Recent Experience on Coach InteriorsAnd

Future Opportunities

Integral Coach Factory, Chennai, India

10-10-2015

ICF - 1955 to 2015….

• 1955 First coach

• 1962 EMU Train set

• 1981 Underground Metro Train for Kolkata

• 1994 DEMU Train set

• 2001 EMU with 3-phase propulsion system

• 2008 Stainless Steel Coach

• 2013 DEMU with 3-phase propulsion system

• 2015 50,000th Coach

Variety of Builds

Variety of Builds

Stainless steel coaches Mainline express coaches

EMU Train set – 3 phase propulsion DEMU Train set – 3 phase propulsion

Variety of Builds

Kolkata Underground Metro Air Conditioned Train set

Kolkata Underground Metro – 3 phase Propulsion

Variety of Builds

Self Propelled Accident Relief Train

Duel Fuel DEMU Train Set - Runs on CNG

Golden Chariot for Karnataka Tourism (2008)

Maharajas Express for IRCTC (2010)

Variety of Builds

ICF exported Coaches and Bogies to various Countries

Exports

Recent experience on Interiors

Governing Specifications

• Raw materials for Interior furnishing of Indian Railway Coaches should comply with:

– Spread of Fire UIC 564-2 OR ( Class B )

– Loss of visibility due to Smoke UIC 564-2 OR (Class A )

– Toxicity NCD1409 (toxicity index <1)

– Limited Oxygen Index IS:13360 (Min 32)

– Heat release rate R1(HL2) of EN:45545-2

• IR is working towards migration to EN:45545 standards.

Interior Panelling

FRP

Aluminium Composite Panel (ACP)

Polycarbonate

POLYESTER RESIN

PHENOLIC RESIN

EPOXY RESIN

Interior Panelling

FRP PanellingUsed in Stainless steel body mainline coaches On 3-phase EMU train sets and DEMU Train sets.

•Aesthetic finish

•Mouldable

•Longer lead time

•Non-recyclable

Interior Panelling

ACP Panelling• Core: Inorganic oxide of

Aluminum• Used on Kolkata Metro coaches,

a few rakes of 3-phase EMU and a few mainline coaches.

•Aesthetic finish•Not mouldable , but formable•Used with Alu extrusions•Recyclable.•Non-availability of ACP meeting Railway FST requirements (A2 grade –EN -13501) in India.

Interior Panelling

• Polycarbonate ABS blend material for paneling

Mouldable RecyclableLight weight (500 kg less per coach)Longer lead time

Interior Panelling

Future requirements

FRP for all AC and Non-AC Stainless steel body mainline coaches and 3-phase EMU Train sets.

ACP in Diesel Train sets and metro coaches

Polycarbonate on trial basis on Mainline coaches.

Seating

Polycarbonate

Cushioned

Thermoformed

Injection Moulded

PU Foam

DTPB

Silicone Foam

FRP Seats

Seating System for Commuter Trains

Polycarbonate thermoformed seat

Cushioned SeatUsed in Intercity coaches like DEMU and day coaches

•Extensively used in 130 EMU train sets and Kolkata Metro coaches

•High rate of production

•Glued to SS frame and endcapped

•Non-uniform thickness due to thermoforming.

•Difficult to replace broken seat top

•Extensively used in intercity trains

•DTPB or PU foam cushion

Seating System for Commuter Trains

Polycarbonate Injection-Moulded seat

• Currently used used in 3-phase EMU train sets

• Better dimensional control

• Varied colours and more aesthetic.

• Inserts are moulded in to the polycarbonate sheet for better structural integrity.

CUSHIONING MATERIAL

– PU foam – Good cushioning comfort. Does not meet stringent FST standard with respect to Toxicity (<1 toxicity index). Used along with fire barrier cloth on day coaches

– Densified Thermal Bonded Polyester blocks (DTPB) – Meets FST and widely used in IR.

– Silicone Foam – Meets FST. Better cushioning comfort. Developed and under trials .

Seating

Future requirements

Polycarbonate seats for commuter trains FRP/polycarbonte seats for Metro trains Cushioned seats for intercity trains Revolving seats for tourist cars and high end applications

Experience on Thermoplastics

Commuter Coach Window

Door glass

Look out Glass

– Silicon hard coated Polycarbonate used for look out glass (Taber abrasion 1000 cycles, % haze < 12)

Handholds

Hand holds & Snack Table

Snack Table

Thermoplastics - Polycarbonate

• Light weight

• Good mouldability

• Recyclabel

• Performance is good – window glass, door glass, snack table and hand holds.

• Scratch formation on look out glass of driver cab

• PC raw material not available in India.

• Long Lead time.

• Product design and process engineering left to the fabricator.

• With ABS combination, meeting Toxicity requirement is difficult.

Lighting and PIS

IR is changing over to LED system from existing Fluorescent Lights.

• Compartment lights• Emergency light• Passenger alarm light• Tail light• Berth reading lights• Berth indication lights• Lights for toilet/ wash basin

GPS based Public Information System

LED for Commuter trains LCD on Metro Trains currently production

Luggage Rack

• Stainless steel luggage racks are for commuter trains and general coaches.

• Luggage racks made from Aluminum extruded section is used in AC chair cars. Aesthetic. Will be provided in all day coaches.

