CHALLENGES AHEAD

 Traditional commodity Basket – Coal, Ore & packaged commodity.

 Competition from road
 Demand from industry
 Need to diversify commodity basket.
 Focus sectors
• Steel
• Fly Ash/Cement
• Auto Car Carrier
STEEL COIL CARRIER
 EVOLUTION
• Transporting Steel products is a
challenging business for Indian
Railways.
• Traditionally Steel products are
transported in BRN and BOXN wagons.
BFNS-
• First wagon designed specifically for
steel coils and sheets.
• Five pockets for loading and securing
steel coils.
BRN –
• Modified to have foldable Bulkhead to
facilitate loading.
 EVOLUTION
BFNSM :
• Takes advantage of higher axle load-
22.9t
• Length optimised leading to a increase of
44 % over BFNS.
• Continuous groove removes constraint of
loading location.
• Oscillation trial cleared at 110 kmph both
in empty and loaded condition.
• Robust design viewed favourably by
industries.
• 4 rakes in service.
 COMPARATIVE PARAMETERS

Existing Length Tare Wt. Width Pay No. of Through

Wagon (mm) (tonne) (mm) Load Wagons Put
(tonne) per
Rake

BFNS 14645 26.71 3045 64.89 43 2790

22.9t

BFNSM 10963 22.0 2945 69.6 58 4036

BRN 14645 23.3 2930 68.292 42 2868

22.9t
 BFNV WAGON

• During the last conference consensus among stake

holders to have a coil carrying wagon with eye to platform.
• This facilitates loading with fork Lifters.
• Loading under OHE is feasible.
• Designed jointly by RDSO and M/s JRIL.
• Proto-type ready by mid January-2020.
Special Features –
• Design for cold rolled coils upto 2000 mm soil dia.
• Feasibility of attaching cover.
• Specially designed locking arm.
• Tare weight (approx.) – 22 t
• Pay Load – 69.6 t
• No. of wagons per rake – 58
• Rake Throughput – 4036.8 t
BFNV WAGON (Proto type manufacturing)
FLY ASH / CEMENT WAGONS

8
BLCS U/F with center sill asy.(middle) & center BTFC U/F with discontinuous center sill (end sill)
sill (end)

TOP ISOMETRIC VIEW

BOTTOM ISOMETRIC VIEW

Complete UF
 BCFC (DESIGN-E)
MAIN PARAMETERS:
• Length over coupler face = 10713 mm
• Tare weight of wagon = 22.9t
• Material of construction= IS:2062 E 450
• Volumetric capacity = 79 m3
• Pay load (Cement) = 68.7t
• No of wagons per rake = 59
• Rake throughput = 4055t
Special feature:
Provided with Air assisted gravity discharge system
 BCCW WAGON
• Length of wagon over couplers – 10713 mm
• Tare weight of wagon – 23.25 t
• Width of wagon - 3248 mm
• Pay Load (Fly Ash) – 63.65 t
• Pay Load (Cement) – 63.65 t
• No. of wagons in one rake - 59
• Rake throughput (Fly Ash) - 3755 t
• Rake throughput (Cement) -3755 t

Special Features:
• Air assisted gravity discharge system
 BCFC (DESIGN-A)
MAIN PARAMETERS:
• Length over coupler face = 10713 mm
• Tare weight of wagon = 22t
• Material of construction= IRSM:44
• Volumetric Capacity= 75.8 m3
• Pay load (Cement) = 67.3t
• No of wagons per rake = 59
• Rake throughput = 3970t
• Special feature = Air assisted gravity discharge system
 BTAP WAGON
• Length of wagon over couplers – 12329 mm
• Tare weight of wagon – 27.32 t
• Width of wagon - 3200 mm
• Pay Load (fly ash) – 58.52 t
• Pay Load (Cement) – 58.52 t
• Pay Load (Alumina) – 60.17 t
• No. of wagons in one rake - 51
• Rake throughput (fly ash)– 2984 t
• Rake throughput (Cement)– 2984 t
• Rake throughput (Alumina)– 3069 t

Special features:
 Air assisted Fluidized bed side discharge system
 BTFC
BTFC:
 Design completed
 Agency for Prototype manufacturing
nominated
Features:
 Air assisted side discharge system.
 Suitable for transportation of
Alumina, Cement & Fly ash
 Optimized within IRSOD
 7% more rake throughput than
existing BTAP wagon.
 No need to modification in existing
infrastructure for loading and
unloading.
16
 COMPARISION OF FLY ASH & CEMENT WAGONS
S.No Description BCCW BCFC-A BCFC-E BTAP BTFC

