Furnishing of AC Coaches

STAGE – 1 ELECTRICAL UNDER FRAME & ROOF WIRING.

The cable required for AC system and others are taken below the trough floor area
in stainless trays and through PVC conduits at roof below carline level (Shop 35). Simultaneously,
wiring at side wall for switches, charging sockets and reading lights are done. The copper cable
used for this wiring is of sizes ranging from 50 mm sq. to 150 mm sq.m insulated with high
reputed PVC material.

STAGE – 2 VESTIBULE DOORS, MODULAR TOILETS, SBC FITMENT.

In this stage, Entrance hand rails at all four-door entrance, Lavatory window, End
wall lavatory exhaust fan, Auto closing SS vestibule sliding doors are fitted at both ends of the
coach. The doors made up of SS skin filled with phenolic resin having 6mm look out glass at the
top. The primary usage of the doors is aversion of fire propagation from one coach to another.
The SBC (switch Board Cabinet) for switching electrical units and FRP modular toilets are drop
downed through roof opening by mobile crane facility. The SS brake piping (Shop 37) done
simultaneously below the trough floor.

STAGE – 3 FLOORING, DUCTING, BODY SIDE WINDOW & FRP TROUGH FITMENT
Flooring starts with thermal insulating of trough floor and below window level.
Earlier 60mm Glass Wool with aluminium cladding used as for the purpose. Now a new material
introduced, 25mm ‘Closed Cell Cross Linked PE Foam’ with aluminium cladding, which is
hazard free. Subsequently, the de-coupling profiled rubber along with 5mm MS back pieces are
inserted in to the hat sections welded along with the SS trough floor. The de-coupling rubbers are
provided for the purpose of eliminate the vibrations transferred from running gear. The 19mm
Macore ply wood having a core made up of cork for sound insulation is floated over the de-coupler
rubber arrangements. So that it is called as ‘Floating Floor’. The floor boards are secured by
means of screws. The floor board joints are sealed with water sealing agents (such as Anabond
777 R) to avoid water seepage. The fire protection coating is done at prescribed locations. The SS
floor skirting done around the modular toilets. The SS floor side mouldings (FSM) screwed over
the banks of the floor boards. Over the floor boards double layered heterogeneous PVC or Rubber
sheets with anti-skid properties are pasted with water-based adhesives which is fire retardant.
The floor sheet joints are welded by PVC hot air welding in the case of PVC sheets and sealant is
used in the case of rubber sheets. At door and gang ways 2.5mm SS slip free sheets laid over the
floor sheets and secured with screws. Step rails are provided at door entrance. The flooring
masked by dummy sheets to avoid any damages during further furnishing.
Ducting done for the purpose of distribution of conditioned air to the passenger
area. Ducting done between both the RMPUs (Roof Mounted Package Unit – 6.5 tones each)
provided for air conditioning. Pre-assembled, insulated, aluminium ducts are used for ducting.
Cross braces are available in the roof structure for supporting the ducting arrangements. Baffles
pre-assembled in the conduit ducting system to increase the velocity and reduce the pressure of
the air stream. This ducting arrangement connected to the RMPU by means of flexible canvas
arrangement. Diffusers are available in each duct for the distribution of conditioned air in the
passenger bay. The first duct close to RMPU in the ducting arrangement having velocity and
moisture elimination arrangement. The ducts are secured with cross brace by means of fasteners.
 The body side window having aluminium frame with double sealed window glass
arrangement pasted to the car body by PU based adhesive (such as ‘sikaflex – 265’,
‘Anabond’,’Henkel’, etc.). The windows are fitted from inside of the coach and up to the
completion of curing, a fixture is used to apply pressure over the pasting area. The double sealed
window glass made up of 6mm and 4mm thick toughened and safety glasses respectively and
middle gap filled with ‘krypton’ gas to act as thermal and sound insulator. This glass arrangement
secured with aluminium frame by EPDM profile rubber (Ethylene Propylene Dyne Monomer).
Each coach having 14 normal windows, 4 Emergency windows and 4 hopper type windows at
lavatories, apart from that 4 look out glasses of same nomenclature are provided at shell doors.
The FRP trough below RMPU is pasted over the shell opening which required for
modular toilet and SBC drop down. Recently the design changed as SS reinforcement is used in
the FRP trough. The trough pasted to the shell by PU based adhesive. The transition ducts made
up of SS fitted with shell, over the trough arrangement, to provide a ducting arrangement between
RMPU and aluminium ducts inside the compartment. Through this transition ducts conditioned
air from RMPU to passenger compartment and circulating air from passenger compartment to
RMPU passes. The RMPU connected to this transition ducts by flexible canvas.
The underframe electrical equipment loading such as water pump, Battery box,
IV (Inter Vehicular) coupler, etc. and under slung capsule type water tanks fitment and
plumbing piping done simultaneously.

