1. Scope Summary
Document control: Items stated as dimensions, material grades and fixed quantities are taken from the supplied drawings. Manpower, machine quantities, QC hold points and duration are planning recommendations for review and must be aligned with the approved railway/customer QAP, WPS and site conditions before execution.
4repair drawings reviewed
382 kgapprox. floor strengthening weight / wagon shown on RSSK-6662M
4 nos.corner stiffening plates / wagon shown on RSSK-7009
Ø25 mmcrack-arrest holes shown on floor repair drawing
| Repair area | Drawing basis | Primary work | Quantity basis |
|---|---|---|---|
| Floor plate / floor strengthening | RSSK-6662M | Crack arrest, crack repair, fit pressings/angles/stiffeners, weld and finish | Fixed strengthening schedule shown on drawing; approx. 382 kg |
| Corner stanchion & headstock joint | RSSK-7009 | Fabricate and weld stiffening plate at corner/headstock/solebar joint | 4 stiffening plates per wagon |
| Upper deck cross member | Upper Deck Cross Member | Remove local floor plate, fit boxing plate, weld, reinstate floor | As required after inspection |
| Roof | Roof Repair | Clean and weld crack, fit support angle, plug weld, finish and paint | As required per crack location |
2. Material Requirement
2.1 Floor strengthening – RSSK-6662M
| Item | Description | Size / length | Qty / wagon | Material |
|---|---|---|---|---|
| 1 | ISA | 50×50×5 × 762 LG | 24 | IS 2062 E250 A Cu |
| 2 | ISA | 50×20×5 × 812 LG | 12 | IS 2062 E250 A Cu |
| 3 | Pressing | 200×50×6 × 1985 LG | 4 | IS 2062 E250 A Cu |
| 4 | Pressing | 125×50×6 × 835 LG | 4 | IS 2062 E250 A Cu |
| 5 | Pressing | 125×50×6 × 1105 LG | 4 | IS 2062 E250 A Cu |
| 6 | Pressing | 125×50×6 × 1238 LG | 4 | IS 2062 E250 A Cu |
| 7 | Pressing | 200×50×6 × 1270 LG | 16 | IS 2062 E250 A Cu |
| 8 | Pressing | 200×50×6 × 1230 LG | 2 | IS 2062 E250 A Cu |
| 9 | Stiffener | 190×40×5 THK | 72 | IS 2062 E250 A Cu |
| 10 | Stiffener | 115×15×5 THK | 20 | IS 2062 E250 A Cu |
| Approx. total weight shown on drawing | 382 kg / wagon | |||
2.2 Other repair materials
| Repair | Material / component | Drawing information | Planning quantity |
|---|---|---|---|
| Corner/headstock | Item “X” stiffening plate | 8 mm plate; IS 2062 E-250 A Cu; developed geometry as drawing | 4 nos / wagon |
| Upper deck cross member | Boxing plate | Approx. 1005 mm developed length; 6 mm thick; formed profile as drawing | 1 per defective location |
| Roof | Support angle | ISA 50×50×4 reduced to approx. ISA 50×17×4; 250 mm long; Ø8 plug-weld holes | 1 per roof crack location |
2.3 Consumables
Welding
- Approved MIG/MAG wire and/or SMAW electrodes as per WPS
- CO₂ or Ar/CO₂ shielding gas where MIG/MAG is approved
- Contact tips, nozzles, liners, earth clamps
- Anti-spatter compound
Cutting / drilling / finishing
- Cutting, grinding and flap discs
- Ø25 mm annular cutters / drill tooling
- Ø8 mm drill bits for roof plug-weld holes
- Plasma consumables / gas-cutting tips
- Wire brushes, emery, cleaning solvent
- Primer, top coat, thinner and masking materials
3. Manpower Plan
Recommended execution team: approximately 10–14 persons per active wagon/work front. This is a planning recommendation, not a quantity specified by the drawings.
