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NSTRUCTIONS FOR CORRO::ll()r'~-­.OF ICF GUILT B.G. E~~'1lJ

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Technical pa;nphlet No. C-7715

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Corrosion _r~pail"s

Documentation

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B:"No • ,::--DescriQti2!!__----.;-_- ­. _­1. Corrosion repair of solebar at

Body Bolster.

2. . Corrosion repair of solebar at doorways.

3· .Arrangement of tread plate at doorway to avoid corrosion.

4. Modification to the existing cover sheet- Motor Coadl.

Modification to the existing cover sheet-trailer coach.

Corrosion repairs of trough floor.

Corrosion repair of roof sheet .~round ventilator. - ­

8. Corrosion repair of body panelsand door pockets.

Window sealing arrangement

10. Corrosion repair of rain water gutter.

11. Check list for inspection and- record of corrosion repairs-Non drivingtrai ler (reF).

12. -do': Motor coach'Bt ac (lCF)

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NQ-.--_-AI-t:No •_

77081

77082

.. 7i083

.77174

77J.75

77J76

77J.77

77J78

··77l79

77180

77181

77J.82" .

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Nil

Nil

Nil

Nil

Nil

'Nil

Nil

Nil

\Nil \13. -do- Dri-o:i ng Motor coacl1- ac (rCF) 77183 Nil

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14. -do- Motor coach'B';dc(lCF) 77184 Nl1

15. -do- Driving trailer AID (lCF) 77185 N:tl

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Instruc£ions-for~'co'~r6s10n-:'rePa1r" o'f; ICFbUilt ", ~'~:~;:i~:~ ~;,!.~', .' E=-.=.:N:.:::U--=1~n:.::te=.cg,-=r..:::::a::::l=--=c;..:::o~a~c;.:.:h:=;e..::s:..::l(..::BG~)•...-;.....~. ( ":--"': "1' ~"".-t4. -1 \,.. ",. ..-.;' .:- '", __ _ ~_ ...,..-s ............ -- ~!K..V·-~~~·" 10 .-,1'_. ~"':. ~""l".;:·_~~';;'t-.-~2",. .i~v: ~::::c~;-::~~JJ~.r...·~,~·<t.J.:·..-9~ y-- .',,~.. ,,-,.f.l~~ ... _·t j"~"~";' ,- ..~: J'"-'''''

. . ...... f\ -ri'.~ .... '" ....... ~ .. ~ '1'''' ~~." t"".........- .. ~ . ­- -r rIntroduction: t:.~,i ~~~,;i'I, '::~-;. , ~ .'1:1,.;. ~,j .l';.~"" ,~'''"' •. ", .1. U.:.:~t t~ i_. ····~:<~:.:·lt-.:}·:'·,.:( ... ~·::.·~j~~:~~fJi·~· .. ,?··::-.'<':"~.~~;~·,~":~1'; ~ _ \~ " ,. ~

1.1 Integral.Coach Factory;:lMadras,'!delivered ·the first lot,; of all-YJ9lded all-steellintegral' '00 AC/EMU',coache s for: r:, . the Cal~utta ~rea.in ,the·-year.1963-·64.:A~largenumber.1 '1 '. of EMU coaches .~e: since'-been~1>laceJi--Qn'thesuburban:r....,:,·:.

.- lin~f Calcutta',&: Bombay',.area and'more suci). coaches ,are " baing a<1ded ye.ar after year.to the ;existing', fleet. : ','.

De spite the use' oft':6op~;;':be:a~ing ~'s'tee'ii~:the "~an~fa.~ture, Of cOach shell:and r:application of.prOtective ',Paint<after,.; .. proper. surface ,preparation1some parts of, the coach'shell.:· have (shown, a 'te mie ncy ~ to co rrode '~afte r, some time.·: in se rvice •

, MJ.n:T of these 'parts tare ;stres~"bear1ng':members';ow~ng.."! '':'

to the 'integral design~of'·;the,~coachr.shell.:~Thorough-:" (j pe riodic inspec·ttoo"toolocate:corioded::mmoors. and ·their " : time ly (replaceme nt f:ts::;e sse ntial,r.inrorde r:':to~:ensure that'·'~· the ":E:MU~: cq.ache,s. ~are j strua.tU~al1y sQund . .~... </J -".:-.1. ~;~; . l' ~ . ~ .~

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1.3 This· teoc.lnical·pampnle t is being -;issued' to ise rYe 'i.~·as a handy · booklet 'to the ,Railways fo.r the inspection 'of .ICF..-built : ·.. EMU' coaches for locating,'corroded.members and carrying . out nece~sary.,rep.~r~,.:~~d;,mo~~.~i;~atio~;.,,'."::f: :.:' _,: '!'7:':~

1.4 The i~str~cti~n's' c;-~t~ined 'in thi~'~ tech~i'C~':'p'amphlet. ::,,' are intended to' serve only as a guide and the 'Railways / may, in addition, adopt":any other.measures .,they consider necessa.ry pn the ,basis o~ ·their:service'expe,iience ~,for, ID,3,intaining EHU :,coaches .;Ln.a sound copdi tiop. .,. '..

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1.5 · CO:X:rDsion is a chemical~ phenomena or'.oX1da.·tion pf:.,steel:-: surfaces whiCh results in reduction of section and the re fo re ·10 s S 0 f·, s,tre ng th. ,. Oxidation take s pl.ace woo Ii .. steel surfaces are eXl-i0sed to atmosphere .'iathe presence of moisture., . In ,.all. me tal: integ ral coache s,' 'the steel . ' surfaces are protected ,from atmos1Jheric contact py the e.pplicationof suitable primers' 'and paints. ' ;Surface s y,tdch 'are not finish Pta; nted have, b§eJ].J}iven ~oats 0:['

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l51:'tuminous e I' olution which ives ad:ded·Pl'oLe-ction ~o he steel surface.§. ue 0 some reason

·other the, pro:t@ctive' f~lm breaks down, tl;le ,·1ntlibi tive primer acts as' a second-li.ne of",defence.·-":rf 'for some' reason, the' primer also breaks down, corrosion: of the' " steel. surf:lce s .starts. ' ',' "

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General'instructions for . inspection in Workshop.," .', . . .' ; - ,~j ~ ;~"'. ", " . .'

Hr..e n the EHU coache s .... are re'ce ived in the 'Workshops, f re a:i.rs they ·,should be· thoroughly inspected for ~10 co e . '.

staff 'WhO ,have su ~c~ent knowledge of integral cbache s. Adequate implements such -;J,S spiked hammer, torch etc. should be provided to enable proper and thoroughinspection be ing carried out.

• .•• 2/­

2.

above sho~ld~/-'/­

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T~~chl1ical Pamphlet No.C-77l5 -& 2 :­

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2 • 2 All EMU coache s of 6 years age and . inspected very carefully for signs of corrosion, as

such coaches generally have been found tot1eed corrosion repairs. The period of 6 years is ~d on available information and the reports re~d from Railways with regard to extent of corros~noticed on ICF built EMU cOaches. It is.however,J::ikely that corrosion on some EMU coache s may set in wi thin a period of six. years. For this re ason all eOache s of le ss than siX ye a~e­should" fi.j;',~t be visually inspected and if signs'of' corrosion~ ~oti.~eQ., .they' should.. also be subjectc~ to tb~i:ough de taiJe d inspection,,' . ..--­

--------------.... N6rma+ly, EMU c,oache s th().~ll--IY inspected, and -attended to forcorrosioh ~palrs in accordance with the instruc­tions given in the pamphlet should not require corrosion repairs at the' Same location for a furthe rpe riod' of six to seven years, but in view of factors such as non­aVailability Of materials of> the prescribed quality and. sp:cification, variation in quality of ~orkJ2anshiP.and ell.matic and seIVice' condi tions; from Railway, to Rail~lay, ' 1 t is difficult to predict the. period wi til any deg ree of accuracy.;oj It will. 'the refore, be nece saar.>' that on subse­quent vis1tsof these EMU cOaches to shops for l'OH,'a11 coache s irre spectiv.e. of age. and the degree of dttention given in the previous PORs: should' be SUbjected to a thoroug visual examination•. Where' onset of corrosion is suspected, a more thorough inspection in terms of para 2.6 and 2·7 should be carried out.' '. " " ..',

