB) 0 60 kN
60(ICF) subsequent
inflatability test
LC50 Inflated 0 ± 80(LHB) 0 60 kN Stability Depot
0 ± 60(ICF)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 35 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

LC51 Inflated 0 ± 80(LHB) -30 60 kN Stability Depot

0 ± 60(ICF)
LC52 Inflated 0 ± 80(LHB) +20 60 kN Stability Depot
0 ± 60(ICF)
LC60 Inflated 0 ± 75 (LHB) 0 90 kN for 120 kN Stability Service
0 ± 55 (ICF) 115 kN for 140 kN
120 kN for 160 kN
165 kN for 180 kN
LC61 Inflated 0 ± 75 (LHB) -30 90 kN for 120 kN Stability Service
0 ± 55 (ICF) 115 kN for 140 kN
120 kN for 160 kN
165 kN for 180 kN
LC62 Inflated 0 ± 75 (LHB) +20 90 kN for 120 kN Stability Service
0 ± 55 (ICF) 115 kN for 140 kN
120 kN for 160 kN
165 kN for 180 kN
LC70 Inflated 0 ± 60 (LHB) 0 120 kN for 120 kN Stability Service
0 ± 50 (ICF) 140 kN for 140 kN
160 kN for 160 kN
180 kN for 180 kN
LC71 Inflated 0 ± 60 (LHB) -30 120 kN for 120 kN Stability Service
0 ± 50 (ICF) 140 kN for 140 kN
160 kN for 160 kN
180 kN for 180 kN
LC72 Inflated 0 ± 60 (LHB) +20 120 kN for 120 kN Stability Service
0 ± 50 (ICF) 140 kN for 140 kN
160 kN for 160 kN
180 kN for 180 kN

For LHB/ICF bogie air springs, after completion of shear endurance test mentioned in para
8, Inflatability test of air spring assembly shall be done at ±56 mm lateral displacement at
respective vertical loads mentioned in para 6.4.2 of Section-A of this Specification for
different types of air spring assemblies. For this Inflatability test, air spring assembly shall
be inflated upto specified vertical loads from tare to full load conditions as mentioned in
para 6.4.2 of Section-A of this Specification and above shall be shifted laterally by 56 mm
as detailed above. Further, deflate the air spring assembly on same loads and hold for
atleast one minute in deflated condition. Now inflate the air spring assembly in same load
conditions. Air spring assembly should inflate smoothly on all load conditions from tare to
full load.
For VB-2/ VB-1/ EMU/MEMU-US bogie air springs, after completion of shear endurance
test similar Inflatability test with Load Cases as per para 6.6.4 of Section-A shall be done.
10) Burst pressure test of air spring bellow after endurance test, as per para 6.7 6.8 of
Section - A of this Specification.
11) Load vs deflection characteristics of emergency spring in vertical and lateral mode as
per paras 6 and 7 of Section - B of this Specification.

12) Endurance test of emergency spring alongwith vertical and lateral characteristics for
minimum 1 million cycles, as per para 8 of Section - B of this Specification.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 36 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

13) Hysterisis loops of emergency spring in vertical mode with following vertical pre load:

S. No. Type of air spring Vertical pre load

i) 180 KN capacity 50, 115, 165 & 180 KN
ii) 160 KN capacity 50, 60, 90, 120 & 160 KN
iii) 140 KN capacity 50, 70, 115 & 140 KN
iv) 120 KN capacity 60, 90 &120 KN
v) 160.8 KN capacity (VB-2) 60, 76.6, 111.8, 122.7 &160.8 KN
vi) 160 KN capacity (VB-1& EMU/MEMU-US) 50, 70, 100 & 160 KN

14) Lateral characteristics (Load Vs. Deflection) of air spring assembly in no-air condition.
15) Material test report (supported by standard test specifications).
16) Any other test felt necessary by the manufacturer.
17) Leak test of air spring bellow as detailed at para 10.2.2 of Section A of this
Specification.
18) Type test of emergency spring shall be carried out as detailed in Section B of this
specification and reports as per annexure I to VII of Section B of this Specification
provided with the same.
19) Tolerance in different dimensions of air spring assembly should be as per IS 2102 (Part
-I) and mentioned in Type Test Report / drawing.
20) Tolerance in measured values during characteristic tests should be mentioned in type
test report given as under:
S. No. Characteristic Tolerance
1 Pressure Force Characteristic + 5%
2 Load Deflection Characteristic + 10% + 12.5%

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 37 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

ANNEXURE - B
CHECKLIST FOR INSPECTION OF AIR SPRING
As per inspection and testing Clause no.10.0
1. Dimensional and visual check (10% of the Lot Qty or minimum 10 whichever is maximum)
1.1 Visual Inspection
SN Particulars Specified Observation
1. Finish Smooth
2. Cut Nil
3. Burrs / Flash Nil
4. Rust / Corrosion Not Allowed
5. Weld / Paint Marks Not Allowed
6. Flatness / Parallelism OK/Not OK
7. Identification As per Specification
8. OK/ Not OK
9. Marking -
9.1 Top Plate OK/ Not OK
9.2 Bottom Plate OK/ Not OK
9.3 Emergency Spring OK/ Not OK
9.4 Identification plate OK/ Not OK
10. Colour & shade OK/Not OK (As per para 6.13.1)

1.2 Dimensional test

SN Particular Specified Observation
1. Base Plate Length
Width RDSO
Thickness Approved Drg.
/ RDSO
Mounting hole dia. Specification
Centre distance of
mounting holes (single /
both side)
PCD (in case of 180 KN
capacity air spring)
Height of lug (For VB-2
VB-1& EMU/MEMU-US)
Diameter of lug (For VB-2
VB-1& EMU/MEMU-US)
2. Top Plate Spigot Dia.
Spigot Height
Top plate dia.
Cross section diameter of

3. Air Bellow Diameter of air bellow at 6

diameter Kg/cm 2 under design
height.
4. Min. height Min. height of air spring
of air spring under full load with no air RDSO
and without spigot (mm) Approved Drg.
2. Leak Test of Air Spring: As per Clause 10.2.2 of section A.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 38 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Pressure after 60 Pressure after 15 Pressure drop with

Air Springs
SN minutes when minutes when inflated in specified limit
Number
inflated at 9 Kg/cm2 at 6 Kg/cm2 (Yes / No.)
1
3. Pressure v/s Load test of Air Spring assembly: As per Clause [Link] of Section - A.

