WD-WPS-BOXNR-2010

ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 1 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2
SINGLE
DC (+), 27-31
1) GMAW BEVEL .. 1.2 a) IRS M46-03 CL-IV 2 180-220 FLAT
VOLTS
BUTT

Cu COATED
SINGLE FLUX /SOLID
DC (+), 27-31
SECTION-AA 2) GMAW BEVEL .. 1.2 a) IRS M46-03 CL-IV 2 180-220 FLAT,H/V WIRE
VOLTS
STRINGER TO CROSS TIE ISMC 100X50X5 BUTT (ER81T1W/80-S-
(IS:2062 Fe 410 CUWA TO STRINGER. 4
ISA 75 X 75 X 8 G) &
3

IS:2062 Fe 410 CUWA) (IS -2062 Fe

ROS S T
C I E

SHIELDING GAS
410 CUWA) (IS -2062 Fe 410 CUWA) Co2 or ARGON +
1-5 % O2
DC (+), 27-31
3) GMAW FILLET 4 1.2 a) IRS M46-03 CL-IV 1 180-220 FLAT,H/V
VOLTS

5 ISA75X75X8 CROSS TIE.

(IS -2062 Fe 410 CUWA)
SINGLE
DC (+), 27-31
1) GMAW BEVEL 5 1.2 a) IRS M46-03 CL-IV 2 180-220 FLAT
VOLTS Cu COATED
BUTT
FLUX /SOLID
DETAIL-BB WIRE
CENTER SILL TO CROSS TIE 2
4 (ER81T1W/80-S-
(IS:2062 Fe 410 CUWA TO CENTER SILL G) &
( Z - SECTION )
IS:2062 Fe 410 CUWA) SHIELDING GAS
(IS -2062 Fe 410 CUWA)
Co2 or ARGON +
DC (+), 27-31 1-5 % O2
2) GMAW FILLET 4 1.2 a) IRS M46-03 CL-IV 1 180-220 FLAT,H/V
VOLTS

1
ISA75X75X8 CROSS
TIE.
(IS -2062 Fe 410 CUWA) SINGLE
DC (+), 27-31
1) GMAW BEVEL 1.2 a) IRS M46-03 CL-IV 2 150-180 FLAT
VOLTS
BUTT

Cu COATED
FLUX /SOLID
DETAIL-CC ISMC 250X82X9 WIRE
SOLE BAR TO CROSS TIE ,SOLE SOLE BAR 5

3 (ER81T1W/80-S-
BAR TO STEFFENING PLATE
(IS -2062 Fe 410 CUWA) G) &
(IS:2062 Fe 410 CUWA TO
SHIELDING GAS
IS:2062 Fe 410 CUWA)
Co2 or ARGON +
1-5 % O2
DC (+), 27-31
2) GMAW FILLET 5 1.2 a) IRS M46-03 CL-IV 1 150-180 FLAT,H/V
VOLTS

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

SPECIFICATION NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/UNDERFRAME/01 NIL

14/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 2 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

SIDE SHEET ( 3.0 THK.)

( IRS M 44 - 97 ) 1 a) VI DC (+), 27-31 H, V
1) GMAW FILLET 3 1.2 1 200-250
3 (IRS M46-03) VOLTS FLAT

2
SECTION-AA
MIDDLE TOP COPING TO a) VI DC (+), 27-31
CUT TO SUIT 2) GMAW FILLET 3 1.2 1 200-250 FLAT SOLID WIRE
SIDE WALL (IRS M46-03) VOLTS
ER308L AND
SIDE WALL TO SIDE
ARGON + 1-5 %
STANCHION
O2
(IRS: M - 44 TO IRS : M - COPING ( 6.0 THK.)
3
3 SIDE STN. ( 6.0 THK.)
44 ( IRS M 44 - 97 ) 3
( IRS M 44 - 97 )

DOUBLE a) VI DC (+), 27-31

3) GMAW 3 1.2 2 200-250 H,V
FILLET (IRS M46-03) VOLTS

a) VI DC (+), 27-31
1) GMAW FILLET 3 1.2 1 200-250 H,V
SIDE SHEET ( 3.0 THK.)
(IRS M46-03) VOLTS
( IRS M 44 - 97 )
1

SECTION - BB 2
SIDE CRIB ANGLE TO
SOLID WIRE
FLOOR PLATE
ER308L AND
SIDE CRIB ANGLE TO
ARGON + 1-5 %
SIDE WALL FL.PLATE ( 4.0 THK.)
( IRS M 44 - 97 )
O2
(IRS: M - 44 TO IRS :
M - 44
SQUARE a) VI DC (+), 27-31
2) GMAW .. 1.2 2 200-250 FLAT
BUTT (IRS M46-03) VOLTS

1 0 .0

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

SPECIFICATION NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/BODY SIDE/01 NIL

15/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 3 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM
JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

END TOP COPING ( 6.0 THK.)

