WD-14-ABR-2007

(Supersedes WD-14-ABR-2000)

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

SPECIFICATION FOR NON-ASBESTOS

‘K’ TYPE COMPOSITION

BRAKE BLOCKS FOR FREIGHT STOCK

OF INDIAN RAILWAYS

WD-14-ABR-2007

ISSUED BY

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

LUCKNOW

February, 2007 PRICE: RS.

 WD-14-ABR-2007

SPECIFICATION FOR NON-ASBESTOS ‘K’ TYPE COMPOSITION BRAKE BLOCKS FOR FREIGHT
STOCK OF INDIAN RAILWAYS

1. SCOPE

This specification covers the technical requirements of non-asbestos ‘K’ type composition brake
blocks for application on freight stock of Indian Railways. These brake blocks have a high co-efficient
of friction and called ‘K’ type brake blocks.

2. REQUIREMENTS

2.1 GENERAL

2.1.1 ‘K’ type brake blocks have an average co-efficient of friction of approximately 0.25.

2.1.2 The ‘K’ type composition brake blocks shall be non interchangeable with cast iron as well as low
friction composition brake block (`L’Type) already in use on freight stock. The parameters for freight
stock using ‘K’ type brake blocks are given in the Annexure-I.

2.1.3 The composition of the material and the manufacturing process for series production of ‘K’ type
composition brake blocks must always conform with that of the composition brake blocks for which
approval has been given by RDSO and no change shall be made in the composition and drawing
against which approval has been granted.

2.1.4 The use of asbestos is prohibited.

2.1.5 The use of Lead and Zinc in the metal state or in the form of compounds is not allowed. The same
applies to all other components, if in the form of powder, particles or gas produced during the use of
the brake blocks, which may constitute a danger to health.

2.1.6 The composition of the material constituting the brake block must be chosen so as to give the best
balance between: -

-2 the braking characteristics,

-2 the wear and service life of blocks,
-2 wear on the running surface of the wheels,
-2 the effect on adhesion between the rail and wheel.

2.1.7 The characteristics laid down in this specification must be maintained for the complete usable
thickness of the braking material.

2.1.8 The supplier will advise the detailed procedure for disposal of used/condemned composition brake
blocks and will also associate with railways to set up facilities for disposal of used/condemned
composition brake blocks.
 WD-14-ABR-2007
2.2 FRICTION

2.2.1 As far as possible the co-efficient of friction must be independent of the initial braking speed, the state
of bedding-in of the brake block, the specific pressure as well as the temperature and atmospheric
conditions.

2.2.2 The tolerance bands of the instantaneous and average coefficient of friction shall be as per
Annexure-III of this specification. The definition of the friction co-efficient is given in Annexure- II.

2.2.3 During bedding-in, the coefficient of friction must not vary by more than +15% from the value
obtained when bedding-in is complete.

2.2.4 Under the influence of dampness i.e. under wet conditions, the average coefficient of friction must not
vary by more than +15% in relation to the value obtained during braking when dry with other
conditions remaining the same.

2.2.5 After prolonged braking followed by braking to a stop, particularly high temperature occurs (maximum
375 0 C on the opposing friction surfaces). The average coefficient of friction must not vary, with the
other conditions remaining the same, by more than + 15 % in relation to the value obtained during
braking in the cold and dry state.

2.3 GEOMETRICAL CHARACTERISTICS

2.3.1 The controlling dimensions of brake blocks shall conform to the requirements given in the RDSO
drawing No. WD-00006-S-01 with latest Alt. placed at Annexure-IV.

2.3.2 The constructional features of the brake block must enable them to wear down to a thickness of
10mm, including the back plate, without the latter or the securing components with the brake head,
coming into contact with the running surface of the wheel.

2.3.3 Weight of Brake Block shall be shown in the drawing

2.4 MECHANICAL, PHYSICAL AND CHEMICAL CHARACTERISTICS

2.4.1 The various elements making up the brake blocks must be spread uniformly in the body of the block.
There must be no pitting, flakes or other defects. The material must not attack the opposing friction
surface or give rise to the formation of metallic inclusions.

2.4.2 The blocks must not cause more serious heat damage to the wheels (hot spots, cracks, flaking) than
would be caused by cast iron blocks used in the similar way on the similar wheels.

2.4.3 The values of density, hardness, compression modulus, cross breaking strength, acetone extract, ash
content (loss on ignition) and back plate pull off strength must be given for acceptance purposes.
 WD-14-ABR-2007
2.4.4 The brake block and its back plate must be designed to withstand the forces likely to occur during
service. The durability of assembly can be checked with the test arrangement shown in Appendix-6
of UIC 541- 4 , back plate must not become detached from the composition material.