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2.4 O'nset" _..$l£ro~ion 1j;' indic,i;ltAd...gy_!laki~ of paints , f. a ng' ·of ne''ta:4prt~~1j[''§Jlq-I:U~t!pgI:::--Com~6nents­']. ~so2e"baT"'':ln<r"*froug1inoor which are'notvisltne

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o . t~o~s ~n/r~s~~. ~.~ ~ ;', : . ' ,', /' '. ' ' Tro h loor; Entire area of t ~h floor bJelo t door­ways and ,ys adjoining doorway d· under the/1ugg com:p:lrt. nt should_ be examine~vis . lly f~O/below f signs r corro on, supplemented by ping th a spi hamIW •. ', If, Sign . o!corros;1-6n are.noti . d the parts ShOJl.' ~, ..~ho~ough ..cleal)E!d by:'''scraping ~ an intensive inspect~on cd.~ried,ou to' ue te rmine the/ex.;.. t· of. corrosion: ?-6>~h~. troug~. floo~.,·· Lon viau·a). e:x~m19a~ic>_ ~gn ofheavi

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~c1es snould ~~ 6Y:!aPPllig-WT1h~h~ .~~tfimer ~@ft¥~to thoro.ugb vi"SUn exami.n:ti~~

, ,.' .. '. " - '. . Classification;;. Shell 'members and locations prone to corrosion' can be c1as.~i.fied into two cate,gorie s - .

"vulne rab:J.ell.andllno.t·:;so vulne rab1e ..n Though. all parts of the coach are' :to:' be' per~odically inspectE;ld' to en~ure that there is no corrosiori in any of the'members, Particular. attel1tion. sho,uld be, paid to members and locations' categori~4'as"vulnerable. n '," . . _,~.~:.~'-.'~'._~'. _, -._:~':,::",,:~.~ r·J ..!:t~::::j':~- ..-" ..:, :•. \ ~:"'~ ,-...... :,': . '_ r

oeedure for ins ctio,n 0 '.Velnerable' IOOmbe

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2.6 Procedure for inSl?Q,£..tion of 'Vulnerable' UEmbers and locations in workshops.

2.6.1 Trough floor: Entire area of trough floor below the dooI"..ways ilnd bays adjoining doorways and unue r the lugg age compart­mentsshould bee.xamined visually ,from oolow for signs of corrosion., supplemented by tapping with a· spiked harnnier. If signs, of corrosion are _noticed;' the ·parts should be thoroughly c1e ane d'by scraping. and an intensive "inspection carried. out to de te rmine the extent of corrosion' ttl the trough floo r. :-If on v isu.ll e xamina tion sig n of he avy corrosion are noticed in trough J'loor at doorways and luog J.ge .comp.... rtme nt, the aluminium Cheque red f1;oor plate and floor unJerl~ys Should be removed and the vermi~ulite fillingscrQped o£f to facilitate thorough examination of trough floor. The trough flOor be low the doorways and lUggage comp<lrtments found to b3 budly 4,ffected by corrosion should 00 cut anu. removed. A' 'new piece of trough floor of similar Shape/and size, sl10uld be wleded in position. AS the trough floor is a stress bearing

- t:lember of the EMU coach bod;>, a perfect \oJelding should 00 ensured while re!Jlacing the corroded !Jortion of the

. trough floor. For corrosiOn repair of trough floor ~; sketch 77176 may 00 referred to.

. .... 4/­.... ~.

-: 3 :- :Techni~al Pd.mph~et No.C-7715'­ ---\­

-....... . .. ' _. . ., ·'-·r' ....·· -. : .' "Vulnerable" rrembers anu. locations' :~-,<~;:i-::-'--~'::":"':;-

Trou€;h floor~bel~w'a~o~a~~\rid'Unde;·.ih~~'luggag~ compu.rtne nt ",.....: ,""~",,,,, .,~ 2" .,. '.' .'.,- . ­..~, _~:.(, .;, .;,' i~~.~L:.~.·· :>i~;o'> : ':.-~' .

2.5.1.2 Sale' bar and bOdy pillars t.i.djoining doorways and sliding door.}ocke~s. ": ~ ,. '~>' . . .... '.~ : : :." ... ; ~\ f-'"'r:~-:.~ ~ . L ....~. : ..... :.~ -: ..... " .

2. 5•.1~3 Body paqels' adjacent to' sliding door poc\{et. .: .' . ,"'! .~. '; ~ ·t ".:. ~. .", ", " ... ' I ,,~;' , _.' .':: t ..• ;

2.5.1.4 RaiD wate r g utte r moulding s .at the j unction of roof anJ bodysides.· ~" ,,~ .. . '.. I

1 Not so vulne rable I 'membe rs and' locations:

2.5.2.1 ,Trough :floor 'at :locations other than those described in para 2.5.1.1.~

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~.5.2.2 Solebar and lJill.:.lrs at locations other than those described in-pa:ca'2.5.1.2 .

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2.5.2.3 .side :panels at,~windowfairing. i. __

2.5.~.4 Body. end wall panels and pillars ~ • .:

2.5.2.5 Roof sheets beneath and around ventilator$. ..... ~ . '.,.-. .. :_,~ , .• i:;'

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2.5.2.7 Be \j'i bulk he a.d partitions.

'!-\:, c~~ni~::.l ~:J.ruphle t No. C-7715 -: 4 :­

~~6.2' Solebar and body pillars

The sole bar and bOdy pillars in the bay unde rand adj oi the bOdysid~ doorw~Ys anu vendor's comp~rtments should ex:uJ1ined visually from below and siues of' the coacCl~' A 2.7.3 torch light may be used to facilitate inspection. The ulJper POrtion of the sole bar. above the trough floor however, cannot be Visually inspected. If 'incidence of.\ corrosion is noticed in the bottom portion of the soleb the -trough floor and the caver plate of the boxed secti

, should be cut to a requisite length fOr examihing the i , , \ top half of the sole bar~.

, 2.6.3 Body pane Is & sliding door poc ke ts.

Tha pocks ts for the sliding doors should be opened' and the accumulated dust dislodged and. thoroughly cleaneL1~ If on visual e xamin\J. tion signs o,f .corrosL..m are noticed. the side weill shee t be cut and the pilla.rs thoroughly . examined, the trough flOOr should also be removed· an<l t sole bar and panels thoroughly examined to; .iscertain th 2.7·5 extent of corrosion, for repllrs 1'8 fe r sketch 77178.,····:

2. 6.4 · )hin \/ate r gutte r ~" . . .~,:.;?~:':::;;.:. ::. The~: CUI shaped.'rain water gutter run~ng~~~i~~":f'thB':~~,$""\ ,. length of coach' re Visually inspected and the accumu­

lated dust ilisloged and thorpughly cleaned.':; TfJ signs of corrosion are noticed, lUI shape moulding be cut' and modified as indicated in sketch 77180."~;l\(j .r..

- . . .:;l:~,-";;>· '.

Frace dure for inspe c tio'n of not' so-vulne rable ' . rnembe rs "

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'. At locations other. than those described at~>para 2.3.1·:,' ~. the entire area of trough floor should"~ visually'

"'E?xamined thoroughly from relow sUPP1ema'!1'ted~by t"apping . with. a spiked hammer. for signs of,corrosion·. In case

corrOsion is noticed,: the affected' and surrbunding· , " areas should. be thoroughly. scraped, clean~d. and minutel

./ inspected to asse"ss the extent of corrosion.> .Re}Jlace , the· trough' floor as. indicated in sketch. 77l76, ,:,', , .

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2: 7 2: Sole bar and T\J.' 11 'rs' ',' ,..' . ,"'1( "" ' "::'. !': I~ "~.:'.. ' • • .!::: a _,~., ' ,'. "",-""", "c."" d [. '"!.t;~;."",.4...,· ..l .. "~'~~.- .

