"*fi{r] i..

t14;Ti }A 't*i{i"{ (iovcniurent i:i lndiu-lllin istn ol' ll*i l r,t vs

j1.fr..llir'r jJiw;-t r]r rpa qr6a Itescarc h Dr:si*r,r &. $iandards llrgunisalicn
tfiffi$ " ll{r i}]
1 Lucknuw - 1l{r t't I 1

npBX {$$:l?} 24$1?00 ntn (n52i:) 2450115

rmx {0$??) ?458Sf}fi illr) (il522J ;4S5310

Fax No. 0522-2453916

No. MWSPD/BG/BOXNS Dated '.%..08.2016

q516iero (nfr),
1. ftq t-d-d, E-{qfr ffi effiflT, gq-i- 400 001.
2, Td ffi, MI +iT, ot6rcT-dT - 7oo oo1.
3 sf,{ i-C, qdET El-sq, T$ ft"fr - i.io 00j.
4. EfH"T ffi, qrd ersr, N - 600 oo3.
s, qlS'T fta W-, t-d F--clqq, n-oqqreTE - 500 071
6. ER"T Td ffi, qrd-{ frq, o)_c-otar - 700 043.
7. Td-dr ffi, .irsgr - 273 012.
8. T-d-dr {nqrd k4d, qrffi.q, Xffire - 7Bi 011.
e. q-trfl ffi, z-+.t , gq-{ - 4oo o2o.
10. Td qra i-f,-i, 6r$gi - 844 101.
i1. Td f,Aq fcn, fi-ft i'c-d ol-Cfi, W @rqftr, qEtg_ggrT 7s1 016.
12. sid-{ qr4 t-d-.}, Elfr€.t trs ,gorer-flq - 211 oO1.
13. sd{ qFqq - 302 006.
l-f,.}, v-qgq
i4. qRlT q-Pqq fd-i, gq-fr - 580 023.
'1s. qtraq qta i-f,d, E-qegq
qq
- 482 oo1.
16. ER"T Td i-dd, GrR { 3ilfrrfl R-f,Rrg{ - 4e5 004

Subl Final speed certificate of Broad Gauge Bogie Open wagon type 'BOXNS'
for operation upto a maximum permissible speed of 85 km/h in empty and
65 kmph in loaded condition over Indian Railway B.G route

1.0 Broad Gauge Bogie Open Wagon type BOXNS is a modified design of 25t axle
load open type wagon to RDSO Drg.No WD-14014-S-01 fitted with newly
developed low weight low height bogies and twin pipe air brake system. The
bogie is suitably modified to reduce its unsprung mass and is structurally fit for
25t axle load operation. The bogie is designated as 'Light Weight Low Height
bogie' or LWLH bogie. The bogie is fitted with indigenously developed
optimized suspension, spring loaded CCSB and 840 mm dia wheels. The
suspension consists 06 outer, 06 inner, 02 snubber outer & 02 snubber inner in
each nest of a bogie.

1.1 ln order to assess the riding quality and stability of 'BOXNS', detailed oscillation
trials have been conducted over Pandrasali(PRSL)-Dangoaposi(DPS) section in
Chakradharpur(CKP)Division of South Eastern Railway. Test results are
contained in RDSO's report No. RDS0/20161T GIMT -1 4631F Rev.-0, Amendment
Nil dated 12-08-2016.Oscillation trial results rndicate that 'BOXNS'wagon has
exhibited satisfactory riding and stability behavior up to a test speed of 110
N{W/SPD/tsGlBOXNS Page 1 of8
 kmph in empty and upto 100 kmph in loaded condition on straight track, station
yard,2 o curve track on track maintained to other than C&M-|, VoL-l Standard.

2.0 Based on the design features and satisfactory test of oscillation trial as
contained in RDSO trials report No. MT-1463/F of August 2016, it is certified
that'BOXNS'wagon to RDSO Drg. No. WD-14014-S-01 may be permitted to
run up to maximum speed of 85 kmph in empty and 65 kmph in loaded
condition subject to the following conditions:

2.1 Track

2.1.1(a) The track shall be to a minimum standard of 60Kg rail (90UTS) on sleeper
with 1660/km density and minimum depth of ballast cushion below sleeper of
300mm, which may consist of at least 150mm clean and the rest in caked up
condition on compact and stable formation.

(b) For track to a minimum standard of 52Kg (90UTS) rails on sleeper with M+7
density and minimum depth of ballast cushion below sleeper of 250mm, which
may consist of at least 100mm clean ballast and the rest in caked up condition
on compact and stable formation, the Maximum permissible speed in loaded
condition shall be restricted to 45+5 kmph.