Test should be carried out as per the formats as below:

Pressure v/s Load Test

S.N. Pressure in Specified Vertical Load (kN) Measured Vertical Load

kg/cm2 or bar (As per Type Test Report) (kN)
1. 1
2. 2
3. 3
4. 4
5. 5
6. 6

4. Test for Emergency Spring:

4.1 Vertical load v/s deflection Test: As per Clause [Link] of Section - A.

Test should be carried out as per the formats as below:

S.N. Specified Load (vertical) Specified Deflection Measured

in KN (vertical) in mm Deflection in mm
(As per Type Test Report) (As per Type Test Report)
1.
2.
3.
4.

4.2 Bonding strength test (for metal bonded emergency spring design)
Bonding strength test of 02 samples from each batch to be done as per para 5.0 of
Specification no. RDSO/CG/S/23002, Rev. nil during the
purchase inspection. The test piece shall be taken from the same batch used for the
manufacturing of the emergency spring.

Sample size for the tests at S. No. 2, 3 & 4 & 5 above are given as under:

Lot Size upto 10 25 50 75 100 Above 100

(nos.)
Number of 2 3 4 5 6 5 6% of Lot
Samples subject to min 6
Check

5. Radial and Axial stiffness of Air Spring system at tare load & one option load
6. Internal/ routine tests of Air Spring assemblies for ICF/LHB/VB-2/ VB-1&
EMU/MEMU-US Coaches:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 39 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Following routine tests shall be done internally by the firm for air springs for ICF/LHB/VB-
2/ VB-1& EMU/MEMU-US Coaches and submit the tests report during the inspection calls:
-
S. No. Test Qty./ Sample
1 Force v/s Pressure 100%
2 Pressure resistance (leakage) test 100%
3 Q.-stat. Radial/ Lateral stiffness at tare & optional load to full load 100%
4 Q.-stat. Axial/ Vertical stiffness at tare & optional load to full load 100%
5 Characteristic (Load deflection & stiffness of the additional spring) 100%
6 Height of the additional spring 100%
7 Weight of air spring bellow 100%
8 Burst pressure test 1%
9 Material certificate 1 / batch
10 Dimensions & weight of the air spring system 1 / batch
11 Marking 100%
12 Interface Dimensions 1 / batch
13 Rubber properties (Shore-hardness / tensile strength / elongation
at fracture / density / elasticity) Batch
14 Bonding strength test (for metal bonded emergency spring design). 1 / batch
Specification no.
RDSO/CG/S/23002, Rev. nil)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 40 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

(SECTION B)

REQUIREMENTS FOR
EMERGENCY RUBBER SPRINGS USED IN AIR SPRINGS

1.0 SCOPE

1.1 This Specification Covers the technical requirements relating to material, constructions
and tests for emergency rubber used in the air spring for bogie having pneumatic
suspension at secondary level. This does not include all the necessary provisions
required for a supply contract.

1.2 This Specification specifies the operating and performance requirement and method
of testing the emergency spring. These Emergency rubber springs are used in
conjunction with the air bellow and are an integral part of air spring acting in series or
parallel with the load and stiffness provided by compressed air inside the air bellow.

1.3 The emergency rubber springs are subjected to static and dynamic loading in
compressive and shear modes simultaneously during operating conditions. The
maximum compressive and shear loads are given in subsequent paragraphs.

1.4 The Emergency rubber spring shall be capable of withstanding wide climatic variation
prevailing in the country without physical deterioration and change in compressive and
shear stiffness characteristics.

2.0 REQUIREMENTS:

2.1 Material

2.1.1 Rubber:
The Emergency rubber spring used in the air spring should be manufactured from
natural rubber suitably compounded to conform to the requirements stipulated in
Specification.

2.1.2 Steel:

a) The end mounting plates and inter leaves, shall be of stainless steel or corrosion
resistance steel or equivalent.
b) In the preparation process of metal plates or inter leafs it shall be ensured that all sharp
edges and burrs are removed and they are chemically treated and cleaned
before shot grit blasting as per IS: 9139-GM30.

2.1.3 Bonding of Metal to Rubber (for metal bonded emergency spring design):

a) Before applying primer coat for achieving the required bond strength between metal
part and rubber, the metal parts which are ready for use should be stored suitably to
avoid contamination on the surface.
b) The process and bonding agent adopted for bonding of rubber to metal plates shall be
of proven quality.
c) The temperature and moulding time shall be optimized for proper curing of rubber.
d) The rubber should be smooth and free from pinholes, blister and other visual flaws.

2.2 Operating conditions:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 41 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

2.2.1 The emergency rubber spring is an integral part of Air spring and acts in series or
parallel with the compressed air provided inside the air bellow, taking full load.

2.2.2 The maximum dynamic load on the air spring is 50% more than the static gross
vertical load.

2.2.3 Under deflated condition of air spring the Emergency rubber spring acts as bumper /
suspension and supports the full operating vertical and shear load at such lower speed
which is considered safe as per standing criteria.