. ' At l()cations~the'rtha~ those de scribed ~t para 2.,3.2' , . the entire le ng th. of solebar be examined from the botto" . and side' of the' coach' un<le rframe .':'!.- Torcn light' may be .

....~-:. used t6 fa'cili tate".'inspection.;,> .Accumulated;.'..Just should cl1sl bdged' .tho~oughlY"amI' structural Ill9mberS, scra-peA to ':

..•. the extent' p'ossible.t If corrosiq.n is noticed" side \.JaIl . S11.7e ts in t he area' whe"re the corrosion.... has.l1een obse Ned

should 'be' cut ,covering'. sufficient length' for ttl,orough : examination of solebar and pillars and to facil~tdte subsequent" attention, z:efer sketch 77081 for carrying out necessary repairs~ In order to inspect corrosion at ' solebar & yi11..Lr c Onne c tion, i nsiill3 panelling.~ fl?~,:Z::

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t'-.( .... : , :-: Technical Fampnlet No.C-7715

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sheets may be removed if' corrosion' is. not?-ced, the same· '~'~f,be attenued to::·I,.,~·" . .'

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The entire siele "wall Should be . visually .examined for ", ·signs ofcorrosion,:particularly"at ·window)fd.1rings~ In

,'case corrosion has~beenobseIVed'the d.ffected parts .'should be •cleaned a.nd~carefullyexamined-andimmeu.iatelyattended to· "';.. ~'."', ". . :-,j .. , ,y.,,:,. ''':J .\.'. . . , ~

. •. " ~ '-. _:-~'t'~'~{_~:f.:-~.:. ~:, ", .l~ '.>~ ~ :~ ~-.. ~~ "} ~~_:'~~_. ~~ ~ _" . Body end w:J.ll pane Is & pillars '

The end wall J:.anels and pillars' shoulct"b3 inspected. for .'. corrosion by opening the int.erior panelling. If signs of

corrosion are noticed, the end \\Iall sheets and.or yillars : must be:. cut to the extent of corroded portion marked · for attantion.... :,/ ',; :

., :.··l··~·· . ,."; -:

> ~. : • .:. ",2.7·5' '. ,

The-- roof shee ts' should b8 visually examined' fl,round the ventilators and if any c·:>..rrosion is noticed" '·the· same

· may' be re paire d in the manne r as' S1 own in ske tch 77177. .\.; .-.:'.,. . .

2.7.6' ·Seat frarre: . .

..Seat frarre is generally made, up of tubes and bolted to ..toe trough floor. through' the aluminium floorsheet. /

.. _.l'his j unction.a:t .the floor should' be visually examined 'for corrosion•. If signs ufcorrosion' are noticed., the' seat ·frames. should.be ·removed and affected·parts atte nde d to. ·r· ':t~,~· . .. '. "~J~':.::' ;}..... -. ":.\ r;"'".:. . ".'."~.. -!v,»·t:J,:_~;,~~·~1;·.. "~ 1l·.~.~;;> .,;,., ,~_:"

fie mi' bulk he ad .&pa'rti tions •• , , -:-. .~.

Square' tube s at the junction of the floor should be .. visually examined for corrosion.' .If signs.Qf Gorro~.ion

are noticed, the ...ffected parts snoula be attended to · imme diate ly..., " "', ,.' '..

2·7.8 . Cross be are rs . \. . ,

Normally cross-bearers are less prom to corrosion but incase trough floor and connecting sole bar is corrode a , the cross be are r be the n thQroughly examined for corrosion and the 'affected cross-bearer should be atte n<i.ed to. .

.. ... 6/­

-'l'E; chnlcdl PaT~J:;nlet No. C-Tl1.5. 6 :- t~fc

Ii -:

' 3.2.1 :.:, • :;j C'leck list. t .",

.~f,:.if, C~~~~:;~fa~~:~~li~~ ~~r:~l~~t;:ui~aCh "2.:' ..•~ be distinctlyniarked to indicate the entire area r affected by corrosion requiring repairs, by re1-'lacement/; mOdification, as :'the case may be" A}l1-'I'OJ.;rid.te items t· 3·2.2

,in the cLeck list (RDSO Sk. 77181 to Elk. 771d5) shoulLJ. [ \ be fi~led in showing de tails of 'the members to be ~,. '.. atte naed ,for corrosion repairs.

" ~. 9 Inspection at Cdr shed. , . :; .. . ~c. • , .•

Wi th systematic inspe ction and repairs uf the se coaches~·.." ,. . 1'0 r co rro sio n in the Railway wo rl::shop s 'as de tai Ie d .:.-~ 3 · 2 •3 .. in this pamphle t, it should be lJossib];-3 to ensure I '

that cOaches having extensivecorrosi0n are not in service. ~hen considered necessary, .fla.ilways may organise inspection of coaches at car __~heds. Coaches

! wi th be avy corrosion should be, de spatcued to Railway Il workshops. , . ~:,~, r . '

I, •ot: /0' ~, < ~ ...

3. Corrosion'repalrs.

.'I' 3.1 General .. .,! :.,'

- . ' "", f' The re}ilacement.· parts used. for co.rrosion. repairS S~lOl11~.,:3.. .....• 2.4.be given proper surface treatment and applied with '::' , protective, pa:~rits•.' Relatively th_~ck sec,tions such as ". ~ . sole. bars & cross bearers should preferably be grit or~c, sand bld,sted' ,and given' a protective: coatof red oxide r'· " zinc c;lromate primer paint imrnediately';thereafter. ~. Tilin m'i1d stee 1 shee ts used for trough floor, pillars,~ side wall Sheets, partition,~ost, pillars,sqou~d also~ .be. subjected, to !)roper surface tredtment-like' 'phos- ' phdting and subse quent prime r. R:iilwaYs Should develc facilitie s for, this purfJose .", It is essential to use coplJer bearino' steel s11eets for r8,Pairs of these, coact \\ €lding electrodes and paints Should be of the prescri ­bed quality conforrr.ing to the relevant IS/IRS spec.l.fic tion, particulars of whiCh are given in AnneXure, XI ~jhere the cor,rosion noticed is of a very minor nature'.

"; and has j ust,·~ta.rt~d, ,the re is no need to re nevi parts, The paint"and rust snould be thoroughly' cleane.9-: to re ach the bare me tal and the' surface treated' wi th two. coats Of p'rirrer~" ~In addition,'underframe uember·s 3 ,.. 5 should be given fOur coats of bitumen solution. .~.

'. TDesign im~rovements/modifications. s

1)&:v~r<:tl;design i~~~vements/modiii~ationsfor elimin1 l'"rnnlIDlslng corroslon, have been issued by rCF/ROsa l'I) fti!'s to time to Baste rn Railway. Brie f·de tc;l.~lls of th

together With the action to be taken by the' Railways t give n bl? low:

•••i'· l'; " . &'~'-'

'" .. ',

Technical Pamphlet r~Q.c-7715

. .. }il,'-::';'r'::"l _r '.,j

.-._.•:-;.;~.f ..-...~:": "'. •... _' ......t. .. :.

-: ? :­

Exfoliated Vermiculi'tE~,:

<-Com.\,JJ.e te' trough floor is filled: wi th EXl01iated Ve rmiculi te mi>..-ed With bitumen'.~:;"It must':be'ensured'that'c:ls and when trough floor is cut land: repldced'due to: corrosion, it

,must be care fullyre filled. wi.th J~,x1 oliated Vermiculite as shown .in. sketch 77176.'

._---...,

-3.2.3, Sealing of WindOW' sills.

To prevent the seepage of water throUgh the gap, between the side wall vressing and window sill, the existing ga"" !if any, should be close,aas ,shown in, sketCh 77179. ICP' hds already implemented this preven­-tivelT:easure on all !:;:HU cOd-ches curr€ntly under manu­fdcture. Railways snould introduce this",modificationvn those, EHU cO::l.ches where this modification has not been inc Jr,forated, yet so as to prevent seepage of water and thereby reduce corrosion on bodyside wall and sole bar.

<: .

