Global View Workshop26th-27th March’08

Freight Wagon Designs for

Indian Railways

By G.C. Budhalakoti

Ex. Dir. Wagon, RDSO

Historical Background

Pre-independence (upto 1947)

• 25 types of wagons designed by M/s Rendol Palmer in 75 years

• Axle load was 16.3 t

• Pay to tare ratio ranging from 1.09 to 2.64

Post-independence (upto 1960)

• 9 wagon designs developed by various designers from all over the world.

• Some of the important wagons are BOBS, BWS

• Axle load max. 22.9 t

Historical Background

Post-independence (upto 1960)

• After formation of RDSO in 1957, responsibility of development of design taken by RDSO.

• First wagon designed by RDSO was BOX wagon in 1960

• Between 1960 & 1980 wagons with vacuum brake having UIC bogies were designed by RDSO.

• In 1980, BOXN wagon with air brake, Casnub bogie. CTRB & CBC was introduced.

• Since then BOXN and other wagons like BCN, BTPN, etc. having Casnub bogie became workhorse of IR freight transportation.

• Max. Axle load 20.32 t, Max. speed 100 Kmph

ORIGINATING TONNAGE(Million Tonnes)

195.9318.4

473.5

726 790 850

1100

0

200

400

600

800

1000

1200

1980-81 1990-91 2000-01 2006-07 2007-08* 2008-09* 2011-12*Note:* Estimated

RDSO, Lucknow, INDIA

New Design of Wagons (IR)

Design of 22.9 t A/L - BOXNHL & BCNHL(wagons under production)

* No. of wagons per rake increased from 44 to 58

5.64

Crores

3.402.31 (of BCNA)

4106

(40%)2496

(of BCNA)

*BCNHL

3.56

Crores

3.452.50 (of BOXN)

4118

(22.25%)

3369

(of BOXN)

BOXNHL

ToFrom ToFrom

Additional

earning per

rake per year (in Rs. Crores)

Pay to tare increase

from

Throughput increase (in tonnes)

Wagon

New Design of Wagons (IR)Design of 25 t A/L Wagons

4.75 Crores

Design on hand(no. of wagons per rake

increased from 54 to 58)

2.572.01 (of BOBSN)

4176

(26.4%)3305

(of BOBSN)

BOBSN25

5.49 Crores

Design completed3.102.17 (of BOBRN)

4385

(35.8%)3229

(of BOBRN)

BOBRN25

4.31 Crores

Design completed3.252.45 (of BRN)

3210

(32.3%)2425

(of BRN)

BRN25

5.21 Crores

Design completed3.352.50 (of BOXN)

4466

(32.6%)3369

(of BOXN)

BOXN25

4.88 Crores

Design completed(no. of wagons per rake

increased from 52 to 58)

3.763.42 (of BOY)

4582

(24.3%)3686

(of BOY)

BOY25

ToFrom ToFrom

Addl.

earning

per rake

per year (in Rs. Crores)

RemarksPay to tare increase

fromThroughput increase

(in tonnes)

Wagon

DOUBLE STACK CONTAINER

OPERATION ON FLAT WAGONS

• Double stack container operation on flat wagons started in March’06

• Limitation of axle load (20.32 t) & speed (max.75

Kmph), resulting in restriction in container loading

• Bogie upgraded and Speed certificate for operation at 22 t axle load and speed of 100 Kmph issued in 2007.

Road Railer trains (Development with M/sKPC)• Can be converted into trailer hauled by a truck and

into normal wagon

• Carry white goods, automobiles, manufactured

goods, perishables, fragile cargo,part load,etc.

• Faster turn around time

• Trials already done on IR

• Number of wagon per rake- 50

• Articulated Bogie, Slackless coupling

• Kirloskar Pneumatic Co. manufacturing one rake

for braking distance trials

ROADRAILER CHASSIS IN ROAD MODE

ROADRAILER CHASSIS IN RAIL MODE

Double Stack Container Train entering in Botad Yard

Flyash Wagon (New traffic)

• Recently designed wagon for bulk

transportation of flyash

Special features are:-

- Pay to tare ratio –2.14 for Flyash (3.02 for Cement )

- No. of wagons/rake – 58

- Stainless steel (IRSM 44) underframe & body

- Rake throughput of 2732 t

- Can carry cement-rake throughput 3875 t

- Axle load 22.9 t max. with Cement

Autocar WagonsDedicated wagon for transportation of autocars

• New Design Bi-Level Autocar Wagon type ‘BCACB’ -

Features

- Can carry upto 294 autocars.

