FOOT RESTS

DIFFICULT TO HOLD
IMPORTED COACH RCF COACH
 ROLLER BLIND

IMPORTED COACH RCF COACH

 LUGGAGE RACK

IMPORTED COACH RCF COACH

GAP IN THE JOINTS

DIFFERENT COLORS OF FRP PROVIDED
IN THE DOOR WAY AREA

MIS-MATCH IN COLOURS
 WATER LEVEL INDICATOR

IMPORTED COACH RCF COACH

MOISTURE
 FREQUENT BREAKAGE OF
DESTINATION BOARD COVERS

FRAME
 CHEQUERED FLOORING

IMPORTED COACH RCF COACH

NOT FULLY COVERING THE

ENTRANCE
CENTER TABLE MOLDING PROVIDED OF
WOODEN PLY INSTEAD OF STEEL /AL.
FOLDING TYPE ARM REST GRAZING WITH
BODY PANELS WHILE LIFTING
RECLINING GEAR LEVER KNOBS
WORKING OUT

KNOB
ICF TYPE VESTIBULE DOOR
LHB
TYPE

VESTIBULE DOOR
 Flush
Button/Switch

Toilet Paper Holder

Hand Grip

Water for toilet use

Ashtray or Lotah

LHB MODULAR
TOILET
 AIR VENT
MIRROR

FLUORESCENT
LIGHT
ASH TRAY

WASH BASIN
LHB MODULAR
TOILET
COMPOSITE MODULAR TOILET
HONEY COMB PARTITION FRAME
 STATUS

• Design of ICF type ACCN coach and

MG ACCW with Honey comb partition
frame has been developed.
• Prototype MG ACCW with honey comb
partition frame is in hand.
 FRP SIDE WALL & ROOF
PANELLING
EXISTING DESIGN MODIFIED DESIGN

• Paneling of LP on side wall • FRP panelling for side

& NFTC on roof
wall as well as roof
• Aesthetically not pleasing
• Aesthetically pleasing
• Frequent problem of
breakage • Less prone to breakage
• LP sheet cann’t be
repainted • Can be repainting
FRP SIDE WALL & ROOF PANELLING
LHB COACH INTERIOR
ROLLER BLIND ON WINDOWS
LUGGAGE RACK
European Style Toilet

Indian Style Toilet

COAT HOOK PROVIDED IN LAVATORY
PASSENGER COMFORT
BACK SIDE OF SEAT ATTENDANT SEAT
Reading lights provided in Lugagge Rack
Sliding Coat
hooks
provided in
Luggage
Rack
 PASSENGER
CONVENIENCE
SPACIOUS
ENTRANCE
AREA
 AIR -----
PROVIDED IN
CEILING OF
LAVATORY

LAVATORY ENGAGED
INDICATOR IN
PASSENGER AREA
WIDER
PASSENGER
COMPARTMENT
DOOR WITH
BIGGER GLASS
UNIT
Flush Button/Switch

Toilet Paper Holder

Hand Grip

Water for toilet use

Ashtray or Lotah

Drain
110V/220V Socket
for shaver
Push button for
water supply

Water out let

for hand wash

Soap Dispenser
 AIR -----
MIRROR

FLUORESCENT
LIGHT
ASH TRAY

WASH BASIN
DETAILED DESIGN FEATURES

OF

LHB COACHES
 LHB COACH DESIGN MAJOR FEATURES
1. LENGTH OVER BODY - 23540 mm
2. MAX. DISTANCE BETWEEN INNER 12345 mm
WHEELS (11887mm)
3. MAX. BUFFER DROP 75 mm
4. MAX. TARE WEIGHT 40.287t
5. NO OF PASSENGERS 78 (2ND ACCZ)
56
6.
(EXEC. ACCZ)
TEST SPEED POTENTIAL 180 KMPH
7. SPERLING RIDE INDEX OF COACH 2.5 BUT NOT EXCEEDING 2.75
8. MAINTENANCE CRITERIONITEMS OF WEAR & TEAR SHALL
NOT REQUIRE REPLACEMENT / RENEWAL BEFORE 1
MILLION KMs.
9. USE OF STAINLESS STEEL AND LESS BOGIE MOVING
PARTS SHALL REDUCE MAINTENANCE REQUIREMENTS
EMERGENCY WINDOW
 Handle