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',3.2.1 stiff~-ning of solebar at the doorways. '­,"~ , ," ,1. ,'I.,:,',,"',,'

.""'~.~-. ~ ". ;.~.;.,:.; ,....~ ~ .:'~:":_:_':''': ,""; ·.. _"':"~f. ~_. .­ _.' . "1:5 incidence of corrosion in the'solebars'has been :'~~dominant in the luggage compartme nt doqrways, 'the sole­bj,r in the ,doorways 'are reqUired -to be'replaced as indi­cated in sketch 77082.-'" , .

s

:F'loor in lut.ga;-;e compartn~nt.

The flooring arrangement in the luggage compartment ~s similar to that provided in the passenger compartment. Due to frequent loading and unloading of luggage the floor sheet gets distorted and water and ccrro'sive~tntLtters find their way, into the trough floor. The Exfoliated

.... .8/­

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. ..~ ;,;):~; , '. , ... .-",,,'• .'. '_I Cover sheets of sole bar.

EHU COaches currently undermarlUfactureat ICF are J:,irpyided wi th modified cove r shee t for the sole bars with opening at the bottom -to allow accumulateu water to drain out freely from the solebar as shown in sketch . No.ICF/Sk-1-1-133~ In the E~ru coaches built and supplied by IeF in the Pd.st no openings we:re provided in the curved. cover plate of the solebar. To prevent accumulation of water in the boxed section of solebar of the existing EHU coa.ches, the curved cover plate shall be modified to ~rovid: Ofening at the bottom ~f t~e sole-bar ~s.shown ~n ske wch 77174 and 77175. Tras w~ll also fac~l~tate inspection, cleaning and painting 0l sole-bars from insiCle.Central, Eastern, South Eastern and western Railways should ensure that the modificcl tions to\the sole-bar curved ,cove r plcite indiCated in RDSO tlK.77l74 & Sk.77l75 are ccirried out, as and when COaches Pd.SS ·through shops for ,} Oli.

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I.~'I.; chnic J.l' l'.:.imphle t Nu. C-7715 -: 8 : - ,:"'­

Vermiculite mixed with bituToon loses its strength, and ': 3 , corrosion st3.rts on the trough floor_ The corrosion : • to the trough flooring should be attended to as indicatl'.· in para 2.7.1 and Jiluminium cover sheets provided as pel:ICF' -Prr;. K') .Ei'm-lr-l-OOl. .

3.3 Procedure for corrosion repairs:

De tailed procedure fOr corrosion repairs of various \ members are ·giv.en in the Annexure and the relevant

drawingG are indicated inl the following table.

Part An;Iexure Re f .DIl ----------------------------------" 1. Corrosion repdir of solebar at body I Sk.77031 alt.L .

bolste r. . 4. 2. Corrosion repair of sole bar II Sk. 7'1082 'AltJ

at doorway.

3. Arrangement of tread l-'late at III Sk.77083 Alt.) QOOnvay to avoid· corrosion.

4. Hodi fie a t.i on to the side wall IV Sk.77081 & 771 shee ts and body pillars.

5. Lodification to the existing cover . V Sk.77'174 Sl.~e t motor &. tr~~l.e r coach. Sk.77175

6. Corro sion reYair' or. trough floor. VI Sk.77176

7. Corrosion repairEior roof sheet VII' Sk.77177 u.ro.llnd ve ntilator. .

3. Corrosion repair,'of body Panels VIII Sk.77178 and .door. pockets.

9. vJindow S8 aling arrange me nt. IX Sk.7717l.J

10. Corrosion repairs Of .~ain water X . Sk.77180 gutte r. ; " . - '- - - - ~ - - - - - - - - - - - - - - - - "- - ­. .

3.4 \'Jhe neve r' a 1-'ortion of the sole bar is replace d. during corrosion repairs, the bottom portion of sidewall 1'illa r s at this location, sbould also be simultaneous re!-l.:.i.ced.

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-.• 9 .-• Technical Pamphlet tlo.C-7715

Corrosion repairs are required to be carried out to th8 be st standard of workmanship. Trained and expe rienced welders should be deputed for carrying out \tJelding under careful supervision of qualified welding supervisors. Sui table arrangements should be made for dry storage of electrodes. APproved Class B II electrodes suitable for vertical and overhead welding should only be used for corrosion repairs. Reference may be made in this connection to the approved brands of electrode s issued by RDSO. frocedure de tailed in "Code of Practice for 1Jdinting of all 1118 Loal COdche SU shoulu be followed for cle aning and painting of surface s which are attended to during corrosion repairs. Effective supervision and inspection should be introduced at all im~ortant st~es

Iof corrosion repairs. ~.....'!;, !

!Jocumentation

Afte r corrusion repairs are coml-le ted, particulars should te e nte red in the check lists_ The check lists shown on ske tch 77181 to 77185 pertaining to diffe rent type of EMU coache s which are on line in Calcutta & Bombay area in large numbe r. Sui table change s 1n the list may be made to suit o the r type of coache s. A diagram of the coach in standard A-4 size should be marked sUitably to indicate the parts of the shell re placed during corrosion repair with specific de tails of the location and extent of corrosion. The diagram and the che ck list Should be file d in a folde r main­

...tained for each coach.

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1.

~~RE-I. Tecl1nic~1 I'amphle t

-.,.,---:---..... No. C-7715. ' lu~tI~g~1~us~!~r_QQItQ~~u_Se2a!rS_Q!_S~le9ax-a~_~ j)"l~s.tu_aud~ttiD&-I~ck1~.....TtU1.o~~a~e1a.

(~!~t_!ID5Q._~e.tgtL'Z2QflL.!!1L.1) , ,

1 .1 SU)Dort coach bony on the bony bolster, where solebar is not to be ~ttenrled to.

1 .2 Sup~ort co~chbony on'wooden trestles on both the sides of" \" bolster where soleb~r is to be renl~ced. '.~ .

~., ' 1 .3 Snpno rt the SU1')erstruc ture 0 f the co~ch body through the winnow s where the soleb::lr is to be cu t ~s shown in \ sl;:etch 77082. I

Cut off side ,

w::lll· sheets to fI height of ,

about 300 nn fran the fioo.r"flnrl sieie wpll "1ill?rs to a height of 250 pm in the ClreB 1,'nere the ~oleb~r is un0er renlacetTlent. ,

Tvclc weld tei:1POr~ry nild steel st~.Ys· to the bl1dy bolster ~nei solebpr ps showrt in sketch No.77e81. The location on the s'~lebFr shoulrl b,o reM;onnbly f~r from the noint 101here it is to be cu t fa r re""ll ~c 81"1 ent.

1 .6 Cut the c ro S3 be~rers, if Elny, ptt~ched to the solebar po rtion• to be. renewed.,· • 1 ".' • ..."

1.7 Cut 0 ff the trough floo r. to· a (Ust~nce of 350 mr.t froM solebar ~nG to p length of 1800 mID in the bolster prea as shown.

1.8 ." Cut the soleb8r to p distpnce of pn,rox1mntely 200 rnrn f1'''BY fr0r.1 the ""loint of reTJlflcement Ann nre""l~re the edges for 'V' butt'Yreld joints?~ showninSk.- 77082. Cpre should be . exerci~ed so RS not to npmpr,e the body bolster when cutting the solebrlr~ CF1refully grind the body bolster wi thout dampge it. .

1!Ield the lifting tflckl e fixing bracket to the new solebp r.

T~ck weln cl new "1icce of solebpr whose edges pre siMilarly ')rc~pred for a' V' butt weld~ , '.•

\

1 .11 1"eld the soleb~r on eith'~r Eide ~fter ensuring str~iGhtness and over ~ll :?lignment.

'..reId bony bolster to thp. new solebC'lr.

In CF1se of d~rl~f~e to the eeigp.s of the bony oolster or if F.lny '''I, rt of the body bolster neC'lr the solebFlr i~ to be r871alced frlr c r 'rJY1sion, the f01lo'Yring ""lrocecture mFlY be ado''lted:- .

(8.) Cut off the trough flnor in cpse of trfliler coaches'. Cut the taD nl~te, bottom plflte of the b0rlybolster.