2.1.2 The welds shall be protected by joggled fish plates as per provisions of Para 6.4
and Para 8.14 of USFD Manual and Para 6.3 of AT welding manual and other
policy instructions of Railway Board. The maintenance of Rails and Rail joints
shall be ensured as per Para 250 & 251 of IRPWM. ln addition, wherever
condition warrants on account of corrosion on rail/weld collar, wear on rail,
cupping of welds etc., necessary precautions shall be taken for fish
plating/joggled fish plating.

2.1.3 Zonal Railway shall insure further detailed examination of track as deemed fit,
based on the age cum condition basis, overdue renewal and condition of
formation etc as per provisions of Chapter-lll of IRPWM-2004 regarding
permanent way renewals.

2.1.4 The maximum permissible speed on curves to be decided on the basis of the
existing provision of lndian Railway Permanent Way Manual Reprint-2004.

2.1.5 For track maintained to lower standard than that mentioned above, the Chief
Engineer shall decide the lower maximum permissible speed on the basis of
maintenance condition. ln this connection, Railway Board's letter No.
654//DO/SR/26 dated 19120-10-1966 may be seen. When the Chief Engineer
considers that the road bed is not compacted or there is improper drainage, he
shall suitably restrict the maximum permissible speed depending upon the local
conditions.

2.1.6 USFD testing shall be carried out at a frequency, one grade higher than the
specified frequency in the USFD manual. On section with GMT more than 60,

MW/SPD,tsGlBOXNS Page 2 of8

 the exiting stipulated frequency of once in one and a half month as per USFD
Manual may be continued.

2.1.7 Only weighed raked will be moved on the section after unloading/correction of
over loaded wagons, in case unloading/correction is not possible then speed of
rakes shall be restricted as applicable for CC+8+2 ton loaded rakes as
mentioned in unified JPO issued by Railway Board's letter No. 2007lCE-lllTS/8
dated 02.04.2009.

2.1.8 Zonal Railway shall set up a regular rail grinding regime which is considered
necessary, to check development of rolling contact fatigue defects in rails due to
25T axle load operations.

2.1.9 Thick Web switches shall be provided on the section for permitting speed of 60
kmph tn loaded condition. However, in case of overriding curved switches, the
speed shall be restricted to 50 kmph.

2.2 Bridges

2.2.1 The clearance refers to Bridges "Standard Spans" with standard design of
girders, slabs, pipe culverts, piers and abutments etc. issued by RDSO for
BGML, RBG, MBG-1987, HM Loading and 25T Loading-2008 Standard.
However, the bearings of span 76.2m (clear) designed for BGML standard
loading as per RDSO's drawing No. BA-'11154 shall be strengthened by
providing two additional anchor bolts.

2.2.2 Superstructure & Bearings of "special Spans" (designed and constructed by

Zonal Railways based on site requirements) including all arches and
substructure of all bridges (all Standard Spans & Special Spans) are to be
examined under the directions of the Chief Bridge Engineer concerned and
certified safe with respect to current lndian Railway Standard Codes with up to-
date correction slips.

2.2.3 Other specific restrictions are applicable which are indicated in relevant
Speed Certificates of hauling single/multiple locomotives issued by RDSO.

2.2.4 This clearance is subject to the following parameters of 'BOXNS wagon.

(i) Maximum axle load (empty) - 4.96 t
(ii) Maximum axle load (Loaded) - 25.0 t
(iii) Maximum braking force at Rail level per axle - 10 % of axle load
(iv) Maximum C.G height from Rail level (Empty) - 1030 mm
(v) Maximum C.G height from Rail level(Loaded) - 2253 mm

2.2.4.1 ln Empty Condition, Superstructure & Bearings of all Standard Spans of BGML,
RBG, MBG, HM Loading and 25T Loading-2008 Loading Standards are fit for
100 kmph.

