1. Recent Experience on Coach Interiors And Future Opportunities Integral Coach Factory, Chennai, India

2. 1981 Underground Metro Train for Kolkata
ICF 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
,000th Coach

3. Variety of Builds

4. 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

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

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

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

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

9. Recent experience on Interiors

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

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

12. 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

13. 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 ) in India.

14. 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

15. 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.

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

17. 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

18. 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.

19. 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 .

20. 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

21. 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

22. Hand holds & Snack Table

23. 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.

24. 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

25. 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.

26. 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.

27. 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

28. 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.

29. 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

30. 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

31. 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

32. 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 m3/hr fresh air
Reduction of 1000 PPM of CO2 levels from the existing highest levels of 2450 PPM
Diffuser Grills

33. 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.

34. 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.

35. 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

36. 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

37. 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

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

39. 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.

40. Retractable Steps Future Requirement
Retractable footsteps for ease of disembarking

41. 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

42. 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

43. To Conclude Current coach production on IR ~ 4000 /Annum
Will go upto ~ /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

44. THANK YOU