WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

SHEET NO. : 1 OF 8

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

SECTION-AA
STRINGER TO CROSS TIE
(IS:2062 Fe 410 CUWA TO
IS:2062 Fe 410 CUWA)

WELD
SIZE (MM)

1) GMAW

SINGLE
BEVEL
BUTT

..

2) GMAW

SINGLE
BEVEL
BUTT

ISMC 100X50X5
STRINGER.

3) GMAW

WELD
VOLTAGE
WELD
SEQUENCE &
/POLARITY POSITION
REMARKS

NO. OF
PASS

CURRENT

10

11

12

1.2

a) IRS M46-03 CL-IV

180-220

DC (+), 27-31
VOLTS

FLAT

..

1.2

a) IRS M46-03 CL-IV

180-220

DC (+), 27-31
VOLTS

FLAT,H/V

FILLET

1.2

a) IRS M46-03 CL-IV

180-220

DC (+), 27-31
VOLTS

FLAT,H/V

1) GMAW

SINGLE
BEVEL
BUTT

1.2

a) IRS M46-03 CL-IV

180-220

DC (+), 27-31
VOLTS

FLAT

2) GMAW

FILLET

1.2

a) IRS M46-03 CL-IV

180-220

DC (+), 27-31
VOLTS

FLAT,H/V

1) GMAW

SINGLE
BEVEL
BUTT

1.2

a) IRS M46-03 CL-IV

150-180

DC (+), 27-31
VOLTS

FLAT

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

WELD
TYPE

13

ISA 75 X 75 X 8

(IS -2062 Fe
410 CUWA)
ROS S T
C
I E

(IS -2062 Fe 410 CUWA)

Cu COATED
FLUX /SOLID
WIRE
(ER81T1W/80-SG) &
SHIELDING GAS
Co2 or ARGON +
1-5 % O2

DETAIL-BB
CENTER SILL TO CROSS TIE
(IS:2062 Fe 410 CUWA TO
IS:2062 Fe 410 CUWA)

ISA75X75X8 CROSS TIE.

(IS -2062 Fe 410 CUWA)

CENTER SILL
( Z - SECTION )
(IS -2062 Fe 410 CUWA)

DETAIL-CC
SOLE BAR TO CROSS TIE ,SOLE
BAR TO STEFFENING PLATE
(IS:2062 Fe 410 CUWA TO
IS:2062 Fe 410 CUWA)

ISMC 250X82X9
SOLE BAR

ISA75X75X8 CROSS
TIE.
(IS -2062 Fe 410 CUWA)

(IS -2062 Fe 410 CUWA)

PREPARED BY
FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO
SPECIFICATION NO. G-72 (REV.3 )OR LATEST

Cu COATED
FLUX /SOLID
WIRE
(ER81T1W/80-SG) &
SHIELDING GAS
Co2 or ARGON +
1-5 % O2

2) GMAW

FILLET

APPROVED BY

1.2

a) IRS M46-03 CL-IV

DATE

150-180

DC (+), 27-31
VOLTS

Cu COATED
FLUX /SOLID
WIRE
(ER81T1W/80-SG) &
SHIELDING GAS
Co2 or ARGON +
1-5 % O2

FLAT,H/V

DOCUMENT NO.

REV NO.

D/WPS/BNR/UNDERFRAME/01

NIL

14/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

FILLET

1.2

2) GMAW

FILLET

1.2

3) GMAW

DOUBLE
FILLET

1.2

1) GMAW

FILLET

1.2

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 )

1
3

SHEET NO. : 2 OF 8

a) VI
(IRS M46-03)

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

200-250

DC (+), 27-31
VOLTS

FLAT

200-250

DC (+), 27-31
VOLTS

H,V

200-250

DC (+), 27-31
VOLTS

H,V

H, V
FLAT

SECTION-AA
MIDDLE TOP COPING TO
SIDE WALL
SIDE WALL TO SIDE
STANCHION
(IRS: M - 44 TO IRS : M 44

2
CUT TO SUIT

COPING ( 6.0 THK.)

( IRS M 44 - 97 )

3
3

a) VI

(IRS M46-03)

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

SIDE STN. ( 6.0 THK.)

( IRS M 44 - 97 )

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 )
1

SECTION - BB
SIDE CRIB ANGLE TO
FLOOR PLATE
SIDE CRIB ANGLE TO
SIDE WALL
(IRS: M - 44 TO IRS :
M - 44

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

FL.PLATE ( 4.0 THK.)

( IRS M 44 - 97 )

SQUARE
BUTT

..

1.2

a) VI
(IRS M46-03)

200-250

DC (+), 27-31
VOLTS

FLAT

1 0 .0

2) GMAW

PREPARED BY

APPROVED BY

DATE

DOCUMENT NO.

REV NO.

D/WPS/BNR/BODY SIDE/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO

SPECIFICATION NO. G-72 (REV.3 )OR LATEST

15/25

DIAGRAM
JOINT REFERENCE

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

1) GMAW

FILLET

1.2

END TOP COPING ( 6.0 THK.)