(b) . Tl=lck "reId the two webs I?r ton pnct bottom ""l1~t(3s to the new soleb~r hpvint; C'l ""lacking niece. "leld the shif'fcning ribs for the lifting t~ckle brC'lcket to the sl1lebar.

••••

1 •

1 •

1 .: :1<'ull weld the solebRr :>ieco on either sirle.

Full waIn the b0ny enlster wob, to~ ~ bottom plRtes ~ s shown At section .' AA' 0 f sketch 77081.

, r f f",f

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(d)

(e)

. " '

i·:.c.:.1 : ~l ;~c t ~io. C-T115 -' 2 ~~§~:lcon " '

"feY' THclC:~Teld the solebl1r Tliece on both sirles ~md check for , .' ::,-tr£lightness ~nd over Fill Fllignr:m@nt of the solebar [tnd

body bolster web !1ieccs .. · . ' . . '". _.'

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h181d tl::e trough floo r. t 1.: "

~.Jold nGW bociy Y'Jillprs Anti sine ,.,,~ll panel. t: ':Jc11d the solebnr cover sheets 'V/ith bntt0m openings to allow r dr,dnpi·e of HPtar ~mn f?cilitate ins"lection as flh0wn in RDSOI<­skGtch 77174 & 77175 for motor ~nd traUer conches r3srectiv ~

, . 1 .5 lh to: - (1) If 'soleb0 rs Are to be renlpc'3rl on bn th side 0 f tho ,+.

bony bolster, thE'! joints shr'Juld be staggered rind .­bo,thenrts of the botiy bolster should not be t 1 .6 At.tennorl to,simultpncnusly.o' l'

'" (ii )RcmcH~l of the sr'JlebF1r nepr the bony b01stGr sh0ul

be tnk8n At ,the i~8tstAge After renewing the 'solebp,r, if ,so np.encd pt other locFltions.

1 .9 '.

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ANN QXURZ-II . Te crJnical fampiJ:Ieti{o.-C:ff15

--__ JlJ.s.t~sti~s-!Qr-~D.rtQ,.s.iQ.u-U.c~e!r-c.!-Sol.~g£q:;-aj;-dQo.nl3Y:'S.

--{B~fJ!_N!§Q_§~E}~gh_'l'lQ§.~_&~!-!.:.l ,'v'

81.1;1'1(" rt c0;>ch bony on ''';'Cloflan' t"'estles on bnth the sirles 0 f

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~,' . 'b0~stGr whero S0lebaris to be re~l~cGd" ~s Sh0wn in It,.sJ,;:otch 77082. Ii i

1 .2 f)

ii

I PI")vi(~e ::l(lr~itil"\nAI wn()~en supn0rtsnn' citlh1r sine of the s'··lebp r to be cut fc r rd~l~ceJ'l1ent p s shown in sketch 77082.

~Cut ~ff sir'le VI~ll she0.ts to p h~ight of aoout 300 rom ci"'lvc.ring th~~ l(~~gth of ClD'1J'Oximately 200 mm on 8i tharsiro r)f the s0lebflr to b\~ reTJl::lced.

Out the 000r ni1lp.~s to p. height 0f ~bout 250 rom in the p.'Y'cr where the soleh~r is U:Ii...~er rc~lpcement.

Cut the cross bC::lrors, if· pny ptt~chect to. the solebAr :)'Jrti0n to bl~ rIJ'1lpcGn Pf; ~hovm in sketch 77082.

O"'cm out thp. fioor ::1nr1 cut the trnur:h floor to n distance o f 400 rU!l from the sol ebC! r ::>nrl 'to ~ length 0 f ~bClU t 2400rnrn ~s shown At rlot~i1 'X' of sketch 77082.

1.8 Cnt thooxistin~ corroded soleb::lr to Aoistance of R::'lnroxi­lJ"'1t:.ly 150 nun FH-lrlY fr0m thp. ncdnt of rO'1lAcement f1nct pro­"::>1':., the cvlr:os f0r 'V' butt weld joints AS ,shown at

'-ZGcttc·n 'DB' of s!{etch 77082.

1.9 Trck waIn thG new niece of soleb~r wh0se eflges nre stmil~rly

';lrG"::-rco fqr <=l 'V' butt veld.'

1.10 Uf:lcl the new soleb~r "n either sirte <=lfterensuring straiGht­ness rn~ nver pll ~lir,nnent.

1.11 C::>rcfully welr~ the crnss b!JrtT.'Grs, if ~ny to the new solobpr.

1.12 In cpse of nprt~ge t" th(~ e;lges of th~ cross be::lrer or if Fny ;1prt 0fthc Cr0SS beArer ne~r the soleb~r is\ to be r,~,lrlcc('1 f0r c r1 rJY)si0n, the f,,110wing "1T'Ocedure J11~y be ",r~o~tect~

'.'

('c) Cut off the trrlur;h noor t" ~ rtistance ~s indicatod rt 1.7 Above. Cut tha ton & bl"\ttnm finnges Rna web ':"1f the cross barrer to the dimGnsions shown pt rtetail 'Y' 0f skr>tch 77082.

(b) 1.JCJr~ tho \'Job Dicco tn th0 soleb::lr pn rl th(~n the t,~l r"~ . bottoJ71 fiC!nges.

(c) Trck ',Tnl r1 snlnbnr "1i~cn nn brlth sir'les & check· for strri~;htncss I'1hrJ "vc r ~ll Ali{~nr.1en t () f the s01~ bar c-n<:" crnss bcprer. ' .

• ••• 2

-"

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, ; r -

p . -_.~!,-..,--~--- ---~ -.­ ~ .:.

2 AHNEXURE-IIcontd. t Tectcnic:J.l F.ll:Jiblet Na.C-77l5

(d)' Full w8lrl the snleb?r "liece on pith8r side.

1~lelct the CJ:V"lSS bc~re~ wab l")i~ce to the web of the existing cross bt1:=tr(;r ~t ~n ~ngle. of 60()C nS shown pt Detph" 'Y' of slz;:etch 77082.

( f) Feld tho bnttom f( to'!1 n~mr;es of tho cross bc:pr0r to the existing cross bePorer F1S s}-:own nt' r.

r'!ot·pil 'Y' n f skutch 77082.

1 .13 HG1Cl the- trfiugh fionr cFlrefu11y.

1.14­

1 .1 5 l!oJ d thn soleb:=t r C0.VC r shra tr, with bo t.t'om o"1cning to AllOt ;

r1r;:-inpt::e of HPter nnrl f~cilit?tc ins'1p.ctinn ps'shown ill !­I=F'Sor::: sketch 77174-~ 77175 for Mot()r ;:mti trFliler c0etchd" rcs,~ctively. ~

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_ .;. " ANNEXU=IE-III Technical Pamph1et-No:C=?'7I? I

'. Instructions to pvnid corrosion .... I .: i Pt-(ioorwP.y trean-nIlIfe 1irea. - .: ..............~..................,.............. ,.". ......-.................._--­

1 .. ) Rcm0~o tho exis.t1ng: .. troan nlptes Pond expmine thet-.p.0or and s,lobar.·!.'" :...:,;....:;~:.'._... .. '-' ...

.. .. '-. .~~... ~

~ .. ) Prr,vir'le screwing niec0. for fixing new trepn nI::lte to IeF Drr,. No. EHU -1 -9-33~,if. no t pI reA rty done.,

• t • .", ~ , •

3) No screws shnuln bH used for fixing 'p,lum1niurn chequered' floor plAte over the ~rea of ..t"hebnxsection of soleb~r.,

•• I 1­

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ANNEXUIlE-I VTe cimical ·b.l.m.tihle·t No'. C-?7l5 . ," . -- --"'-----_.............. ... ..... . ' " ~ ... . " --" .. .. .. ~ -' ....~:

...... - 1". -., --"••

1• 1 . R.::nowr-U. 0 f sinG we'll., .shoe ts •. . ' '.

