Indian Railways to receive first batch of aluminium-bodied coaches by February 2022

As reported by a railway official, Indian Railways (IR) is anticipated to receive its first batch of aluminium-bodied coaches by February 2022. In a technological transpose for railways, the Raebareli based Modern Coach Factory (MCF) is considering manufacturing aluminium coaches. However, the first set of 3 coaches for Kolkata Metro are expected to be ready by early next year, whereas, in due course, IR expects to get aluminium coaches for Rajdhani and Shatabdi Express style premium trains.

MCF has inked an INR 128 crore agreement with South Korean firm Dawonsys for this enterprising project. The execution of the project has been detained by the COVID-19 pandemic, as it hit hard both India and South Korea. The design for the metro coaches is believed to be concluded by the end of this month.

"The South Korean firm will share the designs and once MCF approves they will be made in South Korea and brought in India in knocked down condition," the railway official said.

"To begin with they (Dawonsys) will manufacture these coaches in South Korea and slowly the transfer of technology will take place to MCF," the official added.

The three standard gauge metro coaches will comprise two driver motor cars and one trailer coach with a speed potential of 100 kmph.

The contract also reveals that it has provision for manufacturing 8 broad gauge locomotive-hauled coaches. These include three AC-3 tier Sleeper coaches, two AC-2 tier sleepers, one AC-1 sleeper, one AC hot buffet car and one AC DSLR with Driver/Guard cabin. These Rajdhani style sleeper coaches will have a speed potential of 160 kmph. Of these 8 coaches, 4 will come fully assembled and the rest will be received in knocked-down condition and assembled here. The South Korean firm's staff will provide hands-on training to MCF officials as part of the deal.

Furthermore, designs for self-propelled aluminium coaches with speeds of up to 225 kmph will be provided. This will help MCF manufacture Shatabdi style aluminium coaches. The self-propelled coaches will support Indian Railways to run superior train sets in line with its aim to connect major cities with chair car train services.

The major reasons for aluminium-bodied coaches:

• Aluminium coaches are lightweight compared to stainless steel deriving in lower haulage cost and better fuel efficiency.
• Aluminium is corrosion resistant which gives an extended coach life of 40 years - that's 5 more years of revenue.
• Modular interiors with easily removable components during maintenance and retrofitment.
• Reduced weight permits for increased speed potential on the existing Indian Railways tracks.
• Low life cycle cost with reduced wear and tear of components.
• Hollow extrusion design allows for commendable crashworthiness in case of an accident.
• Short time is required to build hence increasing production capacity.

The Indian Railway Board has given its green signal for manufacturing 500 aluminium coaches once MCF has the required infrastructure. The new aluminium coaches will be distinguished to Shatabdi and Rajdhani Express coaches in regards to comfort, safety, exterior and interior. The technology and expertise to manufacture aluminium-bodied coaches will be another jewel in the crown for railways which presently makes stainless steel coaches.