OBJECTIVE:-

At the end of the session you wi ll be able to get

knowledge about the ICF Coaches-

1. Introduction
2. Types of coaches in INDIAN RAILWAY
3. ICF COACH SHELL/ BODY
4. Salient Features of ICF Coach Shell / Body
ICF COACH aoD Y
1
 Introduction
• In 1954 Steel body coach design was taken from M/5 Schlieren Switzerland for
manufacturing of ICF Coaches at Perambur.

• Initia lly original speed of ICF coach was 95 kmph since secondary suspension
was laminated spring.

• Initial coaches manufactured were with Vacuum brake and later modified into
twin pipe graduated release air brake system (under frame mounted).

• The codal life of ICF coaches (normal utilisation coaches) is 25 years and light
utilisation coaches are 40 years.
The construction of ICF coachin Stock is classified into THREE ma·or arts-

• SHELL or the SKELETON pap .

• Furnishing or the provision of Amenities.
• Bogie or the running Trolley parts.
 Desi n Parameters:-
The construction of coaching shell are based on the need to provide maxim um
degree of comport & safety of passenger during journey. This can be achieved by
taking care of the following aspects--
• Heat & corrosion resistant items.
• Spacious and comfortable seating arrangements along with luggage spaces.
• Maximum Ventilation an~ a wide view.
• Adequate Lighting arrangement.
• Air Conditioning/Fans to minimize discomfort during hot weather.
• Efficient and hygienic sanitary arrangements.
• Resistance to Environmental effect such as temperature, Humidity, Rainfall,
corrosive Atmosphere etc.
• Safety devices for safe operation in all working conditions.
 Descri tion of shell-
• The Integral shell is made of a frame work of series of hoops consisUi ng of floor
cross beams, Body side pillars and roof carlines located transversely at regular
intervals to fit the Door & Windows.
• These hoops are connected together by Sole bars, waist rails, Cant rail & Carlines
longitudinally.
• The frame work in side wall is covered by 2 mm thick sheets & 1.6 mm thick roof
sheet of coden steel.
• Corrugated sheet is made of 2 mm thick Carten steel.
Under Frame:-
• Under frame acts as support for mounting equipments like Air brake system
consist of BC,DV, BP,FP,AR, CR, all pipe connections, AC unit, & Battery are placed
in under frame.
• Under frame also contain Body bolsters, Head stocks (outer & inner),Sole bar
cross beam, trough floor, Side bearer centre pins etc.
End Wall:-
• End wall consists of four vertical pillars of Box section.
• These pillars are transversely connected by' Z' sections and are welded to the
head stock at the bottom and to the Roof at the top.
Head stock:-
• The head of Board gauge integral Coaches consists of outer and inner head
stock connected by Tubular firame
• Two nos. Buffers are fitted (in one side) in the outer head stock at a distance
of 1956 mm to transmit the Buffing force to the under frame structures.

IT
 l,.Ll9'11'°Y

CAR LNE

CANT RAil

PILI.AR

LIGHT ~L

WAtSTRAtl

SIDE WALL~ EET

TI-RO LGH
R.OOR ICF COACH SHELL
Font Par~raph Drawing Editing

SOLE B
i AR OF ICF & LHB
 Centre Pivot Arrangement
---------=- -- -
 --
....
....
•••• ..--,.
'1111 == BOLT
Ill .

•••• ~····
~ Centre pin
 Font J .I Ed~l~g

Salient Features of ICF Coach Shell Bod

All Metal : -
• ICF coach shell is made up of steel channel frames of thin sections.
• Only the seats & luggage racks which are made up of wooden
members.