1 • 1 .1 Su~port c(lpch' bo('ly rt booiy roIsters. •. j' ~,

1.1.2 , Cut the sitiewp.l1. sheet. requi T"ihg .·~cnlAcemen t ~nn' grind,.' the burnt enges. •

1 .1 .3 Prc]1['1"'O ;:l new side wp.ll sheet v,i th 5rrrn cliamct9r h0lesat (";ppropri~tc; IUCAtiol'J.s for 11lug welning to the sir1l; wRl1. ,illprs when required pnn'~~ck we~1 .~Qe Sp.mp. on Rll the f")ur. si(los.

1 .1 .4 C~:Qck the sire WAll for strAightness. t I t' ~'.

1.1.5 lJulcl the sirle wpll sheet~ nn :::1.1.1 four sines And T)lug weld,: tho S~P1e to b-,0.y sin e ,illArs, if thF! insi~,c T)~,neling Md~\.:... flc>or:I.ng hFlve not been removed for Any other llurnose.': In case th~ insicl e 'J RnGl s p,nn trough fi00 r hAVe be en rCI!lIJ ....~.' flJr sr,me ' other nurpose, side w~l1 sheets may be wel;~ed .' with the bony llillprs from insine.

1 .1 .6 Qrint4 flush the welclcd joints nn pll the four siiles to !) bt? in a sm00 th ex te rio r fini sh.

1 .1 .7 If si~e WFlII sheets Anjoining the bony sine windows are roqui ref tfJ be renewed on ACC(mnt 0 f co rro sinn OY),o rtuni t"";'~' sb:',u.ld be p,v?iler'l of for incnrnorating the winnow seRling .....~.•~ p. rrang c.m18n t p s s h0wn in Sk.77179., :::"

1 .2

1 •. ' ,

1 • 2.2 HUl:\t:"'ve the insi~e Y)pnels,' n00ring ?ncl nOf)r sine moulrlin~,~, , tlJ Gpin pcccss to the bony '1i1IArs. 1 f

'VThon mr,re th?n two consecutive '1illp.rs Are cfJrroned, cut 1 pI tern r te br'ry llillflrs on thG Sflme sine to A height of ~ an,r--,xL11fltely 250 mm AS shnwn in thH sketch, exercising c.(. tl'\ ensure thAt the, solebAr is nfJt ~!:lmFlgp,(l. . I

1.'2.4 Clc~~ the surfflcc ("If the sole bAr thornughly of rust Gte. t 1 .2.5 !,.;:i< wclct the new iY>cy nUbr 'lort to the .,Ulpr "n~ s~lol..

b~r. I "

1 .2.6 Chock ~nn ensure strAightness ~n~ Ali~nrn'ant of the bf)~Y " ~illFrs. ' -'_.......

-~

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. ,," A.'l'NEXURE-IV. / .. 2 ­

Technical Pamphfet-~o.C-7715 liUll. ,..le16 the ~.;:> r:-_ h~rl!.~_~.1 ..;:>J:- ..tn." th!3 .0.riginA1. nill ~ r .

..& ··s"'l ebp r •.

1.2.8 Cut off the TCI!l~ini~g ")illprs"~ffecterl by corrosion ~md ::lttonct to them in, similPT m~nner ps indicfltc'd A.bove. .'

. . ' ... . . .

1 • 2.9 Rc~)laca the bony si,-le w~ll sheet as 1n~ic'At!rl in n~ra 1 ~bnve. . ~ I'L .

~1.2.10 Clo2.11 ~mr. ')~1nt the 'inner surf~ce of the rei)!;:>ceo side .wcll . r"ncl bflny -:->Ulnrs. ",.. . .... " . . . "<

1.2.11 RC;11t:co fionr, flo0r sine 1lln ulning aft<'lr .rolay1.ng the flooring ~s sh~wn in ·Sk.77176.

d 1 .2.12 RO'''laceinsine ;nnnels" ~nn other fittings.d

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inrlicated (

fr 77175.

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Te chnical 'Pamphle t No. C-7715

Ir.scructirms to J11octif'".f co,rer sheet rnc.77174 -~""'---------""---~""""""-~--'--"""-'-"--------"-"'----'-"'-'----""-~~ '31.1.1nort c0~ch b00Y fin the bolsters.

Cut off' Cf)ver' sheets' P.S o,er the ctimensinns, 111 the sketch 77174 ann 77175., .

Dr~innut pil wpter ~ccumulptect in the box ~nct ins~ec~ the sC'lob~T' f0~ ;:'!ny corrosion. ~.

, . .. , . J

Re;)le.ce the'solebar if c0rroned ~s ":lOr Annexure-Ir~ R

Cle~m the shpr'1 erlr,os &- ri"\unct off All the COrneT'S' :IS

. 'y1. 2'

. :,1l Sk •77171+ an0 7717 5'• .

c: Cn[',chcs plreAriy 'turned out by rCF fitten with norHfi9 i C()ver ~he'3ts ~s ~)er ICF!Sketch-1-1-138 neorl no morlifi but sh'" uln be ins?') ec terlon rro si0n, if <my.. I

A

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~' .10

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C1!,,",unc1 the ventil~t()r tn Po suitnble distflnce on b0th sinos 'Hi tfi.::-:ut n::,!]~r,ing the' c~rlines. Pu rlines m::lY be cut if unFv()jJl~ble ~n'" rewelried tn J'11aintflin'continuity. Refe I' Sk.77177 •

If corrnsion in the maf sheet is noticed, out off the sheet

, "

Cut off the c~rrn0ed ventilfltnr bnse flnd renl~ce the same if no c(.rrosion is noticect fin the roof sheet.

'(Refer RDSO Sketch No.77177) ~~~-~~~~-~~-~~---~- .

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Rer.lOVC the ceiling bel0w the roof ventilAtors ,Rna rem0ve insul?ting mflterirl1 from inside. . ._,

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'ChIucal Pamphlet No.C-7715 "f ,;.'

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. 1.4 HC'1(,ye the ventil~t()r tube" ,for re-use.

1.5 .,' Fr)vide-flbac!{ing -:Ji~ce of 2rnm thick :pII munci. • • ,. - .' ". 'i" -1 ,.

. . .. 1.6 Pr8'·)~re fl new' rrl0f sheet wi th ventilAtor b?se, flfter

,'inqorting ·the ventilptor tube.' ... :

'~lclrl-theroo f sheet ASSeMbly to the roof.

Clepn and pfli~t•.

Rcfi.."{ pirduct c::lsing.

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NltJ~UR~

. Technical Pamphlet No.C-77l5

Instructions to re'1lACe C0~l""'rlerl t;r)ugh fionr Sk.77176'. ----~~~~~-~----~~~-~-i~~~~-~~~--------------- .

. 1.2 ClGan PAint ~nct rUstj"ifAny in the 'Bdjacent nortions of

tI"1~gh fioo r.

~~ . 1.1 Cut off the c()rron~d trn'lgh fl00r to the length And width

required.

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1 .3

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1 .6

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1 .8

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Wcl~ is~l~ting pl::lte of ?I!ID1 thick 'All round, the cut ways AS shown in Sk.77176 After grinding the edg8 of the

. t I""'lllgh fiop r.

Pre~Are ? new trnugh floor to the ctirnension required pncl ~fl qk, ~el d the; SAI?8, to the .,la te s on eithe r side.

-, •Ensure proper fllignrnent of the,' replaced nArt with that

of tho Adjoining PArts. . ' . ... . .. ....

T/·T(~l(l t'rough fioor to - the isnlating' nlAtes :both at ~_op Rlld DO ttom.~' ..

~-JGl(l intem1ttently,the trough fioor'l~ngit~din'ally to the' su;Y")n rting ni sce Ann arljoining trough floor.. Ensu rethe pliGnmsnt in the longitudinal directi0n bysuitpbly cutting off the tr0ugh floor to m~tch' with, the ne", 'trough floo r.

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ANN EXURE-VI II --.. . Technical' PampTJet "No:C:'77i5

'IDstxut~un_!QI_C~~IQ~!~n ~~~i~S_Q!-9cdY_naugls_ang' . CJ.Q.L:m~ili-.6l>.Z'l1Z!!... . . , . ", - ) 1

. SU:1.nrt thd' cnach' bncly on bn1y ~l~t~r~. :~t·· i

ROr.1"n) the slir:l1'dg rlO('l rs.