2.4.5 The brake blocks must not reduce the adhesion between the wheel and rail to an unacceptable
degree compared with that normally obtained from vehicles fitted with cast iron brake blocks.

2.5 MARKING

2.5.1 The marking on back plate and clamp of each brake block shall be as per Drawing No.
WD-00006-S-01 with latest Alt. placed at Annexure IV.

2.5.2 These marks shall be punched in such a manner so that the block can be identified even after being
fully worn in service.

2.5.3 The condemning limit shall be marked in orange colour on the side of brake block, manufactured to
drawing no. WD-00006-S-01, with latest Alt.

3. ACCEPTANCE PROCEDURE

3.1 FOR NEW SUPPLIER: -

3.1.1 The tenderer seeking to supply brake blocks to Indian Railways must have a technical collaboration
with an foreign manufacturer who has experience in manufacturing rail road brake blocks. The
foreign collaborator must have complete manufacturing and test facilities including full scale
Dynamometer for manufacturing and testing of brake blocks. The collaborator will have to give
detailed information including type acceptance test data run and their verification procedure as per
clause 2.2 and other details in accordance with clause no 2.4.3. The test on dynamometer will be
carried out by the collaborator as per test scheme given in annexure- V.

3.1.2 The condition of foreign collaboration is strictly applicable for those companies, which are not in the
business of manufacturing friction composition materials for industrial use. However, the companies,
which are in the business of friction composition material for industrial use and have established all
the requisite manufacturing and testing facilities including full scale rail dynamometer for indigenous
manufacture of the Railway brake block and are following a quality assurance plan to the satisfaction
of RDSO may be exempted by RDSO from the requirement of foreign collaboration. Such firms
should submit dynamometer test results after testing of samples on their own dynamometer.

3.1.3 The firm cleared for regular supply of `L’ type composition brake block for freight or coaching or Loco
may also manufacture the `K’ type brake block. The first lot shall be manufactured in presence of
RDSO officials. Sample of brake blocks will be drawn by the RDSO representative for dynamometer
testing at RDSO.

3.1.4 The tenderer will have to produce adequate evidence from their collaborator in support of good
performance of the collaborator and adequate experience in manufacture and supply of composition
 WD-14-ABR-2007
brake blocks for Rail Road application.

3.1.5 The tenderer shall also submit a copy of approval certificates issued to their collaborator by any of
railroads for composition brake blocks.

3.1.6 The tenderer shall submit a copy of memorandum of understanding (MOU) jointly signed by the
tenderer and collaborator.

3.1.7 The tenderer shall submit list of past supplies made by their collaborator to different railroads along
with specifications followed for manufacture and supply of brake blocks.

3.1.8 The tenderer shall submit the list of plant and equipment available along with capacity, no. of such
equipments, manufacturer name etc available with collaborator.

3.1.9 The tenderer shall submit detailed drawing of the brake block in line with clause 2.3 for approval of
RDSO.

3.1.10 The tenderer will have to submit from the collaborator, the results of dynamometer test of samples
carried out by the collaborator according to test scheme indicated in Annexure V. The details of
friction properties as per clause 2.2 and other details of test results in accordance with clause 2.4.3
shall also be furnished.

3.1.11 The information in para 3.1.1 to 3.1.10 should be presented together with a request for type
acceptance test by RDSO.

3.1.12 The supplier will submit six number of brake blocks for type acceptance test on RDSO’s brake
dynamometer and samples will be tested as per Test Scheme given in Annexure-V The testing
charges will be paid by the supplier.

3.1.13 During the tests, the blocks must not reveal any sign of combustion, formation of flaking, sweating of
the binding material, permanent grating or other defects.

3.1.14 The wear should be uniformly distributed over the entire depth of the block, it should be as low as
possible and be largely independent of the type of brake load application. The specific wear value of
each brake block found by weighing should not exceed 5 cc/kw hr.

3.1.15 The blocks tested on the dynamometer must meet the requirements given in para 2.2 of this
specification.

3.1.16 On successful completion of the dynamometer testing at RDSO, the brake blocks shall undergo
field trials. The field trial shall be carried out in two phases. The first phase shall consist of field
trials of 1500 imported brake blocks. On successful completion of the field trials of imported brake

blocks, 1500 indigenously manufactured brake blocks shall under go the field trials in second
phase. The supplier has to submit the drawing as per clause 2.3 and QAP as per clause 3.2.2 for
 WD-14-ABR-2007
approval before undertaking manufacture of these brake blocks.

