Technical Pamphlet, No. CMI-K302

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INSliRtJCTIONS FOR CORROSION REPAIRS

0F ICF/RCF BUILT M.G. COACHESI

! . (Supersedes Technical Pamphlet No, 6905)

(April-2003)

Issued by

Research Designs & Standards Organisation

(Ministry of Raiiways)

Manak nagar, Lucknow - 226 011

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Amendment Slip no. i to CMI-K30-~ lllstructioilS forCorrosion Repair ofiCFfRCF Built MG Coaches.

1. Amendment (,r clauses:

i" .•' --•.- ••------.-.- ----------.- -, - ~,---- ---,----------. --',

I ;-i'-\~~l(~~~~~I\'c .... ~!~I~,c:---·-- -~ Vestibule IiOlnC'CC'\S ~2

3," Pg.~'

2:(>5'" Lines

6,7,8

.:. '.-,wind the burnt edge.:: ". '" grind and chamfer the burntedoes .Prepare side wall sheet with edgeschamfered and 5 mm dia. Holes

6 . Pg. ·18 Prepare .new side wall sheet with 51.1.3 L mm dia. Holes

f-:;;--1..;L~in~e!-t1;--\-=---c-~.-cc---,...-;:----:---c-.,..,.--+.,:;-.,-..,..::.-....,..:..,;-....;.;'~-_c_- ...j. 7 PS.·19' , Check.the tum under for straightness Check the straightness of repaired

1':3.5 .' ""'.,':'".",. .1.. turn-under.with ,the existing '(Urnunder

8 I'g.191.3.6

9 Pg.23 .,

1.1.2 ,.

10 Pg.231.1.3

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Weld intermillently the body pillars':with tum under

SuppOrt '-, the' ~ antitelescopic.stanchions at the bottom and sole baron suitable wooden standsGas cut 'the end wall sheet ensuringthat no damage is caused to the antiteleooopic stanchions. ,8ole bar etc.

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Weld intermittently to the bodypillars and over complete lengthwith sole barSuitable metallic stand should beprovided at the bottom of outerhead stock .Gas cut the end wall sheet ensuringthat no damage is caused to the antitelescopic stanchions and sol bar.Remove all scale and paint ofdifferent patches and pockets ofouter headstock' and cleanthorouahlv all bumt ola<:es.

2... Sketch-80177 refened at page DO. 19 8t clause 1.3 is superseded by Sk-80177.A11.(I)(copyenclosed) "

INDEX

Technical PamphletNo. CMI-KJ02

C'",

S. DESCRIPTION ANNE- PAGE

N. XURE No.

1 INTRODUCTION 1

2 INSPECTION 2

3 CORROSION REPAIR 7

4 PROCEDURE FOR CORROSION REPAIRS 115 DOCUMENTATION 126 INSTRUCTIONS FOR STIFFENING OF SOLE BAR I 137. INSTRUCTIONS FOR CORROSION REPAIR OF SOLE BAR II 158 INSTRUCTIONS FOR CORROSION REPAIRS OF SIDE III 18

WALL SHEETS BODY PILLARS AND TURN UNDERS

9 INSTRUCTIONS FOR CORROSION REPAIR OF TROUGH IV 20FLOOR

10 INSTRUCTIONS FOR CORROSION REPAIRS TO HEAD V 23STOCK

11 INSTRUCTIONS FOR CORROSION REPAIR OF END VI 24WALLS AND END WALL STANCHIONS.

12 INSTRUCTIONS FOR CORROSION REPAIRS OF ROOF VII 25SHEET AROUND VENTILATIONS

13 INSTRUCTIONS FOR CORROSION REPAIRS OF BODY VIII 26SIDE DOORS

14 INSTRUCTIONS FOR CORROSION REPAIRS OF SEAT IX 27PILLARS OF PARTITION WALLS

15 INSTRUCTIONS FOR CORROSION REPAIRS FOR X 30LONGITUDINAL PARTITION FOR FIRST CLASS AND

OTHER COACHES

16 PROCEDURE FOR LAYING OF FIBER GLASS TISSUE ON XI 31COACH SHELL

17 MODIFICATION TO VACUUM RESERVOIR SUSPENSION XII 32ARRANGEMENT

18 SPECIFICATION FOR MATERIALS USED IN CORROSION XIII 33REPAIRS OF SHELL

LIST OF DRAWINGS APPENDED

Technical PamphletNo. CMI-K302

S. DESCRIPTION DRGNo. ALT.N. No.

1. LAVATORY PAN C/LF-1880 3

2. SOLE BAR STIFFENING AT MIDDLE DOORWAYS SK. -79193 NIL.OF 3 DOORS ASIDE SHELL AND MIDDLEDOORWAYS OF SLR SHELL

3. SOLE BAR STIFFENING AT LUGGAGE SK. -79194 NILCOMPARTMENT DOORWAYS OF SLR SHELL

4. SOLE BAR STIFFENING AT DOORWAYS OF SK. -79195 NILPARCEL VAN SHELL

5. WINDOW SEALING ARRANGEMENT SK. -76014 NIL

6. SKIRTING PLATES FOR VACUUM RESERVOIRS SK. -76075 NILANO BATTERY BOXES

7. MODIFIED LAVATORY FLOORING ARRANGEMENT SK. -76076 'NIL

8. CORROSION REPAIR OF SOLE BAR (OTHER THAN SK. -76077 NILLIFTING PAD & BOLSTER LOCATIONS)

9. CORROSION REPAIR OF SOLE BAR AT LIFTING SK. -76078 NILPAD & BOLSTER LOCATIONS

10. CORROSION REPAIR OF SIDE WALL SHEET BODY SK. -76079 1PILLAR AND TURN UNDER

11. TUBULAR FRAME BELOW END LAVATORIES OF 2 SK. -76080 NILDOORS & 3 DOORS ASIDE SHELL.

12. TUBULAR FRAME BELOW MIDDLE LAVATORY SK. -76081 NIL

13. TUBULAR FRAME BELOW GUARD'S LAVATORY OF SK. -76082 NILSLR COACHES.

14. CORROSION REPAIR OF HEAD STOCK. -

15. CORROSION REPAIR OF END WALL AND END SK. -76084 NILWALL STANCHIONS.

16. CORROSION REPAIR OF ROOF SHEET AROUND SK. -76085 NILVENTILATOR.

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Technical PamphletNo. CMI-K302

17 CORROSION REPAIR OF BODY SIDE DOORS SK. -76029 NIL

18. CORROSION REPAIR OF PILLARS & PARTITION SK. -76086 NILWALL

19 CORROSION REPAIR OF LONGITUDINAL SK. -76087 NILPARTITION WALL IN FIRST CLASS COACHES.

20 CHECK LIST FOR INSPECTION & RECORD OF SK. -K3010 NILCORROSION REPAIRS ICF-2 DOORS ASIDE SHELL(15 WINDOWS)

21. CHECK LIST FOR INSPECTION & RECORD OF SK. -K3011 NILCORROSION REPAIRS ICF-2 DOORS ASIDE SHELL(17 WINDOWS)

22. CHECK LIST FOR INSPECTION & RECORD OF SK. -76088 NILCORROSION REPAIRS ICF-3 DOORS ASIDE SHELL

23. CHECK LIST FOR INSPECTION & RECORD OF SK. -76089 NILCORROSION REPAIRS ICF SLR SHELL

24 CHECK LIST FOR INSPECTION & RECORD OF SK. -76090 NILCORROSION REPAIRS ICF PARCEL VAN SHELL

25. BOnOM SIDE WALL SHEET WITH ELONGATED SK. -80177 NILHOLES FOR COACHES WITH SEALED WINDOW(NON-AC COACHES)

26. LAYING OF FIBER GLASS TISSUE ON UNDER SK. -K3009 NILFRAME SANDWICHED BETWEEN TWO LAYERS OFBITUMINOUS EMULSION

27. MODIFIED VACUUM RESERVOIR SUSPENSION SK. -K3012 NILARRANGEMENT FOR MG COACHES

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Technical PamphletNo. CM1-KJ02

INSTRUCTIONS FOR CORROSION REPAIRS OF ICFfRCF BUILT MG COACHES

1.0 INTRODUCTION

1.1 All welded all steel integral light weight MG coaches manufactured at IntegralCoach Factory, Chennai and Rail Coach Factory, Kapurthala have beenaccepted as a standard on Indian Railways. These coaches incorporate anumber of pressed steel sections made out of thin sheets varying in thicknessfrom 1.6mm to 4mm and plates of thickness 5mm to 16mm in the construction ofthe coach shell. These sheets and plates are considerably stressed due to coldforming and welding, therefore, it is essential that these coaches are maintainedin good condition free from corrosion. The trough floor, which is designed as anintegrated part of the shell and takes major buffing ioad, needs particularattention. Corrosion is such a phenomena that when once it sets in, it spreadsrapidly and may reduce the life cycle of stress bearing members of the shell. Itis, therefore, essential to stop the on setting of corrosion particularly at suchlocations or places of the coach shell, which are not easily accessible forinspection and attention. Therefore, immediate attention should be paid by theRailways to arrest corrosion as and when noticed so that the strength of thecoach shell is not impaired. It is understood that slight corrosion, when noticedand not attended, may eventually result in perforation in the long termnecessitating heavy repairs.