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1.2 i

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1.4

1.5

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. 1 .6

1 .11

. 1 .1:2

1.13

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1 .16

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Remove the semi-bulk he~rl to g~in Access to the insiia b·:')ny shoot's. . ' ". ~~ --­

R~Fl"VC tho insirle penels, fio"ring rnrl fionr sirte mf'lulr'lings tn grin f-\ccess to the lnr'ly "ill~rs item 3 ()f' sketch ~7178.

'\ '

!'!11,:n pll the throe "illpTs (item .1, 2 & 3 ('If Sk.77178) F'ro cr.rrocleri. Cut (If "illp.rs to item 1 & 2 to A h"ight of F,b'Jut 250 l!1lll ~s shf")\·m in thn sketch, exercising Cflr8 tr1 ensure th~t the solebAr isn"t rlpmageri. .,

Cle<\n the surface of the solebJ'r thorouthly of ros·t ate.

'£::>C]( J'Jclrl thA new "1prt ~lllpr to th~ orig1n~l ;lillRr :::.nr' sr.lc .bp.r.

. '

Cl:.:c!( pnn ensure s,trRightness ;:Inti ;=tlignment·of·these ~illars.

Rc)lF'cO th~:! bdrly' siria w~llsheet ;:1S inrlicated in para 1.1' () f lJU1cXure-IV.

, (jl·.;~n pnrl '1pint the inner surfrlce () f the renlrlced siria w?ll pnr' b0 rly ;lillars.

R:.:(llF'cO fir)("'r, Uoor sioe m.,ul(~ing After rel~ying th,) n,:,o ring ~ s shr,wn in Sk. 77176.

, HCJ01pce insitia ,~nAls pnr1 nthAr fi ttings.

\

Rc"lAce the .seni bUlk he?i!.

Fit tho slit1ing ~(')() rs pnn other fittings.

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ANNEXURE­--------­1 •

R':'1L'10'T8 the sirle' '''All ~?ncls·. bAlow the b0nysinc winr10ws. \ .. ' ' •. '.;. . '.r ; , : .'

ROl:1nvc thn winliow f1ssembly comnlnte. .. , .

:'];{~mind thl'J sine w~ll'~ t ~ .

mmc.l "from insiiie 'for any co rI':> sJ . '. , . .

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In cRsesi~e w~ll'ppnel is cnrronen it must be 8ttcncted\'"; to as cx':'")lp.:lnen in .JUmoxureI.

" . ~. . III'

~·J.;l(' i ten N('l~f. 1, 2,3, pnd '+ 0 f reF Drg .NO .EHU..1-4-082 to ,the winck"w, sills. Ann n1l1Ars~ . 1 4 . . Pr- vico nt'"\n-l'!1et?llic nAcldngs. of suitF.lble thickness b.~t,,jccn the winnow runners Ann the plAtes ps shown in onlprgeci views 'o"f sk'.77179. .

~.. ,: ..,. Fix the win~ow Assembly n!"'T)r.-rly resting rm i tern No.1 of IeF Drg. N0.mm-1-4-o82 Anci ~s shown Rt view'Y'of Sk.77179.

Fix the s10e wall PAnels • . . ,'

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TeC~niC~Pamp'h1e~No. C-7715

Instruction f~r re~~ir of R~in w~tcr gutter Sk.77180. ~---~-~~-~---~---~-~-~-----~~~~~-~~~~~~

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1 .1'U""shpflc'-fiiin w~ter gutter is nroviried on old DID coaches.

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T~10~~ are. t?Ujb.1,,::m,s?ec.te~:.J().t.corro.sion:· ,.' _. r '-' ~ •.,.'.:_",""'._:':..'.'.. _ •• _ •• ,-~-~ .. ,j,r_"'-'J'".~ •• ""'''~''''''-,"'......" •

1.2 In c?se there is no corrosion" fill accumulatecl oust· sh"uld .. ~.' "'be'rol'!l~ved ~nri','U' 'sh~ne'rpin w::lter' gutter'cut ;:ts indicRtcd

i.n scctiN~ 'lIA' (L1oc1ifieri when not corroded).' It will .' l''")o!c'like ..'V" shfl"1erain.,w~ter gutter-.···

••••:..,,-...~ ,,'~ ~ .... ", .. ; •• r .. ~•••••~ ,'.:.' .... _,.... ~:~ " •• '-&

1.3 .,}:'ncr.'..se there: :is' cl')rrosion, :cut the existinl1rfl,in wRtar ;:guttcr pt lc~st 100 run more thfln the corrodcrl'length on

, w . ·GPch end. '\':' ,,~~... ~.. '.'~ .... ,.~~.

'..Told tl:1e" new.,rain H~terp;utter, h;:tv:tn~ nrof~.le similHr'Lu• ICF Drg. Nn.EHq-1-6-069 pfter su,'orttng.on pill~rs. The length of:·new gutter to 'be ctecine((t.o. suit the lengthof cc'rrosion" ' ,I' .

Check if ~ll.;the riO() 1"s h:we been "ro'Virfect with r;:tin "1/14 ter gutter to IC1,r,D.rg.No.EHU-1-6-029 ann ~s shown At Section ,..•. /.. '"'-"­'. "

, JBB' .·of Sk.771Slo.·. .

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I f no such" r~in w?ter gutter 'hp s been provlcted over the ,-----:-·00orwClYS•. It must be 11rOvi.c'led. , -zt f-r'~l/C.);;

RAin wptcr gu~ters ~r()vinort must be naintect ~t~nti-. : cn rro s ion, . -;'; '..

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'l'L' c'-~:!ic j,l P.;lmphle t No. C-7715 \' :

ANNEXU BE XI. . \'

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\1 SPECIFICATIONS FOR MATERIALS USED IN CORROSION REPAIRS I'

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-.-.-.-.-'-.-.-.---.-.-.-.-.-'.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.I: 81. . . ( ,. , '1' •j - -,r . i , No. Item , . ': . Specification. I '

• I , -.-.-)-.-.-.~.-.-.-.~.-.'~.~.~.-.-.-':~~'-.-.-.-.-.-.-.-.-.-.- .. ~-

1. Stee 1 shee ts fOr. manufacture of, IRS M.36· ­trough floor, pillars ,. braclte ts and' for side wall shee ts and roof shee ts.

2. Red-Oxide. Zinc Chrom.J.te. Primer palnt IS: 2074-- 62. . "... '

f· .~ '.;' ., .,'. ..! • ,.

3· Bituminous anti-corrosive paint,' IRS P.29-68 solution type brushing q}lality.

4. L~i tun;linoul? ,emulsion,. paint • (::;,.:.• :, ." ~.l. ;.~ ••t.·.~,. . _~'.-~.:~.... ~, ..... ~.~,;.

5. ,~,ji;16 ctrode s'" . Class ~B2' of 'dpiro / brand. of ele.ct;r:ode

.. . .. ~ . ~ ..

6. Ii loorlng \conil'osi'ti~n'/ ... 18:254-73 Grade 3 "

7. Floor boards " ;' Bijcl.sal, Be nte dk1'

Jarub,. Kindal, Asno, H~116ck,

., GhiCkrdssdY, , Anctarnan .Padauk and

* Provided the se are 'y, €ll-seasoned.

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::.[:~{ ~~:;' <:" . ..·;::i . Technical Pamphlet :No~" C-7715 .';'?~}~

~N~XURE XII~;'~' .)<

~5 ~ .20 • - ......, ;0'..... 1".... .

,,'.,;5.'+,:,7 ' . ~.; .

. ' . . .•. ,~,.~:~>;,' ·;'.:1 '-2 ' ;~" ·I:.,'.t{-> \..•.,l«~.;( ...."'.,.. I . ",', , " . 5 :.. 9

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water

Hagne sia' "

Silica ... ;, . . : '.:::; ~ ~ .;" .

