GROOVED RUBBER SOLE PLATE

(GRSP) 6MM
QUALITY ASSURANCE CIVIL DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION,
(MINISTRY OF RAILWAYS)
MANAK NAGAR, LUCKNOW-226011

SAILENT FEATURES OF GRSP 6mm

Specific Guidelines: QC-G-7.1-3 Ver. 1)

Specification : IRS:T-47-2006
Raw Material : Natural Rubber (Ribbed Smoked
Sheet Grade I to IV)
Drawing No. : RDSO/T-3703, RDSO/T-3711
Gauge Drg. No.: RDSO/T-8119 & RDSO/T-8120

GROOVED RUBBER SOLE PLATE

COMPONENTS

TYPICAL MIX PROPORTIONS

PROCESS

PRODUCTION INFRASTRUCTURE

KNEADER

MIXING MILL

HYDRAULIC PRESS

TESTING EQUIPMENT

TEST PARAMETERS

PRE-PRODUCTION TEST

Pilot Test Study is conducted at regular interval to

ascertain the properties of major raw material. If results
are satisfactory only then further production is allowed.
Mix/Batch Testing is carried out to ascertain the accuracy
of production process as per clause 3.1.2 of IRS- T47/2006.
Rheometer is used to ascertain properties like optimum
curing time and curing temperature

TEST PARAMETERS

FINISHED PRODUCT

Hardness Test
Tensile & Elongation test before & after aging
Relaxed Modulus
Tension set test
Compression Set Test
Load Deflection Test
Electrical Resistance Test
Ash Content Test
Specific Gravity Test
Dimensional Test

FINAL LOT-WISE INTERNAL INSPECTION(A lot shall consist of 10000 nos. of GRSP)
Parameter

Sample Frequenc
Size
y

Acceptance Limit /
Specified Value

Method of Insp. Equipment Used

75 (Min)

Hardness Tester

Shore A Hardness
Tensile Strength (before ageing)

5
5

Each Lot
Each Lot

120 Kg/cm2 (Min)

Tensile Strength (after ageing )

Each Lot

100 Kg/cm2 (Min)

Tensile Retention (after Ageing)

Elongation at Break (before ageing)

5
5

Each Lot
Each Lot

80% Min
200 % (Min)

Elongation at Break (after ageing )

Each Lot

150 % (Min)

Elongation at Break retention

Each Lot

65% Min

Relaxed Modulus (before ageing)

Each Lot

45-60 Kg/cm2

Relaxed Modulus change (after

ageing)
Compression set test

Each Lot

+30% /
-10% (Max)

Each Lot

Tension set test

Each Lot

25% Max

Load Compression Test

Each Lot

0.4 - 0.6 mm

Electrical Resistance (before

immersion)
Electrical Resistance (after
immersion)
Specific Gravity
Ash Content

Each Lot

Each Lot

3
3

Each Lot
Each Lot

Dimensional / Visual Checking

Marking

As per Each Lot

Spec.
100% Each Lot

30% Max

100 M (Min)
100 M (Min)

Tensile testing machine

Compression set apparatus

Tension Set apparatus
Load deflection Testing Machine
Million Mega ohm meter
Million Mega ohm meter

30% (Max)

Analytical Balance
Muffle furnace & Analytical Balance

As per Drg.

Dimensional Gauges

As per Drg

Visual

1.35 (Max)

LIMITS OF TEST RESULTS OF INSPECTION

(RDSO/M&C/RP-198/2006 (Provisional) )
Characterstics

S.N.

Specified Value

Specified Value

Specified Value

COMPOSITE PAD

COMPOUND A

COMPOUND B

75 min.

60 min.

Hardness, Shore A (for A side + 2 of hardness of test pad A, for B side +2 of

hardness of test pad B)
Tensile strength
a) Before Ageing (Kg/cm)

120 min

120 min

150 min

b) After ageing (Kg/cm) 100 1.C for 96 +0/-2 hrs.

c) Retention After ageing (%)

100 min

100 min

125 min

80 min

80 min

80 min

a) Before Ageing (%)

250 min

b) After ageing (%) 100 1C for 96 +0/-2 hrs.

c) Retention After ageing (%)

180 min

200 min
150 min

350 min
270 min

60 min

65 min

70 min

25 - 45

45 - 60

20 -35

b) % Change after ageing at 1001C for 96+0/-2 hrs.

Compression Set.(%) Subject to 50% compression at 100+/-1 deg.C for 24 +0/-2
hrs.

(+30/-10)

(+30/-10)

(+30/-10)

30 max

30 max

25 max

Tension Set. (%) Subject to 50% stretch at 100+/-1 deg.C for 24 +0/-2 hrs.

25 max.

25 max.

20 max.

0.60 to 0.9

0.40 to 0.6

0.80 to 1.2

Load Compression at 15 t. Load (mm)

Electrical Resistance (Mega Ohms)

(i)

Before Immersion

100 Min.

(ii)

After Immersion in distilled water for 48 hrs at room temp.

100 Min.

Elongation at Break
3

Relaxed Modulus at 100% elongation

a) Before Ageing (Kg/cm)

Specific gravity

(i)

Layer A

0.02 of specific gravity of test pad A

(ii)

Layer B

0.02 of specific gravity of test pad B

10

Ash Content

(i)

Layer A

1 of ash content of test pad A

(ii)

Layer B

1 of ash content of test pad B

THANK YOU

RAW GUM ELASTOMER IS MIXED BY THE ROTORS.