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1.2 Corrosion is a chemical phenomena of oxidation of steel surfaces which resultsin loss of section and therefore of strength. Oxidation takes place when steelsurfaces are exposed to atmosphere in the presence of moisture. Steelsurfaces of integral coaches are protected from coming in contact withatmosphere by the application of inhibitive zinc chromate red oxide primer.Surfaces which are not finish painted have also been given 3 to 4 coats ofbituminous emulsion which gives added protection to the steel surfaces alongwith primer from the moisture. In case where bitumen paint film breaks downdue to some reason or the other iike the abrasive action of sand or the otherparticles, red oxide zinc chromate primer acts as a second line of defenceagainst corrosion. Corrosion of steel surfaces starts only when both the bitumenand the primer suffer from mechanical injuries. Since 1979 low alloy high yieldstrength corten type steel to specification IRS-M-41 is being used for coachconstructions.

1.3 Several instructions have already been issued from time to time for attending thecorrosion repair work on ICF built BG coaches. This technical pamphlet;ncorporates aJi such instructions and some more details in a consolidated formto serve as a guide line for carrying out corrosion repairs of ICF built MGcoaches. These instructions, in general, explain as to how the coaches are to be

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Technical PamphletNo. CMI-K302

inspected for locating corroded members and the procedure for attending tothese members. As brought out above that these instructions contained in thisPamphlet are intended to serve as a guide only, therefore, the Railways may, inaddition, adopt any other measure (s) considered necessary so as to ensure thesound health of coaches in service.

2.0 INSPECTION

2.1 Onset of corrosion is indicated by flaking of paints, flaking of metal, pitting andrusting. Components like sale bar, trough floor etc, which are not visible fromboth sides, should be examined by tapping with a spiked hammer.

2.2 Shell members and locations prone to corrosion can be classified into twocategories viz. 'vulnerable' and not 'so-vulnerable'. Though all parts of the coachare to be periodically inspected to ensure that there is no corrosion on any of themembers, particular attention should be paid to members and locationscategorised as 'vulnerable'.

2.3 Vulnerable members and locations:

2.3.1 Tubular frame below lavatories and trough floor in bays adjoining lavatories inall types of coaches and under the luggage compartments of SLRs, parcelvans.

2.3.2 Sole-bar, bOdy pillars, turn-unders in the bays, under and adjoining lavatories inall types of coaches.

2.3.3 Sale bars, turn unders and pillars above lifting pads.

2.3.4 Sale bars and pillars behind the sliding door pockets of SLR's & parcel vans.

2.3.5 Sale bars, pillars and turn-unders at door corners.

2.4 "Not so-vulnerable" members and locations:

2.4.1 Trough floors at locations other than those described in para 2.3.1.

2.4.2 Sale bars, pillars and turn unders at locations other than those describlld inparas 2.3.2 to 2.3.5.

2.4.3 End stanchions and end wall sheets.

2.4.4 Head stocks- Inner and outer along with stiffening tubes.

2.4.5 Roof sheet around ventilators.

2.4.6 Body side doors.

2.4.7 Lavatory partition walls.

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Technical PamphletNo. CMJ-K302

2.4.8 Longitudinal partition wall in First class, AC First class, Ladies compartment ofthree tier sleeper and other coaches, where provided.

2.4.9 Seat pillars and transverse partition walls.

2.4.10 Side wall sheets.

2.4.11 Water tank ceiling construction.

2.4.12 Vestibule hoods.

2.4.13 Battery box frame.

2.4.14 Vacuum reservoirs & suspension straps.

2.5 General Instructions for inspection in Workshops:

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2.5.1

2.5.2

Pre-inspection of coaches is most essential aspect for identifying onset ofcorrosion. It must be done after dismantling under slung components such asbattery box, vacuum cylinder, vacuum chamber, brake shaft and electrical paneletc. and placing the coach on trusties of suitable height above the pit. All thepockets of under gear, head stocks and old welding beads on sale bar surfacesmust be cleaned thoroughly of mud etc. to have clear visibility of cracks andcorrosion.Coaches received in the workshops for repairs should be thoroughly inspectedfor identifying the corroded members by competent and trained staff who havethorough knowledge of integral MG coaches. Instruments such as spikedhammer, torch, head light etc. should be provided to the staff to enable them tocarry out proper and through inspection. On the basis of information availablewith regard to extent of corrosion on coaches provided with sealed windowarrangement, it is seen that these coaches generally require their first corrosionrepair after 9-11 years. It would, therefore, be necessary that post 1977 builtcoaches of 9 years age and above should be. given a close and careful andvisual inspection for signs of corrosion, as these coaches are likely to leadcorrosion repairs. However, it is essential to inspect visually all coaches comingto shops irrespective of their age because in some cases corrosion may set inprior to 9 years of age. If signs of corrosion are noticed, then these coachesshould be subjected to detailed inspection.

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2.5.3 Normally, coaches thoroughly inspected and attended to for corrosion repairs inaccordance with the instructions given in this pamphlet should not requirecorrosion repairs at the same location for a further period of six to seven years,but in view of factors such as non-availability of materials of the prescribedquality and specification variations in quality of workmanship and climatic andservice conditions from Railway to Railway, it is difficult to predict the period withany degree of accuracy. It will, therefore, be necessary that on subsequent visitsof these coaches to shops for POH, all coaches irrespective of age and thedegree of attention given in the previous POHs should be subjected to a

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Technical PamphletNo. CMl-KJ02

thorough examination. Where onset of corrosion is suspected, a more thoroughinspection in terms of paras 2.6 & 2.7 should be carried out

2.6 Procedure for inspection of 'vulnerable' members and locations inworkshops:

2.6.1 Trough floor- Non AC coaches manufactured by ICF from 1968 to 1981 havebeen laid with bituminised exfoliated vermiculite on the trough floor be' low theluggage compartment of SLRs and parcel vans and adjacent bays of lavatories.On coaches built since 1982, the trough floor and the under frame meml)ers areprovided with FRP tissue sandwitched in.between layers of bituminous e,mulsionthe trough floor at these locations should be examined visually from below forsigns of corrosion supplemented by tapping with a spiked hammer. If signs ofcorrosion are noticed, the trough floor should be replaced as described inAnnexure IV. In case of replacement of trough floor below luggage compartmentof SLRs, LRs and bays adjacent to lavatories under doorways and also for thewhole trough floor in a coach, FRP tissue should be laid over trough floorfollowing the procedure detailed in Annexure-XI

2.6.2 Sale bars, body pillars and turn unders:

2.6.2.1 Turn under with elongated holes: The sale bars, body pillars and turn unders inthe bays under and adjoining lavatories should be examined visually from thebelow the coach and through the elongated holes in the turn under afterremoving accumulated dirt and cleaning the inside surfaces. A torch light may beused to facilitate inspection. The inside of sale bar above the trough floor,however, cannot be visually inspected. If incidence of corrosion is noticed in thebottom half of the sale bar, flooring and interior panelling should be removed forexamining the inside top half. If heavy corrosion is noticed, the side wall shouldbe cut to a height of 300 mm to 500 mm from the bottom of the turn undercovering sufficient length and all the exposed parts, after scraping and cleaningshould then be examined to determine the extent of corrosion.

2.6.2.2 Turn under without elongated holes: Coaches without elongated holes in theturn under, should be visually examined, supplemented by tapping with spikedhammer on the bottom of the turn under as well as the lower half of the sale barfrom inside. If corrosion is suspected, a 100 mm dia hole in the bottom of turnunder in the suspected area should be cut without damaging th" pillar, forexamining the inside. If signs of corrosion are noticed, side wall up to height of300 mm to 500 mm from bottom of turn under should be cut for thoroughexamination.

2.6.3 Sale bar, turn under and pillars above the lifting pads: The above membersshould be examined visually in the same manner as described at para 2.6.2. Ifsigns of corrosion are noticed, the side wall sheet above Ihe lifting pads shouldbe cut to a height of 300 mm to 500 mm above the turn under and to a length of

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Technic.1 PamphletNo. CMI-K302

half a metre on either side of the lifting pads and the structural members scrapedcleaned and examined minutely to ascertain the extent of corrosion.

