Rolling Stock Department
Integral Coach Factory (ICF) is the World’s largest Railway Passenger Rolling Stock manufacturer with its total production of coaches since inception touched 70,000 coaches on 10th Oct. 2022. ICF manufactures all varieties of coaches ranging from LHB type mainline coaches, Vistadome tourist coaches, Special coaches for Heritage tourism & Defense, Wide-body Electrical Multiple Units (EMU), Mainline EMUs (MEMU), Metro coaches, Diesel Multiple Units (DMU), Self-Propelled Accident Relief Trains (SPART), Self-Propelled Inspection Car (SPIC) and the latest state-of-the-art Vande Bharat trainsets. ICF also exports coaches and DMUs to various countries in the Afro-Asian region.
The factory has mainly two divisions viz. Shell Division and Furnishing Division located two kilometers apart in the heart of Chennai city of the state of Tamilnadu in India.
Shell Division
Shell refers to the metallic car body of the railway coach. The Shell structures and Bogies (also known as rolling gear) are fabricated in the Shell division. Various parts of the Shell viz. underframe, sidewall, roof, endwall, partitions are manufactured separately and integrated by welding to form Shell structure. The predominant materials used for Shell structure is Stainless steel and Corten Steel (a special grade of steel with Corrosion Resistant property). The bogies are also fabricated and assembled with wheel sets, suspension elements and braking devices. The Shell is lowered on two bogies. The Shell along with bogies is further moved to Furnishing division on a dedicated railway track using shunting locomotives.
.jpg)  |
Though ICF was set up to manufacture all steel welded Shells in technical collaboration with M/s Schlieren of Czech Republic, the factory started manufacturing Stainless Steel Shells since 2012 and has completely switched over to Stainless Steel Shells from 2018. The technology for Stainless Steel Shells was obtained from Linke Hofmann Busch (LHB) of Germany through transfer-of-technology. The LHB design coaches provide higher passenger capacity due to longer coach and are lighter, safer and durable compared to the erstwhile ICF Corten Steel coaches.
TO enhance the production capacity of LHB design Stainless Steel Shells, an annex to the existing Furnishing Division was started in the year 2014, which is known as LHB division.
Major production shops in Shell & LHB divisions, their area of work and important machines available are listed below.
|
SHOP No.
|
NAME OF THE SHOP
|
IMPORTANT MACHINES
|
|
10
|
Sheet metal shop
(Detail parts)
|
Sheet cut-to-length machine
LASER cutting and welding machine
LASER cutting machine
CNC Profile bending machine
CNC Press brake
|
|
11
|
Heavy sheet metal shop
(Bogie sub-assemblies)
|
CNC press brake
MIG welding sets
|
|
12
|
Wheel shop
(Wheel & Axle)
|
CNC axle turning machine
CNC Axle Grinding machine
Horizontal Drilling & Tapping
Wheel press
CNC Surface Wheel Lathe
|
|
13
|
Heavy fabrication shop (Bogie Bolster)
|
3-Axis Bogie Bolster Machining Center
|
|
15
|
Spring Shop
(Coil springs)
|
Automated spring manufacturing line
|
|
16
|
Machine shop
|
CNC Turning Center
CNC Axle Drilling & Tapping
CNC Vertical Turning Lathe
|
|
18
|
Sub-assembly shop
(End part, partitions)
|
MIG welding sets
|
|
20
|
Side Wall and End Wall assembly Shop
|
Robotic spot welding center
MIG welding sets
|
|
21
|
Roof assembly and Underframe assembly
|
MIG welding sets
|
|
22
|
Body Shell assembly Shop
|
MIG/ TIG welding sets
|
|
23
|
Bogie frame assembly Shop
|
Robotic welding center
5-axis machining center
CNC plate straightening machine
LASER cutting machine
Shot-blasting plant
MIG welding sets
|
|
24
|
Bogie assembly Shop
|
|
|
26
|
Final Shell assembly and dispatch
|
|
|
19
|
New LHB shed (LHB, Vande Bharat Shells)
|
CNC Plasma cutting machine
CNC press brake
CNG Edge milling machine
Robotic welding - bogie frame
3-axle machining center
5-axis machining center
CNC Laser cutting and welding center
Robotic spot welding center
Shot blasting plant
Traverser
|
Furnishing Division
Interior furnishing, exterior painting, electrical equipment, other testing & commissioning works are carried out at Furnishing Division. Furnishing sequence of works include painting, sound & heat insulation, flooring, windows, wiring, brake work, gangways, doors (Automatic/ manual), mounting of water tanks, bio-toilet tanks, toilet modules, AC (Air-Conditioning) equipment, AC ducting, interior panels, fire detection systems, lights & fans, luggage racks, seats/ berths, passenger amenity items, emergency chain, numbering and instruction stickers etc.
  |
In case of Self-Propelled (or) Distributed Propulsion Rolling Stock (DPRS) like EMU, MEMU, Metro, Trainsets etc. additional furnishing works for providing traction equipment, cables, cable trays, Train Control & Management System (TCMS), Passenger Information system, automatic doors, Brake Computers etc. are required to be done. Furnishing division has 25 kV OHE system and dedicated commissioning sheds for Basic Units/ Rakes for DPRS trains.
Major production shops in Furnishing division, their area of work are listed below.
|
SHOP No.
|
NAME OF THE SHOP
|
IMPORTANT MACHINES
|
|
28
|
Electrical Mainline shop
|
Electrical wiring works Non-AC coaches
|
|
29
|
Electrical DPRS assembly shop
|
Electrical wiring works of DPRS coaches
|
|
30
|
Main assembly shop
|
17 assembly lines to cater to furnishing of all types of coaches with 9 stages for each line.
|
|
32
|
Machine & Carpentry shop
|
Interior doors, seats&berths, wall panels, floor boards, AC ducts, partitions
|
|
35
|
Electrical AC coach shop
|
Electrical wiring works of AC coaches
|
|
37
|
Air brake assembly shop
|
Disc Brake system in LHB coaches
EP Brake system in DPRS coaches
Air Brake system in SPART/ DETC
Air Spring Control System
|
|
39
|
Train lighting shop
|
Electrical preparatory & wiring harness
|
|
54
|
Paint Shop
|
Complete interior and exterior Primer, Surfacer, Putty works and Enamel painting and stickering works are being done in this shop.
|