EMERGENCY WINDOW
HOPPER WINDOW FOR LAVATOTRY
 Roller Blind
• Roller blinds have been provided on
the windows in compartment area
instead of curtains. The blind is
manually operated. These blinds have
three positions i.e. full open, half open
and full closed.
ROLLER BLIND ON WINDOWS
Stopper for roller blind
FIXING

DETAILS

OF

ROLLER

BLIND
AC 2 TIER
AC 3 TIER
FOLDABLE SNACK TABLE
 Doors
LHB coach has :
• 4 body side doors
• 2 compartment doors
• 3 lavatory doors
• 2 vestibule doors
• 1 pantry door
• 2 Roller shutters for pantry storage
area
 Body side doors
• Hinged type swing sandwich doors
• Stainless steel body filled with
phenolic resin for better heat
insulation.
• Inside panel of door made up of
FRP
• Provided with sealed window glass
unit.
ENTRANCE
DOOR
 Compartment door
• Single flap sliding door
• Stainless steel body filled with phenolic
resin for better heat insulation.
• Manual opening, auto closing type door
• provided with rubber sealing at the
door leaf for hand safe feature
• provided with air grill for air circulation
• Fitted with 6 mm glass for viewing
COMPARTMENT DOOR
SLIDING MECHANISM OF DOOR
 Vestibule door
• Double flap sliding door
• Manual opening and auto closing type door
• Provided with rubber sealing at the door
leaf for hand safe feature
• Stainless Steel body filled with phenolic
resin for better heat insulation and
security of the coaches
• Fitted with 6 mm glass for viewing
• Door opens only 250 mm when gangway
bridge plate is in the folding position.
 Pantry doors

• Double flap sliding door

• Manual opening and auto closing
type door
• Provided with rubber sealing at
the door leaf for hand safe
feature
• provided with air grill for air
circulation
Vestibule door

Pantry door
 Lavatory doors

• Double flap bi-fold door for

better space utilisation
• made up of sandwich
construction
• Provided with rubber sealing at
the door leaf for hand safe feature
• Provided with air grill for air
circulation
 Rolling Shutters

• Made up of aluminium extruded

sections.
• Lockable with a key
• Located opposite to the pantry
Storage
area for
Serving
Trolley

Storage
area for
Pantry
SEAT AND BERTH SECTION:-

In this section
seats are mounted
in the coaches. In
sleeper coaches
berth is also
mounted.These
are different for
different types of
coaches.
 DESIGN OF
LHB NAC COACH
 FEATURES OF LHB NAC
–
COACH
FRP panel on side wall and roof
– Compact FRP lavatory module
– Controlled discharged toilet system
– Modular type luggage rack
– Center Buffer Coupler
– Axle mounted disc brake system
– Modified FRP windows
– D coupling element in floor
– LHB type door with provision of NAC window
 FEATURES OF LHB NAC
COACH
• Two piece aluminum water tank each of capacity
390 litres (4 in a coach)
• Bolted stainless steel partition frame
• Interlocked stainless steel shell
• LHB type passenger alarm system
• Stainless steel roof ventilator
• Air brake system similar to LHB coach
• Seating capacity of 99, 78 & 36 in GS, SCN and
SLR coaches, respectively.
• Screw less FRP panelling on side wall and ceiling
MAJOR SUBASSEMBLIES
• Seats
• Luggage racks
• Windows
• Ceiling panels
• Body side doors
• Water Tank
• Partition frames
 Seats and Berth
GS AND SLR
• SS frames
• Compreg batons
• Floor mounting
• Round corners.
SCN
• Same as that of existing
coach
 LUGGAGE RACKS OF GS & SLR
TRANSVERSE
• Stainless steel frames
• Compreg batons
• Inclined for injury free

