QUALITY AUDIT REPORT

CORROSION REPAIR OF
COACHING STOCK

NO. 02/2011

CARRIAGE & WAGON WORKSHOP

EASTERN RAILWAY, LILUAH

JANUARY 2011

QUALITY ASSURANCE (MECHANICAL) DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226 011

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 QUALITY AUDIT REPORT
CORROSION REPAIR OF COACHING STOCK
CARRIAGE & WAGON WORKSHOP, LILUAH

As per Railway Board’s directives vide Letter No. 2009/M(W)/814/35/Safety, dated

11.11.2010, Quality audit of Liluah Workshop has been carried out by Shri M.A.
Alam, Director/I&L/Kolkata and his team on 18th January 2011. The quality audit was
done in accordance with Coaching Maintenance Manual, Technical pamphlet No. C-
7602 Rev.1 after preparing the check list. Shri A.K.Pandey, CWM/LLH and Shri
Rishikesh Prasad, Dy.CME/Mfg/LLH had given all assistance to facilitate quality
audit. During audit AWM/C&W/LLH along with SSE and JE of Workshop
accompanied RDSO team.

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.

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6. Shop has no facility for shower testing to check roof leakage. Roof leakage
attention is not adequate and roof is attended on condition basis (on the basis
of open line report only)
7. Inner head stock is replaced when thickness is less than 6 mm or on condition
basis. Similarly, Outer headstock is replaced when thickness is less than 4
mm or on condition basis. LLH shop is carrying out replacement of outer head
stock only when outer head stock is required to be replaced. However when
inner head stock is to be replaced, then inner head stock, outer head stock
and stiffeners are replaced. Items are replaced separately. Shop has recently
started changing of complete assembly consisting of outer & inner head stock
and stiffeners in some coaches. These are assembled, welded and fitted in
coach as a set. Status of fitment of assembled head stocks during last
three months is as under:
Nov’10 – 1 set
Dec’10 – 1 set
Jan’11 – 3 sets

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.

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12. Quantum of providing SS inlays with PVC flooring is not adequate. Shop is
providing SS inlays with PVC flooring in coaches only against RSP provision
and status for provision of SS inlays during last three years is as under: –
2008 – 09: 02 nos
2009 – 10: 14 nos
2010 – 11: 19 nos.
13. Documentation for corrosion attention is not adequate. Shop is not strictly
maintaining corrosion diagram. Details of corrosion attention with diagram
and check list for each coach is not maintained at LLH shop.

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 Quality Assurance Directorate (Mechanical)
RDSO Lucknow
Check Sheet for Quality Audit of
Corrosion Repair of the Coaches during POH attention at shop
(Based on CAMTECH Maintenance Manual for BG coaches
of ICF Design and Technical pamphlate No. 7602/ Rev 1)
While doing the audit, ensure that the below mentioned activities are carried out as
specified in the maintenance manual. Wherever the activities are not performed
correctly indicate the method adopted or the nature of non-compliance.

SN REQUIREMENTS CLAUSE OBSERVATIONS

1 Ensure that the coaches are
given POH at the specified
intervals.
2 Ensure that the coach body is
lifted off the bogies using two
25t cranes each or by four lifting
jacks of 15t each and coach
body is not lifted from one end
only.
3 Ensure that the entire under
frame is cleaned of dust, rust,
scales etc. from the underneath
through turn under holes.
4 Ensure that the portion, which
gets covered and becomes
difficult to reach after the coach
is lowered, is painted with one
coat of anti-corrosive paint
before lowering the coach body.
5 The system exists to inspect
and repair of under frame
members after the coach body
is lifted off the bogies and
placed on trestles.
103 POH attention is being given at 18
months interval for conventional
coaches and 36 months interval for
LHB coaches.
105c Coach body is lifted by two crane in
105d lifting shop and by hydraulic jacks in
M shop and SCR Shop (Corrosion
repair shops):
Liftind shop has following cranes:
25 T – 4 nos.
40 T – 2 nos.
105f Partially ensured. Cleaning is not
adequate.
105g This is being ensured in lifting shop.
202a Inspection is being carried out in
lifting bay jointly by inspection wing
and shop supervisor. On the basis
of inspection, coach is categorized
for attention as under:
1. Light corrosion (less than 70.4
man hrs)
2. Light medium corrosion (> 70.4
and < 500 man –hrs)
3. Medium corrosion (.501-1000
man hrs)
4. Heavy corrosion ( > 1000 man
hrs)
Status of corrosion attention from

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
July’10 to Dec’10 is as enclosed
as annexure.

