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Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 1 of 17
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
lR;esot;rss
PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE
BRN/BRNA/BRNAHS
ISSUED BY:
MINISTRY OF RAILWAYS, GOVERNMENT OF INDIA
RESEARCH DESIGNS & STANDARDS ORGANIZATION
LUCKNOW-226 011
MAY, 2015
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 2 of 17
ITEMS LIST
S.No. Description Length Quantity
1. Hex. Hd. bolt M10x100 100 mm 4
2. Check Nut M10 - 4
3. Wing Nut M10 - 4
4. Plain Washer - 8
5. Piano Wire 14 m 2
6. M.S. Strip 50x6Th. 200 16
7. Stopper for central girder - 4
8. Optical Pyrometer/Heat sensitive
crayons to measure temperature up to
750°C
- -
9. ISMC 250x82 2.5 m 2
10. ISMC 250x82 830 mm 2
11. ISMC 250x82 819 mm 4
12. ISMC 150x76 618 mm 2
13. ISMC 100x50 2845x2 mm
14. Rib (Shown as Item No.1 in Fig.1) - 24
15. Side Bearer Supporting Plate (Shown
as Item No.2 in Fig.1)
542x160x20 mm 4
16. Centre Pivot Supporting Plate (Shown
as Item No.3 in Fig.1)
509x390x20 mm 2
17. M-20 Nut-Bolt with Standard Washer
for Item No.2 in Fig.1
90 mm 8
18. M-22 Nut-Bolt with Standard Washer
for Item No.3 in Fig.1
100 mm 8
19. Suitable Turn Buckle More than 1200mm 2
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 3 of 17
1. DRAFT PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON
TYPE BRN/BRNA/BRNAHS INTRODUCTION
1.1 Railways have been reporting about loss of camber at the centre in Bogie Rail
Wagon type BRN/BRNA/BRNAHS after a period of service. Due to this
sagging wagon ends get lift up. Railways experience difficulties in maintaining
the buffer height.
1.2 In view of the difficulties faced by the railways to maintain the wagons, a
procedure for carrying out re-cambering of wagons has been drawn up and is
given below. The re-cambering of wagons should preferably be done at the
time when wagons require POH.
2. PROCEDURE FOR MEASUREMENT OF CAMBER OF INCOMING
WAGONS
2.1 Cut the centre pivot top huck bolts/Rivets and side bearer nut bolts and run out
the wagon bogies. Support the wagon body on trestles of equal height as
shown in fig.1 and clamp them with nut and bolts at side bearers and centre
pivot location, so that the body weight is borne equally by the trestles as shown
in fig.2. Secure the trestles with rails. Also place suitable stoppers below
headstock of such a height, so that after recambering process headstock does
not bend below the limit of required CBC height, as shown in fig.2.
2.2 Weld vertically 8 Nos. of steel plates, each having a slot and of size
200x50x6mm on the bottom of the sole bar at center line of the body bolsters
and wagon head stocks as shown in fig.3. The slot of 11x50mm provided in
each plate is to pass the piano wire through it. The plates so welded should be
erect and parallel to each other.
2.3 Place a piano wire along the length of the wagon passing through the
rectangular slots in the plates welded to the sole bars and head stock. Secure
the ends of the piano wire to 100mm long hexagonal head screws provided
with wing and check nuts and washers.
2.4 Tighten the piano wire adequately to ensure that the piano wire is straight and
there is no kink or sagging effect at any location along the wire length. This
can be done by loosening adjusting the check nut.
2.5 Adjust the height of the screw by moving up or down in the rectangular slot of
the plates welded at wagon head stock so that the distance between the top of
the piano wire and bottom of the sole bar at body bolster locations is equal.
Once it is ensured, tighten the wing nuts without disturbing the distance
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 4 of 17
between the top of the piano wire and bottom of the sole bar at the center of the
body bolster locations.