2.3 Environmental conditions:

2.3.1 Emergency spring being an integral part of air spring which is provided at secondary
stage in mainline coaches is subjected to following environmental conditions
mentioned in para 3. - .:

Maximum temperature at sun : 600 C

Ambient Temperature : -25 0C to to +500 C
Average relative humidity : 70% to 90%, 100% on several days
Rail fall : Fairly heavy, maximum being 200mm in 24
hrs. typical to coastal areas
Atmosphere : Dusty for several months of the years
Elevation : 2m (MSM) to 3500m (MSM) approx. and
atmospheric pressure upto 0.65 atm approx.

3.0 STIFFNESS CHARACTERISTICS:

3.1 The vertical and lateral stiffness of emergency rubber spring can not be specified
precisely as it acts in series with the vertical and lateral stiffness provided by
compressed air inside air bellow, under inflated condition of air spring and their
reciprocal equivalence determines over all stiffness characteristics which is guided by
Specification for air spring system.

3.2 Under the deflated condition of air spring, the stiffness and damping of emergency
spring is decided on transmissibility considerations which should be as minimum as
possible at higher frequencies. However, minimum height of air spring under full load
with no air and without spigot shall be strictly maintained as per S. No. 4 of Annexure
VIII of Specification.

4.0 TESTING OF EMERGENCY RUBBER SPRING:

The emergency rubber spring shall be subjected to following tests independently.

a) Bonding strength test (for metal bonded emergency spring design).

b) Vertical load Vs deflection test. (Before and after endurance test)
c) Shear load Vs deflection test. (Before and after endurance test)
d) Endurance test (vertical & lateral)
e) Creep test.
Test (b) and test (c) are required to be conducted before and after test (d)

4.1 Load conditions:

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 42 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

4.1.1 Static Vertical Loads

The tare/min and gross vertical loads, on each air spring for different type of BG
coaches are given as under.

S. No. Air Spring Coach Type Min./Tare Load Gross Load

1 180 KN capacity EMU Coach (HCC 50 KN 180KN
DMU Coach
2 160 KN capacity LHB Coaches (FIAT 50 KN 160KN
3 160.8 KN capacity VB-2 coaches (Y-Frame 50 KN 160.8 KN
bogie)
4 160 KN Capacity VB-1 & EMU/MEMU-US 50 KN 160 KN
(Y-Frame bogie)
140 KN capacity ICF Coach (ICF Bogie) 50 KN 140KN
5 LHB Coaches (FIAT 50 KN 140KN
6 120 KN capacity LHB Coaches (FIAT 60/50 KN 120KN

4.1.2 Shear Loads

The maximum operating shear load on particular type of air spring shall be calculated
as under:

a) Max shear load = Maximum load (180/160/160.8/140/120KN) X Max. friction coefficient

Max. shear load should be calculated in deflated condition.

OR
b) Max. Shear Load = Max. value of (Lateral stiffness of air spring x Corresponding def.)

Lateral stiffness should be calculated upto maximum lateral deflection as mention in

para. 6.2/Section A of Specification.

For shear endurance test and shear load vs deflection test, the value of maximum
shear load may be obtained by both the above methods and used that value of shear
load whichever is higher.

5.0 BONDING STRENGTH TEST:

The objective of this test is to determine bond strength between metal plate and rubber,
under pre-determined load or deflection. This test is conducted as per IS: 3400 (Part
XIV). The bond should be capable of bearing a minimum stress level of 35 Kg/cm 2.

6.0 VERTICAL LOAD vs DEFLECTION TEST: (Before Endurance test)

The emergency spring should be subjected to three successive load cycles up to 150%
of gross static vertical load as specified in para 4.1 (Section B) at quasistatic
frequency of 0.1Hz. for pre conditioning. In the fourth cycle the emergency spring shall
be compressed with a load of 0.50 KN and the deflection taken as zero at this point.
The fourth cycle is completed to record force vs deflection curve in the form of
hysterisis loop for a deflection range as obtained during initial three load cycle (loading
and unloading). The load and deflection values shall be recorded digitally and the
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 43 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

values shall be provided in the form of X Y plot and digital table. (Ref. Annexure I).
The following geometric parameter shall be recorded:

S. No. Parameters Before Endurance Test After Endurance Test *

1 Free height (mm)
2 Outer dia (mm)
3 Vertical axis orientation
(mm)
* Ref. Para 9.0

Vertical deflection in emergency spring should be given in tabulated form and with
tolerance in value of deflection at different vertical loads upon which test had been
done.

7.0 SHEAR LOAD vs DEFLECTION TEST: (Before Endurance test)

In this test the base plate of emergency spring is rigidly clamped to a fixed horizontal
plate and shear load is applied at the top of emergency spring to measure the shear
load Vs shear displacement characteristics. The maximum lateral load shall be 150%
of maximum shear load as specified in para 4.1 which shall be applied in both
directions (Positive and Negative) from the mean position at a quasistatic frequency of
0.1 Hz. The pre-conditioning of emergency spring is done by giving three successive
lateral load cycles and in the fourth cycle measurements are taken for applied shear
load and corresponding shear displacement of emergency spring. The above test is
conducted under gross vertical loads.

The measurements shall be done using digital methods and the measured data shall
be provided in the form of hysteresis loop and tables (Ref. Annexure II). The following
geometric parameters shall be recorded as:

S. Parameters Before Endurance After Endurance Test *

No. Test
1 Free height (mm)
2 Outer dia (mm)
3 Vertical axis orientation (mm)
* Ref. Para 10.0
Shear deflection in emergency spring should be given in tabulated form and with
tolerance in value of deflection at different shear loads upon which test had been
done.

