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CORROSION REPAIR OF
COACHING STOCK
NO. 02/2011
JANUARY 2011
Observations:
1. Thick sections required in corrosion repairs (5mm or more) are not grit/shot
blasted.
2. Painting of head stock with M&C/PCN/123/2006 for high performance
anticorrosion epoxy coating is not ensured. This item has not been stocked
and procured by shop.
3. Shop is not carrying out MIG welding for corrosion repair of coaches.
4. Shop has no inverter base machine for welding.
5. Shop is not using correct electrode as recommended by RDSO for corrosion
attention of coaches. Shop is using A2 class electrode instead of class D
electrode for IRS M-41 steel. Even for SS welding, shop is using M-1 class
electrode instead of M-2 class electrode. Shop is now reported procuring M-2
class electrode.
LLH shop is carrying out replacement of approx 40 inner head stock for which
40 sets assembled inner & outer head stock are to be replaced. Facility and
infrastructure is yet to be developed to carry out this activity.
8. Welders are deputed for training at BTC attached to workshop for training.
Samples are prepared as stipulated in IS 7310 Pt I, and finally certified by
CMT/LLH. Records have been checked. Few certificates were checked and
observed that all samples prepared for certification are not being checked in
accordance with IS 7310 Pt I provision.
9. Out of 262 welders deployed in M shop and SCR shop for corrosion attention,
104 welders are yet to be certified by CMT. Up-gradation of 104 welders to
higher grade is yet to be done.
10. For light corrosion, quality of cleaning to scrap off the rust to bare metal and
re-paint is not adequate.
11. To prevent corrosion of battery box frames, hot galvanized battery box is not
used. Battery box is fitted with FRP trays only.
6 The underframe members 202c (i) System exists to check the corroded
should be thoroughly inspected members and other defects.
for locating cracked/ bent/
corroded members. Corrosion is
indicated by flaking of paint,
flaking of metal, pitting and
scale formation. Components
like sole bar and trough floor
which are not visible from both
sides should be examined by
tapping with a spiked hammer.
Proper illumination will be
required to carryout the check. A
component will require repair/
replacement, if it has lost more
than 20% of its thickness.
7 Particular attention should be 202 c (ii) To check the corrosion arising of
paid to the more vulnerable vulnerable location such as sole
members and locations listed bar, body pillars, tubular frame and
below:- turn under, side body panel is cut
Sole bar, body pillars, turn through oxy-cutting of
under and tubular frame/ recommended size.
trough floor below lavatories
in all types of coaches and For checking corrosion arising of
the luggage compartments trough floors, floor board is removed
of all SLRs and parcel vans. and trough floor is examined in the
Sole bars, body pillars, turn suspected corrosion area.
under and pillars above
lifting pads
Sole bars and pillars behind
the sliding door pockets of
SLRs and parcel vans.
Sole bars, pillars and turn
under at the door corners.
Head stock.
Sole bars, pillars and turn
under near coach body
bolster.
7 Procedure for inspection of 202d This is being ensured.
underframe members for
corrosion attention in case of
vulnerable and not so -
vulnerable locations should be
followed as given in RDSO
technical pamphlet No. 7602
(Rev.1)
Consumption of electrode is
enclosed as annexure II.
Corrosion shops have 4 nos. MIG
welding machine. But shop is not
using MIG welding process for
corrosion attention.
b) All body shell replacement 3.1.2 Shop has recently installed hot
components less than 5mm (C- phosphate plant with pollution
thickness used for corrosion 7602) control equipment. Components
repairs should be hot phosphate such as trough floor, sole bar piece,
and applied with protective turn under piece; channels, pillar
paints. Cold phosphating should bracket small etc are given hot
be done on areas where welding phosphate attention. After hot
has been carried out on hot phosphate, items are given anti –
phosphate components. corrosive paint.
IRS M-41 trough floor is also
provided with tissue paper after hot
phosphate.
PVC flooring over ply wood 3.2.19 PVC flloring over compreque sheet
(C- is being done.
7602)
Status of PVC flooring is as under:
m)
2008 -09: 2490 coaches
2009 -10: 2309 coaches
2010 – 11: 1836 coaches
Battery box frames: 3.2.21 Hot galvanizing is not being
To prevent corrosion battery box (C- done. FRP trays are fitted
frames are now being hot 7602)
n) galvanised. The battery boxes
should be fitted with FRP trays
to ICF drg. No.GS-7-1-018
during POH
Annexure
Corrosion attention of coaches during last six months