ZINC METALLISATION OF LONG RAIL PANELS लंबी रेल पैनलों का जिंक धातुकरण

ZINC METALLIZATION OF LONG RAIL PANELS
Why of metalizing required?
Why anticorrosive paint is not sufficient?
Where metalizing panels are used?
Necessity of metalizing: IRPWM para 613 efficient maintenance of rails results in increased service life of rails i.e. Prevention of corrosion
a) In case of the new rails to be laid during track renewal/doublings/other construction projects in identified corrosion prone areas. This should preferably be done in Flash Butt Welding Plants.
b) For severe corrosion prone areas, wherever possible, Zinc metallisation in lieu of bituminous painting in centralized plant/ Flash Butt Welding plant can also be done. The Zinc metallisation shall be done as per procedure laid down in Technical Specification for Zinc Aluminium metallisation of Rails (IRS: T-51).
c) Painting should be done in two coats of thickness of 100 microns each by anti-corrosive bituminous black paint conforming to IS: 9862 after an interval of 8 hours between two coats. All the liners and Elastic Rail Clips shall also be painted with anti-corrosive black bituminous paint after duly cleaning the surface.
d) In identified corrosion prone areas, bituminous painting of rails shall be done once in a year on inside of gauge face including web and flange and once in three years on non-gauge face side of rail including web and flange.
e) Greasing and sealing of liner contact area – In identified corrosion prone areas, the rail liner seat should be greased using graphite grease IS-408-1981 Gr. O specification after proper cleaning.
f) Shifting of liner locations – Shifting of liner location on rail foot at regular intervals is desirable to ensure that the effect of corrosion is not allowed to build up at liner locations and render rails vulnerable to fractures due to increased depth of liner bite pits.
First time in Indian Railway has been initiated as pilot project zinc metallization of 10 rail panels at Flash Butt Welding Plant, Moula-Ali, South Central Railway in the year of 2011 under the leadership of Pradeep Kumar, PCE & SP Sahu CTE
All engineering officers and IRSE probationary officers are visited since First time at Flash Butt Welding Plant, Moula-Ali, South Central Railway
Followed the RDSO guide lines for Zinc Aluminium metallization
IS codes referred for Zinc metallization of 10RP:
a) IS 2451 Specification for Chilled Iron Grit
b) IS 5905 Specification for Cleanliness & Surface Roughness
c) IS 5909 Specification for Surface Roughness grade
d) IS 460 Specification for Test Sieves
e) IS 209 Specification for Zinc wire
f) IS 5666 Specification for Etch Primer
g) IS 104 Specification for Zinc Chromate Primer
h) IS 2339 Specification for Aluminium Paint
i) IS 51 Specification for Zinc Chrom
j) IS 3203 Specification for Measurement of Thickness
k) IS 13213 Specification for Aliphatic Acrylic Polyurethane Paint (Two Pack)
All materials are tested and conforming at Railway Metallurgical Lab at Lalaguda (3rd party), connected equipment and fuels etc, then started the metallization
a) Sand blasting
b) Zinc metallization 2 coats each 75µ thickness (total 140 to 150µ)
c) Itch primer
d) Zinc chromate (45µ)
e) Aluminum paint 2 coats each 35µ thickness (total 70µ)
Total thickness required is 250µ
These panels are laid at km431/13 to 432/17 between Gunadala-Vijayawada in Vijayawada division
After seeing this in the year 2012 Zinc metallization started at Engineering workshop, Sabarmathi, Western Railway
a) Sand blasting
b) Zinc metallization 2 coats each 75µ thickness
c) Aliphatic Acrylic Polyurethane Paint (Two Pack)
Afterwards same thing adopted at Flash Butt Welding Plant, Moula-Ali
There are quality tests 1) Adhesion test (scratch test) 2) Salt water test for 3 to 6 months
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अस्वीकरण- कुछ सामग्री उचित उपयोग के तहत शैक्षिक उद्देश्य के लिए उपयोग की जाती है। कॉपीराइट अधिनियम 1976 की धारा 107 के तहत कॉपीराइट अस्वीकरण, आलोचना, टिप्पणी, समाचार रिपोर्टिंग, शिक्षण, छात्रवृत्ति और अनुसंधान जैसे उद्देश्यों के लिए "उचित उपयोग" के लिए भत्ता दिया जाता है। उचित उपयोग कॉपीराइट क़ानून द्वारा अनुमत उपयोग है जो अन्यथा उल्लंघनकारी हो सकता है। गैर-लाभकारी, शैक्षिक या व्यक्तिगत उपयोग उचित उपयोग के पक्ष में संतुलन का सुझाव देता है। वीडियो में प्रयुक्त कॉपीराइट सामग्री का सारा श्रेय सम्मानित स्वामी को जाता है।