2.6.4 Head stock: Remove the ABC and examine outer and inner head stock and... tubular frame carefully for incidence of corrosion.

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2.6.5 Pillars behind the sliding door pockets of SLRs & Parcel vans: The pockets forsliding doors should be opened and the accumulated dust dislodged andthoroughly cleaned. If on visual examination, signs of corrosion are noticed theside wall sheet should be cut to a height of 300 mm to 500 mm above the turnunder and to a distance of one metre on either side of the sliding door cornersand the pillars thoroughly examined. The trough floor to a width of 300mm fromsole bar should also be removed and the sole bar thoroughly examined toascertain the extent of corrosion.

2.6.6 Sole bars, pillars at door corners: These members should be examined visually inthe same manner as described at para 2.6.2. If corrosion is noticed, the turnunder to a width of half a metre from the door corner should be cut and theaccumulated dust dislodged. The structural members should be thoroughlyscraped, cleaned and examined carefully to assess the extent of corrosion

2.7 Procedure for inspection of 'not so-vulnerable' members and locations inworkshops:

2.7.1 Trough floor: At location other than those described in para 2.3.1, the entire areaof trough floor should be visually examined thoroughly from below, supplementedby tapping with a spiked hammer for signs of corrosion. In case corrosion isnoticed, the affected and surrounding areas should be thoroughly scraped,cleaned and minutely inspected to assess the extent of corrosion.

2.7.2 Sole bars, body pillars, turn unders at location other than those described underpara 2.3:

2.7.2.1 Turn under with elongated holes: Visible portion of sole bars through theelongated holes and from the bottom of the under-frame should be examined.To facilitate inspection, the accumulated dust in the turn under should bedislodged through the elongated holes and structural members scraped to theextent possible. If corrosion is noticed, side wall sheets in the area where thecorrosion has been observed should be cut to a height of 300 mm to 500 mmfrom the bottom of turn under covering sufficient length for thoroughexamination and to facilitate subsequent attention.

2.7.2.2 Turn unders without elongated holes - Coaches without elongated holes in theturn under should be visually examined, supplemented by tapping with aspiked hammer on the bottom of the turn under as well as the lower half of thesole bar from inside. If corrosion is suspected, a 100 mm dia hole in thesuspected area should be cut without damaging the pillar, for examining the

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Technical PamphletNo. CMI-K302

inside. If signs of corrosion are noticed, side wall up to a length of 300 mm to500 mm from bottom of turn under should be cut for thorougtl examination.

2.7.3 End wall stanchions and end wall sheets: The end wall stanchions should beinspected for corrosion by opening the interior panelling. If signs of corrosion ".are noticed, the end wall sheet may also be cut to the elctent of corrodedportion marked for attention

2.7.5 Body side doors - The interior of the body side door should be carefullyinspected after removing the panelling.

2.7.6 Lavatory partition walls - Visible portions of the partition pillars at its junctionwith the fioor should be examined for incidence of corrosion. If corrosion isnoticed the fiooring around the area should be' removed for thoroughexamination.

2.7.7 Seat pillars and partition walls: Square/round tubes at the junction of the fioorshould be visually examined for corrosion. If signs of corrosion are noticed, thefiooring around the area should be removed for more detailed e:<amination.

2.7.8 Side wall sheets -The entire side wall should be visually examined for signs ofcorrosion.

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•2.7.9 Water tank ceiling construction- This should be visually examine'd for signs of

corrosion by removing the lavatory ceiling.

2.7.10 Vestibule Hoods: The vestibule hood should be visually examined for signs ofcorrosion all round its joint with the end wall and any cracks on the hoodparticularly at comers under the vestibule suspension bracket

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2.7.11 Battery box frames: The battery box frame should be visually eiXamined forsigns of corrosion or cracks at welded locations.

2.7.13 Vacuum Reservoir & Suspension Straps: The vacuum reservoir and itssuspension straps should be thoroughly examined for signs of corrosion at theirsurface of contact.

2.7.14 Longitudinal partition wall in first class, ladies compartment in non-AC sleeperand other coaches wherever provided - All such coaches where longitudinalpartition wall have been provided should be inspected by removin\l the guiderail, joint moulding and panelling and the components corroded distinctiymarked for attention.

2.8 Check list:

After completion of inspection of the entire coach shell, including members andcomponents which may not have been listed in paras 2.6 & 2.7, the members

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Technical PamphletNo. CMJ-K302

affected by corrosion should be distinctly marked to indicate the entire areaaffected by corrosion requiring repairs by replacementlmodificalion, as the casemay be. Appropriate items in the check list (RDSO Sketch Nos.K3010,K3011,76088,76089 and 76090) should be filled in, showing details ofthe members to be attended to for corrosion repairs.

2.9 Inspection at Sick lines:

With systematic inspection and repairs of these coaches for corrosion in theRailway workshops as detailed in this pamphlet, it should be possible to ensurethai coaches having extensive corrosion are not in service. When considerednecessary, Railways may also organise inspection at primary coachmaintenance depots to identify coaches having heavy corrosion which can bedispatched to Railway workshops for corrosion repairs.

3.0 CORROSION REPAIRS

3.1 Material & treatment of components

3.1.1 For repairs of integral coaches low alloy high tensile corten steel sheets andplates to specification IRS-M41-97 are to be used. The thickness of steelsheets/plates to be used to replace the corroded parts shall be the same as hasbeen used in new manufacture of coaches.

3.1.2 All body shell replacement components less than 5 mm thickness used forcorrosion repairs should be hot phosphated and applied with protective paints.Cold phosphating should be done in areas where welding has been carried outon hot phosphated components.

3.1.3 Zinc rich primer should be used where spot welding is done.

3.1.4 Components of 5 mm or more thickness should be grit blasted and immediatelyfollowed by application of red oxide zinc chromate primer.

3.1.5 Welding electrodes and paints should be of the prescribed quality conforming tothe relevant IS/ IRS specification, particulars of which are given in Annexure-XIII.Where the corrosion noticed is of a very minor nature and has just started, thereis no need to renew parts. The paint and rust should be thoroughly cleaned toreach the bare metal and the surface treated with two coats of primer. In additionunder frame members should be given four coats of bituminous solution.

3.2 Design improvements / modifications

Several design improvements/ modifications for elimi~ating/minimising corrosionhave been issued by the RDSO/ICF from time to time. Brief details of thesetogether with the action to be taken by the railways are given below:

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Technical PamphletNo. CMI-K302

3.2.1 Stiffening of sale bars at doorways:

3.2.1.1 Strengthening of the sale bars under the middle doorways of MG main linecoaches, SLR and parcel vans by boxing from the inside face of the sale barswas specified earlier, as shown in ROSa Sk. Nos. 76071, 76072 and 76073respectively. This involves cu!ling of trough floor and tra,nsverse members andrailways had expressed difficulties in carrying out this modification. In order tosimplify the modification work, it was decided that railways may carry outsideboxing of the sale bars instead of inside boxing.

3.2.1.2 To simplify modification work, railways may in future stiflen the sale bars byboxing from outside instead of inside as shown in ROSa Sk Nos. 79193,79194 and 79195. Such of the coaches which have not been modified so faras per ROSa Sk. Nos. 79193, 79194 and 79195 should bl3 modified to stiffenthe sale bars by boxing from outside during corrosion reparrs.

3.2.2 Tubular frame below lavatories: Tubular frame as per ROSO/SK Nos. 76080,76081 and 76082 should be provided below lavatories of main line and guard'scompartment of SLR coaches respectively.

3.2.3 FRP tissue sandwitched between layers of bitumen

3.2.3.1 Since 1982 FRP tissue sandwitched between bituminous coats has been laidon trough floor, sidewall and body pillars up to waist rail height and the entireunder frame as shown in ROSa Sketch - K3009.

3.2.3.2 On the post 1982 built coaches, whenever corrosion repair is carried out onportion laid with FRP tissue, patch repair of the FRP tissue s:hould also bedone to the extent to which the original lining is removed for repairs to thecorresponding parts.

3.2.3.3 On the pre 1982 built coaches, not laid with FRP tissue originally, wheneverentire trough floor is required to be renewed, FRP tissue should be laid overthe trough floor. Also, whenever the trough floor in bay adjacent to lavatoriesunder the doorway is required to be renewed, it should be laid with FRP tissue.

3.2.3.4 The procedure for laying of FRP tissue is laid down in Annexure-XI

3.2.4 Trough floor:

13 mm dia. holes provided in the valleys of through floor for drainage ofcondensed water were increased to 19 mm so as to allow faster drainage. Thismodification may be incorporated in all coaches, if not already done, whenevertrough floor is laid with FRP tissue, these holes should be pierced throLlgh.