8.0 ENDURANCE TEST:

a) The Endurance test is conducted to assess suitability of the emergency springs for
use in air spring provided at secondary stage suspension in coach bogie by
simulating service/ field conditions in the laboratory.
b) The test on emergency springs shall be conducted only when the results of load
deflection characteristics are obtained and found satisfactory.
c) The test shall be conducted in vertical and shear modes.
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 44 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

8.1 Vertical Endurance Test:

a) The emergency spring is subjected to a pre compressive load, which is equal to the
gross load as specified in para 4.1 on an endurance testing machine. This load is
taken as datum and further tests are conducted in load control mode.

b) With load datum as given in para (a) above, the plunger is made to oscillate vertically
in sinusoidal manner at a frequency of 1.0H z or more with 50 % of maximum gross
load on the air spring such that the maximum compressive load on the plunger does
not exceed 150% of the gross vertical load.

c) Endurance test shall be conducted for a total 1 million cycles at a stretch with
conditions as stipulated in para (a) and (b) above.

d) During endurance test of 1 million cycle if the temperature build up in emergency

spring exceeds 7CC with respect to the ambient air temperature in the surroundings,
the oscillating frequency of the plunger can be reduced by 0.5H z.
e) At the end of every 0.2 million cycles following parameters are required to be
measured (Ref. Annexure III)

i. Hysteresis loop for 5 successive cycles of loads Vs deflections record (after

every 0.2 million cycles of endurance testing)
ii. Plunger oscillating frequency.
iii. Emergency spring temperature rise.
iv. Ambient/Room temperature.

At the end of 1 million cycles following measurements/observations shall be recorded

after 30 minutes from load release.

S. No Parameters Results
1 Adhesion of bond.
2 Obvious signs of failures.
3 Excessive wear or Abrasions
4 Free height
5 Permanent set.

8.2 Shear endurance test:

a) The base plate of emergency spring is clamped rigidly on a fixed horizontal table and
subjected to a vertical pre compressive load which is equal to gross vertical load as
specified in para 4.1 acting at the geometric centre of top plate. The test is conducted
in load control mode and a horizontal force with sinusoidal frequency of 1.0H z or more
having peak load value as + 150% of maximum shear load as specified in para 4.1
is applied simultaneously for 1 million cycles.

b) During endurance test of 1 million cycle as per para (a) above, if the temperature build
up in the emergency spring exceeds 70 C with respect to the ambient air temperature
in the surroundings the horizontal Oscillating frequency of the plunger can be
reduced by 0.5 Hz.
c) At the end of every 0.2 million horizontal oscillating cycles of the actuator plunger
following parameters are required to be measured. (Ref Annexure IV)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 45 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

i) Hystersis loop for 5 successive cycle of horizontal load vs horizontal

displacement record. After every 0.2 million Cycle of endurance test
ii) Actuator plunger frequency.
iii) Emergency Spring temperature rise.
iv) Ambient/room temperature.

At the end of 1 million horizontal cycle, following measurement /observations shall

be recorded after 30 minutes from vertical and lateral load release.

S. No Parameters Results
1 Adhesion of bond.
2 Obvious signs of failures.
3 Excessive wear or Abrasions
4 Free height
5 Permanent set.
6 Tilt angle of vertical axis.

9.0 VERTICAL LOAD vs DEFLECTION TEST.( after endurance test )

This Test is required to be conducted after satisfactory Endurance test and shall be
carried out on the similar line as given in para 6.0.

10.0 SHEAR LOAD vs DEFLECTION TEST: (after endurance test).

The test is required to be conducted after satisfactory shear Endurance Test and shall
be carried out on the similar lines given in para 7.0.

11.0 SUPERIMPOSITION OF ACQUIRED DATA :

The following data obtained before and after Endurance Test shall be superimposed
over each other as details given below:

11.1 Vertical Load Vs Deflection test data

The object is to determine the loss in vertical properties/characteristics of rubber due

to endurance test. The characteristics test obtained vide para 6.0 and 9.0 shall be
superimposed over each other in the form of hysterisis loop and comparative digital
table (Ref. Annexure V).

11.2 Shear load vs deflection test data

The object is to determine the loss in shear properties/characteristics of rubber due to

shear endurance test. The characteristic data obtained vide para 7.0 and 10.0 shall be
superimposed over each other of hysterisis loop and comparative digital table. (Ref
Annexure VI)

12.0 CREEP TEST

The Creep Test is conducted on an emergency rubber spring by applying a

predetermined maximum vertical load, which is borne by the spring for a sufficiently
long period to determine the magnitude of permanent set or loss in free height under
the influence of load with respect to time.
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 46 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

The predetermined maximum vertical load (150% of gross static load should be
applied) continuously for a period not less than 5 14 days. The following measurements
are required to be taken.

1. Magnitude of applied vertical load.

2. Free height of rubber spring (before and after creep test)

3. Height of rubber spring with respect to time. The height of the spring
should be measured after every 3 hrs for the first 2 days (48 hrs) and after
every 6 hrs. thereafter.

The vertical deflection vs time curve should be drawn for the minimum period of 5 14
days. It can then be extrapolated depending on the expected working age of rubber
spring (Ref. Annexure VII). Creep test shall be done on separate sample.

13.0 GENERAL

a) All the tests mentioned in this specification shall be conducted on the same
specimen of Emergency rubber spring except creep test. Creep test shall be
done on separate specimen of Emergency rubber spring.
b) All measurements shall be given in SI units.
c) The test results shall be furnished by contractor in the form of a type test report.
d) Digital photographs /pictures of test rig should be provided by the contractor in
type test report.
e) Any other relevant details in support of accuracy of test shall be given in type
test report.

************

SECTION-C (SCHEDULE OF TECHNICAL REQUIREMENTS)

INFRASTRUCTURE & FACILITIES REQUIRED FOR MANUFACTURE & TESTING

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 47 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

OF AIR SPRING ASSEMBLIES.

1.0 SCOPE

This Section covers the infrastructural requirements for manufacture and supply of
following Air Spring assemblies: -

(i) Air Spring assembly (180 KN Capacity) for higher Capacity Loads used on
EMU/DMU/ MEMU Coaches for ICF type Bogies.

