Maintenance of Coaching Shell(ICF+LHB) & their Components(excluding furnishing) in open line &Workshops-exterior mtc,including painting,vinyl wrap,electronic display boards.

Maintenance of Coaching Shell(ICF+LHB) & their Components(excluding furnishing) in open line &Workshops-exterior mtc,including painting,vinyl wrap,electronic display boards.ObjectiveList the name of repairable parts.Know the procedure of maintenance.List the process of paintingIntroductionMainly 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

Cant RailLight RailWaist RailSole BarTrough FloorCar LineBody PillarSide Wall SheetCross BeamCorrosion in Coaches

Corrosion Prone Area in Passenger CoachTrough FloorAdjacent to lavatory,door ways & kitchen area of pantry car.Side wall bottomBelow lavatory & between body side pillar.Sole BarIn the lavatory area & door ways.Body PillarBottom portionCorrosion Prone AreaCross BearersJoint between sole bar & cross bearers.Body Side DoorBottom of doorRoofVentilator & its area.Battery BoxesCorrosion due to acid action.

Parts of the Shell requires Corrosion RepairHead StockSole BarSide Wall membersTrough FloorRoofPartion wall,Seat pillar/Mounting plateBody bolster,centre pivotFloor channelAreas corroded in ICF CoachesAreasPossible causesInner Head stock below lavatoryDust & water seepage from lavatoryMain door bottom portionDust depositionTurn under below lavatoryWater seepage & dust depositionLow er portion of lavatoryWater loggingLower portion of side wall near lavatoryDust deposition & water seepageTrough floorWater loggingLower portion of body pillar & turn underWater seepage from pantry & lavatoryHeavy Corrosion

Heavy Corrosion

Heavy Corrosion

RCF Coach

Procedure of Maintenance of Under frameThroughly inspected for locating cracked/bent/corroded membersCorrosion checkedBy flaking of paint/flaking of metal,pitting & scale formation.Sole bar & trough floorBy tapping with a spiked hammer.Replacement needs after reducing 20% of its thickness.Corrosion Repair to Under frame MembersCoach body kept on trestlesUse corrosion resistant steel sheet.Electrodes of approved brandsPaintsRed oxide zinc chromate primerBituminous anti-corrosive solutionMethod of repairWhere corrosion just startedPaint & rust throughly clean to reach the bare metal & give two coats of primer & two coats of paint.Where heavy corrosionReplace the itemCorroded Head Stock(ICF)

Corrosion Repair ProcessHead StockBefore replacing,stripSide buffers,PVC flooring,end partition,draw gearBefore 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 BarStripInterior 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 MembersStripInterior 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 PaintAlkyd paintPU paintEpoxy paintPainting ProcedureSurface preparation.Priming of surface.Putty,filler,etc.Under coatsTop coatsSurface PreparationBlasting processSand blastingShot blastingGrit blastingWet blastingHydro blastingShellUnblasted ShellBlasted Shell

PrimerPurposeActs as barrierMakes the surface more paintableProvides corrosion protectionBetter adhesion for coatings

PuttyA dough like stiff paste applied by knife. Used to fill dents & to level undulationsExcessive coating thickness (275 microns max) to be avoided to minimize flaking

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

UndercoatUndercoat 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 CoatTop coat finishing to IS:8662/1993:-Normally one or two coats for required DFTPurpose: Provides aesthetics of colour and glossProtects against environmentProtects from:destructive UV light ingress of air & moisturechemicals and corrosive fumes.

Fully Painted Coach

Painting Schedule in POH1st Day-Remove old painting.2nd Day-One coat primer.3rd Day-One coat brush filler.4th Day-2nd coat filler with putty5th Day-Rub down with SiC paper6th Day-One coat of undercoatPainting Schedule7th DayFlat with SiC paper & apply one coat of enamel finish8th DayFlat with SiC paper gr-400 & 2nd coat of synthetic enamel finish9th DayLettering.Thank You