Recent Experience on Coach Interiors And Future Opportunities Integral Coach Factory, Chennai, India 10-10-2015

1981 Underground Metro Train for Kolkata ICF - 1955 to 2015…. 1955 First coach 1962 EMU Train set 1981 Underground Metro Train for Kolkata 1994 DEMU Train set 2001 EMU with 3-phase propulsion system 2008 Stainless Steel Coach 2013 DEMU with 3-phase propulsion system 2015 50,000th Coach

Variety of Builds

Stainless steel coaches Mainline express coaches Variety of Builds Stainless steel coaches Mainline express coaches DEMU Train set – 3 phase propulsion EMU Train set – 3 phase propulsion

Kolkata Underground Metro Air Conditioned Train set Variety of Builds Kolkata Underground Metro Air Conditioned Train set Kolkata Underground Metro – 3 phase Propulsion

Self Propelled Accident Relief Train Variety of Builds Self Propelled Accident Relief Train Duel Fuel DEMU Train Set - Runs on CNG

Golden Chariot for Karnataka Tourism (2008) Variety of Builds Golden Chariot for Karnataka Tourism (2008) Maharajas Express for IRCTC (2010)

ICF exported Coaches and Bogies to various Countries Exports ICF exported Coaches and Bogies to various Countries

Recent experience on Interiors

Governing Specifications Raw materials for Interior furnishing of Indian Railway Coaches should comply with: Spread of Fire UIC 564-2 OR ( Class B ) Loss of visibility due to Smoke UIC 564-2 OR (Class A ) Toxicity NCD1409 (toxicity index <1) Limited Oxygen Index IS:13360 (Min 32) Heat release rate R1(HL2) of EN:45545-2 IR is working towards migration to EN:45545 standards.

Aluminium Composite Panel (ACP) Interior Panelling FRP Aluminium Composite Panel (ACP) Polycarbonate POLYESTER RESIN PHENOLIC RESIN EPOXY RESIN

Used in Stainless steel body mainline coaches Interior Panelling FRP Panelling Used in Stainless steel body mainline coaches On 3-phase EMU train sets and DEMU Train sets. Aesthetic finish Mouldable Longer lead time Non-recyclable

Core: Inorganic oxide of Aluminum Interior Panelling ACP Panelling Core: Inorganic oxide of Aluminum Used on Kolkata Metro coaches, a few rakes of 3-phase EMU and a few mainline coaches. Aesthetic finish Not mouldable , but formable Used with Alu extrusions Recyclable. Non-availability of ACP meeting Railway FST requirements (A2 grade –EN -13501) in India.

Polycarbonate ABS blend material for paneling Mouldable Recyclable Interior Panelling Polycarbonate ABS blend material for paneling Mouldable Recyclable Light weight (500 kg less per coach) Longer lead time

Interior Panelling Future requirements FRP for all AC and Non-AC Stainless steel body mainline coaches and 3-phase EMU Train sets. ACP in Diesel Train sets and metro coaches Polycarbonate on trial basis on Mainline coaches.

Thermoformed Polycarbonate Injection Moulded PU Foam DTPB Cushioned Seating Polycarbonate Cushioned Thermoformed Injection Moulded PU Foam DTPB Silicone Foam FRP Seats

Polycarbonate thermoformed seat Seating System for Commuter Trains Cushioned Seat Used in Intercity coaches like DEMU and day coaches Extensively used in intercity trains DTPB or PU foam cushion Polycarbonate thermoformed seat Extensively used in 130 EMU train sets and Kolkata Metro coaches High rate of production Glued to SS frame and endcapped Non-uniform thickness due to thermoforming. Difficult to replace broken seat top

Polycarbonate Injection-Moulded seat Seating System for Commuter Trains Polycarbonate Injection-Moulded seat Currently used used in 3-phase EMU train sets Better dimensional control Varied colours and more aesthetic. Inserts are moulded in to the polycarbonate sheet for better structural integrity.

CUSHIONING MATERIAL PU foam – Good cushioning comfort. Does not meet stringent FST standard with respect to Toxicity (<1 toxicity index). Used along with fire barrier cloth on day coaches Densified Thermal Bonded Polyester blocks (DTPB) – Meets FST and widely used in IR. Silicone Foam – Meets FST. Better cushioning comfort. Developed and under trials .

Future requirements Polycarbonate seats for commuter trains Seating Future requirements Polycarbonate seats for commuter trains FRP/polycarbonte seats for Metro trains Cushioned seats for intercity trains Revolving seats for tourist cars and high end applications

Experience on Thermoplastics Commuter Coach Window Look out Glass Silicon hard coated Polycarbonate used for look out glass (Taber abrasion 1000 cycles, % haze < 12) Door glass

Hand holds & Snack Table

Thermoplastics - Polycarbonate Light weight Good mouldability Recyclabel Performance is good – window glass, door glass, snack table and hand holds. Scratch formation on look out glass of driver cab PC raw material not available in India. Long Lead time. Product design and process engineering left to the fabricator. With ABS combination, meeting Toxicity requirement is difficult.