01 Tare weight (t) 23.25 22.0 22.9 27.32 27.5

02 Pay Load (t) 63.65 67.3 68.7 58.5 64.1
03 No of wagons per 59 59 59 51 49
rake
04 Rake throughput (t) 3755 3970 4055 2984 3205
05 Discharge System Air assisted Air assisted Air assisted Air assisted Air assisted
gravity bottom gravity bottom gravity bottom side side
discharge discharge discharge discharge discharge
06 Discharge pressure 0.2 kg/cm2 0.2 kg/cm2 0.2 kg/cm2 2.0kg/cm2 2.0kg/cm2
07 Volumetric capacity 67m3 72.8 m3 76 m3 61.6 m3 67.5 m3
(loadable)
08 Population 02 rakes 03 rakes Prototype
under under
manufacture manufacture

Density of fly ash=0.95 kg/m3

AUTO CAR CARRIER
 AUTOCAR CARRIER

• Beginning was made in 90s with

introduction of NMG rakes.
• Coaches converted for carrying Automobiles.
• Low cost, high speed but single level loading.
BCACM (2008) –
• First Autocar carrier with bi-level loading.
• Fixed middle deck restricted loading of
SUVs.
 AUTOCAR CARRIER
BCACBM wagon (Design-A):
– Introduced in March-2014.
– 17 no’s of A-Design rakes are in
operation.
– Movable Bi-Level Auto-car Carrier.
– 27 no’s of wagon in a rake.
– Optimized for 318 no’s small cars per
rake and max pay load of 15tonnes
per wagon.
– Due to movable deck height SUVs,
can be accommodated in the wagons.
– Max. speed 100kmph in empty and
95kmph in loaded.
 AUTOCAR CARRIER
BCACBM wagon (Design-B)
(2018) :
• Incorporated suggestions received in the first
conference held in July-2017.
• Dimensions and Capacity of the wagon same as
Design-A wagon.
• 23 rakes in operation
• Permission granted for 54 rakes.

Key Features
• Corrugated roof sheet.
• Corrugated upper deck.
• Solid floor plate.
• Box-type fabricated side stanchions.
• Twin air brake pipe arrangement.
 NEW DESIGN OF AUTOCAR WAGON
New Design of Auto Car Wagon
• Side Opening for loading of two
wheelers provided, in existing
BCACBM-Designs.
• Prototype ready at M/s Texmaco,
Kolkata.
• Rake owned by M/s APL Vascor.
• Loading options –
 In Cassettes
Stand alone vehicle.
 FUTURE DESIGN OF AUTOCAR WAGON

Double stack dwarf container profile

• Height of existing wagon – 4305 mm
• When SUV loaded in Lower deck, Upper deck remains
un-utilized.
Double stack dwarf container profile- 4877 mm
Within this profile two options explored –
• Height – 4730 mm
• Length 1 – 14.133 m – Optimised for Sedan
• Length 2 – 23.555 m – Optimised for small cars
• Feasible for IR (Selected routes), Eastern & Western DFC
SOD
 FUTURE DESIGN OF AUTOCAR WAGON

Comparison with Existing Wagon -

S. No. PARAMETERS EXISTING BCACBM OPTION-1 OPTION-2

1 Length of wagon over 23555 mm 14133 mm 23555 mm
Couplers
2 Max. no. of small cars 318 per rake 270 per rake 324 per rake
3 Max. no. of SUVs 135 per rake 264 per rake 264 per rake
4 Max. no. of Sedans 264 per rake 270 per rake 264 per rake

NOTE: Cost of one rake of Option-1 will be higher than Option-2

 FUTURE DESIGN OF AUTOCAR WAGON

FUTURE DESIGN (WDFC Profile)

• Overall length (over CBC)- 23555 mm
• Width - 2900 mm
• Height – 6820 mm
• Tare weight (approx.) – 48 t
• Pay Load – 30 t
• No. of wagons per rake – 27

Special Features –
• 3 units of 2 A-cars and 7 B-Cars
• 3 levels of loading.
• Upper deck is fixed & middle deck is
movable.
• Optimised for 486 small cars, 399
SUVs.
Special Commodities Wagon

26
New design of wagon for special commodities
• RORO wagon
• Dwarf Container
• Multimodal wagon

27
 RORO wagons
 During conference on “Wagon Design” at Vigyan Bhawan held in March 2019,
demand was raised by stakeholders to develop a design of RORO wagon:
 Following options were examined:
Parameters SOD Wheel Floor Max. Permissible Truck dimension No. of
Dia. Height variants

mm mm Height Width Length Nos

Option-1 IR_SOD 1000 1269 2701 2550 12000 37/115

Option-2 IR_SOD 840 970 3032 2550 12000 92/115

Option-3 EDFC 1000 1269 3831 3000 12000 114/115

TRUCK PARAMETERS:
Type of Variants = 115 nos.
Max. Height = 3970 mm, Max. Width = 2550 mm, Max. Length = 12000mm, Gross Load=60t
 New design of RORO wagon