( IRS M 44 - 97 )

SHEET NO. : 3 OF 8

ELECTRODE/
WELD
ELECTRODE/WIRE/F
WIRE SIZE
SIZE (MM)
LUX SPECIFICATION
(MM)
8

a) VI
(IRS M46-03)

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

100.0

SECTION-AA
MIDDLE TOP COPING TO SIDE
SHEET
SIDE
SHEET TO SIDE STANCHION
(IRS: M - 44 TO IRS : M
- 44

12.0

NO. OF
PASS

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 )

2) GMAW

FILLET

1.2

1) GMAW

DOUBLE
FILLET

1.2

a) VI
(IRS M46-03)

200-250

DC (+), 27-31
VOLTS

FLAT

200-250

DC (+), 27-31
VOLTS

H,V

3 2

3.0
6.0

3
3

SECTION-BB
DOOR WAY CROSS BAR
PRESSING TO DOOR WAY
BACK PLATE DOOR WAY BACK
PLATE TO END SHEET
(IRS: M - 44 TO IRS :
M - 44

a) VI
(IRS M46-03)

6.0

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 )

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

CROSS BAR PRESSING

( 6.0 THK.)
( IRS M 44 - 97 )

2
3

2) GMAW

FILLET

1.2

1) GMAW

DOUBLE
FILLET

1.2

a) VI

(IRS M46-03)

200-250

DC (+), 27-31
VOLTS

FLAT

200-250

DC (+), 27-31
VOLTS

H,V

BACK PLATE ( 6.0

THK.)
( IRS M 44 - 97 )

3
3

DETAIL AT - K
SDOOR WAY CROSS BAR
PRESSING TO SIDE
STANCHION SIDE
STANCHION TO END SHEET
(IRS: M - 44 TO
IRS : M - 44

a) VI
(IRS M46-03)

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 )
3
3

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

CROSS BAR PRESSING

( 6.0 THK.)
( IRS M 44 - 97 )

2) GMAW

DOUBLE
FILLET

1.2

a) VI
(IRS M46-03)

200-250

DC (+), 27-31
VOLTS

H,V

BACK PLATE ( 6.0

THK.)
( IRS M 44 - 97 )

PREPARED BY

APPROVED BY

DATE

DOCUMENT NO.

REV NO.

D/WPS/BNR/BODY SIDE/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO SPECIFICATION

NO. G-72 (REV.3 )OR LATEST

16/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

DIAGRAM

JOINT REFERENCE

SHEET NO. : 4 OF 8

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

200-250

DC (+), 27-31
VOLTS

H,V

END TOP COPING ( 6.0 THK.)

( IRS M 44 - 97 )

LADDER PLATE ( 6.0 THK.)

( IRS M 44 - 97 )

DETAIL AT - P
SIDE TOP COPING TO TOP
LADDER BARCKET CORNER
STANCHION TO TOP
LADDER BARCKET

a) VI
(IRS M46-03)

100

(IRS: M - 44 TO IRS : M - 44

LADDER PLATE ( 6.0 THK.)

( IRS M 44 - 97 )

145

END TOP COPING ( 6.0 THK.)

( IRS M 44 - 97 )

LADDER PLATE ( 6.0 THK.)

( IRS M 44 - 97 )
5

PRESSING ( 8.0 THK.)

( IRS M 44 - 97 )

1
3

1
3
CRIB CRF ( 50X50X4 )
( IRS M 44 - 97 )

SECTION - AA
SOLE BAR TO FOOT STEP
END
CRIB ANGLE TO SIDE SHEET
(IRS: M 44 TO IRS : M - 44

a) VI
(IRS M46-03)

100

DETAIL AT - Q
SIDE TOP COPING TO TOP
LADDER BARCKET END
SHEET TO TOP LADDER
BARCKET
(IRS: M - 44
TO IRS : M - 44

LADDER PLATE ( 6.0 THK.)

( IRS M 44 - 97 )

3.0
1
3

a) VI
(IRS M46-03)

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

HEAD STOCK ( ISMC 250X52X8)

( IS:2062 )

2
3

2) GMAW

PREPARED BY

FILLET

APPROVED BY

1.2

a) VI
(IRS M46-03)

DATE

200-250

DC (+), 27-31
VOLTS

H,V

DOCUMENT NO.

REV NO.

D/WPS/BNR/BODY END/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO

SPECIFICATION NO. G-72 (REV.3 )OR LATEST

17/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

SHEET NO. : 5 OF 8

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

20 PIPE ( IS:1239 PART -1 HEAVY )

DETAIL AT - X
HEAD STOCK TO LADDER
BRACKET LADDER
BRACKET TO LADDER PIPE
(IRS: M - 44 TO IRS : M 44

a) VI

(IRS M46-03)

50X6 FLATE ( 2143 LONG.)

FLATE 145X8 ( 100 LONG.)
( IRS M 44 - 97 )

( IRS M 44 - 97 )

END STN ( 6.0 THK.)

( IRS M 44 - 97 )

DETAIL AT - Y
SMIDDLE TOP COPING TO
END STANCHION
(IRS:
M - 44 TO IRS : M - 44

END MIDDLE COPING ( 6.0 THK.)