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)

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 SN REQUIREMENTS CLAUSE OBSERVATIONS

i) Sole bar, body pillar and This is being ensured. To examine

turn under corrosion, oxy-cut as recommended
under at lavatory area is done.
 Examine visually
supplemented by tapping
with a spiked hammer sole
bars, body pillars and turn
under in the bays under and
adjoining lavatories from
below the coach and
through the elongated holes
in the turn under after
removing the accumulated
dirt and cleaning the surface
through then holes. If
corrosion is suspected at
places in the coaches
without elongated holes in
the turn under, a 100 mm
diameter hole should be cut
in the bottom of the turn
under without damaging the
pillars for examining the
inside.
 If incidence of corrosion is This is being ensured. To examine
noticed in the bottom half of corrosion, oxy-cut as recommended
the sole bar, the trough floor is done.
should be cut to a width of
300 mm and requisite length
for examination of inside top
half.
 If heavy corrosion is noticed, This is being ensured. To examine
the side wall should be cut corrosion, oxy-cut as recommended
to a height of 500 mm. from is done.
the bottom of turn under
covering sufficient length
and all the exposed parts,
after scraping and cleaning,
should be examined to
determine the extent of
corrosion.
ii) Sole bar, turn under and
pillars above the lifting pads
 Examine the above members This is being ensured. To examine
in the same manner as corrosion, oxy-cut as recommended
described para 202d (i ) is done.

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
 If signs of corrosion are
noticed, the side wall sheet
above the lifting pads should
be cut to a height of 500 mm
above the turn under and to a
length of half metre, on either
side of lifting pads. Scrape
the structural members, clean
and examine minutely to
ascertain the extent of
corrosion.
iii) Sole bar and pillars at door
corners
 Examine the above This is being ensured. To examine
locations visually. If corrosion, oxy-cut as recommended
corrosion is noticed, cut is done.
the turn under to a width
of half metre from the Accumulated dust is removed and
door corner. Remove structural member is cleaned before
accumulated dust. examination to assess the extent of
Structural members corrosion
should be thoroughly
scraped, cleaned and
examined to assess the
extent of corrosion.
iv) Sole bar, turn under and
body pillars at locations other
than those described above
 Examine visible portion of This is being ensured. To examine
sole bar through the corrosion, oxy-cut as recommended
elongated holes of turn is done.
under and from bottom of
the underframe.
 Remove the accumulated This is being ensured. To examine
dust in the turn under corrosion, oxy-cut as recommended
through elongated holes and is done.
scrape structural members
to the extent possible. If
corrosion is noticed, side
wall sheet in the area of
corrosion should be cut to a
height of 450 mm. from the
bottom of turn under
covering sufficient length for
thorough examination.
v) Head stock
 Examine visually inner head Inner head stocks, outer head stock,
stock, outer head stock, stiffening are examined for corrosion
stiffening immediately attention.