Alumina.' . -.~. -' ,

.... ,

Po.t<lsh :/,.':.. .; ,{<~< .~.:

;. .Lim :',' ... ". ;

. Fe rric' Oxide , ~~. ., . ~: .. '~ ,~ J';' ~".'.

.. ' ,~ ,... ~

." Che mic al COIDt,O sitiQ;,

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i) Ve rmiculite Grclue .B, 75% by volume or 5~ by \oJ8ight, and

ii) bitumen,85/40 a~ailable from M/s. Burtnah Shell, Calcutta, and the J.r .othe r bra~Che 5/' '. '

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,'.'. , .. . ......: ': .~. <I:' ";,· ..·t>·.~ . ~.... ~.;",... ,~ ••:.. . .. • ~. f -

. ', .., : ,.lo: ••

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alldsmall .quantiti~ s or ;:r, ~n, »,' S &. Cl•..'.' "1 .' ','" •.:.

(b) T,~e',:m;:lterial is availa~ fro~ Mis. T~rma1.In:sulation,:13i;~.S~ Circ ul"r iIoad, l4,adras-;28, and Mis. Burn & Co. Ltd. ,

. :.Ha~~I'~n~,· It is,. ho-weVtr, not a. pro!Jr.ie. tory '~tem.. , .... ::i!':1;,:.;'~". :.'. ,., , :. . . /';';;;:';~;::::::: .. '! ',: '~",:.:,~". .

~Bi tume l1ised. Ve rmiculi te ;:. ...!~>~ . _. ~ '<.... '" .j " ," ', •• ,;.',.~;:~"'t.. :.,. ... ;:t. " ,;;:.,~~ ;.;;,; '­ , • ", .f~'.,'~ ;(,. " .' The·.bitumeni~~edv~rm1~~lite tv be' us~d' for fi~~ng 1n ,c.o.~ruta.t-i.on..:should copsist!'f .- ",' ..

; •. '1 ~ ••~ . , •• "'~!~,. f

.' ~l •••. ' •• ~." • ':,' ••.•.• 1 ': '.

·::\>1.;' ... '·.· ..

'", . ,

.' .... . . \ ... . :: M~TERIAL Sl'ECIFICATIONS ~ SOURCES OF PROCUREMENT.·' .

'..I(~Ol1;~w{~ve~c~~\i~~:t:':-·~~t· ,·!::Ei~'·'·", ", (a) No lRS~"':ISI orBS"?;speclfiatiO~ for exf,?liate .vermiculi~ .; "•• ;,eJdsts at pre sent, werniietliteis.,micaceous mire ral ~vJ.ng . ; ,'.' basal ,cl~ a:v age. ~ an~ ';·re adi1.y spllts ;into :.ld.mina

e " whiCh are

'.' soft, .i-!J..J.able and inelast~.·The 'specificgravity of~the , IDP.te rial ra~e s from 2. 2 ~ 2,.7):,ilnd 'the me1ting point .

, 1320 to 1350 C. Grade B lCi,ch haS a sele<;:tion particles . . .' 'l/lOthto' 1/3rd of an i~ weighing about":lOlb/cu. ft.

normally. and 1.2 Ib/cu. ft. linen compclc.ted is recomm3nded "for use'.'" The Chemic1;:ll c~osi tion of the'.ye rmiculite . is indicated be low: _ ',>~'. ;.,~ '. "I' .. . .

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,·:;i;~\;··."·~~~it~~;~1T~f,II~~l~;1{\~~t~i~.· ,,,: ;;:'·...0Yi.. :.;!j,,· .. ·:'.;· .. ~< .

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Technicp.l l?nm"lh1' 2 - No.c-7715.·

Armexure-X11 ( ••• '. ,'°'1' ­ ">L~.";"'~ _ ~ .:';)~ ..;; .. , _;.::~',:'.' ..'~.~._. . ... ; . \lJi. t11;:lan;.'u C! ~0lu +ion' Fln~" 4Yr'ul <:lion: ': '3. ....._ - ';:If..".._ .... --:.,.- w. _s .!It __ ., ':.J..WII!":.iI.:.;._ ....:tI> .........--r

i"< "',.' '····f'

~) ,s71ecificflti()n 0 f the bi tumin()us ) , s-:ilu tion:.: :; " '1,':,. ,:; ~'. :. ,J'. " ~, ;~l

.~.;- :.........~ \ . :. \ v.~· ';'" -'~ ~'"/. " . l . ~.,:": I

.:. ,. . (4-co Fl ts Sys tS!l:n) , 1 S given ,below: ­•..-......~:,'.... ' .•..:., l., ":"._. I,. " ." .. ,..... " .., . "." • ',.~, .......•.••"' -;- - ·~"r. ",.. _ ,'-Vi::..·· ." -:. • ,.',,',•. :. e~·.i':'"

,', ':;i'y :'~';'i I st Co.at {C()l'jl"1.N0 .'11, . ~ -~~~ ~~~~~~~~-~

'~, .' ~ -~, .. : ~ ~ '. ,'. '\..., .• ,f~';.i;': ~ ',: .~ ,: .; ".,'.

, HoxnhlAte 85/2';'; :.';.' 50 "1t. by wt. '.' '., .. ' ' .. ~. ,1

50 .nt., by wt.

, 2nr~ COAt (Comn. No.2) ":}..'::.: . ·'i..S~i'1!1 P0 siti9n.j.!i9.1,,·,~~:~:;,..~:;~.:~: '<" ' . '.~.. _

'Re~ oxirletn 18:45 30 ~t.bywt. (Cr' lour unsnec ifien)

.)r0. Coat (Comp. No. ·3) '~'" "":

',CC'MpO si tion N0 .. t Short fibredasbe stos( ~5% passing 50 BSS and l~

. passing 100 LSci me sh) . .!.' ..

..4th Coat (Comp.No.4) 70 pt. by wt. ., Com~osition No.1 ",,- ' .

'---.....J '"

- Short fibred:;asbe stos (~5%' 22 lJt. by wt. ',. ( " lJassing 50 BBS and' 10%"":" .. :~:. F' .

,'<';~'::"'1i:,~:ls,Sing 1~() ;SS~, lJ~Sh).·, . ;:-:~ F • .6'~ ~ ." , •••~-~~.:, ~I ~"~. ~,. ..:.:,. : '.-' ~..... '.,'~ . '., ," '. ,', .~' t.~

. " ;.:ll.:.l.,,;. l_~luminium' pdste.:(n~n 'leafing):i 8 pt., by wt. < "~~~ -:::'~< .t. '".i)" : '~. ~ti::;(t~.·~ '.~'.' ..... ;.. :.~. to' :,.··~f·~.:J~ ....

. ' b) ." ~i t!:roll!lm!§_1ltl.l!1~!2!l':' ' . l,. " .:;. I-""J.-.~ ." , ~ .'~.). '.' ~ ,"

.,:"-:::-,: ',,_:.~ Dituminnus emulsion't('l Iniiif\n Patent SnecificAtion ,:-f,;):,. No. 56192 is:·!p.v~ilflble· fMm H/s.Sh~limAr TAr Pl"0ducts .-' 'Lto., 6 Ly()ns Rflnge, CFllcu~ta~~c who hFlVO been license

I by theN~ti'inAllleseAreh })evelo1')ment Cn rno r~ tion, 0 f , t";'I., ,·~1n(~iA on exclusive,b~sis~:'~ '.

; : ,: c) ,\.:' Bj tuninnus snlu tinn c Fln benbtFlinerl· f1'0m M/s. Shalimar 'rp r Pr"rtucts Ltd., ibr ?ny"~ ther -'aint mi=lnuf~cturing c-·ncem.'-~' '"....

,

. ~. Z1.1).Q_Qh.!:n..me~~_B~d_Q~~2.rlJD~r: .,".... ..~' . ..;' ~\

. Tb~ .;1rinor recommended f'0r use sh-·uld confnnn to IS:Speci c?ti-,n Ur1.2071+ ~nr1 ttJ.s cpn bo obtflinerl from flny ry-Aint r1Flnuf~cturor.