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3.2.5 Sealing of window sills:

To prevent seepage of water through the gap between the side wall and windowsill, window sealing arrangement as per ROSa Sketch - 76014 has beenintroduced on all coaches turned out by ICF since 1975. Coaches without suchsealing arrangement, should be provided with this arrangement at the time ofcorrosion repairs.

The coaches with sealed window sills turned out by rCF were not provided withelongated holes in the turn-under and the thickness of turn under sheets wasalso reduced to 2 mm. Subsequently, from 1982 onward, coaches have beenprovided with sealed window sills with elongated holes in the turn under of 5 mmthickness. This decision was once again reversed and it was decided not toprovide any holes in the turn unders and reduce its thickness to 2.0 mm.

During 2000-01 RCF has turned out 100 MG coaches of ICF design withelongated holes in the turn under. The thickness of the turn under sheet for ACcoaches is 3.15mm whereas for non-AC coaches it is 5mm. The elongatedholes of size 215x85 mm have been provided on the turn under as shown inROSa Sketch-80177. RCF sought the opinion from railways about the twodesigns i.e. with elongated holes and without elongated holes. Railways haveopined that elongated holes are considered better for corrosion prevention ofturn under and sole bars. In view of the railways experience it isrecommended that elongated holes of size 215x85 mm may be provided onall coaches during corrosion repairs.

3.2.6 Body side doors:

Originally the body side doors were provided with a closed bottom as shown insection 'cc' of Sketch - 76029. This results in accumulation of dust and water inthe confined space leading to corrosion of the door bottom. Since 1961, bodyside doors have been modified as shown at detail 'X' on Sketch -76029 withcompletely open bottom and a removable inside panel to facilitate inspection ofthe out side panel. Body side door should be modified as indicated in Annexure­VIII, if not already done.

3.2.7 Skirting plates for vacuum reservoir and battery boxes:

A skirting plate as shown in Sketch -76075 has been provided to protect vacuumreservoir and battery boxes from the lavatory discharge. This should beincorporated, if not already done, on all coaches where vacuum reservoirs andbattery boxes are located near the lavatories.

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3.2.8 Lavatory pan with longer neck:

The neck of the lavatory pan have been increased by 100 mm as shoV>T1 in Drg.No. C/LF 1880 AIL-3 to avoid drain water from spilling over trough floor andconnected members. It is essential that at the time of corrosion repairs in the ,"lavatory area or renewal of magnesium oxy-ehloride flooring compositiion in thelavatories, pans having shorter neck may be used only after we,lding anadditional piece to the neck to bring it in conformity with Drg. No. C/LF-188oAIL3.

3.2.9 Till 1989 PVC flooring was used only in upper class coaches whereas decoliteflooring was used in lower class coaches. In Feb. 1989 Railway Board approvedthe use of PVC flooring in all type of lower class coaches also. The flooring incoaches will consist of a base of compreg sub-floor covered with PVC sheet.Following ICF drawings give details of PVC flooring arrangement over plywoodsub-floor. Since plywood has been replaced with compreg, therefore, thesedrawings may be read with compreg instead of plywood. •i)ii)iii)Iv)v)

MG/SCN-4-1-101MG/SCN-4-1-104 (Sheet 1 & 2)MG/S and MG/SCN-4-1-102MGIWGSCWAC -4-1-002MGIWGSCWAC -4-1-007

- Flooring in lavatory- Coach flooring- Flooring arrangement in lavatory- PVC sheet floorin9- Lavatory flooring.

PVC flooring of 2mm thickness shall conform to RDSa specification C-8515.12mm thick compreg shall conform to RDSa specification C-9407.

Adhesive to fix the PVC flooring to compreg will be neoprene based rubberadhesive of Dunlop S-758 or Fevicol SR-998 make.

Joints of PVC should be hot air welded. The detailed procedure for laying ofPVC flooring is given in Technical Pamphlet No. C-9001.

3.2.10 Vestibule hood:

Till 1988, vestibule hood waS being manufactured out of 2.5 mm thick sheeLThis design was suitable for vestibules with aluminum frames. With theintroduction of mild steel frame for vestibules, the hoods were found to becracking at comers, where suspension bracket are located. In case no corrosionis noticed on the vestibule hood, they should be strengthened as per RDSaSketch -92108. However, if the hood is heavily corroded and needs replacementit should be done to ICF Drg. No.MGfT-1-5-046.

3.2.11 Battery box frames:

To prevent corrosion due to acid from battery coming in contact with batteryboxes, battery boxes should be fitted with FRP trays, if not already done.

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Technical PamphletNo. CMI-KJ02

3.2.12 Vacuum Reservoir Suspension Arrangement:

In order to prevent falling of vacuum reservoirs due to slackening of thesuspension straps as also of dislodging of the reservoirs due to jerks during run,the reservoir suspension arrangement was modified to provide (i) loop typelocating lugs on the reservoir, (ii) replacing the timber packing between thereservoir and the under frame by steel supporting pads permanently welded tothe under frame and (iii) increasing the size of the straps. Also to overcome theproblem of corrosion occurring on the contact surface between the strap and thereservoir, a layer of FRP tissue has been pasted around the reservoir over thesurface of contact using bituminous emulsion. The above modifications areincorporated in ROSa Sk.-K3012. These modifications should be carried outon all coaches during corrosion repairs, if not already done as detailed inAnnexure-XII.

_, 4.0 PROCEDURE FOR CORROSION REPAIRS:

Detailed procedure for corrosion repairs of various members are given inAnnexures and relevant drawings as indicated in the following table:-

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S.N. Part Annexure Reference drg.1 Stiffenina of Solebar I 79193 to 791952 Sole bar II 76077, 760783 Side wall sheet, body pillars & turn unders III 76079,801774 Trouoh floor IV 76080 to 760825 Head stock V -

6 End walls and End wall stanchions VI 760847 Roof sheet around ventilators VII 760858 Body side doors VIII 760299 Seat pillars and partition walls IX 7608610 Longitudinal partition walls in 1~ class X 76087

coaches11 Procedure for lying of fibre glass tissue on XI K3009

coach shells12 Modification to vacuum reservoir XII K3012

suspension arranaement

4.1 Wherever a portion of the sole bar is to be replaced during corrosion repair, thebottom portion of side wall pillars at this location, should also simultaneously bereplaced.

4.2 Corrosion repairs are required to be carried out to the best standard ofworkmanship. Trained and experienced welders should be deputed for carryingout welding under careful supervision of qualified welding supervisors. Suitablearrangement should be made for dry storage of electrodes. Approved brands ofclass 0-2 electrodes for corten steel to IRS-M-41-97 and class C2 electrodes forother mild steel suitable for vertical and overhead welding should only be used

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Techoical PamphletNo. CMl-K302

for corrosion repairs. Reference may be made in this connection to the approvedbrands of electrodes issued by RDSO. Procedure detailed in 'Code of Practicefor painting of all metal coaches' should be followed for cleaning and painting ofsurfaces, which are attended to during corrosion repairs. Effective supervisionand inspection should be introduced at all important stages of corrosion rep,.irs.

5. DOCUMENTATION:

After corrosion repairs are completed particulars should be entered in the CheckLists. The Check Lists shown on Sketch Nos. K3010, K3011, 76088, 7E;089,76090 pertaining to coaches, which are on line in large number and are typical.Suitable changes in the list may be made to suit other types of coach'3s. Adiagram of the coach in standard A-4 size should be marked suitably to indicatethe parts of the shell replaced during corrosion repair with specific details of thelocation and extent of corrosion. The diagram and the check list should b" filedin a fold"r maintained for each coach.

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ANNEXURE -I

1.0 INSTRUCTIONS FOR STIFFENING OF SOLE BAR:

1.1 Middle doorways of 3 doors aside shell and Middle doorways of SLRshell- (Refer RDSa Sketch - 79193)

1.1.1 Support the coach body at the body bolsters.

1.1.2 Remove the foot boards.

1.1.3 Remove the step sheets for the foot board and modify the same as shown asdetail 'Y' in Sketch - 79193.

Cut off Ihe side wall sheet 10 a height of 300 mm to 500 mm and to a length of500 mm on either side of doorways.

Cut off the door corner sheets and doorway pillars to a height of 300.

Prepare the sale bar stiffener and weld as shown in the Sketch - 79193.

Prepare door corner sheets and doorway part pillars as shown at detail 'Z' inSketch - 79193

Weld doorway part pillars and corner sheets to the existing pillars and cornersheets and to the sale bar stiffeners as shown at section 'M' in SK. - 79193.Weld sidewall sheet as explained in Annexure III.