2.6 Let the height between the top of the piano wire and the bottom of the sole bar
at body bolster location be 'a'. Rotating the wing nuts without disturbing the
clearance 'a' mentioned above tighten the piano wire finally. Measure the
clearance between top of the piano wire and the bottom of the sole bar at the
center of the under frame on either side. Let this clearance be 'b'. Therefore, the
camber of the under frame at the center shall be 'b-a'. Likewise the vertical
distance between the top of the piano wire and the bottom of the head stock at
the wagon ends on either side is measured. Let this clearance be 'c',’d’, etc.
Therefore, the camber (lifting) of the under frame at its ends shall be 'c-a',’d-a',
etc.
2.7 If the reverse camber is measured at the under frame center by the procedure
given above. Re-cambering of the under frame at its center shall be carried out
as per the procedure detailed below.
3. PROCEDURE OF THE RECAMBERING (LIFTING) OF WAGON BY
APPLICATION OF HEAT AND FORCE AT WAGON UNDERFRAME
MEMBERS
3.1 Follow instructions given at Para 2.1 above to run out the bogies and placing of
the wagon body on trestles of equal heights as shown in fig.2. Place load of 8
ton on wagon floor near headstock.
3.2 Place 4 No. stoppers under the central girder (2 Nos. on either side of the
wagon) at locations shown in fig.2. Place stoppers i.e. 4 Nos. below the central
girders up to they are tight with central girder bottom flange. Provision of
securing at the wagon body bolsters would ensure that the level of the under
frame at these locations remain undisturbed during the process of lifting the
wagon under frame and also it will not droop while heating the girders.
3.3 The heat source can be oxyacetylene mixtures. The torch nozzle should be a
medium to large "rosebud" type. But it would be preferential to select a multi
nozzle torch to save the time as well as uniform heating of sections as shown in
fig.9. The temperatures shall be monitored by optical pyrometer/heat-sensitive
crayons in the real time as the heating progresses.
3.4 Heat cambering should be limited to low carbon steels. IS:2062 Fe410CuWA
steel should not be heated above 600°C, during the cambering process. The
consequences of overheating are not readily apparent to the naked eye but
nonetheless they are present in the form of microstructure changes in the steel.
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 5 of 17
Most heat cambering is accomplished by heating wedge-shaped segments at
intervals along the length of the member. If the member is over-heated beyond
the transformation temperature, there will occur "islands" of altered
microstructure; in other words, the steel will be non-homogenous. This is to be
avoided at all costs.
3.5 Remove floor plate of width of about 1.5 feet in entire width just upon the
location of heating zone. This will facilitate the removal of heat of cutting
flame as well as the resistance of underframe for recambering. Then cut the slit
at the cross-section of Side Rail at the location where floor plate has been
removed as shown in fig.2. Fix two, any suitable Turn Buckles at the location
of Head Stock and Rails with the help of suitable brackets.
Schematic Diagram of Differential Heating
3.6 Start the flame spreader at point A as shown in figure above. Heat spot A to a
light red colour 600°C. Proceed slowly in a serpentine path in the direction of
the arrow. Direct the torch toward that direction, moving slowly, bringing each
area to a light red colour. The area of differential heating B A C should be
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 6 of 17
roughly the shape of an isosceles triangle with the angle at A varying from 20°
to 40°, the larger number producing more movement. It is not necessary to
return to point A to reheat. When the web heating is finished, start the flange
heating at point D and proceed toward the center. (The flange heating may be
started, using an additional torch, as the web heating is nearing completion.)
Always advance the torch along the path bringing the steel to a light red colour
as it proceeds. The flange to be heated is on the concave side of the camber
curve; consequently, point A should be about 50mm, in from the convex side
of the camber curve. Heating zone shall be the girder and solebar locations as
shown in fig.2&5. These all locations shall be in straight line of underframe
cross-section. And floor plate shall be removed above these locations only. All
the prescribed locations shall be heated simultaneously to ascertain uniform
heating of underframe cross section. During heating, turn the screws to tighten
both turn buckles to facilitate the lowering of head stock. Continue this process
of heating and lowering of Head Stock with the help of Turn Buckles upto 10-
15mm lower than the standard limit of 1105mm, so as to compensate the
spring-back tendency of underframe when all loads are removed. Take the
measurements of respective locations to ascertain that adequate camber is
achieved, after that heating process should be stopped. For best results, let the
heated member cool by itself. Now, properly weld both slits of side rails, then
weld and grind flush the floor plate at its location. Note that the heat wedges
do not necessarily have to be equally spaced, but they should be symmetrical
about the centre line of the span (see Fig. 5&6). Care should be taken in
spacing the supports so that the member will not sag too much as the heating
progresses (see Fig. 2). For best results, allow the beam to cool naturally. If the
initial heating does not provide enough camber, additional wedges may be
heated until the desired results are obtained. In order to cut down the time
expended on heat cambering, several wedges can be heated simultaneously, as
required.