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 SN REQUIREMENTS
behind the buffers and the
junction of the sole bar at
the head stock for incidence
of corrosion.
 Examine carefully the base
of buffer assembly as
corrosion has been primarily
noticed at this location.
 Examine carefully the buffer
base of head stock by chalk
test or sound test for cracks
and dents. Buffer fixing
holes should not be
elongated and no minor
cracks to be allowed.
Replace head stock if the
wear is more than 4 mm i.e.
when the thickness is below
4 mm.
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CLAUSE OBSERVATIONS
Base of buffer assembly is
examined for corrosion arising.
Chalk test is not done. Only sound
test is done.
Shop has facility for pressing single
piece inner & outer head stock
through press brake.
Inner head stock is replaced when
thick is less than 6 mm or on
condition basis. Similarly, Outer
head is replaced when thickness is
less than 4 mm or on condition
basis.
LLH shop is carrying out
replacement of outer head stock
only in case only outer head stock is
required to be replaced.
In case inner head stock is to be
replaced then inner head stock,
outer head stock and stiffeners are
replaced in set. Complete assembly
consisting of outer & inner head
stock and stiffeners are assembled,
welded and fitted in coach as a set.
However, this has been started
recently and status of last three
months is as under:
Nov’10 – 1 set
Dec’10 – 1 set
Jan’11 – 3 sets
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 are yet to be
developed to carry out this activity.
 SN REQUIREMENTS CLAUSE OBSERVATIONS

vi) Trough floor This is being ensured.

 Examine the trough floor in Shop has MC of both SS trough
the bays adjoining the floor & IRS M-41 trough floor.
lavatories and under the SS trough floor:
luggage compartments of MC – 4 coach sets (100 pc)
SLRs and parcel vans from IRS M-41 trough floor:
below for signs of corrosion, MC – 8 coach sets (200 nos)
supplemented by tapping
with a spiked hammer. This is being ensured.
 If signs of corrosion are
noticed in the above
examination, the part should
be thoroughly cleaned by
scraping and an intensive
inspection should be carried
out to detect the extent of
corrosion in the trough floor.
 Magnesium oxychloride or This is being done. Compreque with
plywood/compreg with PVC PVC overlay is provided. In addition
overlay flooring in the for non AC coaches, epoxy flooring
lavatories and bays adjacent of floor-koat is provided in lavatory
to lavatories of all coaches area, door way and gangway area.
over six years old should be
broken and trough floor
thoroughly examined for
incidence of corrosion.
vii) Tubular frame below
lavatories
 Examine visually the tubes This is being ensured.
and joints for incidence of
corrosion.
 Corroded tubes shall be This is being ensured.
replaced. If corrosion is
extreme, entire tubular
frame should be replaced..

8 Corrosion repairs to 202 e

Underframe Members
i) Corrosion repairs should be
carried out as per instructions
laid down in RDSO Technical
Pamphlet nos. C-7602 (rev.1)
for ICF coaches.
It is essential to use corrosion
resistant steel sheets for
corrosion repairs of coaches.
LLH shop is following guidelines for
corrosion repair as stipulated in
technical pamphlet nos. C-7602
(rev.1) for ICF coaches.
Corton steel IRS M – 41 is used for
corrosion attention.

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
Welding electrodes and paints
should be of the prescribed
quality conforming to the
relevant IS/ IRS specifications.
 Corrosion resistant steel SS trough floor is also used in
sheet for trough floor, pillars, addition to IRSM-41 trough floor.
side-wall and roof to IRS
M.41 - 97.
 Electrode of approved For IRS M -41 grade, recommended
brands. Electrode is RDSO class ‘D’ or AWS
8018. However, LLH shop is using
RDSO class A2 electrode for
corrosion attention.

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.

 Paints: Red oxide zinc This is being ensured.

chromate primer – IS 2074-
62. Bituminous anticorrosive
solution to IRS P30-96,
solution type, brushing
quality.

ii) Where the corrosion noticed This is being ensured.

is of a very minor nature and
has just started, there is no
need to renew the parts. In
those areas, the paint and the
rust should be thoroughly
cleaned to reach the bare metal
and the surface treated with two
coats of red oxide zinc chromate
primer. In addition, underframe
members should be given two
coats of bituminous solution.
Where the corrosion repairs are This is being ensured.
carried out on the underframe or
its paint coat is damaged, the
underframe should be painted
with two coats of red oxide zinc
chromate primer followed by the
four coat system of anti-
corrosive bituminous paint.
For carrying out corrosion This is being ensured.