Clean and paint. Parts I sub-assembly, which would become inaccessible afterassembly I welding should be properly cleaned and painted before assembling.

(Refer RDSa Sketch - 79194)

Luggage compartment doorways of SLR coaches

Support the coach body at the body bolsters.

Remove the footboards and step sheets, if not already done earlier.

Cut off the side wall sheet to a height of 300 mm to 500 mm and to a length of300 mm on body bolster side and 500 mm on the other side of doorways ofluggage compartments.

1.2.4 Cut off the door corner sheets and doorway pillars to a height of 300 mm.

1.2.5 Prepare the sale bar stiffener, cover plates and closing pieces and weld asshown in the sketch.

1.2

'01.2.1

1.2.2

., 1.2.3-

1.2.6 Prepare door corner sheets and doorway part pillars as shown at detail 'X'.

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Technical PamphletNo. CMJ-K302

1.2.7 Weld doorway part pillars and comer sheets to the existing pillars and GOmersheets and to the sale bar stiffeners as shown at section 'AA'. Weld sidewallsheet as explained in Annexure III.

1.2.8 Clean and paint Parts I sub-assemblies, which would become inaccessible afterassembly I welding should be properly cleaned and painted before assembling.

Note: Foot-Boards are· not to be provided for the doorways of luggage campa/tments.

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Technical PamphletNo. CMI-KJ02

ANNEXURE • II

1.0 INSTRUCTIONS FOR CORROSION REPAIR OF SOLE BAR.

1.1 At locations other than the lifting pads and bolster:

(Refer RDSO Sketch· 76077)

1.1.1 Support the coach body on bolster as shown in sketch.

1.1.2 Support the coach body near the sale bar portion under replacement through thewindow opening on wooden struts as shown in Section 'AA' of the sketch.

1.1.3 Provide additional wooden supports on either side of the sale bar to be cut asshown in the sketch.

1.1.4 Cut off the side wall sheets and turn under to a height of 300 mm to 500 mmcovering length of approximately 200 mm on either side of the sale bar to bereplaced.

1.1.5 Cut off the trough floor, cross bearers and body side pillars at the loeationswhere the sale bar portion is to be renewed. Ensure that cross bearers are notdamaged.

1.1.6 Cut off the sale bar and grind the edges and prepare for a 'V' Butt joint as shownin the Sketch.

1.1.7 Prepare a new sale bar piece of the requisite length with edges suitable for a 'V'Butt joint.

1.1.8 Tack weld the new sale bar piece at both ends.

1.1.9 Check and ensure straightness of the sale bar and overall alignment.

1.1.10 Tack weld cross bearers, if any, to the new sale bar piece.

1.1.11 Weld both ends of the sale bar.

1.1.12 Weld cross bearers, support piece and trough floor.

1.1.13 Weld new body pillar part, sidewall sheet and turn under as detailed inAnnexure III. These components also require replacement whenever a part ofsale bar is replaced for corrosion.

Note: i) If sale bar of length more than 2400 mm requires replacement, the sameshould be done in lengths not exceeding 2400 mm at each stage.

ii) If sale bars are to be replaced on both sides, the joints must be staggered andboth ends should not be attended to simultaneously.

iii) If the sale bar at head stock loeation requires renewal, the sale bar to adistance of 300 mm towards body bolster from the inner head stock should alsobe replaced as shown in detail 'X'.

Page 15 of34

Technical PamphletNo. CMI-K302

1.2 At Body Bolster and lifting pad locations:

(Refer ROSa Sketch -76078)

1.2.1 Support coach body on the body bolster, where sale bar is not to b,g attended to.

1.2.2 Support coach body on wooden trestles on both the sides of the bolster wheresale bar is to be replaced as shown in the Sketch.

1.2.3 Support the superstructure of the coach body through the window openingswhere the sale bar is to be cut, as shown in Section 'AA' of Sketch -76077.

1.2.4 Cut off sidewall sheets with turn under to a height of 300 mm to 500 mm andside wall pillars to a height of 300 mm in the area where sale bar is underreplacement.

1.2.5 Tack weld temporary mild steel stays to the body bolster and sale bar and bodybolster and inner head stock as shown in Sketch, The location on the sale barshould be reasonably away from the point where, it is to be cut for replacement.

1.2.6 Cut the cross bearers, if any, attached to the sale bar portion to be lCenewed.

1.2.7 Cut off the trough floor to a distance of 180 mm from sale bar and to a length of600 mm in the bolster area.

1.2.8 Cut the sale bar to a distance of approXimately 200 mm away from the point ofreplacement and prepare the edges for a 'V. butt weld joint as shown in Sketch ­76077. Care should be exercised not to damage the body bolster "hen cuttingoff the sale bar. Carefully grind the body bolster without damaged

1.2.9 Tack weld a new piece of sale bar whose edges are similarly prepared for a 'V'butt weld.

1.2.10 Weld packing piece (ICF Drg. No.MGIT-1-1-D16) to the soJe bar as shown insection 'AA' of Sketch - 76078.

1.2.11 Weld the sale bar on either side after ensuring straightness and overallalignment.

1.2.12 Weld body bolster to the new sale bar.

1.2.13 In case of damage to the edges of the body bolster or if any part of the bodybolster near the sale bar is to be replaced for corrosion, the following proceduremay be adopted: -

a) Cut off the trough floor to a distance of 350 mm from the sale bal' and to alength of 600 mm in the bolster area. Cut the top plate, bottom plate and websof the booty bolster to the dimensions shown in section '66'.

b) Prepare a new sale bar of the required length. Weld the two web pielces (item1) to the new sale bar piece.

c) Weld rib (item 2) to the two web pieces (item 1).

d) Weld packing piece (ICF Drawing No. MGfT-1-1-016) to the sale bar asshown in Section '66'.

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e) Tack weld the sale bar piece on both sides and check for straightness andoverall alignment of the sale bar and body bolster web pieces.

f) Full weld the sale bar piece on either side.

g) Weld the body bolster web piece's (item 1) to the webs of the body bolster atan angle as shown in Section 'BB'·

h) Weld the bottom flange of the body bolster (item 3) to the sale bar and thebody bolster as shown in Section 'BB'.

i) Weld rib (item 2) to the bottom flange (item 3).

j) Weld the top flange piece (item 4) to the body bolster and sale bar.

k) Weld trough floor to the support piece.

1.2.14 Weld new body pillars turn-under and sidewall as explained in Annexure-III

Notes- i) If sale bars are to be replaced on both sides of the body bolster, the jointsshould be staggered, and both ends of the body bolster should not be, attendedto simultaneously.

ii) Renewal of the sale bar near the body bolster should be taken at the laststage after renewing the sale bar, if need be at other locations.

. , 1.3 At lifting pad locations (Refer RDSa Sketch - 76078), '.

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1.3.1 Follow instructions enumerated at 1.1 above for replacement of the sale barportion.

1.3.2 Before welding the turn-under and side wall sheet, weld the modified lifting padas shown in Section 'CC' of Sketch - 76078.

Page 17 of34

Technical PamphletNo. CMl-K302

ANNEXURE - III

1. INSTRUCTIONS FOR CORROSION REPAIRS OF SIDE WALL SHEETS,BODY PILLARS & TURN UNDER.

(Refer RDSO Sketch - 76079 & 76014)

1.1 Renewal of sidewall sheets.

1.1.1 Support coach body at body bolsters.

1.1.2 Cut the sidewall sheet requiring replacement and grind the burnt edges.

1.1.3 Prepare a new side wall sheet with 5 mm diameter holes at appropriate locationsfor plug welding, to the .side wall pillars when required and tack weld the sameon all the four sides.

1.1.4 Check the sidewall for straightness and ensure overall alignment.

1.1.5 Weld the side wall sheets on all four sides and plug weld the same to body sidepillars, if the inside panelling and flooring have not been removed for any otherpurpose in case the inside panelling and trough floor have been removed forsome other purpose, side wall sheets may be welded with the body pillars frominside as shown in Section 'M' of the Sketch and plug welding avoided.

1.1.6 Grind flush the welded joints on all the four sides to obtain a smooth exteriorfinish.

1.1.7 In case pillars are renewed, FRP tissue paper should be pasted.

1.2 Renewal of Body Pillars:

(Refer RDSO Sketch - 76079)

1.2.1 Support the coach body on the body bolsters.

1.2.2 Remove the inside panels, flooring and floor side mouldings to gain access tothe body pillars.

1.2.3 Cut off the turn under and side wall sheet up to suffcient height so as to fullyexpose the corroded body pillars.

1.2.4 Cut off alternate body pillars on the same side to a height of approximately 320mm or 410 mm or 500 mm as the need may be, as shown in tho sketchexercising care to ensure that the sale bar is not damaged. Prepare the edge ofpillar for 'V' butt-welding.