LONGITUDINAL
• Cast-steel structure
• Cast-steel brackets
• SS pipe supports
BODY SIDE WINDOW

• Concealed screws
• Flushed with side panel
 CEILING PANELS

• Aesthetic pleasing screwless FRP panel

• Inbuilt housing for light & fan
 BODY SIDE DOOR

• SS LHB TYPE DOOR

• Provision of NAC WINDOW
• Latch from inside
 WATER TANKS

• 385 litre Al water tank

• Two piece design with better reliability
• Corrosion resistant
PARTITION FRAMES

• Stainless Steel
• Bolted P/F’s
 USE OF COMPOSITE MATERIALS
“ALUCOBOND” LAVATORY
CEILING PANEL & ALUMINIUM
HONEY COMB PARTITION PANELS

IMPROVED AESTHETICS
VERY GOOD SURFACE FINISH
CORROSION RESISTANCE
 BETTER RIGIDITY
HIGHER STRENGTH TO WEIGHT
RATIO
CAN UNDERGO PROCESSES SUCH
AS ROLLING, BENDING, CUTTING,
WELDING ETC. WITHOUT LOOSING
OUT ON IT’S PROPERTIES

FLOORING BOARDS - CORK

SANDWICHED BETWEEN
COMPREG TO ABSORB NOISE
LHB RAJDHANI PAINTED SHELL
LHB SELF GENERATING SHELL
SALIENT MECHANICAL DESIGN
FEATURES
OF
LHB SG COACHES
 Seating Capacity
LHB ICF
• First Class Sleeper (FAC) - 24 18

• Two Tier AC Sleeper (AC2T) - 52 46

• Three Tier AC Sleeper (AC3T) - 72 64
• SCN - 78 72
• GS - 99 90
• SLR - 30 20
WINDOWS
Emergency
openable
window

• It is similar to the fixed unit

• Four units are provided
each coach to allow
emergency evacuation of
passengers
• A handle connected to the
rubber profile opens the
glass unit of the
emergency window
HOPPER WINDOW FOR LAVATOTRY
 Body side doors
• Hinged type swing sandwich doors
• Stainless steel body filled with
phenolic resin for better heat
insulation.
• Inside panel of door made up of
FRP
• Provided with sealed window glass
unit.
 VESTIBULE DOOR
• DOUBLE FLAP SLIDING DOOR
• MANUAL OPENING & AUTO CLOSING TYPE
DOOR
• PROVIDED WITH RUBBER SEALING AT THE
DOOR LEAF FOR HAND SAFE FEATURE
• DOOR OPENS ONLY 250 MM WHEN GANGWAY
FIRE RETARDANT
BRIDGE PLATE IS IN FOLDED POSITION. PROPERTIES:
• STAINLESS STEEL BODY FILLED WITH
PHENOLIC RESIN FOR BETTER HEAT
INSULATION AND SECURITY OF THE
COACHES
• FIRE BARRIERS ON ALL FOUR EDGES.
• INTUMESCES (EXPANDS WITH HEAT)
TO FORM A HARD CHAR THAT TIGHTLY
SEALS PENETRATIONS AGAINST FLAME
SPREAD, SMOKE & TOXIC FUMES
• EXPANSION BEGINS AT 121 DEG C,
SIGNIFICANT EXPANSION 176 DEG C,
EXPANSION 8-10 TIMES
New Design of Lavatory
Doors
•No interface with door frame
•In built micro switch for WC
indicator
•Breakage free sunk-in handle
for pulling the door
•Forked latch for keeping the
door closed when not in use
New Design of
Lavatory Doors
•Good looking D-handle for ease
of opening from inside
•Single point locking between
two leaves of t he door
•Micro switch operated by this
latch , no alignment problem
 FRP ITEMS