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
repairs to underframe members,
the coach body should be lifted
off the bogies and kept on
trestles.
For repairs to side wall and end
wall, no lifting is required.
iii) The parts of a coach
requiring corrosion repairs most
commonly are:
1. Head stock (refer figure 2.4)
For replacement of head stock,
the following parts need be
stripped first:
 Side buffers.
 Plywood/compreg and PVC
flooring.
 end partition and electrical
wiring
 draw gear assembly.
 end portion of BP/FP in case
of air brake coaches.
Before the corroded portion is This is being ensured.
cut off, the auxiliary head stock
and the two sole bar ends
should be firmly supported to rail
lines. The corroded head-stock
is then replaced as per
annexure-v of RDSO Technical
pamphlet no. C-7602 (Rev.1).
Only 8 mm thick corrosion
resistant steel sheets should be
used for head stock
repairs.
2. Sole bar
For carrying out repairs to sole This is being ensured.
bar, it is necessary to strip first
the interior fittings, laminate
panelling and window frames.
Before cutting off the corroded
portion of sole bar, both the
adjacent ends should be
supported to the rail lines. The
new sole bar piece should be
welded from outside and inside.
To facilitate welding from inside,
the coach body should be lifted
and kept on trestles.
2.1 Stiffening of sole bar at
doorways

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
As incidence of corrosion in sole This is being ensured.
bar is predominant in the
lavatory areas and adjoining
doorways, the sole bar was
strengthened in all coaches
manufactured since 1974 by
providing a box section as
shown in RDSO sketch nos.
76011 & 76012.
The doorways of luggage This is being ensured.
compartments in SLRs were
strengthened as shown in
RDSO sketch no. 76013. These
modifications should be carried
out in all coaches during POH, if
not already done. On coaches
which have not been
manufactured or so far modified
in accordance with above, this
can be done as shown in
RDSO's sketch nos.
78102, 78103 & 78096.
2.2 Corrosion repair of sole
bar
Repairs to sole bar for This is being ensured.
replacement of corroded
portions at the locations
mentioned below should be
carried out as per the respective
RDSO sketches indicated:
 At locations other than lifting
pads and body bolster –
RDSO sketch no. 76018.
 At body bolster and lifting
pad locations - RDSO
sketch no.76019.
3. Side wall members
For repairs to side and end wall This is being ensured.
sheets, the interior fittings,
laminate panelling and window
frames should be stripped first.
Corrosion repair of side/ end
wall sheets, body pillars and
turn unders should be done as
per RDSO sketch no. 76 020.
4. Trough floor
For replacement of trough floor, This is being ensured.
first decolite/ plywood flooring
needs to be stripped. Corrosion

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
repairs to trough floor at the
locations mentioned below
should be done as per the
respective RDSO sketches
indicated:
 At end lavatories of two-doors
and three-doors aside
coaches - RDSO sketch no.
76021.
 At end lavatories of four-
doors aside coaches - RDSO
sketch no.76022.
 At middle lavatories of four -
doors aside coaches – RDSO
sketch no. 76023.
9 ROOF REPAIRS 203
203a Roof repairs
i) In ICF coaches, roof should be Roof attention is not adequate.
checked for corrosion. Special There is no system to check roof
attention should be paid at leakage through Shower test. Roof
location where gutter mouldings is attended on the basis of open line
are welded and ventilators report for roof leakage during rainy
bolted. Corroded roof should be season.
repaired according to the
instructions given in annexure
VII of
RDSO Technical pamphlet no.
C-
7602 (Rev.1) for corrosion
repairs of
ICF coaches.
203b TRA type Roof
Ventilators repairs
i) Examine the roof ventilator for Ventilators are attended on
damage or corrosion or leakage. condition basis and defective
If no corrosion is observed then ventilators are replaced.
seal the joints and crevices with
water proof sealing agent.
Ventilators found beyond repairs
should be replaced as per
RDSO technical pamphlet No.C-
7602 (rev.1) annexure-VII. The
securing bolts should be
replaced whenever a ventilator
is removed. Otherwise, they
should be checked for tightness.
Loose and corroded bolts
should be
replaced.