GPS based Public Information System LED for Commuter trains Lighting and PIS IR is changing over to LED system from existing Fluorescent Lights. Compartment lights Emergency light Passenger alarm light Tail light Berth reading lights Berth indication lights Lights for toilet/ wash basin GPS based Public Information System LED for Commuter trains LCD on Metro Trains currently production

Stainless Steel Luggage Rack Aluminum Extruded Luggage Rack Stainless steel luggage racks are for commuter trains and general coaches. Luggage racks made from Aluminum extruded section is used in AC chair cars. Aesthetic. Will be provided in all day coaches.

Flooring – Sub layer Cork sandwiched between layers of Macore boards is used for sub floor with PVC top floor in Stainless steel body AC coaches. Aluminum Honeycomb sub floor with PVC top flooring is being tried for air conditioned electric train sets.

Slip-free Stainless steel flooring Flooring- Top Layer PVC flooring PVC top floor is provided in all main line coaches Slip-free Stainless steel flooring Stainless Steel ‘slip free’ top floor is provided for commuter trains viz. EMU and DEMU as well as doorways of conventional mainline coaches. Halogen free rubber-on-rubber flooring on Metro coaches – under implementation

FRP Modular toilets and Stainless steel Modular toilets in AC Coaches It is planned to adopt Modular toilets in non-AC coaches also. FRP Modular toilet – Loss of lusture over time. Stainless steel Modular toilet – formation of water stains.

Bio-toilet Hygenic disposal of toilet waste. Anaerobic Bacteria degrades fecal matter into gas & liquid. Track and station premises will be kept clean. 100% implementation on Conventional coaches from March 2013. All new coaches are turned out with Bio toilets from current year. 11,000 nos fitted at ICF so far. Future Plan: Vacuum Toilets with bio- digester tanks

FULLY SEALED GANGWAYS Used on Kolkata Metro air conditioned train sets Currently being used on Fully Air Conditioned Electric Train set for Mumbai Suburban Functionally performance is good Turnbuckles holding the vestibules giving up Will be used on all Air Conditioned trainsets and Metro coaches

AIR CONDITIONING The tonnage of Roof Mounted Package Unit (AC) for various trains 6.5 tons on Main line AC coaches – 800 coaches/annum 11 tons on Metro Coaches – Project based 15 tons on AC trainsets for suburban - Project based

FORCED AIR CIRCULATION Air Handling Unit Mumbai Suburban trains operate under super dense crush loads For comfort of passengers, Forced Air Circulation system was introduced which pumps 16000 m3/hr fresh air Reduction of 1000 PPM of CO2 levels from the existing highest levels of 2450 PPM Diffuser Grills

Insulation Sound Insulation Sound insulation Paint Floor board laid over rubber decoupling elements Sound insulation paint coated on whole interior of Stainless steel Coaches Floor board made of cork sandwiched between compreg sheets, and laid over rubber decoupling elements. The above insulation Increases weight by 500 kg per coach.

Glass wool Thermal Insulation Resonoflex Thermal Insulation Glass wool cladded with aluminum foil is pasted on walls and ceiling for heat insulation. Additional layer of cross linked polyoiefin foam (Resonoflex) is provided upto window level in LHB AC coaches.

Water based and eco friendly Insulation Future Requirements Water based and eco friendly Coatings that provide sound as well as heat insulation planned for development. Light weight

Transview Tourist Coaches Large windows on side walls, end wall as well as roof for panoramic view Roof glasses glazed for opalescence through electric controls, for making opaque when necessary On board entertainment facility and LCD display Revolving chairs that can be oriented in train running direction. Automatic doors at compartment entry Modular pantry

Anub huti Super Luxur y Coach es Superior Interior Paneling Designer toilets Diffused Lighting IR planning to manufacture Anubhuti Super Luxury coaches with Improved interiors for higher travel comfort Plush upholstery, designer toilets, diffused lighting, better ergonomics, LCD screens, personalized pantry  LCD TV behind each seat with Armrest keypad control Wi-Fi facility Smart display Foldable Arm rest Snack Table

SLIDING DOORS Electrically operated Pocket doors Provided in air conditioned EMU and Kolkata Metro. Manually operated Pocket doors Provided in all commuter trains.

Automatic Pivoted Door Future Requirement door actuator Manually operated pivoted doors provided in all types of mainline passenger coaches presently. Automatic Pivoted doors are required for main line coaches to replace existing manual operated doors.

Retractable Steps Future Requirement Retractable footsteps for ease of disembarking

FIRE SUPPRESSION SYSTEM Fire suppression system currently being installed in power cars Fire/smoke detection and high pressure water mist suppression system To be tried out in AC and NON-AC coaches in a big way. System yet be proven in Non AC environment

CCTV Camera Planned to provide in Ladies compartment of EMU, DEMU, SLRD and all AC coaches – on a large scale Network video recorder (NVR) having 2 TB hot swappable hard disk 30 days recording IP Cameras having infra red sensors for recording even during dark. GPS antenna for real time location and speed. CCTV Video Stream GPS Coordinates Speed & Time

To Conclude Current coach production on IR ~ 4000 /Annum Will go upto ~ 5000 /Annum Large variety of coaches – around 50 variants produced each year Large scale up-gradation of interiors is planned Lead time needs to be reduced Local Engineering support and manufacturing base needed

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