3.7 Once the heating starts, it should not be interrupted until the serpentine path
described below is completed. As the heating proceeds, the member may start
to bend in the direction opposite to that intended. However, after the heating is
finished and the beam starts to cool, the beam will commence to straighten and
then continue to bend in the desired direction.
3.8 As these members would get cooled, under frame camber should be gained.
Tight the Turn Buckles as needed.
3.9 As a precautionary and strengthening measure, weld channel pieces vertically
at web from top to bottom at the centreline of wagon, at both the girders and
also weld a channel below the floor plate throughout the width at 300 mm
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 7 of 17
offset, both sides from wagon centre line as shown in fig.10. This will help to
prevent the buckling of centre girder and floor plate during service.
3.10 Measure the camber at the centre of the under frame and CBC height at Head
stock during the process of lifting till a positive camber of at least 13 mm and
CBC height of 1105 mm is achieved. Then release the turn buckles and remove
the stoppers and load.
4. CRITERIA FOR ASSESSMENT OF PROCEDURE
After the recambering procedure is done, following points should be
observed:-
4.1 Deflection of wagon under frame shall not be more than 13±2 mm under
vertical load condition and once the load is removed the under frame should
come back to its original position.
4.2 Structural members, member joints, central girders on visual examination
should not show cracks or permanent distortion during tests.
4.3 Since joining knees between bolster and central girder & centre sill and
bolsters are vulnerable to cracks during this process. They should be properly
checked for their efficacy. Gusset plates should also be checked.
4.4 Re welding of knees or joining members may be needed.
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 8 of 17
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Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 9 of 17
C.L
. O
F B
OLS
TE
R
8 TONNE
9144
650650
1474
648
fig.2: recambering procedure diagram
(showing underframe support arrangement and location of
lifting jacks at the central girder portion of the wagon)
xy
8 TONNE
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 10 of 17
fig.3: camber measuring arrangement
'X'
= =
50
16
11
50
15
200
6
100
41
41
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 11 of 17
TU
RN
BU
CK
LE
FA
ST
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ED
BE
TW
EE
N
HE
AD
ST
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ND
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IL
R.L
.
fig
.4:
turn
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ckle
tie
d b
etw
een
he
adsto
ck a
nd
ra
ils
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 12 of 17
fig
.5:
he
atin
g z
on
es o
n c
entr
al girder
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 13 of 17
fig.6
: heating z
ones o
n s
ole
bar
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 14 of 17
fig
.7:
ca
mb
er
me
asurin
g lo
ca
tio
ns
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 15 of 17
fig.8:Schematic Arrangement of weights
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 16 of 17
fig.9:Multi Nozzles heating torch
Document No:
Technical Pamphlet No. G-107 Version No: Nil Date Issued: May-2015
Document Title: PROCEDURE FOR RECAMBERING OF BOGIE RAIL WAGON TYPE BRN/BRNA/BRNAHS
Page 17 of 17
fig.10: Welding of channels at central girder and below floor plate
ISMC-150 CHANNEL TO
BE WELDED AT WEB
AT THE CENTRELINE
OF WAGON, AT BOTH
THE GIRDERS
ISMC-100 CHANNEL TO BE
WELDED BELOW FLOOR
PLATE THROUGHOUT THE
WIDTH AT 300 mm OFFSET,
BOTH SIDES FROM WAGON
CENTRE LINE