Coach shell

Types of coaches
• ICF: - Integral Coach Factory. (Perambur, Chennai) & Rail Coach Factory, Kapurthala (Punjab)
• LHB COACHES: LHB body with FIAT bogie (LinkeHolfmann Busch – German):-
• Maximum Permissible Speed 160 kmph
• Hybrid Coach: LHB Body on Modified ICF Bogie – Running in same of the Durontorake.
• Dimensions of Coach Shell –
• ICF LHB/ HYBRID
• Length Over Buffer 22296 (mm) 24000 (mm)
• Length Over Head Stock 21336 (mm) 23540 (mm)
• Width 3245 (mm) 3030 (mm)
• Height From Rail Level 3886 (old) 4025 (new) (mm)
• Codal Life 25 (Years) 30 (Years)
• Provision of Running Clearance ICF coach:-
• a) ‘A’ Clearance: - For 13 T – 43 +0/-3 mm, For 16 T – 27 +0/-3 mm. It is a clearance to be provided between axle box crown &
safety bolt.
• b) ‘B’ Clearance: - It is a clearance to be provided between bolster top & bottom of sole bar that should be 40 +/- 5 mm to all type
of bogie.
Checking Parameters of LHB coach
• Height of bogie frame top from rail level – 925+0-5mm.
• Clearance between secondary vertical bump stop gap –95+0-5mm
• Clearance between lateral bump stop and traction centre – 25+5-2mm
• Clearance between longitudinal bump stop & traction centre – 8+5-2mm
• Clearance between primary vertical bump stop gap – 13mm or 8mm
• Control arm bracket half round dia. – 85mm
• Height of bogie bolster base plate from rail level – 930+6-2mm
• Clearance between brake disc bottom to rail level – 137.5mm
• Clearance between safety pin & lug of control arm top – 45mm, bottom –37.5mm
• CBC height– 1090mm to 1105mm
• Maximum number of shims at body bogie connection– 11numbers and each having 5mm
• Buffer distance --- 1956mm
 Tare weight of coaches
• LHB Coaches Type of Coach Code No. of Tare
Seat/coach weight
AC first class sleeper(EOG) LWFAC 24 43.34
AC first class Sleeper(SG) LWGFAC 24 47.50
AC SECOND CLASS SLEEPER (EOG) LWACCW 52 44.50
AC SECOND CLASS SLEEPER (SG) LWGACCW 52 48.40
AC THREE TIER CLASS SLEEPER (EOG) LWACCN 72 45.60
AC THREE TIER CLASS SLEEPER (SG) LWGACCN 72 50.60
AC HOT BUFFET CAR LWCBAC 15 42.20
NON-AC SECOND CLASS GS (EOG) LS4 100 35.29
NON-AC SECOND CLASS 3 TIER (SG) LWGSCN 78 36.28
AC CHAIR CAR EXECUTIVE CLASS LWFCZAC 56 40.40
AC CHAIR CAR LWSCZ AC 78 42.27
GENERATOR CUM LUGGAGE& BRAKE VAN LWLRRM 5 52.12
NON-AC- LUGGAGE CUM GUARD VAN(SG) LGSLR 36 35.40
• ICF Coaches Type of Coach Code No. of Tare
Seat/coach weight
AC first class sleeper(EOG) WFAC 24 44.60
AC first class Sleeper(SG) WGFAC 24 53.50
AC SECOND CLASS SLEEPER (EOG) WACCW 54 44.80
AC SECOND CLASS SLEEPER (SG) WGACCW 54 52.10
AC THREE TIER CLASS SLEEPER (EOG) WACCN 72 44.86
AC THREE TIER CLASS SLEEPER (SG) WGACCN 72 51.90
AC HOT BUFFET CAR WCBAC 15 47.90
NON-AC SECOND CLASS GS (EOG) GS 100 37.40
NON-AC SECOND CLASS 3 TIER (SG) WGSCN 78 39.50
AC CHAIR CAR EXECUTIVE CLASS WFCZAC 56 42.60
AC CHAIR CAR WSCZ AC 78 42.80
GENERATOR CUM LUGGAGE& BRAKE VAN WLRRM 5 60.8
NON-AC- LUGGAGE CUM GUARD VAN(SG) SLR 36 40.60
Maintenance Schedule of Coaches
• The following maintenance schedules are to be carried out.
• Coaching Depot Schedule
• Schedule D1 : Every Trip/Weekly
• Schedule D2 : Monthly ± 3 days
• Schedule D3 : Half Yearly ± 15 days
• Shop Schedule LHB Coaches
• Shop Schedule I : 18 months/ 6 lakh Kms whichever is earlier
• Shop Schedule II : 36 months/ 12 lakh Kms whichever is earlier
• Shop Schedule III : 72 months/ 24 lakh Kms whichever is earlier