The imported/ indigenously manufactured brake blocks will be supplied for field trial only after
inspection by RDSO.

3.1.17 Six samples out of 1500 initial indigenously manufactured brake block shall be picked up by the
RDSO to under take full-scale dynamometer test of any two samples. The supplier shall arrange this
testing of blocks on his own/with collaborator. Alternatively the supplier may send the brake block for
testing at RDSO at his own cost. This test will be carried out as per Test Scheme given in
Annexure-V.

3.1.18 Based on the technical evaluation after field trial of 1500 Nos. of brake blocks further action will be
taken for series production of composition brake blocks.

3.1.19 The inspection during series production and supply will be carried out as per clause 4.

3.2 FOR SUPPLIER ALREADY CLEARED FOR INDIGENOUS SUPPLY

3.2.1 The supplier shall submit detailed drawing of the brake block in line with clause 2.3 for approval of
RDSO.

3.2.2 The supplier shall get his Quality Assurance Plan approved by RDSO before undertaking
manufacture of the brake block. The Quality Assurance plan must contain the details of process of
manufacture, process controls and quality records maintained. The QAP must also contain the
acceptable readings of the following parameters along with the method of testing.
a) Compression modulus.
b) Cross-braking strength.
c) Acetone extract.
d) Ash content. (Loss on ignition)
e) Hardness.
f) Density.
g) Back plate pull off strength.
h) Any other tests.

3.2.3 The supplier shall undertake full-scale dynamometer test (as per Annexure V) on the brake blocks
under supply to Indian Railways at intervals as per QAP approved by RDSO. For this purpose
requisite samples shall be picked up by RDSO and the supplier shall arrange testing of the blocks.
Alternatively the supplier may send the block for testing at RDSO at his own cost. To maintain quality,
RDSO at their discretion may pick up samples at any time for testing at RDSO dynamometer.

3.2.4 The inspection during series production and supply will be carried out as per Clause 4.

4. INSPECTION

4.1 For New Supplier :-

 WD-14-ABR-2007
4.1.1 The inspection of the brake block shall be carried out by Director General / RDSO or his authorised
representative at the premises of the supplier.

4.1.2 The inspection will be carried out as per the following procedure:

i) Supplier to submit pre-inspection report for the lots offered for inspection as per the
approved QAP of the firm.
ii) Supplier to ensure traceability of each block to its parent mix batch number & heat No. etc.
iii) The inspector shall inspect the quality records maintained by the supplier for the entire lot.
iv) Each lot offered for inspection shall consist of 2000 brake blocks or part thereof. The lot
No. shall represent the mix, batch numbers and heat No. out of which these brake blocks
have been manufactured.
v) 2% of every offered lot of 2000 nos. brake blocks will be selected at random and checked
for dimensional accuracy. Dimensions are to be checked as per approved drawing of
manufacturer. However, it is to be ensured that blocks from different mix batches will be
taken up for inspection.
vi) Two brake block selected at random from the above lot shall be tested for the following:
a) Compression modulus.
b) Cross-braking strength.
c) Acetone extract.
d) Ash contents or (loss on ignition).
e) Hardness.
f) Density.

The block shall be accepted based on acceptable readings given in the RDSO approved
QAP of the supplier. The method of testing shall be as given in UIC 541-4-OR or as per the
method of testing followed by manufacturer indicated in their approved QAP.

vii) Two brake block selected at random from the same lot to be tested for back plate pull off
strength and accepted based on acceptance values specified in approved QAP of the firm.

viii) Two brake block selected at random will be subjected to any other test to be included in
the QAP of the firm as decided by the manufacturer and RDSO.

4.1.2.1 The brake blocks shall conform to the requirements mentioned in the QAP of the firm and approved
by RDSO. If any of the samples selected as per para 4.1.2 fail to meet the requirements of any of the
requirements, double the quantity of samples stipulated in clause 4.1.2 shall be selected for tests. If
during retesting any of the brake blocks fail to meet the requirements of any of the tests the entire lot
of brake blocks offered for inspection shall be rejected and brake blocks shall be rendered
unserviceable.
4.1.2.2 The rejected lot shall be destroyed.

