Maintenance of Coaching Shell(ICF+LHB) &

their Components(excluding furnishing) in

open line &Workshops-exterior mtc,including
painting,vinyl wrap,electronic display boards.

Objective
List the name of repairable parts.
Know the procedure of maintenance.
List the process of painting

Introduction
Mainly maintenance is required due to

corrosion in the parts of shell.

High population of coaches in IR.
Need regular maintenance in open line &
workshops.

Coach Shell

Car Line

Cant Rail

Body
Pillar

Light Rail
Waist
Rail

Side Wall
Sheet

Sole Bar
Cross
Beam
Trough Floor

Corrosion in Coaches

Corrosion Prone Area in Passenger

Coach
Trough Floor
Adjacent to lavatory,door ways & kitchen area

of pantry car.

Side wall bottom

Below lavatory & between body side pillar.
Sole Bar
In the lavatory area & door ways.

Body Pillar
Bottom portion

Corrosion
Prone
Area
Cross Bearers
Joint between sole bar & cross bearers.

Body Side Door

Bottom of door
Roof
Ventilator & its area.
Battery Boxes
Corrosion due to acid action.

Parts of the Shell requires Corrosion

Repair
Head Stock
Sole Bar
Side Wall members
Trough Floor
Roof
Partion wall,Seat pillar/Mounting plate
Body bolster,centre pivot
Floor channel

Areas corroded in ICF

Coaches
Areas

Possible causes

Inner Head stock below lavatory

Dust & water seepage from

lavatory

Main door bottom portion

Dust deposition

Turn under below lavatory

Water seepage & dust deposition

Low er portion of lavatory

Water logging

Lower portion of side wall near

lavatory

Dust deposition & water seepage

Trough floor

Water logging

Lower portion of body pillar &

turn under

Water seepage from pantry &

lavatory

Heavy Corrosion

Heavy Corrosion

Heavy Corrosion

RCF Coach

Procedure of Maintenance of Under

frame
Throughly inspected for locating

cracked/bent/corroded members
Corrosion checked
By flaking of paint/flaking of metal,pitting &

scale formation.

Sole bar & trough floor

By tapping with a spiked hammer.
Replacement needs after reducing 20% of its

thickness.

Corrosion Repair to Under frame

Members
Coach body kept on trestles
Use corrosion resistant steel sheet.
Electrodes of approved brands
Paints
Red oxide zinc chromate primer
Bituminous anti-corrosive solution

Method of repair
Where corrosion just started
Paint & rust throughly clean to reach the bare
metal & give two coats of primer & two coats of
paint.
Where heavy corrosion
Replace the item

Corroded Head
Stock(ICF)

Corrosion Repair Process

Head Stock
Before replacing,strip
Side buffers,PVC flooring,end partition,draw
gear
Before cutting the corroded portion, the
auxiliary head stock & the two sole bar ends
firmly supported to rail lines.
Replace head stock & 8 mm thick steel sheet
used.

Sole Bar
Strip
Interior fittings,laminate paneling & window
frames.
Coach keep on trestle.
Before cutting corroded portion of sole bar,

both ends give fixed support to the rail lines.

New sole bar piece welded from outside &
inside.

Side Wall Members

Strip

Interior fittings,laminate paneling &

window frames.
Side/End wall sheet, body pillars & turn

unders replace which is required.

Trough Floor(ICF)

Painting of Coaches &

Vinyl Wrapping

Types of Paint
Alkyd paint
PU paint
Epoxy paint

Painting Procedure
Surface preparation.
Priming of surface.
Putty,filler,etc.
Under coats
Top coats

Surface Preparation
Blasting process
Sand blasting
Shot blasting
Grit blasting
Wet blasting
Hydro blasting

Shell
Unblasted Shell

Blasted Shell

Primer
Purpose
Acts as barrier
Makes the surface
more paintable
Provides corrosion
protection
Better adhesion for
coatings

Putty
A dough like stiff

paste applied by
knife.
Used to fill dents
& to level
undulations
Excessive coating
thickness (275
microns max) to be
avoided to minimize
flaking

Filler
Filler to IS:110 /
1983:Used for filling up
of pin holes,
scratches, etc for
getting uniform
surfaces after the
application of putty.

Undercoat
Undercoat to
IS:8662/1993:
Intermediate coating
between primed/putty
applied surface & top
coat.
Purpose:to improve adhesion
between primer/
Putty & top coats.
to protect the primer
provides a base
for the finish coat
for giving aesthetic
look

Top Coat
Top coat finishing to
IS:8662/1993:Normally one or two
coats for required DFT
Purpose:
Provides aesthetics of
colour and gloss
Protects
against
environment
Protects from:

destructive UV light
ingress of air & moisture
chemicals and corrosive
fumes.

Fully Painted Coach

Painting Schedule in POH

1st Day-Remove old painting.
2nd Day-One coat primer.
3rd Day-One coat brush filler.
4th Day-2nd coat filler with putty
5th Day-Rub down with SiC paper
6th Day-One coat of undercoat

Painting Schedule
7th Day
Flat with SiC paper & apply one coat of enamel
finish
8th Day
Flat with SiC paper gr-400 & 2nd coat of
synthetic enamel finish
9th Day
Lettering.

Thank You