• Coaching Depot Schedule

• A Schedule : 1 month + 3 days
• B Schedule : 3 months + 7 days
• C Schedule : 6 month + 15 days ICF Coaches
• Shop Schedule
• IOH : 1 YEAR for 1st IOH + 30 days & 9 months for old coach
• POH : 2 years for 1st POH + 30 days & 18 months for old coach
 Constructional Features of ICF coaches
• In 1954 steel body coach design was taken from M/S Schlieren Switzerland for manufacturing of ICF coaches at
Perambur.
• Light weight integral design
• Centre pivot is free from vertical loading.
• Camber provision which is the negative deflection of underframe given intentionally to compensate the sagging of
underframe when it is fully loaded, so that the underframe can remain straight even after fully loaded.
• The shell of ICF Coach is designed to bear 45 tones of vertical load and 200 tones of longitudinal impact on side
buffers. The coach body so designed that it is more strengthen at end portion as well as in passenger seating portion
and less at the gallery portion.
• reduction in tare weight of these coaches (26-32%) by utilising "stressed skin"concept. The construction of the body
shell in the end at side panel is multi point tag welded. As side panel is welded at waist rail, light rail, cant rail and car
lines by means of CO2 welding provided at perfect distance. 70 % of total developed stresses are absorbed by
corrugated trough flooring. Thus this multi point welding property of the end & side panel is enough to minimize
developed stresses of panels during run. Use of gusset plate, knee & rivets are avoided in ICF coach.
• 2mm thick Corten steel corrugated sheets which is run over the length between the headstock are utilised for the
trough floor to form part of the tubular construction as well as to absorb a large portion of the buffing force. 12-13mm
compressed sheet is placed over the corrugated sheet for surface evenness and to form a tubular shell.
• Anti-telescopic structure has been provided in the end-walls to avoid telescoping of the adjacent coaches and to
absorb the major part of collision energy.
 Contd.
• The integral shell is made of a framework of series of hoops, consisting of floor crossbeams, body side pillars and roof carlines located
transversely at regular intervals, to suit door and window openings.
• These hoops are connected together by Z shaped sole bars (5mm for non-AC & 8mm for AC), waist rails, light rails, cant rails and
carlines longitudinally.
• This framework is sheathed all over by 2 mm thick anti corrosion corten steel (IRS-M-41) on the side walls and 1.6 mm thick corten
steel on the roof.
• The whole forms a tubular shell of integral construction in which the sides and roof panels also share the load.
• In coaches with stainless steel trough floor, no tubular structure is used.
• End wall consists of four vertical pillars of box section connected transversely by `Z' sections and are welded to the head stock at the
bottom and to the roof at the top. During accident, maximum kinetic energy can be absorbed by the end portion and rest kinetic
energy also can be shared by corrugated flooring and other members of body shell. Gallery section is the weakest portion of the
coach.
• Under-frame acts as support for mounting equipment like air or vacuum brake system (brake cylinders, DV, BP & FP pipes, auxiliary
reservoirs, control reservoirs, etc.), air-conditioning system (Compressor unit, Battery, Control rectifier, etc.), train lighting battery
boxes, under slung water tank, etc. it also contain body bolster, head stock, sole bar, cross beam, trough floor, side bearer centre pin.
• The head stock of BG integral coaches consists of outer and inner head stocks connected by two rigid center buffer stiffeners, which
transmits all the buffing forces to the under-frame structure.