- New bogie design with lower wheel dia (760-700 mm)

- Provision of hydraulic cushioning devices

Status: Design completed

• New Design Tri-Level Autocar Wagon type ‘BCACT’ -Features- Can carry upto 444 autocars

- Can run only on Double stack ISO container routes (i.e. presently Jaipur-

Pipavav)

- Provision of various types of cars in three decks

Status: PDC of design May, 2008.

Diagram of Bi-level Autocar Wagon Type

‘BCACB’

Diagram of Tri-level Autocar Wagon Type

‘BCACT’

Ro-Ro Under Wire

• With the new bogie of 700 mm wheel dia

of Autocar wagon, it is now possible to

run Ro-Ro services under wire.

• RDSO has also undertaken the design of

such Ro-Ro wagon.

Dedicated Freight Corridor

Following two new corridors dedicated to

freight traffic movement are being

constructed:-

• Eastern Corridor-

Main traffic- Coal & Ores

• Western Corridor-

Main traffic- Containers

Axle Load - 32.5 t (Final target)

- 25 t (Starting)

DFC (EASTERN)Feeder Route

Main Route

Dedicated Freight Corridor Ludhiana-Son Nagar

Asansol

BondamundaTata Nagar

Durgapur

Mughal SaraiAllahabad

Kanpur

Tundla

Khurja

Hapur

Meerut

SaharanpurAmbla

Ludhiana

Son Nagar

Gomoh

Unchahar

Katni

Nagal Dam

Chandigarh

Panipat

Harduaganj

Paricha

Amritsar

Bhatinda

with Extensions to Durgapur/Bokaro/Tatanagar

Legend:

P R O P O S E D F R E IG H T C O RR ID O R (W ES T ERN )

L E G E N D :-M A IN R O U T EF E E D E R R O U T E

L U D H IA N A

H IS S A R

R E W A R I

D E L H I

T U N D L A

A G R A

L U N I

J O D H P U RP H U L E R A

J A I P U R

- G A M

D IV A

M E H S A N A

P A L A N P U R

M A R W A R JN .

S U R A T

V A D O D A R A

V A S A I R O A D

P IP A V A V

H a z ira

R A JK O T

V IR A M -P o rt

O K H A

P o rtM u n d ra

G A N D H I D H A M

A H M E D A B A D

V A L S A D

M U M B A IT h a l

P o rtM u m b a i

K A N D L A

Approved MMD for DFC

MMD for Feeder Routes of DFC (under consideration)

Future Wagons for DFC/IR (25 t A/L)Possible throughput on existing length of Wagons

10.33 Crores2141 (85.9)80 (4.0)Bagged

commodityCovered

6.47 Crores1186 (32.2)84 (5.0)Iron OreBOY

7.26 Crores1527 (47.2)82 (4.5)CoalBOBRN

7.15 Crores1504 (44.6)84 (5.0)Coal BOXN

Additional

earning per

rake per year (in Rs. Crores)

Throughput

increase/ rake

(in tonnes) & %

improvement

Payload

(in tonnes) & Pay

to tare ratio

CommodityType of

Wagon

25t axle load

Future Wagons for DFC/IR (32.5 t A/L)Possible throughput on existing length of Wagons

Additional

earning per

rake per year (in Rs. Crores)

Throughput

increase/ rake

(in tonnes) & %

improvement

Payload

(in tonnes) & Pay

to tare ratio

CommodityType of

Wagon

17.04 Crores3536 (141.6)104 (4.0)Bagged

commodityCovered

14.06 Crores2578 (69.9)108 (5.0)Iron OreBOY

13.87 Crores2919 (90.4)106 (4.5)CoalBOBRN

13.76 Crores2896 (85.9)108 (5.0)Coal BOXN

32.5 t axle load