(ii) Higher capacity Air Spring Assembly (160 KN) for LHB Coaches having FIAT
Bogie.

(iii) Air Spring assembly (160.8 KN Capacity) for VB-2 coaches.

(iv) Air Spring assembly (160 KN Capacity) for VB-1, EMU & MEMU-U/S coaches.

(v) Air Spring Assembly (140 KN capacity) for Mainline / Rajdhani / MEMU Coaches
for ICF Type Bogies and Mainline/Rajdhani LHB coaches for FIAT type Bogies.

(vi) Air Spring Assembly (120 KN capacity) for LHB Coaches for FIAT Type Bogies.

2.0 REQUIREMENTS
All vendors seeking registration with RDSO shall comply all requirements mentioned
below.
3.0 PLANT, MACHINERY AND INFRASTRUCTURE REQUIREMENTS

3.1 The Manufacturer shall have adequate space and covered area with proper floor to
accommodate the following and for smooth logistics:

a) Damp-free place for storage of raw materials.

b) Adequate manufacturing area.
c) Laboratories for material testing
d) Machining Facilities as per Quality Assurance Plan.
e) Manufacturing facilities along with assembly line.
f) Finishing, Assembly, Rejection and Inspection area.
g) Assembly & testing area.
h) Painting facility
i) Facilities for Storage, Packing and dispatch of finished products.
j) Proper Conveyer/ OHE/ Fork & lift etc. for lifting and transportation of Air Spring
assembly/ sub- assemblies.

3.2 Design & Development facilities (Mandatory for OEM/ Vendor):

i) R&D cell and team of competent & qualified Engineers with experience in air
spring designing & development for Railway passenger coaches.
ii) CAD center for Computer-Aided Design
iii) FEA/ FKM calculation and design validation software
iv) Auto CAD/ UG/ Solid Works or suitable software for drawing & design works
v) Valid license for designing software and tool.
vi) CAM center for Computer-Aided Manufacturing process and control for precise

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 48 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

works.

3.3 Type Testing Facilities (Mandatory for OEM /Vendor):

S. Name of Machine / Capacity / Min. Remarks
no. Equipment / Description / Qty
Software Specification
1 Universal testing Having suitable 01 Testing of bumper, ply-
machine capacities adhesion, static load vs.
deflection of emergency
bumper, metal to rubber
adhesion of emergency
bumper, physical properties of
cured rubber sample of
unaged, heat aged, oil aged
samples
2 DIN Abrader Lab standard 01 Testing of abrasion resistance
3 Ozone chamber Lab standard 01 Testing of ozone resistance
4 Dynamic testing Suitable capacity 01 Testing of vertical, lateral/shear
equipment with load cell actuator, and torsional stiffness, vertical
programmable with hydraulic pump and lateral endurance testing of
and controller, air spring assembly, Testing of
cooling system, vertical stiffness, endurance of
additional reservoir emergency bumper, vertical
load vs. deflection, shear load
vs. deflection etc.
5 Burst pressure Water pump with 01 Testing of burst pressure (Upto
fixture controller 30 Kg/Cm2)
6 Curing press 50ton Having 01 Curing of sample for metal to
suitable capacity rubber adhesion test, test slab
for petroleum resistance testing
7 Ageing oven Lab standard 01 Ageing of test samples for
petroleum / oil resistance, heat
resistance
8 Vernier caliper, 1.0m length, 10bar -- Effective diameter
pressure gauge with 0.01 bar least measurement, pressure
count checking

Suitable testing machinery and infrastructure is required to conduct the complete type
testing and Endurance tests of air spring assemblies and Emergency Spring as
mentioned in this specification. Facilities available at sister/ allied/ principle concern
may also be considered for this purpose on case to case basis on the basis of
practicability

3.4 Manufacturing facilities for Air Spring Bellow (For OEM/Vendor/Allied/ Sister
Concern):
S. Name of Machine/ Capacity/ Description Min.
No Equipment/ Software /Specification Required Qty
1. Weighing balance for Rubber, Rubber -- 01 No
chemicals, Filler weighing

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 49 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

2. Twist checking, tensile testing machine, -- 01 No

shrinkage tester, ageing oven
3. Kneader / Intermix / Banbury mixer for -- 01 No
mixing of rubber compound
4. Two roll mill -- 01 No
5. 3 roll calender for Calendering of inner -- 01 No
liner and outer cover
6. 4 roll calender for Rubber coating on -- 01 No
fabric
7. Bias cutting machine -- 01 No.
8. Build drum -- 01 Nos.
9. Build machine -- 01 Nos.
10. Ton Curing press (min. 85 T) -- 01 No.
11. Hardness tester, Specific gravity -- 01 No
balance, Mooney viscometer,
Rheometer, Lab curing press

3.5 Manufacturing facilities for Emergency Spring: - (For OEM/Vendor/allied/sister

concern):
S. Name of Machine/ Capacity/Description/ Min.
No Equipment/ Software Specification Required Qty
1. Weighing balance for Rubber, Rubber -- 01 No
chemicals, Filler weighing
2. Twist checking, tensile testing machine, -- 01 No
shrinkage tester, ageing oven
3. Kneader / Intermix / Banbury mixer for -- 01 No
mixing of rubber compound
4. Mould -- 1 No.
5. Compression moulding press -- 1 No.
6. Curing press --
7. Carousal chemical storage tank -- 1 No.
8. Scada (PLC)-chemical and carbon -- one
weighing control
9. Kneader for mixing of final batch -- 1 No.
10. Bonding agent application spray unit -- 1 No.
11. Hardness tester -- 1 No.
12. Shot/Grit Blasting machine -- 1 No.
13. Degreasing facility -- 01
14. Testing facilities to test the surface of -- 01
cleaned metal parts by using special ink,
Testtinte 38 mN/m or 30 Accu-Dyne Test
Pen etc.
15. Painting booth for base plate & Metal parts -- 01
16. Hand Grinder & Grinding M/c -- 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 50 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