2.2.4.2 ln Loaded Condition, with CG height of 2253 mm, the following restrictions are
applicable:
MWSPD/tsG/BOXNS Page 3 of8
 a) Superstructure of Standard Spans designed to BGML Loading Standard
upto 47.25m(all effective) are fit for 70 kmph speed whereas 63.0m &
78.8m span (effective) which are fit for 55 & 45 kmph speed respectively.
However all other higher spans are prohibited.
b) Superstructure of Standard Spans designed to RBG Loading Standard
upto 13.1m (effective) are fit for 70 kmph speed whereas 19.4m,25.6m
(effective) is fit for 50 kmph and 31.9m ( effective ) is fit for 40 kmph.
However all other higher spans are prohibited.
c) Superstructure & Bearings of Standard Spans designed to MBG Loading
Standard upto 31.9 m span (effective) are fit for 70 kmph speed except
spans of 47.3m, 63.0m & 7B.Bm ( all effective span ) which are fit for 65
kmph,60kmph and 45kmph speed respectively. However all other higher
spans are prohibited.
d) All Superstructure and Bearings of Standard Spans of HM loading and 257
loading-2008 Standards are fit for proposed speed of 90 kmph.
e) All Bearings of Standard Spans of BGML and RBG have been found fit for
above speeds considering that Bearings of Standard Spans of 30.5 m and
above for BGML and RBG Loading Standard have been strengthened or
replaced in accordance to Annexure 7 of Directives for operation of 251
Axle load communicated vide RDSO Letter No. CBS/Golden/Q/Strength
dated 08.08.2006. ln case where bearings has not been strengthened/
replaced as above, then same has to be done prior to operation of 25 t
Axle Load Wagons.
0 The members of Standard Spans of 30.5m and above for BGML & RBG
Loading Standard where stresses have been found high shall be identified
by 3 yellow bands of suitable width as communicated vide RDSO letter No.
CBS/25T Axle load dated 17.06.2009 and these members are to be kept
under reg ular observation.
g) Location/Members Critical from Fatigue consideration are to be monitored
as detailed in item-Vlll(d) of Directives of RDSO for operation of 25T axle
load communicated vide RDSO letter No. CBS/ Golden/Q/Strength dated
0B-08-2006.
h) Track on bridges and approaches of BGML loading standard spans 2.sm,
3.0m, 4.3m, 5.3m, 6.9m, 10.0m, 13.1m, 194m, 25.6m,31.9m, 47.3m,
63.0m, 78.8m, RBG loading standard spans 1.0m, 1.5m, 2.5m,3^0m, 4.3m,
5.3m, 6.9m, 10.0m, 13.1m, 19.4m, 25.6m, 31.9m and MBG loading
standard spans 1.0m, 1.5m, 2.5m,3.0m, 4.3m, 5.3m, 13.1m and 47.3m (all
effective) shall be strengthened or modified in such a way so as to allow
for dispersion of longitudinal force as per clause 2.8.3.2 of IRS Bridge
Rules. ln cases where dispersion cannot be allowed as per clause 2.8.3.2
such as due to provision of SEJ in bridges etc., the bridge superstructure
inctuding bearings and sub-structure shall be checked for longitudinal force
Mw/SPD/BG/BOXNS Page 4 of8
 without dispersion and certified safe by the Chief Bridge Engineer
Concerned.

2.2.5 The above clause have been arrived considering bridges are in physically sound
condition. ln case the bridges are not in satisfactory physical condition, necessary
speed restriction to be imposed by concern Chief Bridge Engineer of Railway.

2.2.6 Location of bridges on which speed restrictions are imposed shall be notified by
the Zonal Railways and incorporated in the workrng timetable so that all operating
staff is aware of the instructions.

2.2.7 For Non-Standard Spans, the directives of RDSO for operation of 25T axle load
communicated vide RDSO letter No. CBS/GoldeniQ/Strength dated 08.08.2006
and 24.08.2006 shall also be followed strictly for all aspects mentioned therein.

2.3 Signalling

2.3.1 Provision of GR, SR, SEM and all extent instructions issued from time to time
shall be complied with.

2.3.2 On the sections where EBD of more than '1 km is to be catered for, second
distant signal or automatic signaling should be available failing which suitable
speed restrictions to be imposed.

2.3.3 The condonation regarding infringements in schedule of dimensions, if any, shall

be obtained in accordance with local conditions, before initiating the operation.

2.4 Rolling Stock

2.4.1 Before initiating the operation, the Mechanical department of the Railway shall
certify the safety of the rolling stocks. Mechanical department of the Railway
shall also ensure the proper maintenance of the stock.

2.4.2 For movement of wagon on any private or assisted siding for loading or
unloading the consignments, the Chief Engineer of Railway shall be referred to.

2.4.3 Brake of the wagons shall be in good working order during the operation.

2.5 General

2.5.1 All the permanent and temporary speed restrrctions enforced and those that
may be imposed from time to time due to track bridges, curves, signaling and
interlocking etc shall be observed.

2.5.2 The design of 'BOXNS' wagon infringes to clauses 2.(ii) of Chapter lV(A) of
lndian Railway Schedule of Dimensions B G. revised 2004.Railway board has
earlier provided condonation for this infringement vide letters no. 97|CEDO/SR/4
dated 1210211997 in case of container wagon and vide letter no
ZO11|CEDOISD/RS/O5 dated 0210212012 in case of BCACBM (Auto car wagon ).