• A NO. OF FIRE RETARDANT FRP ITEMS HAVE

BEEN USED IN THE INTERIORS FOR:
– IMPROVED AESTHETICS
– ABILITY OF FRP TO BE MOULDED INTO INTRICATE
SHAPES/CURVED SURFACES, AVOID JOINTS
– BETTER STRENGTH TO WT RATIO
– SCRATCH RESISTANCE
– RESILIENCE TO SMALL DENTS
– EASY REPAIRABILITY
– NO VISIBLE SCREWS
– BETTER MAINTAINABILITY
– NO PROBLEM OF
CORROSION
DUAL LOCKS FOR MOUNTING OF
FRP PANELS

• POSITIVE LOCKING
• BLIND ATTACHMENT
• MUSHROOM SHAPED
POLYOLEFIN STEMS
• REUSABILITY
• TENSILE LOAD - 0.7 KG/SQ.
CM
• SHEAR LOAD - 0.7 KG/SQ.
CM
AC DUCT

• SUPERIOR 2 TIER DESIGN

• NO LOSS OF COOLING AIR
• SUPERIOR THERMAL
INSULATION
• BETTER SOUND
DAMPENING
• NO DIRECT BLAST OF COOL
AIR
Mounting of FRP ceiling
panels
•AC ducting insulated from outside
•Duroplastic elastified foam made pf melamine
•Very low thermal conductivity of 0.035 W/moK
•Embossed surface, air permeable, slightly densified for
noise absorption
 SEATS & BERTHS
• FOR MORE COMFORT & INCREASE IN LIFE OF SEAT LATEX RUBBER
FOAM HAS BEEN CHANGED TO PU FOAM
• USE OF REXINE INSTEAD OF CLOTH, TO AVOID SOILING WHILE IN USE.
• DESIGN OF BERTH FRAME CHANGED TO MAKE IT INJURY FREE ON
CORNERS BY PROVIDING PADDING.
• FAC LHB COACH BERTHS WITH ARTFICIAL LEATHER, INSTEAD OF
REXINE.
• MOUNTING HARDWARE FOR SEATS CHANGED TO MAKE IT INJURY
FREE.
• TURN OVER LATCH DESIGN CHANGED TO MAKE IT INJURY FREE
• “CAVALIER” MAKE SAFETY RAIL ON SEATS
• DESIGN OF FRP CEILING PANELS CHANGED FOR MORE OVER HEAD
SPACE
 Space between
berths

Figures in brackets are for the

ICF design coach
 Polycarbonate
Snack Table
•Light weight (Sp. Gravity 1.2)
•High Impact strength (200 N/m)
•High flexural strength (Flexural modulus 2300
N/m)
•Indentation hardness (95 N/sq.mm)
•Legs removed
•Bottle holder below the shelf, away from the floor
•Blue colour in ACCW and ACCN to go with blue
rexine.

•
Improved carpet in FAC
3M Nomad carpet matting 6500
•High wear resistance (1600 crossings per
day)
•Fire resistance to DOC FF 1-70 & DIN
66081
•Washable & UV resistant
 DECALS
• APPROXIMATELY 34
DIFFERENT TYPES OF
STICKERS/DECALS HAVE
BEEN USED IN LHB
COACHES.
• GLOW TYPE STICKERS HAVE
BEEN USED IN THE SLEEPER
COACHES FOR INDICATING
BERTH NUMBERS, BOTH ON
SIDEWALLS & ROOF PANELS.
• ALL EMERGENCY
INSTRUCTION DECALS ARE
ALSO GLOW TYPE (ON
EMERGENCY WINDOWS &
ALARM PULL HANDLES)
 Revised Lav Layout

• New design made with

light shifted above
mirror
• Mirror width increased
• Plumbing and electrical
wiring shroud cross
section reduced
• Shroud moved to corner
• Gravity cocks in place of
Electrical push button
water taps
 New Designs
• Drain cap/cover redesigned
with bigger opening - fitted
in 5th Rajdhani rake
• Existing drain cover holes
elongated into slots
• Slope increased to 3
degrees in drawings and
vendors asked to strictly
provide the same
• For existing coaches 3M
scrapper matting being
procured which permits
water to flow underneath
while keeping the top dry -
provided on trial in 2
ACCWs of 5th Raj Rake
 New Designs
• Anti graffiti, stain resistant, scratch proof, PU
clear coating of Akzo Noble make started w.e.f.
Shatabdi coaches under manufacture at RCF
• Case being processed for getting the same
treatment along with prior repainting of the
base coat done on the coaches already
running in NR & WR at Delhi & Mumbai depots
themselves
 Ventilator with
exhaust fan