Aluminum Extruded Luggage Rack Stainless Steel Luggage Rack

Cork sandwiched between layers of Macore boards is used for sub floor with PVC top floor in Stainless steel body AC coaches.

Aluminum Honeycomb sub floor with PVC top flooring is being tried for air conditioned electric train sets.

Flooring – Sub layer

Flooring- Top Layer

Slip-free Stainless steel flooring

PVC top floor is provided in all main line coaches

PVC flooring

Stainless Steel ‘slip free’ top floor is provided for commuter trains viz. EMU and DEMU as well as doorways of conventional mainline coaches.

Halogen free rubber-on-rubber flooring on Metro coaches – under implementation

Modular Toilets

• FRP Modular toilets and Stainless steel Modular toilets in AC Coaches

• It is planned to adopt Modular toilets in non-AC coaches also.

• FRP Modular toilet – Loss of lusture over time.

• Stainless steel Modular toilet – formation of water stains.

Bio-toilet• Hygenic disposal of toilet waste.• Anaerobic Bacteria degrades fecal

matter into gas & liquid.• Track and station premises will be kept

clean.• 100% implementation on Conventional

coaches from March 2013.• All new coaches are turned out with Bio

toilets from current year. 11,000 nos fitted at ICF so far.

• Future Plan: Vacuum Toilets with bio-digester tanks

FULLY SEALED GANGWAYS

• Used on Kolkata Metro air conditioned train sets

• Currently being used on Fully Air Conditioned Electric Train set for Mumbai Suburban

• Functionally performance is good

• Turnbuckles holding the vestibules giving up

• Will be used on all Air Conditioned trainsets and Metro coaches

AIR CONDITIONING

The tonnage of Roof Mounted Package Unit (AC) for various trains

• 6.5 tons on Main line AC coaches – 800 coaches/annum• 11 tons on Metro Coaches – Project based• 15 tons on AC trainsets for suburban - Project based

FORCED AIR CIRCULATION

• Mumbai Suburban trains operate under super dense crush loads

• For comfort of passengers, Forced Air Circulation system was introduced which pumps 16000 m3/hr fresh air

• Reduction of 1000 PPM of CO2 levels from the existing highest levels of 2450 PPM

Air Handling Unit

Diffuser Grills

Insulation

• Sound Insulation

• Sound insulation paint coated on whole interior of Stainless steel Coaches

• Floor board made of cork sandwiched between compreg sheets, and laid over rubber decoupling elements.

• The above insulation Increases weight by 500 kg per coach.

Floor board laid over rubber decoupling elements

Sound insulation Paint

Insulation

• Thermal Insulation

• Glass wool cladded with aluminum foil is pasted on walls and ceiling for heat insulation.

• Additional layer of cross linked polyoiefin foam (Resonoflex) is provided upto window level in LHB AC coaches.

Resonoflex Thermal InsulationGlass wool Thermal Insulation

Insulation

Future Requirements

• Water based and eco friendly

• Coatings that provide sound as well as heat insulation planned for development.

• Light weight

Transview Tourist Coaches

• Large windows on side walls, end wall as well as roof for panoramic view

• Roof glasses glazed for opalescence through electric controls, for making opaque when necessary

• On board entertainment facility and LCD display

• Revolving chairs that can be oriented in train running direction.

• Automatic doors at compartment entry

• Modular pantry

Anubhuti Super Luxury Coaches

Superior Interior Paneling Designer toilets

• IR planning to manufacture Anubhuti Super Luxury coaches with Improved interiors for higher travel comfort

• Plush upholstery, designer toilets, diffused lighting, better ergonomics, LCD screens, personalized pantry 

• LCD TV behind each seat with Armrest keypad control

• Wi-Fi facility

Diffused Lighting

Smart display

Foldable Arm restSnack Table

SLIDING DOORS

• Electrically operated• Pocket doors• Provided in air conditioned EMU

and Kolkata Metro.

• Manually operated• Pocket doors• Provided in all commuter trains.

P I P

I

Automatic Pivoted DoorFuture Requirement

• Manually operated pivoted doors provided in all types of mainline passenger coaches presently.

• Automatic Pivoted doors are required for main line coaches to replace existing manual operated doors.

door actuator

Retractable StepsFuture Requirement

Retractable footsteps for ease of disembarking

FIRE SUPPRESSION SYSTEM

• Fire suppression system currently being installed in power cars• Fire/smoke detection and high pressure water mist suppression system• To be tried out in AC and NON-AC coaches in a big way.• System yet be proven in Non AC environment

CCTV Camera

• Planned to provide in Ladies compartment of EMU, DEMU, SLRD and all AC coaches – on a large scale

• Network video recorder (NVR) having 2 TB hot swappable hard disk• 30 days recording• IP Cameras having infra red sensors for recording even during dark.• GPS antenna for real time location and speed.

GPS CoordinatesSpeed & Time

CCTV Video Stream

To Conclude

• Current coach production on IR ~ 4000 /Annum • Will go upto ~ 5000 /Annum• Large variety of coaches – around 50 variants produced each

year• Large scale up-gradation of interiors is planned • Lead time needs to be reduced • Local Engineering support and manufacturing base needed

THANK YOU