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
ii) After repairs and refitting, This is not being followed as
ventilators should be tested for shop has no facility for roof
water leakage at their base testing.
joints at the time of roof testing.

203c Roof testing

All coaches after POH repairs Shop has no facility for roof
should be tested under water testing in shower.
spray for roof leakage before
they are finally turned out from
the workshop. For this purpose,
a fixture designed to simulate
monsoon conditions should be
provided in the workshop.
10 REPAIRS TO DOOR 204
HANDLES This is being ensured.
Examine the door handle for
breakage, damages. If the fixing
bolts are loose or missing,
tighten the bolts. Replace the
door handles which are found
beyond repairs.
11 REPAIRS TO DOOR PIVOTS 205
Examine the door pivots for This is being ensured.
corrosion, breakage or wear by
cutting the bottom portion of
outer panel. Cut the corroded
portion of the door pillar (Z
molding) and weld new piece
joining the door pivot pin.
If the female socket is worn or
damaged beyond repairs then
replace it. Replace the bush
provided in the socket.
12 REPAIRS TO PARTITION 206
WALL,
SEAT PILLAR / MOUNTING
PLATE
Examine seat pillar/mounting This is attended on condition basis.
plate for corrosion or breakage,
etc. at bottom ends.
If found corroded, repair the
same as per RDSO technical
pamphlet no. C-7602 (Rev.1).
13 REPAIRS TO DRAW AND 207
BUFFING GEAR SUPPORT
STRUCTURE
Examine the draw gear support This is attended on condition basis.
structure for corrosion, However quality of cleaning to scrap

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 SN REQUIREMENTS CLAUSE OBSERVATIONS
breakage, etc. If the corrosion is off the rust to bare metal and re-
light, scrap off the rust to bare paint is not adequate.
metal, clean well and re-paint. If
the corrosion is heavy, replace
the corroded angle or gusset
plate with new support angle.
Similarly examine the buffing For light corrosion, quality of
gear support structure for cleaning to scrap off the rust to bare
corrosion, breakage, etc. If the metal and re-paint is not adequate.
corrosion is light, scrap off the
rust to bare metal, clean well
and re-paint. If the corrosion is
heavy, replace the corroded
angle or stiffeners.
14 REPAIRS TO BODY BOLSTER 208
Examine the body bolster for Body bolster is not replaced and
corrosion, breakage, wear, etc. repaired as approved in LTO issued
If the corrosion is light, scrap off by CWM/LLH.
the rust to bare metal, clean well
and re-paint. If the corrosion,
breakage or wear are beyond
repair, replace the body bolster.
Check the area surrounding
centre pivot pin mounting
holes for cracks.
15 REPAIRS TO CENTRE PIVOTS 209
Clean and examine the centre Chalk testing of centre pivot is being
pivot for bent, wear, cracks. done.
Cracks shall be detected by
doing chalk testing or magnaflux Centre pivot is changed on
dye penetrant test. If the centre condition basis.
pivot is found cracked or worn
beyond repair, it should be
replace. Check the mounting
bolts for loose or missing.
Tighten and lock the bolts with
locking plate.
16 WATER TANK SUPPORT 210
STRUCTURE
Examine the water tank support Water tank structure is attended on
structure for corrosion, condition basis.
breakage, wear, etc. If the
corrosion is light, scrap off the
rust to bare metal, clean well
and re-paint. If the corrosion,
breakage are beyond repair,
replace the corroded angle with
new angle of suitable size as
per the requirement. Replace