NAA//SPD/BG/BOXNS Page 5 of8

 DG/RDSO has approved the similar condonation required in this case for use in
BOXNS wagon.

2.5.3 The loading spectrum actually passing over the track to be recorded with Wheel
lmpact Load Detector (WILD) and requisite action be ensured for alarms
generated . Zonal Railway shall ensure installation and maintenance of
adequate no. of WILD instruments for this purpose in a time bound manner.

lTd]-{fr: (1) Drg. No.WD- 14014-S-01

(2) Annexure-l -Salient Features of 'BOXNS'
(3) Annexure-ll (List of referred documents)-in a Compact Disc enclosed.

(qft iTq)
ordorft qrq-frlqreFr PTfrfl
stutufr:
(t) g+E-q (ffift-f,d /{fi), W qtd, {6 +rc-q,{ fa"fr - 110001

(Z) Es ta rnq&Tl 3ilg-fi, ewtrf, qrf, aq+o-226001

(3) q-6T s6rrro. (sfr-fi-f,/qrflrutn/iidf, \'q 1rtrqlE),
(i) qta H, E-rq"fr ffi eff-q-{r, 5w{* 4oo oo1
(ii) Td H, +ryfr d-rr, @td-mT-dT - 7oo oo1
(iii) vms W, q-s-YqT Ers-s, r-g fud - 110 001
(iv) qfh"r W, qr-d ereq, N - 600 oo3
(v) qfd-oT qq W, t-o. fr-drqq, m-oqqlelE - 500 071
(vi) Efu'r Td W, .Trf{ ftq, @t-fltrTf,I - 700 043
(vii) .il-{s5 - 273 012
T-d-mi t-f,d,
(viii) Td-dr rfirrf, W, ltffiq XqrEre - 7u all
(ix) qtrqq W, 5'q-i - 4oo o2o
(x) gd qra W, Er$gr - 844 1ol
"-d'td,
Td ddq iFTd, fi=g\ i-c-n zn-d)"ft, H
(xi) q<$€-{gsr,
Us-ivqq,-7s'1 016.
(xii) s-mq qq H, Hfr{-.T r)-s ,{dr6lEl-{ * 211 oo1.
(xiii) s6q qFa-q ffi, u-+gr - 302 006,
(xiv) ERIT q-trqq ffi, ge-fr - 580 023.
(xv) q-R-qq mq ffi, q-qdgq - 482 oo1
(xvi) emw Xa qtq ffi, ell g slrF tl @Tq_+ff, ldcnsrys 4e5 004.
(4) oimlT W #ietq frR--s, qne elw{ co g, d-drf( .l+q, t+es -rr, sftftS n-angq,Tft
gE{ - 4ool14
s16rqo: (1) Drg. No.WD- 14014-S-01
(2) Annexure-l -Salient Features of 'BOXNS'
(3) Annexure-ll (List of referred documents)-in a Compact nclosed.

(qfr rTq)
miiorft qqq- /ardq €Tfu

N{WSPD/BG,tsOXNS
Page 6 of8
 Annexure-l

S.No Description Details

01 Principle dimension of Rolling (Diagram drawing no. WD-14014-S-01 )
Stock a. Length over Couplers/Buffers= 10713
mm
b. Bogie centre distance = 6524 mm
c. Wheel Base = 2000 mm
d. Axle load (loaded) = 251
e. Axle load (Emotv) = 4.91
02 Details of Bogie and wheel a. LWLH bogie with Optimized 257
suspension
b. 840 mm diameter wheels.
03 Details of Brake system Air Brake System
04 Brake Percentage a. Brake Percentage(loaded) =14.27 o/o
b. Brake Percentage (Empty) =42.06 %
05 Details of Coupler and buffer a. AAR type E/F NT-Coupler
b. AAR M901 Draft sears
06 Periodic malntenance schedules Standards of Bogie Maintenance shall be
and standards (safety limits) to be defined prior to regular operation.
followed in respect of safety
items.
07 lnstructions regarding operation a. For wheel &axle ref. para2.8 of
of rolling stock in case of failure chapter-2 of IRCA Part-lll additition-
of any of the safety items. 1973
b. Air Brake Maintenance Manual no.
G-97.
c. Coupler Maintenance Manual no. G-76
(for Workshop staff)
d. Coupler Maintenance Manual no.
G-8O(for Line staff)
08 Carrying capacitv 80.1 5 T