STAGE – 4 PANELLING
The partitions made up of ‘Honey comb’ structure is provided along with SS pillar.
The partition pillars are secured with floor and roof by fasteners. The other end of the partition
secured with body pillar. Chair angles and berth climbing ladders are integrated with partition
pillars. The design of furnishing assembly adopts ‘Poke Yoke’ (Fool Proof method), so it does not
require any skill, all the fixing flanges are available in the shell structure itself.
The side wall extrusions are fixed after partition assembly. The fittings brackets
such as luggage rack fixing bkt, snack table fixing bkt are fitted to the side wall. The partition
angles are fitted for side paneling. The pre-structured FRP side panels provided over this.
Necessary packings and reinforcements are provided before side paneling. The necessary cavities
required for BRL (Berth Reading Lights) and fittings are available in the FRP side panels. The FRP
side panels secured by 3M pressure locks. All the gaps are properly covered by aluminium
mouldings and extrusions to avoid any conditioned air leak. The gap between side panels and
window glass is sealed with rubber. The side paneling done from end to end in the compartment.
The extrusions are fixed over the partitions (C-Rails) for ceiling panel and door
assembly for duct. The FRP ceiling angles are screwed to the partition to maintain the ceiling
profile and to avoid any conditioned air leak. The pre-structured FRP ceiling panels are fixed after
side paneling. The fitment brackets are embedded in the ceiling panels. The ceiling panel and duct
doors are secured by special hammer head bolts (T’ bolts). The duct doors are having square lock
(South co type) arrangement for securing the doors and for easy inspection of ducts. The 3M self-
adhesive type foam is used in the matting areas as gasket to avoid conditioned air leak. The 3M
self- adhesive tapes at the ends panels for aesthetic and to avoid conditioned air leak.

STAGE – 5 MODULAR LAVATORY FITTINGS & NON-AC AREA CEILING.

The modular lavatory fittings such as pan, commode, pipe fittings, etc., are fitted
in the toilets. The FRP attachment walls are fitted along with the shell (service door). The vacuum
flush arrangement and electrical control panel for vacuum flush are fitted. The Bio-Retention
tanks are fitted with under frame below all four lavatories to achieve zero discharge to the
ground.
The pre-assembled linen racks are fixed at the non-power panel end. The steel
almirahs are loaded and fitted at the power panel end.
The Non-Ac area (Door and Gang way) ceiling done with wooden material with
fillings between layers to reduce weight. This ceiling is provided with hinges and square lock for
easy inspection. The FRP door portals are fitted around inside of shell door frame to hide the gaps.

STAGE – 6 SEAT & BERTH AND FITTINGS.

The ‘Recron’ cushioned seat and berths are fitted in this stage (trails made with
‘silicon’ foam and e’leather for wrapping). The double swing inter communication doors are fitted
at both ends of the compartment for improved safety during emergency. The IC doors having
6mm toughened look out glass and in between door panels phenolic resin is filled. At the same
time electrical fittings such as compartment lights, BRL, TOL (Toilet Occupied Lights) and
compartment fittings such as SS Light luggage rack, fixed type Polycarbonate snack table, etc., are
fitted.

STAGE – 7 HV TEST, AIR FLOW -AC TEST & SEQUENCE TEST

After complete furnishing High Voltage test performed by Electrical inspection
(Shop 87). Then the coach restored for AC test by Electrical. The AC test performed by Electrical
inspection, the cut-in and cut-off temperature are noted and compared with specification. If all
the values with in the limits the coach passed. The conditioned air leak, air stream velocity and
flow are checked during air flow test.
All the electrical equipment and their working voltage and current, short circuit,
earthing is checked during sequence test.

STAGE – 8 PIT WORK, FINAL FINISHING, BRAKE TEST

The pit work is done for to check the buffer height, Yaw damper fitment and to
provide all cotter pins and apply required torque to the running gear fasteners.
During final finishing the coach is thoroughly cleaned and various decals are
pasted inside and out side of the coach information and warnings. To reduce the paint pollution
and for aesthetics some of the coaches are provided with vinyl wrapping at the exterior. The
Railway zone, Railway number and other lettering work (Shop 54) done at this stage.
The brake system and Emergency Passenger Alarm performance is checked
before dispatch.
The final Inspection (Shop 82) carried out in various areas and clearance obtained
from the inspection for dispatch.

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