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 SN REQUIREMENTS
the rubber/wooden packing if
perished or damaged.
17 REPAIRS TO FLOOR 211
CHANNEL
Examine the floor channel for
corrosion, breakage, wear, etc.
by cutting opening the PVC and
plywood flooring where the
corrosion suspected. If the
corrosion is light, scrap off the
rust to bare metal, clean well
and re-paint. If the corrosion,
breakage are beyond repair,
replace the corroded channels
with new channel of suitable
size as per the requirement.
18 WELDING
a) Reference may be made in this 3.1.5
connection to the approved (C-7602)
brands of electrodes issued by
RDSO. Welding electrodes and
paints should be of the
prescribed quality conforming to
the relevant IS/IRS specification.
b) Ensure that the welders deputed
are tested and certified by
Chemist & Metallurgist of the
Railways.
c) Ensure that no electric welding
on the coach is carried out
without proper earthing.
d) The distorted and bent parts are
heated and straightened.
e) Welding machines Availabity
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CLAUSE OBSERVATIONS
This is being ensured. Corroded
channels are replaced with new
chanels.
For IRS M - 41 grade,
recommended
Electrode is RDSO class ‘D’ or AWS
8108. However, LLH shop is using
RDSO class A2 electrode for
corrosion attention.
Shop is not using MIG welding
process for corrosion attention.
212 Welders are deputed for training at
BTC attached to shop for training.
Samples are prepared as stipulated
in IS 7310 Pt I, and certified by
CMT/LLH. Records have been
checked and few certificate checked
and observed that all samples
prepared for certification are not
checked in accordance with IS 7310
Pt I provision.
212 This is being ensured.
212 This is being ensured.
M shop
Transformer type: 62 + (12 def)
Inverter type: NIL
MIG welding; 2 nos
SCR shop
Transformer type: 127
 SN REQUIREMENTS CLAUSE
f) Welders skills
19 SURFACE TREATMENT AND
PAINTING
a) Ensure that the system exists 212
for proper surface treatment of
the parts and the parts are
applied with protective paint.
Also, the thick sections such as
sole bars, cross bearers etc. are
grit/shot blasted and
immediately given a protective
coat of red oxide, zinc chromate
primer paint.
b) All body shell replacement 3.1.2
components less than 5mm (C-
thickness used for corrosion 7602)
repairs should be hot phosphate
and applied with protective
paints. Cold phosphating should
be done on areas where welding
has been carried out on hot
phosphate components.
c) Zinc rich primer should be used 3.1.3
where spot welding is done (C-
7602)
e) The coach body is cleaned after 1201
repair.
f) If the condition of the paint so 1201c
warrants or at every 5th POH of
a coach, the paint should be
completely removed to the bare
metal and the coach repainted
QA 02/2011 CORROSION REPAIR, COACHING STOCK, LILUAH, EASTERN RAILWAY PAGE 18 of 21
OBSERVATIONS
Inverter type: NIL
MIG welding: 02 nos
Two shop of LLH are carrying out
corrosion attention and deployment
of welders are as under:
M shop (for heavy and medium) –
total welders 122 (Grade A: 65 Gr
‘B’ 14 & Gr ‘C’- 44)
SCR Shop (For light and medium):
– total welders 140 (Grade A: 37,
Gr B 43, Gr C 60
Shop has no facility for shot / grit
blasting.
Shop has facility of hot phosphating.
Shop has recently installed hot
phosphate plant with pollution
control equipment. Components
such as trough floor, sole bar piece,
turn under piece; channels, pillar
bracket small etc are given hot
phosphate attention. After hot
phosphate, items are given anti –
corrosive paint.
IRS M-41 trough floor is also
provided with tissue paper after hot
phosphate.
This is being done.
This is being followed.
This is being followed.
 SN REQUIREMENTS CLAUSE OBSERVATIONS
as per paint schedule A'. If the
general condition of the paint is
good, follow paint schedule `C'.
g) Ensure that the painting is done 1202 This is being followed.
as per the specified schedules. 1203
h) Paint the head stock and all This has not been implemented
visible members by RDSO till date. Shop has placed indent for
specification No M & C procurement of paint with this
/PCN/123/2006 for high specification but not yet received.
performance anticorrosion
epoxy coating.
20 DOCUMENTATION
After corrosion repairs are 4.0 Documentation is poor. Shop is
completed, particulars should be (C- not strictly maintaining corrosion
entered in the check-lists. The 7602) diagram.
check lists shown on sketch no. Details of corrosion attention with
76032 to 76036 pertain to diagram and check list for each
coaches which are on line in coach is not maintained at LLH
large number and are typical. shop.
Suitable changes in the list may
be made to suit other type of
coaches. A diagram of the
coach in standard A-4 size
should be marked suitably to
indicate the parts of the shell
replaced during corrosion repair
with specific details of the
location and extent of corrosion.
The diagram and the check-list
should be filed in a folder
maintained for each coach.
21 SUPERCHECKING There is no system to carry out
super-checking of repair by
higher official. After corrosion
attention, the same is checked by
supervisor concerned only.
22 STATUS OF CORROSION
RELATED MODIFICATIONS
Stiffening of sole bars at 3.2.1 This has already been implemented.
a) doorways: (C-
7602)
Lifting pads 3.2.2 This has already been implemented.
b) (C-
7602)
Tubular frame below lavatories 3.2.3 This has already been implemented.
c) (C-
7602)
FRP tissue sand witched 3.2.5 IRS M-41 trough floor is given hot
d)
between layers of bitumen (C- phosphate treatment and tissue