1.2.5 Clean the surface of the sale bar thoroughly of rust etc.

1.2.6 Tack welds the new body pillar part to the pillar and sale bar.

1.2.7 Check and ensure straightness and alignment of the body pillars.Page 18 of34

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1.2.8 Full weld the body pillar part to the pillar and sole bar.

1.2.9 Cut off the remaining body pillars and attend to them in like manner as indicatedabove.

-. 1.2.10 Replace the body sidewall sheet as indicated in Para 1.1 above.

1.2.11 Clean and paint the inner surface of the replaced sidewall and body pillars.

1.2.12 Replace floor side moulding as shown in the Sketch and relay flooring.

1.2.13 Replace inside panel.

1.3 Renewal of Tum Unders: (Refer RDSa Sketch - 80177)

1.3.1 Support coach body on the bolsters.

1.3.2 Cut off side wall sheet also to a height of 300 mm to 500 mm to the 'requiredlength.

1.3.3 Clean the surface of the sale bar thoroughly of rust etc. to the bare metal andensure there is no corrosion on the sole bar.

1.3.4 Prepare a new lurn-under (see nole NO.2 below) 10 the length required withedges prepared for a 'V' Butt joint and tack weld the same to the body pillars andbottom of the sale bar.

1.3.5 Check the turn under for straightness.

1.3.6 Weld intermittently the body pillars to the turn under.

1.3.7 Replace the sidewall sheets as given in Para 1.1 above.

Note: 1. Whenever longer length of side wall sheet or turn under is replaced the skinshould be properly tensioned by spot heating before giving anti-corrosivetreatment.

2. The new turn under part should be compatible with the existing turn under onthe coach viz.: -

(i) For a coach with 5 mm thick turn under with elongated holes, the new partshould also be of 5 mm thickness with elongated holes as shown in SK. - 80177and

(ii) For a coach with 2 mm thick turn under, the new part should be of 2 mmthickness without holes and all other dimension as per SK. - 80177.

Page 19 of34

Technical PamphletNo. CMJ-K302

ANNEXURI:- IV

1. INSTRUCTIONS FOR CORROSION REPAIR OF TROUGH FLOOR.

1.1 End Lavatories of 2 door and 3 door aside shell.

(Refer RDSa SK - 76080)

1.1.1 Cut the trough floor below end lavatories to a distance of 676 mm from the innerheadstock and ensure a straight edge of the trough floor.

1.1.2 Clean the paint and rust, if any, on the adjacent portions of inner head stock andtrough floor.

1.1.3 Weld four locating angles of 30 X 30 X 3.2 mm (width 30 mm) as shown in theSketch, to the tubular frame plate and check for straightness

1.1.4 Weld one locating rectangular flat ( item 1) of size 60 x 60 x 8 mm to the ex:istingcross channel as shown in the Sketch.

1.1.5 Prepare the two tubular sub-assemblies in separate jigs.

1.1.6 Tack welds tubular assemblies to the trough floor and inner headstock as shownin the sketch.

1.1.7 Ensure proper alignment of the tubular frame assembly with that of the troughfloor and overall straightness.

-1.1.8 Full weld the tubular frame assembly to the inner head stock and trough floor.

1.1.9 Weld the cross bearer channel 60 x 14 x 3.2 mm at the location shown in thesketch.

1.1.10 Clean and paint tubular frame assembly.

1.2 Middle lavatories of 3 door aside shell:

(Refer RDSa Sketch - 76081 )

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••1.2.1 Cut off the trough floor below the middle lavatories starting from 370 mm

distance from cross member at mid of middle door way to a distance of 1140mm and grind trough floor surfaces straight.

1.2.2 Clean paint and rust if any in the adjacent portions of trough floor.

1.2.3 Prepare the sub-assemblies of the tubular floor in separate jigs.

1.2.~ Relocate the position of one cross bearer and put a new cross bearer a's shownin the sketch.

1.2.5 Tack weld the tubular frame on the under frame.

Page 20 of34

Technical PamphletNo. CMI-K302

1.2.6

1.3.1

1.3.2

1.3.3

1.3.4

1.2.7

1.2.8

1.2.9

1.3

1.3.5

1.3.6

1.3.7

Ensure alignment of the tubular frame with that of the trough floor and overallstraightness.

Full weld the tubular frame to the trough floor.

Weld supporting frame on the tubular frame as shown.

Clean and paint the tubular frame assembly.

Guard lavatories of SLR Coaches:

(Refer RDSa Sketch - 76082)

Cut off trough floor below Guard lavatories to a distance of 845 mm from thehead stock towards body bolster.

Clean the paint and rust if any, in the adjacent parts of the bolster and troughfloor.

Weld item -1 of size 60 x 60 x 8 mm on cross bearer as shown in the sketch.

Weld four locating angles 30 x 30 x 3.2 mm (width 30 mm) as shown in thesketch on plate of tubular frame and check for straightness.

Prepare the new tubular sub-assemblies in separate jigs.

Tack weld the tubular assemblies to the under frame as shown in the sketch.

Check and ensure alignment of the tubular frame with that of the adjoiningtrough floor and overall straightness.

Full weld the tubular frame to trough floor.

Weld one cross channel 80 x 14 x 3.2 mm and another cross channel 60 x 14 x3.2 on tubular frame as shown in the sketch.

1.3.10 Weld a channel 155 x 14 x 3.2 mm as shown in section 'CC' in the sketch.

1.3.11 Clean and paint the tubular frame assembly.

1.3.8

1.3.9

1.4 Trough noor at other locations:

1.4.1 Cut off the corroded trough floor to a length and width required.

1.4.2 Weld isolating plate of 5 mm thick transversely after grinding the edge of troughfloor straight

1.4.3 Prepare a new trough floor to the dimensions required and tack weld the sameto the isolating plates on either side.

1.4.4 Ensure proper alignment of the replaced part with that of the adjoining parts.

1.4.5 Full weld trough floor to the isolating plates both at top and bottom.

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Technical PamphletNo. CMl-KJ02

1.4.6 Weld intermittently the trough floor longitudinally to the supporting piec<, andadjoining trough floor. Ensure the alignment in the longitudinal direction bysuitably cutting off the trough floor to match with the new trough floor.

1.4.7 Drill 19 mm diameter holes in the Valleys between two isolating plates.

1.4.8 Clean and paint.

1.5 Trough floor below luggage compartment of SLRs, LRs etc. & Baysadjacent to lavatories under doorways:-

1.5.1 Attend to corroded floor as detailed at Para 1.1 above.

1.5.2 Provide 40x5 mm thick isolating plates between the trough floors below theluggage compartment and the adjacent passenger compartments or tine bayadjacent to lavatory below doorway and the next way, as the case may be. .•Paste FRP tissue over the trough floor, adjoining areas of sole bar, side wall,body pillars upto waist Rail level and cross bearer, following the procedure aslaid down in annexure-XI. "f./

Note: - If during corrosion repairs whole length of the trough floor needs replacement, inthat event the trough floor, sole bars, side walls and body pillars up to ",aist Raillevel and cross bearer should be pasted with FRP tissues follov~ng theprocedure as laid down in annexure-XI.

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ANNEXURE·V

1. INSTRUCTIONS FOR CORROSION REPAIRS TO HEAD STOCK

1.1 Outer Head Stock:

1.1.1 If corrosion on head stock is significant lhen dismantle the ABC and remove thefloor moulding, end wall panel, flooring and timber floor / plywood PVC flooringto a distance of 300 mm in lavatories and up to the supporting member in thegangway for plywood PVC flooring / 300 mm for decolite flooring.

• 1.1.2 Support the anti-telescopic stanchions at the bottom and sole bar on suitablewooden stands.

~.1.1.3 Gas cut the end wall sheet, ensuring that no damage is caused to the anti-

telescopic stanchions, sole bar etc.

11.4 Patch 5mm sheet on cover sheet (LH / RH / Outer / Inner), bottom plate (LH /RH) etc. whichever are corroded.

1.1.5 If corrosion is very heavy, gas cut corroded plate and replace with a plate of., required thickness (6mm /8mm /12mm).

1.1.6 Before full welding check the overall alignment of headstock then welding shouldbe completed.

1.1.7 Clean and paint.

1.1.8 Weld a new end wall sheet as required..,.1.1.9 Clean and paint.\

1.1.10 Relay flooring and refix the end wall panels and floor mouldings.

1.2 Inner Head Stock:

1.2.1 Apply same procedure as detailed in 1.1 above.

Page 23 of 34

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1.1.1

1.1.2

Technical PamphletNo. CMI-K302

ANNEXURE - VI

INSTRUCTIONS FOR CORROSION REPAIR OF END WALLS AND END WALLSTANCHIONS.