MW/SPD/BG/tsOXNS Page 7 of8

 Annexure-ll

{List of documents referred in speed certificate of BOXNS wagon. The copy of

these documents available in the CD enclosed with the speed certificate)

i) lR specification no. R-19/93 Part-l

ii) Specification no. 02-ABR-02
iii) G-97 of May 1996 with amendment no. 2 of July 2002.
iv) G-80 with Revision 1 of March 1997
v) G-95 with Revision 1 of March 1997
vi) IRPWM-2004
vii) Railway Board's letter no.65-WDO-SR-26 dated 19120-10-1966
viii) Manual for ultrasonic testing of Rails and Welds (Revised 2012)
ix) Drawing no. BA-11 154
x) Drawing no. C-8101
xi) Drawing No. C-8805
xii) Misc. report No. MP-572( Rev-01) of February 1982
xiii) Misc. Report MP-1461 of March 1993
xiv) Rly Board's letter No. 9S/CEDO/SR/18 dated 1410711995
xv) Rly Board's letter no. 2001/CEDO/SR/18 dated 2310812001
xvi) Rly Board's letter no. 9TICEDOISR/3 dated 0710211997
xvii) Rly Board's letter no. 93/CEDO/SR/15 dated 2311211993
xviii) G-76 of September 1987
xix) IRCA Part-lll
xx) RDSO Drg. No. WD-14014-S-01.
xxi) Oscillation trial report No. MT-1463/F

MWSPD/BG/BOXNS Page 8 of8

 MMD - 1D-2004
3143 WIDTH OVERALL
10092 OVER END TOP COPING 3135 INSIDE WIDTH

1642 1690 1572 1572 1690 1642

2300 INSIDE HEIGHT

3581 HEIGHT OVERALL

1273 FLOOR HT. (LV.)
COUPLING LINE
1105(LV.)

WAGON
840 WHEEL DIA. ON TRADE

C.L.OF
LIGHT WEIGHT LOW HEIGHT
BOGIE (25T AXLE LOAD)
R.L.
2000 WHEEL BASE 2000 WHEEL BASE
464.5 1630 6524 BOGIE CNTRES 1630 464.5 1676 GAUGE
2260 JOUNAL CENTRES
9784 LENGTH OVER HEAD STOCK
10713 LENGTH OVER COUPLING FACES

S.NO. DESCRIPTION MEASURE

1 UNDERFRAME ( WITH SIDE STAN., &COR. STAN.) 4.06 t
2 FLOOR PLATE 0.92 t
3 BODY STRUCTURE COMPLETE 3.00 t
4 BRAKE GEAR ON UNDERFRAME & AIR BRAKE FITTINGS 0.70 t
5 C.B.C.COMPLETE INCLUDING UNCOUPLING GEAR 1.32 t
6 BOGIE COMPLETE 9.85 t
7 ESTIMATED TARE 19.85 t
8 PAY LOAD 80.15 t
9 GROSS 100 t
10 AXLE LOAD 25 t
11 RATIO (PAY LOAD TO TARE) 4.04
12 TRACK LOAD DENSITY (GROSS) 9.334 t/m
ONLY FOR PROTOTYPE
13 NO. OF WAGONS IN 636 m. 59
PRELIMINARY SKETCH APPLICATION
14 PAY LOAD PER TRAIN (59 WAGONS) 4729 t UNDER GUIDANCE OF R.D.S.O.(WAGON)
SUPERSEDED BY.
15 GROSS LOAD PRE TRAIN 5900 t BOGIE OPEN WAGON TYPE ``BOXNS''
SUPERSEDES
16 G.G. FROM RAIL LEVEL (EMPTY) 1.03 m SCALE PASSED A.K.ROY 03/15
CHECKED A.K.K. 03/15
17 C.G. FROM RAIL LEVEL (LOADED) 2.20 m
-- 05/14
DIAGRAM
DRAWN SHAILENDRA
DRAWING REVISED (BRAKE SYSTEM BMBS REPLACED BY UNDERFRAME
3 WD-15043 MOUNTED BRAKE SYSTEM & RENAME THE WAGON AS ``BOXNS'' 08/15 KUMAR

18 FLOOR AREA 30.52 sq.m TRACED

2 -- WD-15016 DOORS REMOVED & TABLE REVISED 03/15 COMPARED

19 VOLUMETRIC CAPACITY 69.80 cu.m J.S.NO. WD-14014 05/14
1 -- WD-14036 REVISED 12/14
GROUP
ALT. ITEM AUTHY. DESCRIPTION DATE ASSLY. DRG. B.G. R.D.S.O.
[W] WD-14014-S-01