Outside
wash basin
cum dustbin,
augmenting
the dust bin
capacity in
the coach by Lavatory wash basin
100% anti graffiti, stain &
scratch resistant PU
coating
 Shower room in FAC
•Instant electric geyser for hot
water
•Showers - hand held & fixed on
roof
•Pressurised water supply
•High quality bathroom fittings
with provision of hot & cold water
•Wash basin, mirror, shaver socke
•No WC
 Water Tanks

UNDER SLUNG WATER TANKS

(2X685 + 450 L)

30L WATER TANK OVER

EACH LAVATORY
(Vent valve fitted on the water pump took care of most of the air lock case,
some cases left will be taken care of by this vent valve which will be retro
fitted also)
FLOAT TYPE AIR
VENT VALVE
 Water Tanks

UNDER SLUNG WATER TANKS

(2X685 + 450 L)

30L WATER TANK OVER

EACH LAVATORY
(Vent valve fitted on the water pump took care of most of the air lock case,
some cases left will be taken care of by this vent valve which will be retro
fitted also)
FLOAT TYPE AIR
VENT VALVE
 CONTROLLED DISCHARGE TOILET
SYSTEM
• SPEED SENSED THROUGH WSP
• DISCHARGE VALVE OPENS ABOVE 30 KMPH ONLY
• DISCHARGE AFTER EVERY SET NO OF
FLUSHES (0-15, PROGRAMMABLE)
• DISCHARGE WHILE DECELERATING AT
30 KMPH
• THE WASTE GETS ACCUMULATED IN
RETENTION TANK OF 45 LITRE CAPACITY.
• FLUSHING WITH PRESSURISED WATER,
2.5 L IN ORIENTAL & 1.5 L IN WESTERN
• OVERFLOW PIPE PROVIDED IN
RETENTION TANK
• SLIDE VALVE ON TOP OF TANK
PREVENTS FOUL SMELL FROM
ENTERING THE LAV
Waste Retention Tank

Water supply and

CDTS pipes and
controls hidden behind
the FRP wall panel in
door-way
 CENTRE BUFFER COUPLER
• LHB COACHES HAVE BEEN PROVIDED WITH
TIGHT LOCK CENTRE BUFFER COUPLERS
INSTEAD OF SCREW COUPLING.
• COUPLERS ARE AAR H-TYPE AND HAVE ANTI
CLIMBING FEATURES BECAUSE OF VERTICAL
AND HORIZONTAL INTERLOCKING
• CONVENTIONAL ICF TYPE COACHES HAS ALSO
BEEN PLANNED WITH CBC.

• ENERGY ABSORPTION
MORE THAN 45 KJ
 DISC BRAKE SYSTEM
WITH WSP
BRAKE PADS

BRAKE DISC

SPEED
SENSOR
FOR WSP
BRAKE CYLINDER

BRAKE CALIPERS

• BETTER MAINTAINABILITY
& RELIABILITY
• OPTIMUM UTILISATION OF
ADHESION LIMIT
 Passenger Emergency Alarm

• There is no mechanical
linkage like a chain and these
handles directly operate a
valve venting the brake pipe
• Designed to stop the train not
just warn the driver
WHEEL SLIP/SKID PROTECTION DEVICE
• VESTIBULE FALL PLATE CAN SLIDE AND ALSO LIFT UP.
• WHEN FALL PLATE IS UP, THE VESTIBULE DOOR CAN NOT
BE OPENED MORE THAN 150MM
• VESTIBULE DOOR IS OPENED MANUALLY BUT CLOSES
AUTOMATICALLY
AC Sleeper Car Interiors
Non-AC Passenger
Cars Interior