1 ( IRS M 44 - 97 ) a) VI DC (+), 27-31
1) GMAW FILLET 3 1.2 1 200-250 H,V
3
(IRS M46-03) VOLTS

SECTION-AA
MIDDLE TOP COPING TO SIDE SOLID WIRE

12.0
SHEET SIDE ER308L AND

100.0
SHEET TO SIDE STANCHION ARGON + 1-5 %
(IRS: M - 44 TO IRS : M O2
- 44 SIDE SHEET ( 3.0 THK.)
( IRS M 44 - 97 )
a) VI DC (+), 27-31
2) GMAW FILLET 3 1.2 1 200-250 FLAT
(IRS M46-03) VOLTS

3 2

3.0

6.0 3
1 DOUBLE a) VI DC (+), 27-31
3 1) GMAW 3 1.2 2 200-250 H,V
FILLET (IRS M46-03) VOLTS

SECTION-BB SIDE SHEET ( 3.0 THK.) 6.0

( IRS M 44 - 97 )
DOOR WAY CROSS BAR
SOLID WIRE
PRESSING TO DOOR WAY
ER308L AND
BACK PLATE DOOR WAY BACK
ARGON + 1-5 %
PLATE TO END SHEET
O2
(IRS: M - 44 TO IRS : CROSS BAR PRESSING
( 6.0 THK.)
( IRS M 44 - 97 )
M - 44
a) VI DC (+), 27-31
2) GMAW FILLET 3 1.2 1 200-250 FLAT
(IRS M46-03) VOLTS
2
3 BACK PLATE ( 6.0
THK.)
( IRS M 44 - 97 )

3
1
3

DOUBLE a) VI DC (+), 27-31

1) GMAW 3 1.2 2 200-250 H,V
FILLET (IRS M46-03) VOLTS
DETAIL AT - K SIDE SHEET ( 3.0 THK.)
( IRS M 44 - 97 )
SDOOR WAY CROSS BAR 3
2 SOLID WIRE
PRESSING TO SIDE 3

ER308L AND
STANCHION SIDE
ARGON + 1-5 %
STANCHION TO END SHEET
O2
(IRS: M - 44 TO CROSS BAR PRESSING
IRS : M - 44 ( 6.0 THK.)
( IRS M 44 - 97 )

DOUBLE a) VI DC (+), 27-31

2) GMAW 3 1.2 2 200-250 H,V
FILLET (IRS M46-03) VOLTS
BACK PLATE ( 6.0
THK.)
( IRS M 44 - 97 )

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/BODY SIDE/01 NIL

16/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 4 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

END TOP COPING ( 6.0 THK.)

( IRS M 44 - 97 )

LADDER PLATE ( 6.0 THK.)

DETAIL AT - P ( IRS M 44 - 97 )
SIDE TOP COPING TO TOP
SOLID WIRE
LADDER BARCKET CORNER 5
a) VI DC (+), 27-31 ER308L AND
STANCHION TO TOP 1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS ARGON + 1-5 %
LADDER BARCKET
O2
(IRS: M - 44 TO IRS : M - 44

100
1
3 LADDER PLATE ( 6.0 THK.)
( IRS M 44 - 97 )

145

END TOP COPING ( 6.0 THK.)

( IRS M 44 - 97 )

DETAIL AT - Q
SIDE TOP COPING TO TOP LADDER PLATE ( 6.0 THK.)
( IRS M 44 - 97 ) SOLID WIRE
LADDER BARCKET END
a) VI DC (+), 27-31 ER308L AND
SHEET TO TOP LADDER 5 1) GMAW FILLET 3 1.2 1 200-250 H,V
PRESSING ( 8.0 THK.) (IRS M46-03) VOLTS ARGON + 1-5 %
BARCKET ( IRS M 44 - 97 )
O2
(IRS: M - 44
TO IRS : M - 44

100
1
3 LADDER PLATE ( 6.0 THK.)
( IRS M 44 - 97 )

1
3 3.0

CRIB CRF ( 50X50X4 ) 1

( IRS M 44 - 97 ) 3 a) VI DC (+), 27-31
1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS

SECTION - AA
SOLE BAR TO FOOT STEP SOLID WIRE
END ER308L AND
HEAD STOCK ( ISMC 250X52X8)
CRIB ANGLE TO SIDE SHEET ( IS:2062 ) ARGON + 1-5 %
(IRS: M - O2
44 TO IRS : M - 44
2
3 a) VI DC (+), 27-31
2) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

SPECIFICATION NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/BODY END/01 NIL

17/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 5 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

20 PIPE ( IS:1239 PART -1 HEAVY )

DETAIL AT - X
HEAD STOCK TO LADDER 3 2 3 SOLID WIRE
BRACKET LADDER
a) VI DC (+), 27-31 ER308L AND
BRACKET TO LADDER PIPE 1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS ARGON + 1-5 %
50X6 FLATE ( 2143 LONG.) O2
(IRS: M - 44 TO IRS : M - FLATE 145X8 ( 100 LONG.)
44 ( IRS M 44 - 97 )
( IRS M 44 - 97 )

END STN ( 6.0 THK.)