17. Machine & facility for Swaging / Internal -- 01

Stress Removal
3.6 Manufacturing facilities for Top Plate and other metal parts (For OEM/ Vendor/
Allied/ Sister Concern):
S. Name of Machine/ Capacity/ Description/ Min.
No Equipment/ Software Specification Required Qty
1. Vertical turning Lathe -- 01
2. CNC Lath -- 01
3. Radial Drilling machine -- 01
4. Jig & Fixtures -- 01
5. MIG Welding -- 01
6. Hydraulic Press -- 01
7. Vertical milling centre -- 01
8. Test bench for leakage testing of top -- 01
plate
9. Testing facility for weld test -- 01
10. CMM -- 01
11. Shot/Grit Blasting machine -- 01
12. Degreasing facility -- 01
13. Testing facilities to test the surface of -- 01
cleaned metal parts by using special
ink, Testtinte 38 mN/m or 30 Accu-Dyne
Test Pen etc.
14. Painting booths & Machinery -- 01
15. Hand Grinder & Grinding M/c -- 01

Note: For manufacturing of top plate through casting process, firm should
additionally have adequate facility with suitable moulds & die, Injection
Press, Induction Furness, Tanks for pre coat and de-waxing tank,
dehumidifier & cooling tower, costing equipments, heat treatment facility,
MPI testing machine, contactless thermometer etc. to carry out the entire
manufacturing process with quality control.
3.7 Assembly and testing Facilities:
S. Name of Machine/ Capacity/ Description/ Min. Required
No Equipment/ Software Specification Qty
1. Dust free assembly line -- 01 No.
2. Load cell equipped with computer, Software should give the 01 No.
printer & software for pressure v/s result in tabular and
load test graphical form
3. UTM test bench with computer, Software should give the 01 No.
printer & software for load v/s result in tabular and
deflection test of Emergency spring graphical form
4. Leakage testing equipment with With digital gauges & least 01 No.
digital gauge and supply upto min. count of the gauges
10 Kg/Cm2 should be 0.01 Kg/Cm2
5. Surface table for measurement of With suitable capacity for 01 No.
air spring assembly measurement of offered
air spring assemblies
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 51 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

6. Pneumatic compressor As per requirement of 01 No.

testing and manufacturing
of Air Spring assemblies.
7. Vernier caliper, go/no-go gauges, -- As per
micrometre, plug gauges and other requirement
suitable tools and gauges
8. Weighing balance for Air Spring -- 01 No.
Assembly
9. Salt spray testing machine and -- 01 No.
setup

3.8 Tools and gauges

The Manufacturer shall have at least following testing equipment/facility with
controlled temperature and humidity:
a) Digital Vernier Caliper (500mm): Min. 01 Nos.
b) Dial Gauges (least count 0.01 Kg/Cm2): As per requirement for all leak test
benches and testing machines.
c) D-Tape for measurement of spring dia.
d) Micrometer (100mm, least count 0.0001): Min. 01 Nos.
e) Measuring tapes (3 mtr): Min. 01 Nos.
f) Thread Plug Gauge: Min. 02 Sets
g) Steel Scale: Min. 02 Nos.
h) Digital Weight scale (200 Kg): Min. 01 Nos.
i) Stop watch: Min. 01 Nos.
j) Surface table: Min. 01 No.
k) Radius gauges: Min. 01 Set
l) Torque Wrench (50-450 kgfm)- Min.- 01 No.
m) Suitable gauge for measurement of paint thickness/ DFT
n)
compliance of this specification.
3.9 Limited outsourcing in supersession to above clause 3 in this section of this
specification may also be permitted while ensuring compliance to clause 5.4/5.5
5.5/5.6 of Section-A of this specification.

3.10 Requirements of infrastructure & facilities for type testing & manufacturing in clause
3.3-3.8 in this section are bare minimum requirements. Any other facilities required to
comply this specification or required for fully functional performance of air springs shall
also be ensured by the vendor.

However, vendor may also propose for alternate methodology/ processes for
manufacturing/ type testing, which might require different set of M&P and tools. For
such alternate of methodology & process, vendor shall establish that such M&P and
facilities are adequate for manufacturing & testing of air spring assemblies/ critical
components and compliance of this specification.

4.0 Quality control requirements:

4.1 The firm should have acquired ISO:9000 series certification for the product for which
an approval is sought.

4.2 The Vendor shall have a well-

ensure sustained quality of product being manufactured. The Quality Assurance
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 52 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

ollowing:-

4.2.1 System to ensure that correct raw material is being used. The type of rubber used for
the air spring bellow shall be specified by the OEM.

4.2.2 System to ensure that components having manufacturing defects are identified and
destroyed so that such components are not used during assembly of air spring.

4.2.3 System to ensure that bought out components are strictly as per requirements laid
down in the specification/ drawing.

4.2.4 System to maintain strict control of dimensions and workmanship of components and
assembled product.

4.2.5 System to test and establish that the air spring assembly manufactured by the firm
meets all the requirements laid down in specification / drawing.

4.2.6 System of periodical calibration of equipments/gauges to ensure accuracy of product.

4.2.7 System to ensure cleaning & removal of dust/rust and moisture by dry air.

4.2.8 System to ensure that air spring assembly is properly packed to meet the requirement
of Clause-12 of Section-A this specification.

4.2.9 System to ensure traceability at least up to guarantee period.

4.3 Quality manual of the firm for ISO:9000 should clearly indicate at any stage the control
over manufacturing and testing of the railway product.

4.4 The firm should submit the Quality Assurance Plan (QAP) as per RDSO ISO doc no.
QM-RF-7.1-3.
4.5 The firm should produce a valid IRIS certificate as mentioned in para 5.3 of Section-A
of this specification.
4.6 The firm must ensure that proper analysis is being done on regular basis to study the
rejections at various internal stages and it is well documented.

