Well, only banks charge heavy rates for these forex card. For every transaction, for reloading etc. etc.
But there are many exchanges which provides the same card but no charges are deducted for transactions. Also they provide another add-on card for free, which can be used if the main card gets lost or something.
One of my friend recently visited to Singapore, and he took card from them.
http://www.vkcforex.com/
Another that I find in net is
http://www.matrix.in/Products/Matrix-Forex-Card. They also provide the same features.