(Refer ROSO Sketch No 76084)

End wall sheet

Cut the ccrroded end wall sheet as required.

If the end stanchions are not corroded, replace the corroded part of the end wallsheet.

1.1.3 Clean and paint.

1.2 End Wall Stanchions:

1.2.1 Remove the floor moulding, end wall panel, flooring ccmposition and timber floorIpiywood PVC flooring to a distance of 300 mm from the end wall.

1.2.2 Cut off the corroded end wall stanchions and grind the cut surface square.

1.2.3 Prepare a new end stanchion as shown in the sketch.

1.2.4 Tack weld the same to the head stock and to the end stanchions.

1.2.5 Ensure proper alignment.

1.2.6 Full weld the end stanchions as shown.

Note: - i) If the head stock is also ccrroded and requires repair, the same shouid beattended to first as described in Annexure ''V" before replacement of thecorroded end stanchions.

ii) ICF have turned out ccaches with end stanchions formed out of 4 mm thicksheet to IRS-M-41 instead of 5 mm plate. The replacement of end stanchionsshould, therefore, be with 4 mm or 5 mm thickness according to the stanchionremoved.

1.2.7 Clean and paint.

1.2.8 Relay the flooring.

1.2.9 Replace the end wall panels and floor moulding.

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ANNEXURE - VII

1.' INSTRUCTIONS FOR CORROSION REPAIR OF ROOF SHEET AROUNDVENTILATORS.

(Refer RDSa Sketch No. 76085)

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1.1

1.1.1

112

1.1.3

1.1.4

1.1.5

1.1.6

1.17

Oriental Type Ventilators:

Remove the air-<tuct casing below the roof ventilators and insulating material.

Cut off the corroded ventilator base and replace the same if no corrosion isnoticed on the roof sheet.

If corrosion in the roof sheet is noticed, cut off the roof sheet around theventiiator as shown in RDSa sketch and grind the edges straight.

Prepare a new roof sheet vvlh ventilator base and weld the same in position.

Apply the insulating material.

Clean and paint.

Re-fix air duct casing.

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Technical PamphletNo. CMl-K302

ANNEXURE - VIII

INSTRUCTIONS FOR CORROSION REPAIRS OF BODY SIDE DOORS

(Refer RDSa Sketch - 76029)

1.1 Remove the body side door and place the same on a suitable stand,

1.2 Set louver and glass shutters in raised position.

1.3 Remove the inside bottom panel.

1.4 Check for corrosion of outer panels etc.

1.5 If corrosion is light, scrap off rust to bare metal.

1.6 Clean and paints

1.7 If corrosion is heavy, gas cut the corroded parts and grind the edges straight

1.8 Prepare a new panel along with the modified stiffener as shown in detail "X".

1.9 Butt weld the outer panel to the existing panel along with the stiffeners.

1.10 Clean and paint

1.11 Prepare a new inner panel as shown in detail "X" and secure the same to thebody side door by self-tapping screws.

1.12 If the curved portion of the outer panel and pillar are corroded, the corrodedportions should be cut and replaced by Butt-welding patch plates and then weldground smooth outside.

Note: Body side doors of coaches manufactured since 1961 have been modified byproviding an open bottom to avoid incidence of corrosion. Body side doors ofcoaches built earlier have bottom stiffener. This bottom stiffener should beremoved whenever attention is required for the body side doors andmodifications referred I shown in Sketch -76029, be incorporated.

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ANNEXURE ·IX

INSTRUCTIONS FOR CORROSION REPAIRS OF SEAT PILLARS OF PARTITIONWALLS.

(Refer RDSO Sketch - 76086)

Seat Pillars in coaches with oxychloride flooring.

If corrosion at the bottom of the seat pillars is light, scrape off the rust to baremetal, clean well and re-paint.

If corrosion is heavy, remove the oxy-chloride flooring around the pillar to adistance of 220 x 300 mm and the timber floor (2 slats) to a length of 100 mm oneither side.

Cut off the corroded pillar to a height of 150 mm from bottom of the supportingchannel.

Prepare a new pillar as shown in Section 'M' and to a height of 150 mm with abase to ICF Drawing No.T-1-0-<j25 and weld the new pillar to the supportingchannel and pillar.

1.1.5 Prepare supporting plates items 1 & 2 as shown in sketch and weld the same tothe supporting channel and to the replaced pillar part.

1.1.6 Secure the existing timber floor with the supporting by means of CSK headedscrelNS as shown.

1.1.7 Provide timber packing around the pillar to replace the cut out timber flooringand secure the same by means of CSK headed screws as shown in the sketch.

1.1.8 Relay the decolite flooring and weld the base plate to the pillar at the bottom.

1.1.9 Clean and paint.

1.2. Seat pillars in coaches with PVC flooring

1.2.1 If the corrosion at the bottom of the seat pillars is light, scrape off the rust to baremetal, clean well and re-paint.

1.2.2 If the corrosion is heavy remove the PVC sheets at the location of corroded pillarto such an extent that underneath plywood board is exposed completely up tosupport points (refer ICF I SK. 4-1-135).

1.2.3 Remove the fixing screws of plywood board and lift it from its position.

1.2.4 Cut off the corroded pillar to a height of 150 mm from the bottom of thesupporting channel.

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Technical PampWetNo. CMI-K302

1.2.5 Prepare a new pillar as shown in section OM" and to a height of 150 mm with abase to ICF Drg. No. T-1-0-825 and weld the new pillar to the supportingchannel and pillar. Clean and paint

1.2.6 Pr.epar.e a cover. for seat pillar. to ICF Drg. No. T-4-1-131 for. single seat sleeve "fr.ame to item 37 of ICF f SK. 4-1-135.

1.2.7 Follow the procedur.e for r.epairing PVC floor.ing of ICF I RCF built coaches toC-8701 for. reiaying the floor.ing.

1.3 Partition walls in coaches with oxychloride flooring:

1.3.1 Remove the decolile skirting and panel on both the sides. •

1.3.2 If cor.rosion is light, scrape off r.ust to bar.e metal, clean and re-paint, r.eplacepanelling and floor. and skirting,

1.3.3 If cor.rosion is heavy, cut off the oxy-chlor.ide floor.ing to a distance of 130 mm x •240 mm around the corroded pillars.

1.3.4 Remove the timber. slat to a distance of 160 mm (width 90 mm)

1.3.5 Cut off the cor.r.oded piliar. to a height of 150 mm from the bottom and gr.ind theedges of the pi liar square.

1.3.6 Pr.epar.e a new piliar as shown in Section 'FF' and weld the same to thesupporting channel and piliar.

1.3.7 Pr.epar.e supporting plate item 3, weld the same to the supporting channel andthe pillar..

1,3,8 Secur.e the timber. floor. to the supporting pieces by CSK headed screws asshown,

..

1,3,9 Insert a timber. Plugd

diPpetd ifn bitutmen tdiglhtlYdto thte chbannel aStShOWn,in Section _.•"DD" to pr.event 10 gmen a wa er. an ea Ing a su sequen corrOSion,

1,3.10 Replace the eut out timber. floor by means of a wooden packing and seeur.e thesame to the supporting piece by CSK headed scr.ews as shown in Section 'DD'.

1.3.11 Clean and paint

1,3.12 Relay the timber floor., r.eplace the panel and the skirting on both the sides andr.eplace the joint mouldings.

Page 28 of 34

1.4-.1.4.1

, 1.4.2

1.43

•

Technical PamphletNo. CMI-K302

Partition walls in coaches with PVC I Plywood flooring:

Remove the PVC skirting and panel on both the sides.

If corrosion is light, scrape off rust to bare metal, clean and re-paint, replacepaneling and PVC skirting,

If corrosion is heavy, remove the PVC sheets to such an extent that theundemeath plywood board is exposed completely up to support points (referICFISK-4-1-135)

I

•

. ,

.

-

1.4.4 Remove the fixing screws of plywood board and lift it from its position.

1.4.5 Cut off the corroded pillar to a height of 150 mm from the bottom and grind theedges of the pillar square.

1.4.6 Prepare a new pillar as shown in Section 'GG' of Sk. - 76086 and weld the sameto the supporting channel and pillar.

1.4.7 Prepare supporting plate, item 3 of Sk. - 76086, weld the same to the supportingchannel and the pillar.

1.48 Clean and paint.

1.49 Follow the procedure for repairing PVC flooring of ICF built coaches to C-8701.

Page 29 of3:\.

1.