4.7 The firm should ensure that latest version all the relevant specifications, IS Standards
are available with the firm.
4.8 System for calibration of testing & measuring equipment.
4.9 Facilities included in Section-C of the specification are bare-minimum, entire
responsibility for compliance of the specification shall lie with the vendor
4.10 Firm shall have an internal system of checking of chemical properties of the steel as
well as rubber components or through NABL accredited laboratory.

4.11 The firm shall have a system of component level traceability right from raw material to
the finished product stage.
4.12 There shall be proper stacking of raw material and their record. FIFO system should
be implemented, especially for non-metallic components. Non-metallic components
shall be kept in proper dust & moisture free atmosphere.
5.0 Qualification of Man Power

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 53 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

5.1 The Quality Control Section shall be separately headed by a full time technical expert

least 5 years of experience or diploma in Mechanical/ Automobile/ Mechatronics with

at least 8 years of experience. He shall be free from day-to-day production & testing
responsibilities. He shall be mainly responsible for development for product, failure
analysis, planning corrective and preventive action, control over raw material, devising
actions in case of difficulties in achieving the parameters etc.
5.2 Production/ inspection activities shall be headed by a graduate engineer with at least
5 years of experience or a diploma holder with at least 8 years of experience. He shall
be actively involved in day-to-day activities of stage inspection / compliance of QAP
etc.
5.3 Welders shall be qualified in accordance with prevalent National / International
standard.
5.3 Welding in manufacturing:
Firm should have adequate and proper welding facility at Vendor/ OEM/Sister
concern/Out sourcing with qualified, trained and experienced welders. The quality of
welding has to be according to EN 15085 / EN 25817/ ISO 5817 class B.
Concerned vendor/Sub vendor/Allied/Sister Concern must have EN 15085-2 CL-1
certification for plant/works (if welding work is required on Air spring assembly parts).
At the type approval stage, the manufacturer shall hand over to RDSO necessary
documentation for records.
5.4 Testing of welding seams
The welding seams have to be checked by non-destructive methods via PT (Penetrant
Test) or MT (Magnetic Particle Test)
PT as per ISO 23277
MT as per ISO 17638 and ISO 23278
6.0 DOCUMENTATION
Firm shall maintain the following documents/ records:
6.1 A well-documented Quality Plan.
6.2 Incoming raw material register with Test Certificates references of suppliers and
internal test results.
6.3 Stage inspection results including finished products results.
6.4 Records of internal rejection and its analysis vis-à-vis action plan.
6.5 Records of final products inspection by external agencies (like RDSO/Railways), Non-
Conformity Reports and case analysis as well as action taken thereof.
6.6 There should exist a system of documentation in respect of rejection at customer end,
warranty replacement and in service field performance.
6.7 Records of raw material received and supplies made to Railways against the raw
material. Incoming raw material with TC reference of supplier as well as internal
test/audit checking from outside agency.
6.8 The details regarding Stage inspection and test result.
********************************

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 54 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 55 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 56 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 57 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 58 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 59 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 60 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 61 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure VIII
Leading parameters of air springs and drawings

Type of Air Spring

S. Item 180 KN 160 KN 140 KN capacity120 KN 160.8 KN 160 KN

No capacity capacity capacity capacity capacity (For
For ICF For FIAT (For VB-2 VB-1,
coaches) EMU/MEMU-
Bogie Bogie US coaches)
1 Installed height 255+5-0 294+0-5 255+0-5 294+0-5 294+0-5 300+5-0 300+5-0
without spigot
(mm)
2 Maximum Ø 740 Ø 700 Ø 740 Ø 700 Ø 700 Ø 755 Ø 755
permissible
diameter of air
spring (mm)
3 Maximum Ø 750 Ø 700 Ø 750 Ø 700 Ø 700 Ø 660 Ø 660
permissible Ø 680 Ø 680
external
diameter of top
plate of air spring
(mm)
4 Min. height of air 215 240 210 240 240 250 250
spring under full 252 252
load with no air
and without
spigot (mm)
5 Drawing no. of CG- CG- CG- CG- CG- RDSO/CG/ RDSO/CG/
space envelope K4023 K5065 K4017 K5065 K5065 DRG/23007 DRG/23007
Alt. nil Alt. nil
6 Drawing no. of CG- CG- SKETCH- CG- CG- RDSO/CG/ RDSO/CG/
base plate K4022 K5057 K4018 18228 K5057 DRG/23008 DRG/23008
Alt. nil Alt. nil
7 Length of base 600 404 400 404 404 480 As per 480 As per
plate (mm) drawing drawing
8 Width of base 400 404 400 404 404 480 As per 480 As per
plate (mm) drawing drawing
9 Thickness of 12 (min.) 20 12 20 20 19 36
base plate (mm) (min.) (at
mounting
holes
location)
10 Centre distance 250 344 + 325 344 + 0.2 344 + 0.2 340±0.2 340±0.2
between (at 0.2 (both (both (both As per As per
mounting holes shorter (both side) side) side) drawing drawing
(mm) side) side)

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 62 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