Aerod namic shell: -

• The shell of ICF coaches are made with the curved roof aJ the corners
and curved at turn under
• This curved structure minimize the air resistance during running of the
coach at high speeds.

to add notes
 ,e, I lo •,nw.r ,. u • •
f aragraph

LIGHT WEIGHT
• The wt. of coach shell is reduced due to minimum use of wooden members.
• Use of anti corrosive Carten Steel sheet (IRSM 41) of thicknes s 1.6 mm for roof
and 2 mm thickness for corrugated flooL
• The use of gusset plate, knee & Rivets are also avoided in ICF coaches.
• So weight of the coa ch is reduced 26% to 32% than IRS coach .
• Less material is used. This means saving of material and its cost.
• Since the coach is lighter more Vehicles could be hauled .
• Speed of the trai n also could be increased.
• Being lighter the wear on permanent way & others mechanical parts are less.
Salient Features of ICF Coach Shell Bod
• lnte ral Construction:-

• The shell of ICF coach is formed by welding together body side pillars, roof
carlines, waist rail, light rail, cant rail & sole bar.

• Corrugated flooring, Side panels, end panels & roof are welded together by
means of homogeneous Welding.

• End pillars & side pillars are also connected with panelling work. IT

• This type of structure is known as hoop type structure or Integral construction

 1-01,1 urawt119

Anti telesco ic constr uction:- 1

·• The shell of l·CF Coach is designed to bear 45 tones of vertical 1,oad and 200
tones of longitudinal impact on buffers .
• The coach body is so designed that it is stronger at end portion as well as in
passenger seating portion and iess at the doorway and t ,o ilet portion.
• The maximum kinetic energy during accident is absorbed by the end portion
and get damaged and balance kinetic energy is also shared by the corrugated
flooring and o,ther members ,o f body shell,
• During accident the passenger accommodatiion area of middle portion of shell
safe with minimum damage.
• For Integral all welded constr uction the body & th e Sole bar cannot be
separated in an accident
• Due· to these properties, telescoping of one coa ch int o adjacent coa ch is
avoided during accident. Hence the above type of shell construction is known
as anti telescopic construction. .~.
 FOIU P.aragraph Di'i1\liln9 Editing

d notes
 ANTI CORROSIVE PROPERTY
• To achieve anti corrosive property to the shell of ICF coach, CQrten steel IRSM - 41 is being
utilized for paneling purpose.
• This anti corrosive Carten steel is mostly used in under frame & Lavatory area where

• During manufacturing the process of sand blasting, grit blasting is also given on panel sheet
which is helpful to prepare rough surface for painting resulting in less chances of corrosion.
• Three coats of bituminous anti-corrosive paints are given at welded portion and for other
portion red - oxides paint is applied for anti-corrosive treatment.
• The Trough floor is provided with holes for proper drainage of water.
• Elliptical holes of size 200 x 135 mm are given in turn under portion for proper drainage of
rain water coming from window shell.
• The inside flooring is made of 19 mm thick ply or 12 mm thick cdfv1PREG sheet and 2 mm PVC
flooring is covered over it, avoiding the seepage of water from the floor below to the
corrugated sheets.
• The above precautions and provision of facilities minimizes the incidence of corrosion.
 Salient Features of ICF Coach Shell Bod
Heat resista nee :-
To develop heat resistance property in coach shell following facilities has been provided:-
a) Silver/ aluminium paint coat is provided on outer side of roof which reflects
the sun rays coming outside the coach.
b) In roof ceiling layers of insulting materials like asbestos/ glass wool is provided
which is bad conductor of heat resulted direct transmission of heat inside is
minimized.
c) In carlines, elliptical holes are also provided for proper air circulation from one
compartment to another.
d) No. of ventilators are also provided on top of roof to exit smokes, gases and to
circulate fresh air.
e) Limpet sheet is also provided inside of the roof (2mm thick) which is bad
conductor of heat .
TI
Maintenance Scheduled of ICF Coach
► Trip schedule- After every trip of a coach done by primary
• maintenance depot.
► Schedule A - Monthly (1 month+/- 3 days)
► Schedule B - Quarterly (3 mUi nths +/- 7 days)
► IOH ---1 year for 1st IOH+30 days & 9 months for old
• coaches.
► POH---2 years for 1st POH+30 days&18 months for old
• coaches.