• To minimize air resistance during running, the shell body is specially constructed, the roof and turn under are made in curved shape
which minimize air resistance at high speeds.
• 19 mm thick ply or 12 mm thick COMPREGE ply and 2.00 mm thick PVC flooring is utilized for flooring to avoid seepage of water from
floor to corrugated sheets.
 Contd.
• To achieve anti corrosive property Corten steel IRSM - 41 (max at turn under and lavatory portions) is
being utilized for paneling purpose. At the time of manufacturing sand blasting, grit blasting is also given
on panel sheet which is helpful to prepare rough surface for painting resulted less chances of corrosion.
Three coats of bituminous anti-corrosive paints are also given at welded portion and for other portion
red- oxides paint is applied, for anti-corrosive treatment. Holes in trough flooring are also provided for
proper drainage of water. More than 20% corrosion in any component needs changing.
• Elliptical hole of size 200*135mm are given in turn under frame for proper drainage of water from
window shell.
• To develop heat resistance property in coach shell following precaution or facilities has been provided:-
a) Silver / aluminum paint coat is provided on outer side of roof which reflects the sun rays coming
outside the coach.
b) In roof ceiling layers of insulting materials like asbestos / glass wool is provided which is bad
conductor of heat resulted direct transmission of heat inside is minimized.
c) In carlines, elliptical holes are also provided for proper air circulation from one compartment to
another.
d) No. of ventilators are also provided on top of roof to exit smokes, gases and to circulate fresh air.
e) Limpet sheet is also provided inside of the roof (2mm thick) which is bad conductor of heat.
Salient features of ICF coach
• All metal body
• Aerodynamic Design
• Light weight
• Integral Construction
• Anti telescopic Construction
• Anti corrosive
 LHB coach
• LHB coach body is designed and manufactured by leading German company Linke Holfmann Busch GMBH and bogies are
designed by FIAT Switzerland. Combination of Coach of LHB and Bogies is known as Alstom LHB Coach.
• fit for operation at speed of 160 kmph and has a speed potential of 200kmph with riding index of 2.5- 2.75.
• Coaches are 1.7m longer than ICF coach and has 70mm taper at ends.
• Coaches are fitted with Axle Mounted Disc brakes leads to effective braking & reduction of wear on wheel tread.
• Coaches are fitted with Wheel slide protection device to prevent the wheel from getting skid.
• Coaches are fitted with Brake accelerator in the Brake pipe to facilitate faster release of air for braking.
• Coaches are fitted with Controlled discharge Toilet system designed to discharge the human waste when the speed reaches
above 30 KMPH after completion of 15 flushing.
• fitted with tight lock AAR centre buffer coupler with anti-climbing feature having strength to haul 18 coaches at 160kmph
and 24 coaches at 110kmph.
• Bigger size sealed windows filled with “argon” gas for a panoramic view & heat insulation.
• Better amenities like Flush type swiveling berth reading light, Polycarbonate transparent centre tables, Modular “oriental”
& “western” style toilets.
• Luggage racks are made from Aluminum extrusion lengths and tempered safety glass which can withstand a distributed
load of 100kg/meter and pointed load of 85kg.
• Wider vestibule design for smooth inter coach movement.
• Halogen reading light of 10 watts, fluorescent tubes of 18 watts and night lamp of 10 watt are used.
 Constructional Features of LHB coaches
• Body constructed from Stainless steel body. SS absorbs 2.5 times more energy than carbon steel and retain properties at high temp.