11 Dimension of Ø 32 Ø 44 Ø 44 Ø 44 Ø 27.2 Ø 27.2

mounting hole. (counter (counter (counter (counter (counter (counter (counter
(mm) bore) bore) bore) bore) bore) bore) bore)
Ø 22 Ø 22 Ø 17 Ø 22 Ø 22 Ø 13.5 Ø 13.5
(thru (thru (thru (thru (thru (thru hole) (thru hole)
hole) hole) hole) hole) hole)
12 Mounting Type, High High High High High Bolt ISO 10642 1. Bottom side
Fasteners Size & tensile tensile tensile tensile tensile M12x100* with bogie
Details Grade hexagonal hexagon hexagon hexagonal hexagonal 8.8 A3L, * frame: Hex,
of socket- al socket- al socket- socket- socket- Length of bolt Socket
screw head cap head cap head cap head cap head cap have to be countersunk
screw, screw, screw, screw, screw, relevant due to head screw M-
M20 X 50 M20X55 M16 X 45 M20X55 M20X55 length of shank 12x80-8.8, FS
long, long, long, long, long, and thickness all steel
IS: 2269 IS: 2269 IS: 2269 IS: 2269 IS: 2269 of all clamped locknut M-12
(latest) (latest) (latest) (latest) (latest) parts or Property
class 10.9 class class class 10.9 class 10.9 nonstandard, class-10,
or higher 10.9 or 10.9 or or higher fully threaded Washer ISO
higher higher one needs to be 7089-12-
used. 300HV
Carbody side- 2. Top side
Hexagon head (with car
bolt - ISO 4014- body): Hex.
M16 x 70-8.8. Head bolt M-
Bogie side- 16x70-10.9,
Hexagon socket FS all steel
countersunk locknut M-12
head Screw Property
(Full thread) lS class-10,
6761 M12X80- Washer ISO
8.8 7089-12-
300HV.
Carbodv side-
Hexagon head
bolt-IS 13
64(PART-1)/
ISO 4014-M16
x70-10.9 8.8.
Bogie side-
Hexagon
socket
countersunk
head screw lS
6761-1994-
M12X80-8.8
Type, Hardened Hardened Hardened Hardened Hardened Nord lock
Size & and and and and and washer Carbody side-
Grade tempered tempered tempered tempered tempered NL12 min. Washer to
of washer with washer with washer with washer with washer with 400HV ISO 7089-16-
washe 300 HV 300 HV 300 HV 300 HV 300 HV Carbody side- 300 200HV- (2
r class (300 class (300 class (300 class (300 class (300 Washer to ISO Nos. per
HV -370 HV) HV -370 HV -370 HV -370 HV) HV -370 HV) 7089-16- screw)
hardness. HV) HV) hardness. hardness. 200HV- {2Nos. Bogie side-
A 22, hardness. hardness. A 22, A 22, per screw Washer to
IS:2016 A 22, A 18, IS:2016 IS:2016 Bogie side- ISO 7089-12-
(latest) IS:2016 IS:2016 (latest) (latest) Washer to 300 200HV.
(latest) (latest)
Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 63 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

ISO 7089-12-
200HV.)
Type, Prevailing Prevailing Prevailing Prevailing Prevailing Nut ISO 4032
Size & torque type torque torque torque type torque type M12 8
Grade hexagonal type type hexagonal hexagonal electro FS all steel lock
of nut. nuts (with hexagonal hexagonal nuts (with nuts (with galvanized nut M-16
non nuts (with nuts (with non non (ISO 4042) Property class-
metallic non non metallic metallic 1. FS all steel 108.8,
insert), metallic metallic insert), insert), Locknut M-
M20:B, insert), insert), M20:B, M20:B, 16, Property FS all steel
IS: 7002 M20:B, M16:B, IS: 7002 IS: 7002 class - 8 locknut M-12,
(latest) IS: 7002 IS: 7002 (latest) (latest) 2. FS all steel Property
class 10 (latest) (latest) class 10 class 10 'Locknut M- class-108.8
class 10 class 10 12, Property
class - 8.
Surface finish of Fasteners to be All fasteners
fasteners electroplated to A3L finish of IS:1367 (Part - Zinc flake (screws,
coated (Geomet washers &
321 or nuts) shall be
equivalent) with
Carbody side electroplated
coat, without to A3L finish of
any hexavalent IS:1367 (Part -
chromium,
without any
integrated or
separately
added lubricant,
minimum salt
spray test life
of1000 hours
shall be
ensured.

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 64 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure IX

Details of dimensions of Spigot and O-ring

Spigot for Air Spring assemblies for LHB/ICF/VB-2/ VB-1/ EMU-US/MEMU-US

type bogies

O-Ring for Air Spring assemblies for LHB, ICF VB-2/ VB-1/ EMU-US/MEMU-US
type bogies

Description LHB/ICF Coaches for VB-2/ VB-1/

(mm) EMU-US/MEMU-US Coaches
(mm)
External diameter of spigot (A) Ø 85-0.036-0.071 Ø 85-0.036-0.071
Diameter of spigot without grooves (B) 75.6 + 0.5 75.6 + 0.5 77.3 -0.074
Height of spigot (C) 35.0 + 0.5 45.0 + 0.5
+0.2
Height of Groove (D) 6.7 + 0.6 6.7 + 0.6 6.6
Depth of Groove (E) 4.7 + 0.5 4.7 + 0.5 3.85
Internal diameter of O- ring (F) 74.1 + 0.6 74.1 + 0.6 77.0 -0.5
Cross section diameter of O- ring (G) 5.7 + 0.1 5.7 + 0.1 5.0+0.1
Height of groove 1 from top plate (G1) -- 15.0 ±0.1
Height of groove 1 from top plate (G2) -- 27.0 ±0.1

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 65 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Note - The mating bolster hole diameter where spigot shall be fitted is Ø 85 H8 mm (Bore)
Annexure X

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 66 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure XI

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 67 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 68 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure XII

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 69 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure XIII

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 70 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure XIV

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 71 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 72 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure - XV

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 73 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure - XVI

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 74 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure - XVII

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. 1) Page 75 of 75 Latest (Rev/Amend) issue : Specification No.
January, 2025 RDSO/CG/S/23002, Rev. 01

Annexure - XVIII

Signature
Name & Prepared by: Checked by: Approved by:
designation Ratnaker Tiwari, Satyendra Kumar, Prabhat Ranjan Shukla
SSE/VDG/Carriage ADE/VDG/Carriage Director/VDG/Carriage