CONSTRUCTION OF COACH BODY
BY
[Link]
[Link], STC/SC
ICF DESIGN COACH
All Steel
All welded
All Coil
Light Weight
Integral Design
MAJOR ASSEMBLIES IN COACH
The complete coach is made of two major
portions called
1. Coach Body Assembly and
2. Bogie Assembly
MAJOR ASSEMBLIES IN CONSTRUCTION
OF COACH BODY
Coach Body is made of the following
major assemblies
• Roof Assembly
• Side Wall Assembly
• End Wall Assembly
• Under Frame Assembly
CONSTRUCTION OF COACH BODY
Roof Assembly
• Roof sheet (1.6mm)
• Carlines
• Cantrails
• Purlines (U-stiffeners)
• L- beams (L-stiffeners)
• Roof Ventilators
• Fixing facilities for Fans,
Tube lights, partitions,
berths etc.,
ROOF ASSEMBLY JIG
Side wall Assembly
• Side wall sheet (2.0 mm)
• Body pillars
• Waist rails
• Light rails
• Door corner sheet
• Horizontal & Vertical
Stiffeners
• Window sills
• Fixing facilities for seat&
berth, Luggage racks,
Snack table, Magazine
bag, Bottle holder etc.
FINISHING OF SIDE WALL
End Wall Assembly
• End wall Sheet (2.0mm)
• Four vertical pillars of box
section
• Vertical pillars are welded to
the head stock at the bottom
and to the roof at the top.
• These pillars absorb the
impact energy in case of
collision and avoid
telescoping of adjacent
coaches
• Vertical pillars are connected
transversely by ‘Z’ sections
Underframe Assembly
• Sole bars
• Trough floor
• Cross bearers (Floor
support below trough
floor)
• Head Stock Assembly
(Inner & Outer)
• Body bolster
• Tubular frame
• Other fixing facilities for
Buffer, Draw gear/
coupler, partitions,
mounting of underslung
equipment like water
tanks, battery boxes, AC
equipment, Air brake
pipe lines etc.
UNDER – FRAME WELDING
Underframe Assembly
Body Assembly
Interior partitions & Doors
• Inter partitions between the coupe’s
• Doorway partitions
• Lavatory partitions with water tank ceiling
construction
• Shell doors
ELECTRICAL WIRING
DESIGN FEATURES
• Light weight integral
design
• Hollow girders from the
point of view of
strength and utilization
of material
• Reduction in tare
weight by utilizing
stressed skin concept
and by use of low alloy
fittings
DESIGN FEATURES
• Stressed Skin Concept:
Type of complex structure involving curves and
bendings, where the outer skin combines with
a frame to produce a sound, strong, bent,
curved structure.
DESIGN FEATURES
• Anti-telescopic structure at the end walls to
avoid telescoping of adjacent coaches and to
absorb major part of the collision energy
• Shell is made of frame work of series of hoops,
consisting of floor cross beams, body side
pillars and roof carlines located transversely.
DESIGN FEATURES
• These hoops are connected by sole bars, waist
rails, light rails, cant rails, purlines and L- stiffeners
longitudinally
• Frame work is sheathed all over by 2mm thick
corten steel on the side walls & end walls and
1.6mm thick corten steel sheet on the roof.
• Under frame acts as support for mounting
equipment like brake cylinders, DV, BP & FP pipes,
auxiliary reservoirs, control reservoirs, etc. Air
conditioning equipment, battery boxes, under
slung water tank, etc.
DESIGN FEATURES
• Corrugated sheets for the trough floor to form part
of the tubular construction and to absorb buffing
forces
• Trough floor is provided between the sole bars and
running over the length between the head stocks
of the under frame
• Below the lavatory, tubular construction is
provided in place of trough floor to avoid corrosion
because of seepage of water.
DESIGN FEATURES
• Side bearer loading. Center pivot is free from
vertical loading.
• Good riding quality. Items contributing for good
riding quality are
• Coil springs
• Guide and dash pot arrangement
• Self aligned spherical roller bearing
• Vertical shock absorbers
• Silent blocks
• Anchor links
• Equalising devices
DESIGN FEATURES
• Camber setting:
Camber is the negative deflection of underframe
given intensionally to compensate the sagging
of underframe when it is fully loaded, so that
the underframe can remain straight even after
fully loaded.
DESIGN FEATURES
• Spot Heating:
Heating and cooling of side wall and end wall
sheets to impart strength is called spot heating.
By heating and cooling, the material at that
points gets shrinked and will be stretching the
sheets towards the center of the heated spot.
As these spots bulge in the center, will be
flattened by hammering.
COACH OVERALL DIMENSIONS