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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.

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.


 



Source : Integral Coach Factory CMS Team Last Reviewed on: 16-11-2022  

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