• Roof sheets are manufactured from 1.25 & 1.7 mm thick austenitic stainless steel, roof arches are manufactured from 2
mm ferritic stainless steel, end plate and angle are manufactured from 4 mm ferritic stainless steel. The middle portion of
roof sheet is plain and manufactured from 1.7 mm austenitic stainless steel.
• Side walls are manufactured by TIG Welding of sheets to achieve low heat inputs, less distortion and negligible shrinkage.
The thickness of side wall sheets is 2 mm. Side wall thickness got reduced from 90mm to 60mm.
• Under frame corrugated austenitic trough floor is plug welded from top with the cross members.
 Contd.
• Side wall is welded with under frame by V grooving of sole bar and spot welding with roof. Sole bar is C shaped
of 6mm thickness. Unlike ICF coaches, two cross members(6mm) are provided in place of body bolster in LHB
coaches.
• End wall is made of ferritic steel. To reduce its weight holes provided in all stiffeners. The projection of side walls
towards end is more. This results into more availability of space for passengers and reduction in the gap between
two coaches, thereby reduced wind gap resistance and turbulence. The gap between two end walls is 300 mm
only.

• Pillar rests on sole bar as compared to load transfer through a vertical welded joint in conventional Coaches.
• The design of side wall has eliminated turn under to avoid accumulation of water; muck and resultant corrosion.
• Inter-locking joints of vertical & horizontal members.
 Noise & Thermal Insulation
• Weldable aluminium paint to avoid bi metallic corrosion
• For flooring, 16mm composite Make Ore wood is used which absorb noise and vibration and resistant to fire,
cigratte. It has 4mm cork sandwiched between plies.
• PU based spray insulation BARYSKIN V60DB (2-3 mm thickness in the coach interior, 6-8 mm in body bolster
area) is provided on the interior surface of the car body shell for corrosion protection and sound insulation.
• Heat insulation of the floor side wall lower area and end wall is done with Resonaflex insulation mat (60mm).
• Alucobond” Lavatory Ceiling Panel & Aluminium Honey Comb Partition Panels which improve aesthetics and
surface finish.
Doors
• Body Side Doors
• Hinged type swing sandwich doors
• Stainless steel body filled with phenolic
resin for better heat insulation.
• Inside panel of door made up of FRP
• Provided with sealed window glass unit.
• Compartment Door
• Single flap sliding door
• Stainless steel body filled with phenolic resin for better heat insulation.
• Manual opening and auto closing type door provided with rubber sealing
• at the door leaf for hand safe feature
• provided with air grill for air circulation
• Fitted with 6 mm glass for viewing
• Vestibule Door / Endwall Door
• Double flap sliding door
• Manual opening and auto closing type door
• Fire barrier all around
• Provided with rubber sealing at the door leaf for hand safe feature
• Stainless Steel body filled with phenolic resin for better heat insulation
and security of the coaches
• Fitted with 6 mm glass for viewing
• Door opens only 250 mm when gangway bridge plate is in folded position

• Sealed Window Glass Units

• The sealed window units consists of 8.4 mm outer laminated and 4 mm tempered inner glass with 6 mm
Krypton/Argon gas filling
• Window glass is secured to Al extrusions by rubber profiles
• The Al frame is glued to the car body.
• Water Supply
• Two under slung main water tank of 685litres each is provided.
• Each toilet is provided with one overhead tank of 30ltrs capacity.
• Power car are provided with water tank capacity of 450ltrs.
• Water to overhead tank is feed through an electrically operated pump and monitored through a
Microprocessor based Pump control system.
FIRE RETARDANT MATERIAL USED IN COACHES

• Wood based impregnated compressed laminates

• Fire retardant upholstery cloth
• Fire retardant curtain fabric
• Decorative thermosetting synthetic resin bonded laminated sheets (LP sheets) for interior
furnishing of coaches
• Densified thermal bonded polyester blocks for use in railway coaches for seats and berths
• Fibre glass reinforced plastic (FRP) windows of BG mainline coaches