( IRS M 44 - 97 )

5 1

DETAIL AT - Y
SOLID WIRE
SMIDDLE TOP COPING TO
a) VI DC (+), 27-31 ER308L AND
END STANCHION 1) GMAW FILLET 5 1.2 1 200-250 H,V
END MIDDLE COPING ( 6.0 THK.) (IRS M46-03) VOLTS ARGON + 1-5 %
(IRS: 5 1
( IRS M 44 - 97 ) O2
M - 44 TO IRS : M - 44

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

RDSO SPECIFICATION NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/BODY END/01 NIL

18/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 6 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

SECTION - AA
SOLID WIRE
END TOP COPING TO END
a) VI DC (+), 27-31 ER308L AND
SHEET 1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS ARGON + 1-5 %
(IRS: M - 44 TO
O2
IRS : M - 44

a) VI DC (+), 27-31
1) GMAW FILLET 4 1.2 1 200-250 H,V
(IRS M46-03) VOLTS

DETAIL AT - BB
CORNER STANCHION TO
END SHEET CORNER
a) VI DC (+), 27-31 SOLID WIRE
STANCHION TO SIDE SHEET 1) GMAW FILLET 2 1.2 1 200-250 H,V
(IRS M46-03) VOLTS ER308L AND
SIDE MIDDLE
ARGON + 1-5 %
COPING TO END MIDDLE
O2
COPING
(IRS: M - 44 TO
IRS : M - 44

a) VI DC (+), 27-31
1) GMAW FILLET 5 1.2 1 200-250 FLAT
(IRS M46-03) VOLTS

DETAIL AT - CC
CORNER STANCHION TO
SOLID WIRE
END SHEET CORNER
a) VI DC (+), 27-31 ER308L AND
STANCHION TO SIDE SHEET 1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS ARGON + 1-5 %
O2
(IRS: M - 44
TO IRS : M - 44

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/BODY END/01 NIL

19/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 7 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

4
3 1
DOOR FRAME BOTTOM (5 THK)
IRS M-44

SECTION - AA DOOR SOLID WIRE

FRAME BOTTOM TO DOOR SHEET a) VI DC (+), 27-31 ER308L AND
1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS: M - 44 TO IRS : M (IRS M46-03) VOLTS ARGON + 1-5 %

70
60
- 44 1 O2

48
3

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

DOOR HINGEFOOT ( 12.0 THK.)

( IRS M 44 - 97 )

12

D O O R H IN G E F O O T ( 1 2 .0 T H K .)
SOLID WIRE
DETAIL AT - X DOOR HINGE 8 1 SINGLE

( IR S M 4 4 - 9 7 )
a) VI DC (+), 27-31 ER308L AND
FOOT 1) GMAW BEVEL 6 1.2 2 200-250 H,V
(IRS M46-03) VOLTS ARGON + 1-5 %
(IRS: M - 44 TO IRS : M - 44 FILLET

22
O2

48
22
8

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

D/WPS/BNR/FLAP DOOR/01 NIL

20/25
 WD-WPS-BOXNR-2010
ORIENT STEEL & INDUSTRIES LTD , BALLABHGARH WELDING PROCEDURE FOR BOXNR WAGONS
SHEET NO. : 8 OF 8

ELECTRODE/ WELD
WELD WELD WELD ELECTRODE/WIRE/F NO. OF VOLTAGE WELD
DIAGRAM JOINT REFERENCE SKETCH OF JOINTS WIRE SIZE CURRENT SEQUENCE &
PROCESS TYPE SIZE (MM) LUX SPECIFICATION PASS /POLARITY POSITION
(MM) REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13

SINGLE
4.0 a) VI DC (+), 27-31
1) GMAW BEVEL . 1.2 2 200-250 H,V
(IRS M46-03) VOLTS
BUTT
DOOR FRAME TOP ( 3.15 THK.)
( IRS M 44 - 97 )

SECTION - AA
SOLID WIRE
DOOR FRAME TOP TO
ER308L AND
DOOR SHEET
ARGON + 1-5 %
(IRS: M - 44 TO IRS :
O2
M - 44 DOOR SHEET ( 4.0 THK.)
( IRS M 44 - 97 )
3 2 a) VI DC (+), 27-31
1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS

DOOR FRAME MIDDLE ( 4.0 THK.)

( IRS M 44 - 97 ) a) VI DC (+), 27-31
1) GMAW FILLET 3 1.2 1 200-250 H,V
(IRS M46-03) VOLTS
FLAT ( 12.0 THK.) 35.0
( IRS M 44 - 97 )
SECTION - BB 3 1
SOLID WIRE
DOOR FRAME MIDDLE TO
ER308L AND
DOOR SHEET
ARGON + 1-5 %
DOOR SHEET ( 4.0 THK.) O2
(IRS: M - 44 TO IRS : M - 44 ( IRS M 44 - 97 ) 5 2

6X45 CHAMFER SINGLE

a) VI DC (+), 27-31
1) GMAW BEVEL 5 1.2 2 200-250 H,V
(IRS M46-03) VOLTS
BUTT

PREPARED BY APPROVED BY DATE DOCUMENT NO. REV NO.

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

SPECIFICATION NO. G-72 (REV.3 )OR LATEST
D/WPS/BNR/FLAP DOOR/01 NIL

21/25