| Role | Suggested qty. | Responsibility |
|---|---|---|
| Repair / site supervisor | 1 | Work coordination, drawing control, permits, progress and handover |
| QC / welding inspector | 1 | Defect mapping, fit-up, weld and final inspection |
| Qualified welders | 3–4 | Crack repair, plug/fillet/structural welding |
| Fitters / fabricators | 2–3 | Dismantling, fit-up, alignment, plate/angle positioning |
| Gas / plasma cutter | 1 | Cutting and local removal |
| Grinder / drilling operator | 1 | Surface preparation, crack prep, hole drilling, weld dressing |
| Helpers | 2 | Material handling, cleaning, fire watch support |
| Painter | 1 shared | Surface preparation, primer and finish coating |
| NDT technician | As required | DPT/MPT or other NDT if required by QAP/customer |
4. Primary Machinery & Tools
| Machine / tool | Suggested qty. | Use |
|---|---|---|
| MIG/MAG welding machine 400–500 A | 2–3 | Main structural welding |
| SMAW / ARC welding machine | 2 | Repair welds, difficult access, backup |
| Plasma cutting machine | 1 | Plate and reinforcement cutting |
| Oxy-fuel cutting set | 1–2 | Site cutting / heating / contingency |
| Magnetic-base drilling machine | 1 | Ø25 mm crack-arrest holes and heavy drilling |
| Portable drilling machines | 2 | General drilling and plug-weld holes |
| Hydraulic press brake | 1 workshop | Forming boxing/stiffening plates and pressings |
| Power shearing machine | 1 workshop | Blank preparation |
| Pillar / radial drill | 1 workshop | Fabrication drilling |
| 4–5 in. angle grinders | 4–6 | Cleaning, weld preparation and finishing |
| 7–9 in. heavy grinder | 1–2 | Heavy grinding and dressing |
| Air compressor | 1 | Cleaning, pneumatic tools, painting |
| Chain blocks / jacks / clamps | As required | Positioning, alignment and holding |
5. Repair Methodology – Inspection to Finishing
Receipt→
Initial inspection→
Defect mapping→
Cleaning→
Dismantling→
Crack arrest / preparation→
Fabrication→
Trial fit→
Welding→
Inspection→
Painting→
Final release
| Stage | Method | Control point |
|---|---|---|
| 1. Receipt & identification | Record wagon number, repair location and applicable drawing. | Open job card / repair sheet. |
| 2. Initial inspection | Inspect floor plate, roof, upper-deck cross members, corner stanchions, headstock and solebar. | Mark all visible defects. |
| 3. Cleaning | Remove rust, paint, scale, debris and contamination around suspected defects. | Expose sound metal and actual crack boundaries. |
| 4. Defect mapping | Measure crack length, deformation and affected member locations. | HP1 – defect survey approval. |
| 5. Dismantling / access | Remove local floor/roof plate only where required for access by the repair drawing. | Ensure underlying member is visible and accessible. |
| 6. Crack arrest | For RSSK-6662M floor cracks, drill Ø25 mm holes at crack ends as shown on drawing. | Verify hole at actual crack tip. |
| 7. Crack preparation | Grind/gouge to sound metal according to approved WPS/repair procedure. | QC visual check before welding. |
| 8. Crack welding | Weld existing crack under approved WPS; clean between passes. | Visual inspection. |
| 9. Reinforcement fabrication | Cut, drill and form angles, pressings, stiffeners and boxing plates per drawing. | HP2 – material / dimensions approval. |
| 10. Trial fitting | Position reinforcement, check seating, gaps, orientation and member alignment. | HP3 – fit-up approval before final welding. |
| 11. Tack welding | Tack in controlled sequence to maintain alignment. | Re-check dimensions. |
| 12. Final welding | Complete plug, fillet and continuous welds as shown and as approved in WPS. | Record welder / WPS where required. |
| 13. Cooling / dressing | Allow natural cooling; remove slag/spatter and dress only where needed. | No forced quenching. |
| 14. Weld inspection | VT, dimensional checks and NDT if required by QAP/customer. | HP4 – weld/NDT acceptance. |
| 15. Reinstatement | Refit floor/roof plates removed for access and complete associated welding. | Check profile and alignment. |
| 16. Surface preparation | Clean repaired area to approved paint preparation standard. | Ready-for-paint inspection. |
| 17. Painting | Apply approved primer and finish coating. | Coverage / DFT check if specified. |
| 18. Final inspection | Joint inspection of repair completeness, dimensions, welds and coating. | HP5 – final release. |
6. Inspection & Quality Control
| Check | Inspection item | Acceptance / record |
|---|---|---|
| ☐ | Drawing and repair location verification | Correct drawing revision and wagon area identified |
| ☐ | Parent material / reinforcement material identification | Traceability to approved material documents where required |
| ☐ | Defect map and crack extent | Recorded before repair |
| ☐ | Ø25 mm crack-arrest hole location for applicable floor cracks | At crack end as shown / approved |
| ☐ | Fabricated plate/angle dimensions | Matches repair drawing |
| ☐ | Fit-up, seating, gap and alignment | Approved before final welding |
| ☐ | Welder qualification / approved WPS | As required by customer/QAP |
| ☐ | Visual weld quality | No visible cracks; weld size/continuity to approved drawing/WPS |
| ☐ | NDT where mandated | DPT/MPT/other as specified by QAP/customer |
| ☐ | Dimensional / profile restoration | No unacceptable distortion; member geometry restored |
| ☐ | Surface preparation and paint | Clean surface; approved coating system applied |
| ☐ | Final joint inspection | Repair accepted and job card closed |
7. Finalities / Close-out Requirements
Technical close-out
- All identified repair locations completed.
- Reinforcement parts fitted to applicable drawing.
- All welds visually accepted; NDT completed where required.
- Removed floor/roof components reinstated.
- No loose parts, sharp edges, weld spatter or unprotected bare metal.
- Repaired structure visually and dimensionally acceptable.
Documentation close-out
- Wagon-wise defect / repair sheet
- Material certificates / traceability records where required
- Welder and WPS record
- Fit-up / weld inspection report
- NDT report where applicable
- Paint / coating inspection record if specified
- Customer / railway final inspection and release sign-off
Recommended completion criterion: A wagon should be treated as repair-complete only after the physical work, QC records, coating restoration and final joint inspection are all closed.
8. Source Drawings for Review
Roof Repair