4.2 For supplier already cleared for indigenous supply :-

4.2.1 The inspection of the brake block shall be carried out by Director General / RDSO or his authorised
representative at the premises of the supplier.
 WD-14-ABR-2007

4.2.2 The inspection will be carried out as per the following procedure:

i) Supplier to submit pre-inspection report for the lots offered for inspection as per the
approved QAP of the firm.
ii) Supplier to ensure traceability of each block to its parent mix batch number & heat No. etc.
iii) The inspector shall inspect the quality records maintained by the supplier for the entire lot.
iv) Each lot offered for inspection shall consist of 2000 brake blocks or part thereof. The lot
No. shall represent the mix, batch numbers and heat No. out of which these brake blocks
have been manufactured.
v) 1% of every offered lot of 2000 nos. brake blocks will be selected at random and checked
for dimensional accuracy. Dimensions are to be checked as per approved drawing of
manufacturer. However it is to be ensured that blocks from different mix batches will be
taken up for inspection.
vi) One brake blocks selected at random from the above lot shall be tested for the following:
a) Compression modulus.
b) Cross-braking strength.
c) Acetone extract.
d) Ash contents or (loss on ignition).
e) Hardness.
f) Density.

The block shall be accepted based on acceptable readings given in the RDSO approved
QAP of the supplier. The method of testing shall be as given in UIC 541-4-OR or as per the
method of testing followed by manufacturer indicated in their approved QAP.

vii) One brake blocks selected at random from the same lot to be tested for back plate pull off
strength and accepted based on acceptance values specified in approved QAP of the firm.

viii) Two brake blocks selected at random will be subjected to any other test to be included in
the QAP of the firm as decided by the manufacturer and RDSO.

4.2.2.1 The brake blocks shall conform to the requirements mentioned in the QAP of the firm and approved
by RDSO. If any of the samples selected as per para 4.2.2 fail to meet the requirements of any of the
requirements, double the quantity of samples stipulated in clause 4.2.2 shall be selected for tests. If
during retesting any of the brake blocks fail to meet the requirements of any of the tests the entire lot
of brake blocks offered for inspection shall be rejected and brake blocks shall be rendered
unserviceable.

4.2.2.2 The rejected lot shall be destroyed.

5. TESTING FACILITIES

i) Suppliers shall have complete facilities/gauges for checking of brake blocks according to
dimensional tolerances shown on the drawing.
ii) Suppliers shall have adequate facilities for determining the characteristics as laid down in
 WD-14-ABR-2007
para 4.1.2 (vi) / 4.2.2 (vi). The equipment used for testing shall be able to give output in
print out form of these parameters for maintenance of record.
iii) The supplier shall have in house full-scale dynamometer facilities to test the brake block as
per test scheme laid down in Annexure-V. The frequency of testing samples on
Dynamometer should be as laid down in the QAP approved by RDSO. The supplier shall
submit test results to RDSO.

6. PACKING

6.1 The brake blocks shall be securely packed in cardboard boxes so that there is no damage to brake
blocks during transit. This shall be got approved from RDSO along with drawing.

6.2 Firm having collaborator, Packing should be in accordance with the recommendations of the
collaborator. This shall be too got approved from RDSO along with drawing.

7. WARRANTY

The warranty on account of manufacturing defect shall be 24 months from the month of supply or
duly life cycle i.e.time taken in reaching the wear limit of the brake block, whichever is earlier.
 WD-14-ABR-2007

ANNEXURE-I

PARAMETERS FOR FREIGHT STOCK

S. No. Particulars DATA

1. Maximum axle load (Tonne) 25

2. No. of wheels per wagon 08

3. Wheel dia (mm)
New 1000 mm
Condemning 906 mm
4. No. of brake block per wheel 01
5. Brake block force ( Kg ) / block 2370
6. Max. speed (kmph) 100
7. Type of brake system Air Brake
 WD-14-ABR-2007
ANNEXURE-II

DEFINITION OF CONCEPTS:

As far as tolerances on the co-efficient of friction are concerned, a distinction must be made between:

-the instantaneous co - efficient of friction μ a, which can be defined ,and each moment of braking, by the
ratio of the braking effort Ft to the total force F b

Ft

μ a = ------------
Fb
- the average co-efficient of friction μm, which can be defined through out the duration of the brake
application from the moment when 95% of the brake block force has been established until coming to a
halt. The average coefficient of friction μm is obtained by integration of the instantaneous coefficient of
friction μa, over the stopping distances S 2.

1 S2
μm = --------- ƒ μa, ds where
S2 0

S2 [m] = stopping distance from the moment when 95% of the brake block force Fb has
been applied untill coming to a halt

m [Kg] = proportion of axle load to be braked by the wheel

R [m] = Wheel radius

I bench [kg.m2] = moment of inertia of test bench

I [kg.m2]
nom = moment of inertia corresponding to the portion of the axle load to be braked by
the wheel according to the test programme.