QA 02/2011 CORROSION REPAIR, COACHING STOCK, LILUAH, EASTERN RAILWAY PAGE 19 of 21

 SN REQUIREMENTS CLAUSE OBSERVATIONS
7602) sand witched provided between
layers of bitumen.

Trough floor: 3.2.6

13 mm diameter holes provided
in the event of trough floor for
e) drainage of condensation were
increased to 19mm so as to
allow quicker drainage in
coaches.
Stainless steel trough floor
f)
(C- Already implememnted.
7602) Provision of enlarged holes (19mm)
on SS trough floor for drainage of
water is being done in all new
fitment of trough floor
3.2.7 Shop has MC of both SS trough
(C- floor & IRS M-41 trough floor.
7602) SS trough floor:
MC – 4 coach sets (100 pc)
IRS M-41 trough floor:
MC – 8 caoch sets (200 nos)

Body side doors 3.2.10

Completely open bottom and a (C- This is being followed.
g) removable inside panel to 7602)
facilitate inspection of the
outside panel.
Skirting plates for vacuum 3.2.11 NR. Coach converted to air brake
h) reservoir and battery boxes (C- system
7602)
Lavatory pan with longer neck 3.2.12 This is being followed.
i) (C-
7602)
Lavatory flooring 3.2.13 Compreque sheet flooring + PVC in
j) (C- AC coaches
7602)
Stainless steel inlay in lavatory 3.2.14 Shop is providing SS inlays with
instead of decolite flooring: (C- PVC flooring in coaches only
In order to eliminate any 7602) against RSP provsion and status for
leakage of water or chloride provsion of SS inlays during last
through the floor leading to three years is as under: –
k) corrosion of the underframe, ICF
has started providing a stainless 2008 – 09: 02 nos
steel inlay in the lavatory with 2009 – 10: 14 nos
conventional lavatory pan duly 2010 – 11: 19 nos.
supported as per
Drg.No.ICF/SK-1-0-666 Alt.’d’.
Flooring in pantry cars 3.2.18 Flooring consisting of PVC sheet
(C- over compreque sheet with
7602) Aluminum chequred sheet on top all
l) over the coach except lavtory has
been followed. Renewal in done on
condition basis.

QA 02/2011 CORROSION REPAIR, COACHING STOCK, LILUAH, EASTERN RAILWAY PAGE 20 of 21

 SN REQUIREMENTS CLAUSE OBSERVATIONS

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

Heavy corrosion Med corrosion Light and

Total
Month light medium
outturn NAC AC NAC AC
corrosion
Jul’10 210 14 - 23 1 172
Aug’10 220 17 - 20 1 182
Sep’10 193 8 - 24 3 158
Oct’10 184 12 - 21 3 148
Nov’10 208 10 - 30 3 166
Dec’10 215 21 - 28 3 163

QA 02/2011 CORROSION REPAIR, COACHING STOCK, LILUAH, EASTERN RAILWAY PAGE 21 of 21