THE PRESSURE IS CONTROLLED PNEUMATICALLY OR HYDRAULICALLY.
PRESSURE IS ADJUSTED TO GIVE THE BEST CONTROL OF THE MIXING

PROCESS.
MIXING OCCUR BETWEEN THE MIXING CHAMBER WALLS AND THE ROTORS
MASTER BATCH IS THEN TAKEN OUT FROM KNEADER.

MASTER BATCH IS PLACED INTO THE GAP BETWEEN THE TWO MILL ROLLS.
FILLERS ARE THEN ADDED.
WHEN ALL THE INGREDIENTS ARE COMPLETELY BLENDED (DISPERSED)
THE OPERATOR CAN USE A HAND-HELD MILL KNIFE, AND TAKE OFF INDIVIDUAL SHEETS.

SHEETS ARE IMMEDIATELY COOLED FURTHER TO ROOM TEMPERATURE AND STACKED FOR
FUTURE USE.
IN BATCH TESTING IS CARRIED OUT

TO PROVIDE SUFFICIENT HEAT

TO CHANGE THE UNCURED COMPOUND TO A DIMENSIONALLY STABLE ELASTIC SUBSTANCE
TO ACHIEVE A FINAL SHAPE..
THE UNCURED PIECES OF COMPOUND PLACED IN THE MOLD ARE KNOWN AS PREFORMS.
WEIGHT OF PREFORM CHOSEN TO BE A FEW PERCENT ABOVE THE WEIGHT OF THE FINAL PRODUCT.
THE MOLD IS CONTINUOUSLY HEATED TO A TEMPERATURE, TYPICALLY BETWEEN 150 O C AND 180 O C
CURE TIME OF ABOUT 8 TO 10 MINUTES. THE REQUIRED PRESSURE IS TYPICALLY 7-10.5 MPA..
THE COMPRESSION MACHINE IS GENERALLY HYDRAULICALLY OPERATED WITH TEMPERATURE AND TIME CONTROLLER.
THERMAL ENERGY IS PROVIDED EITHER BY ELECTRICAL COILS OR GAS NOZZLES.

FILLER CAN BE REACTIVE (TO IMPROVE PROPERTIES) OR NON

REACTIVE JUST TO FILL THE SPACE. CARBON BLACK/SILICA IS
ACTIVE FILLER WHEREAS CHINA CLAY IS INACTIVE FILLER

PROCESSING OF RUBBER PADS:

Manufacturing process of rubber pads involves following stages:
Mastication: NR is very tough. It is modified in a kneader to make
it procesasable for further steps,
Mixing: Chemicals, which are difficult to mix and which are used
in small quantities only (namely protective agents and
accelerators), are added so that they are well dispersed. Then
fillers, softeners, sulphur are added in sequence. Mixing is done
to make rubber more homogeneous and achieving uniform
dispersion of various additives.
Vulcanization: Compound is vulcanized in all commonly used
processes hot air with pressure, as transfer moulding, The raw
material is cured and through cross linking and other reaction
convert into stable usable product.

RHEOMETER

Rheometer is an simple and reliable testing

equipment which describes precisely and
quickly curing and processing characteristics
of vulcanizable rubber compounds.
The Rheograph (torque Vs time) indicates:
process behavior
curing characteristics
indication of physical properties

TESTING EQUIPMENTS
Tension Testing
Machine

For testing of tensile strength , elongation and

relaxed moduls

Compression Tensing
Machine

To check load compression

Muffle Furnace

For ash content

24 Hrs Ageing Oven

For tension set and compression set

96 Hrs Ageing Oven

For accelerated ageing for tensile strength,

elongation and relaxed modulus.

Weigh Balance

For specific gravity and muffle furnace

Durometer

For surface shore A hardness

Gauge & calipers

For dimensional , tension & compression set

HARDNESS TEST

TENSILE STRENGTH TEST

ELONGATION TEST

RELAXED MODULUS TEST

LOAD DEFLECTION TEST

ASH CONTENT TEST

SPECIFIC GRAVITY TEST

ELECTRICAL RESISTANCE TEST

COMPRESSION SET TEST

Three sole plates shall be considered for the tests.
Three round test specimens, one from each of the three sample sole plates shall be
cut 37 mm in diameter and whose axial plane coincides with that of one of the
grooves.
For testing IS.3400 (Part X) shall apply.
Thickness of test specimen (To) shall be measured and it shall be compressed in a
compression device to 50% of its original thickness (To) by using suitable spacers.
The assembly shall be kept at 100 + 1o- 2C for 24 + 0 hours in an air oven.
The device shall then be removed from the oven and allowed to cool at ambient
temperature or 30-35 minutes. The test specimen shall then be removed from the
device. The thickness (Tr) of test specimen shall be measured after 24 hours but not
later than 48 hours from the time of removal from the device.
Compression set (%) shall be calculated by the formula:
Compression set (%) = To - Tr X 100/To
The results to be taken into account (criteria value) shall be the second in the series
of three measurements arranged in order of decreasing values.

TENSION SET TEST

VISUAL & DIMENSIONAL TEST