Fb (N) = total block force.

Ft (N) = braking effort.

MW (Nm) = friction moment of the test bench at certain wheel load and speed; determined by
the method specified in Appendix 1 of ORE B126/RP8
I nom = m*R2
 WD-14-ABR-2007
If Irig is not the same as I nom. The weights must be adjusted by applying a correction of the initial braking
speed V nom to V k as follows:

Inom
V k = K * V nom with K =
Ibench
WD-14-ABR-2007

ANNEXURE-III
WD-14-ABR-2007
ANNEXURE - IV
 WD-14-ABR-2007
ANNEXURE-V

TEST SCHEME FOR TYPE ACCEPTANCE TEST FOR `K’ TYPE COMPOSITION BRAKE BLOCKS
FOR FREIGHT STOCK.

1. Wheel Diameter –1000 mm

2. Number of brake blocks/wheel – one
3. Axle load – 25 tonne
4. No.of samples to be tested -- Two(minimum)

Brake Speed Force per Initial Remarks.

application km/h. brake block temp. of
No. (Kgf) wheel
tread
(deg C).
1 2 4 5 6
0.1 to 0.x 60 1000 Braking to stop until 80% surface seated.
Weigh
1.1 30 2200
2.1 60 ,,
3.1 100 ,,
4.1 120 ,,
5.1 30 1100
6.1 60 ,,
7.1 100 ,,
8.1 120 ,,
9.1 30 3300 50 - 60 Braking to stop dry after cooling pause.
10.1 60 ,,
11.1 100 ,,
12.1 120 ,,
1.2 30 2200
2.2 60 ,,
3.2 100 ,,
4.2 120 ,,
5.2 30 1100
6.2 60 ,,
7.2 100 ,,
8.2 120 ,,
9.2 30 3300
10.2 60 ,,
11.2 100 ,,
12.2 120 ,,
1.3 30 2200
2.3 60 ,,
 WD-14-ABR-2007
3.3 100 ,,
4.3 120 ,,
5.3 30 1100
6.3 60 ,,
7.3 100 ,, 50 - 60 Braking to stop dry after cooling pause.
8.3 120 ,,
9.3 30 3300
10.3 60 ,,
11.3 100 ,,
12.3 120 ,,
13 60 3300 100-120 Braking to stop, dry with high initial temperature
14 100 ,, 100-120
15 30 ,, 120-140
16 120 ,, 120-140
17 60 1100 50 – 60 Braking to stop, dry after cooling pause
18 60 3300 weigh
N19 30 1100 20 - 30 Braking to stop, wet after cooling pause
N20 100 3300
N21 120 3300
N22 60 2200
N23 30 1100
24 30 1100 50 – 60 Braking to stop, dry after cooling pause
25 100 3300
26 120 3300
27 60 2200
28 30 1100 weigh
D29 60 - 20 –30 Holding braking for 20 minutes, 35kw per wheel
H30 60 3300 braking to stop after holding braking
Weigh
31 30 1100 50 – 60 Braking to stop, dry after cooling pause
32 100 3300
33 120 3300
34 60 2200
35 30 1100
D36 60 - 50 – 60 Holding braking for 10 minutes, 50kw per wheel (2)
H37 60 3300 braking to stop after holding braking

Weigh

Note: D = Long brake application (holding braking).

 WD-14-ABR-2007
H = Braking to stop after holding braking at its initial temp. without cooling pause.
N = Braking in wet condition with a water volume of 14 l / h for v < 120km/h.
Braking in wet condition with a water volume of 22 l / h for v > 120km/h.

(1) During the test, interruption of maximum 3 days is permitted only before test 1.1, 1.2, 1.3, and D
29.
(2) Braking to stop when the wheel temperature during the test reaches 375º C.
(3) The following parameters shall be recorded / measured during the above test.
a. Wheel tread diameter before and after the test.
b. Surface condition of brake block after the test specially in respect of grooving metallic
inclusions, burning, uniform wear, over-heating etc. and the wheel tyre in respect of polishing,
pitting, flaking, cracking and other defects after the test is over.
c. Max. temperature reached on brake block and wheel tread for each test.
d. General observations regarding smoke, smell, sparks and noise.
(4) Location of brake block, rotation of wheel with respect to brake block fitted on dynamometer and
location of thermocouple are shown in annexure – VI.
----------------
WD-14-ABR-2007
ANNEXURE - VI