Technical PamphletNo. CMI-K302

ANNEXUI~E - X

INSTRUCTIONS FOR CORROSION REPAIR FOR LONGITUDINALPARTITION IN FIRST CLASS COACHES.

(Refer ROSa Sketch - 76087)

1.1 Remove the guide, rail, joint moulding and panelling.

1.2 If corrosion of the sleel members is light, scrape off rust. Insert a timber packingdipped in bitumen at the bottom on the partition pillars to avoid lodgement ofwater leading to SUbsequent corrosion.

1.3 Replace the decolite fioor, extend the same right upto partition as shown insection' CC' of the sketch.

1.4 Replace the panelling, J moulding and guide rail after inserting the klingaritepacking as shown in the sketch.

Note:

i) Attend the transverse partition on similar lines, if corrosion is noticed in thepillars.

ii) If the corrosion in the pillar is heavy, the corroded pillars should be cut to aheight of 150 mm from the supporting channels after removing the timber floorboards and replaced.

Page 30 of 34

•

, .

'.

Technical PamphletNo. CMJ-K302

.,ANNEXURE - XI

-.1.0 PROCEDURE FOR LAYING OF FIBER GLASS TISSUE ON COACH SHELL

(Refer RDSO SK.- K3009)

Proper binding of fibre glass tissue over the surface should be ensured and careshould be taken to see that no air pockets are left while laying the FRP tissue.

Immediately after laying the FRP tissues, bituminous emulsion grade - II to IRSSpecification P-30-96 should be applied as a final coat.

Pierce through the drain holes in the trough floor (except the drain holes indoorway area) from top, immediately after laying the FRP tissues, and touch upwith bituminous emulsion.

One coat of bituminous emulsion grade - I to IRS specification P-30-96 shouldbe applied on the areas as shown and allowed to dry for 8 Hrs.

A second coat of bituminous emulsion grade - I to IRS specification P-30-96should then be applied (some quantity of'ROZ' primer should be mixed up withbituminous emulsion for obtaining a different colour to identify the second coat).

Lay fibre glass tissue to specification ICFIM/D/Spec.027 over the second coat ofbituminous emulsion while it is wet.

1.1.1 Scrap off rust and remove oil, grease & dust.

Apply "ROZ" Primer conforming to IS: 2074-92 to ensure a dry film thickness of40 microns minimum.

1.2

,1.3

1.4•~

1.5

1.6

. ~ 1.7

,1.8

1.9

••1.10

·•

• 1.11

Apply a fourth coat of bituminous emulsion grade - I to IRS Specification P-30-96on the trough floor in the doorways area and the 65 mm dia tubes below theadjoining lavatory area and allow it to dry for 8 Hrs.

A fifth coat of bituminous emulsion grade - I to IRS specification P-30-96 shouldnow be applied (Mix some quantity of 'ROZ' primer with bituminous emulsion forobtaining different colour to identify the fifth coat).

Fibre glass tissue to specification ICF/MJD/spec.027 should be laid over thebituminous emulsion of fifth coat, while it is in wet condition, ensuring properbonding and taking care that no air pocket is left.

1.12 Pierce the drain holes in the trough floor from top and in the tubes from bottomimmediately after laying the FRP tissues and touch up with bituminous emulsion.

Note:-The total dry film thickness of bituminous emulsion should be 0.5 mm minimumexcluding the thickness of red oxide primer.

p."gc 31 of 34

•

Technical PamphletNo. CMJ-K302

ANNEXURE - XII

••

..1.0 MODIFICATION TO VACUUM RESERVOIR SUSPENSION ARRANGEMENT

(Refer RDSO Sketch - K3012)

1.1 Extra pads to be welded on the reservoir, if required, to weld strip for passin'lsuspension strap.

1.2 Strips for passing suspension strap to be welded over the pads. Pads should besuitably repositioned if necessary.

1.3 Suspension brackets to be welded to the under frame.

1.4 Timber packing should be replaced by steel support.

1.5 Laying of FRP Tissue.

1.5.1 A 100 mm width of the vacuum reservoir where it is in contact with thesuspension straps, should be thoroughly cleaned.

1.5.2 After cleaning apply one coat of zinc chromate red oxide primer to IRS P-3'1-71or to IS:2074-92 and allow it to dry. • .

1.5.3 After the 'ROl' primer has dried apply a thick coat of bituminous emulsion to IRSP-30-96. '

1.5.4 A 100 mm wide layer of fibre glass lissue to specification ICF/M/D/Spec.027should be pasted around the reservoir over the bituminous emulsion while it is inwet condition and allow to dry.

1.6 Mount the reservoir on the under frame, bolting the straps to the bracketsthrough spring washers, nuts and lock nuts.

Page 32 of 34

•••

..."

,

•,

(,

••

••

Technical PamphletNo. CMI-K302

ANNEXURE - XIII

SPECIFICATIONS FOR MATERIALS USED IN CORROSION REPAIRS OF SHELL.

S.No. ITEM SPECIFICATION No.

1 Steel sheets for manufacture of

1.1 Trough floor 2mm for IRS: M-41-97 Gr. I, 1.7mm for Austenitic stainless steel.

1.2 Pillars, sidewall sheet, light rail, waist rail 2 mm for IRS: M-41-97 Gr. Iand end wall sheet.

1.3 Carline 2 mm for IRS: M-41-97 Gr. I

1.4 Roof sheet and longitudinal stiffener 1.6 mm for IRS: M-41-97 Gr. I

1.5 Canl rail and Ribs 3.15 mm for IRS: M-41-97 Gr. I

1.6 Other structural members IRS: M-41-97 Gr. I

2 Steel plates for manufacture of

21 Sole bars and turn under 5 mm for IRS: M-41-97 Gr. I

2.2 Cross bearers above and below trough 4 mm for IRS: M-41-97 Gr. Ifloor, end wall stanchions

2.3 Headstock 5,6,8,12 mm for IRS:M-41-97 Gr.1

2.4 Other structural members like sole bar IRS: M-41-97 Gr. Istiffeners

.3 Tubes for tubular frame below lavatory IS: 1239-90 Pt. 1, Tab. 3

4 Non-Structural members

4.1 Sheets like skirting plate for reservoirs IRS: M-41-97 Gr.1and floor side moulding

4.2 Plales IRS: M-41-97 Gr.1

5 Red Oxide zinc chromate primer paint IS:2074-92 or IRS: P-31-71

6 Bituminous anti-corrosjYe paint, solution IRS: P·29-<38type brushing quality

7 Bituminous emulsion paint IRS: P-30-96, IS:158-<31

8 Electrodes

a) For IRS M-41 Class 02 of approved brand ofelectrodes.

b) Other mild steel Class C2 of approved brand ofelectrodes

Page]] of34

Technical PamphletNo. CMI-K302

c) For Stainless steel i) E-124 & Sperinox 1-A of MisAdvani Oer/icon ltd.

ii) 'EUTECSTAINROD A-Mo-L' ofMis Larsen & Toubro ltd.

iii) Philips RS-304 or Philips RSSof Mis Philips

9 Flooring composition IS:254-73 Grade 3

10 Plywood IS: 303-89 EWR AA quality

11 Compreg C-9407

12 PVC sheet C-8515

13 Adhesive Dunlop adhesive S-758 or anybitumen rubber emulsion similarto approved brand S-758

14 Water proof sealing compound IS 1580-91

15 FRP tissue ICF Specification No. ICF/M/DISpec. 0.27

• Provided these are well-seasoned.

Page 34 or 34

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COACH No, ; TYPE OF COACH;

OWNING RAILWAY DATE or BUILT ;

LAST POH ; DATE or ATTENTION .

79 75 73 7' 69 ~ 65 63 6' 59 ~ 55 53 ~ 49 47 45

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PROFORt.lA)i DETAILS OF INSPECTION & CORROSION REPAIRS (FILL INI

ICORROSION REPAIRS NOMI- CORROSION REPAIRS COST OF CORROSION REPAIRSNATED AFTER INSPECTION ACTUALLY EFFECTED INCLUDING OVER-HEADS'

5 No. DESCRIPTION FROM PILLAR No. TO FROM PILLAR No, TOPILLAR No, INDICATE HEIGHT PILLAR No. INDICATE HEIGHT

LABOUR MATERIAL TOTALFROM SOLE BAR BODOM FROM SOLE BAR BODOM REMARKS,

I FOR S- No, 1 & 2 ONLY FOR S No, 1 & 2 ONLY

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AS RESULT OF CORROSION INSPECTION/REPAIRS TOTAL COST

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ICF IRCF COACHES,

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pf\OCEDURE FOR LAYING OF FRP TiSSUE ShALL 'BE AS DESCRIBED

IN TECHNICAL PAMPHLET No. CMI-K302, ANNEXURE XII.

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