( IRS M 44 - 97 )

PREPARED BY

APPROVED BY

a) VI

(IRS M46-03)

DATE

DOCUMENT NO.

REV NO.

D/WPS/BNR/BODY END/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER

RDSO SPECIFICATION NO. G-72 (REV.3 )OR LATEST

18/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

SECTION - AA
END TOP COPING TO END
SHEET
(IRS: M - 44 TO
IRS : M - 44

DETAIL AT - BB
CORNER STANCHION TO
END SHEET
CORNER
STANCHION TO SIDE SHEET
SIDE MIDDLE
COPING TO END MIDDLE
COPING
(IRS: M - 44 TO
IRS : M - 44

DETAIL AT - CC
CORNER STANCHION TO
END SHEET
CORNER
STANCHION TO SIDE SHEET

SHEET NO. : 6 OF 8

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

200-250

DC (+), 27-31
VOLTS

H,V

200-250

DC (+), 27-31
VOLTS

H,V

200-250

DC (+), 27-31
VOLTS

FLAT

200-250

DC (+), 27-31
VOLTS

H,V

(IRS: M - 44
TO IRS : M - 44

PREPARED BY

APPROVED BY

DATE

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

DOCUMENT NO.

REV NO.

D/WPS/BNR/BODY END/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO SPECIFICATION

NO. G-72 (REV.3 )OR LATEST

19/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

FILLET

1.2

1) GMAW

SINGLE
BEVEL
FILLET

1.2

4
3

SHEET NO. : 7 OF 8

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

200-250

DC (+), 27-31
VOLTS

H,V

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

60

a) VI
(IRS M46-03)

48

70

DOOR FRAME BOTTOM (5 THK)

IRS M-44

SECTION - AA
DOOR
FRAME BOTTOM TO DOOR SHEET
(IRS: M - 44 TO IRS : M
- 44

45
DOOR SHEET ( 4 THK)
( IRS M -44)

DOOR HINGEFOOT ( 12.0 THK.)

( IRS M 44 - 97 )

a) VI
(IRS M46-03)

48

22

22

DETAIL AT - X
DOOR HINGE
FOOT
(IRS: M - 44 TO IRS : M - 44

D O O R H IN G E F O O T ( 1 2 .0 T H K .)
( IR S M 4 4 - 9 7 )

12

PREPARED BY

APPROVED BY

DATE

DOCUMENT NO.

REV NO.

D/WPS/BNR/FLAP DOOR/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO SPECIFICATION NO. G-72 (REV.3 )
OR LATEST

20/25

WD-WPS-BOXNR-2010

WELDING PROCEDURE FOR BOXNR WAGONS

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH

SHEET NO. : 8 OF 8

ELECTRODE/
ELECTRODE/WIRE/F
WIRE SIZE
LUX SPECIFICATION
(MM)

DIAGRAM

JOINT REFERENCE

SKETCH OF JOINTS

WELD
PROCESS

WELD
TYPE

WELD
SIZE (MM)

1) GMAW

SINGLE
BEVEL
BUTT

1.2

NO. OF
PASS

CURRENT

VOLTAGE
/POLARITY

WELD
POSITION

WELD
SEQUENCE &
REMARKS

10

11

12

13

200-250

DC (+), 27-31
VOLTS

H,V

4.0
DOOR FRAME TOP ( 3.15 THK.)
( IRS M 44 - 97 )

SECTION - AA
DOOR FRAME TOP TO
DOOR SHEET
(IRS: M - 44 TO IRS :
M - 44

(IRS M46-03)

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

DOOR SHEET ( 4.0 THK.)

( IRS M 44 - 97 )
3

DOOR FRAME MIDDLE ( 4.0 THK.)

( IRS M 44 - 97 )
FLAT ( 12.0 THK.)
( IRS M 44 - 97 )

1) GMAW

FILLET

1.2

1) GMAW

FILLET

1.2

a) VI
(IRS M46-03)

a) VI
(IRS M46-03)

200-250

DC (+), 27-31
VOLTS

H,V

200-250

DC (+), 27-31
VOLTS

H,V

35.0

SECTION - BB
DOOR FRAME MIDDLE TO
DOOR SHEET
(IRS: M - 44 TO IRS : M - 44

a) VI

DOOR SHEET ( 4.0 THK.)

( IRS M 44 - 97 )

6X45 CHAMFER

SOLID WIRE
ER308L AND
ARGON + 1-5 %
O2

1) GMAW

PREPARED BY

SINGLE
BEVEL
BUTT

APPROVED BY

1.2

a) VI
(IRS M46-03)

DATE

200-250

DC (+), 27-31
VOLTS

H,V

DOCUMENT NO.

REV NO.

D/WPS/BNR/FLAP DOOR/01

NIL

FOR WELDING DIFFERENT MATERIAL,WELDING ELECTRODE/WIRE/FLUX ETC. REFER RDSO

SPECIFICATION NO. G-72 (REV.3 )OR LATEST

21/25