Based on feed back received from various stake holders a new

design has been developed:
 Key Feature:
 5 units of 2 A-car and 7 B-car.
 Can carry all length of Rigid frame trucks (12 m).
 45 nos of Rigid frame trucks can be transported in a
rake.
 Possibility of Loading Semi articulated vehicle
having length more than 12 m on two wagons.
 No restriction of width, length and gross load of
trucks.
 Maximum height can not be more than 3000mm in
IRSOD. However, no restriction of height on dwarf
container and DFC routes (3.8m Height).
 New design of RORO wagon

Main Parameters:
Length over couplers:
(A-Car) – 15.4m
(B-Car) – 13.8m
Tare weight – 23 t
Width of wagon – 3050 mm
Pay Load – 60 t
No. of wagon in one rake – 45
Status:
 Detail design developed
 Railway Board has been asked to nominate an agency for prototype
development
 DOUBLE STACK DWARF CONTAINER
• Height from Rail level=4877 mm
• Dimensions of Container:
• Length =6096 mm
• Width =2600 mm
• Height =1930 mm
• Route cleared for operation:
• Jamnagar (NR) to Chawapali (NR)
• S.kka- Surat –Kelve Road
• Surt-Jalgaon-Akola-Shankarpalli route
• Due to movement of Double stack
under OHE, the usually unutilized
space above single stack being
utilized resulting in extra revenue.

31
New design of Multi-Purpose Modular wagon

32
 New design of Multi-Purpose Modular wagon
 Presently wagon designs are being
developed for a particular commodity and
these designs are optimized for that particular
commodity.
 There are certain designs which are slightly
different with each other; but can not be used
for different commodity due to certain
limitations in there design.
 A need has been felt to examine the feasibility
of development of a standard design which
can be universalized for various commodities.
 Accordingly a platform (underframe) has been
developed, which can be used for
transportation of various commodities without
any major modification and also can be
converted into ……….
 New design of Multi-Purpose Modular wagon

FEATURES:
• Provided with 25t axle load LWLH bogie.
• Low floor height, hence more vertical space
within IRSOD.
• Utilizing maximum width of IRSOD
• Can be used for following commodities with
minor modification:
– Steel consignments (flats, rods, sheets etc.)
– Steel coils
– Containers
– Trucks (RO-RO)
LIMITATIONS:
As the design is optimized for transportation of
Truck having length of 12 m, the wagon shall not
optimal for other commodities.
 New design of Multi-Purpose modular wagon

Main Parameters:
Length over couplers:
A-Car - 15400 mm
B-Car - 13800 mm
Floor Height – 1000 mm.
Tare weight – 23 t
Width of wagon – 3050 mm
Pay Load – 60 t
No. of wagon in one rake - 45
OPEN WAGONS

36
 BOXNM2
AXLE LOAD=22.82t
PAY LOAD =68.75t
SPEED=100(E),60(L)

BOXNM2
AXLE LOAD=22.82t
PAY LOAD =68.75t
SPEED=80(E),70(L)
BOGIE:22NLB

BOXNM1 SPRING CONFG.:12(O),8(I),4(S)

FRICTION SNUBBED
DAMPING(Non-METALLIC)

AXLE LOAD=20.32t
PAY LOAD =58.75t BOGIE:22NLB
SPEED=80(E),75(L) SPRING CONFG.:14(O),10(I),4(S)
FRICTION SNUBBED
DAMPING(METALLIC)

BOXN
BOGIE: 22NLB
SPRING CONFG.:12(O),8(I),4(S)
FRICTION SNUBBED DAMPING(METALLIC)
 BOXNHSM2
AXLE LOAD=22.82t
PAY LOAD =68.75t
SPEED=100(E),60(L)

BOXNHSM2
AXLE LOAD=22.82t
PAY LOAD =68.75t
SPEED=90(E),75(L)
BOGIE: 22HS

BOXNHSM1 SPRING CONFG.:14(O),12(I),4(S)

FRICTION SNUBBED DAMPING
(Non-METALLIC)

AXLE LOAD=20.32t BOGIE: 22HS

PAY LOAD =58.75t SPRING CONFG.:14(O),14(I),4(S)
SPEED=100(E),100(L) FRICTION SNUBBED
DAMPING(METALLIC)

BOXNHS
BOGIE: 22HS
SPRING CONFG.:14(O),12(I),4(S)
FRICTION SNUBBED
DAMPING(METALLIC)
 BOSTHSM2

AXLE LOAD=22.32t
PAY LOAD =63.78t
SPEED=100(E),60(L)

BOSTHSM2
AXLE LOAD=22.32t BOGIE:22HS(MOD-II)
PAY LOAD =63.78t SPRING CONFG.:12(O),12(I),4(S)
SPEED=80(E),60(L) FRICTION SNUBBED DAMPING

BOSTHSM1 (NON-METALLIC)

BOGIE: 22HS(MOD-I)
AXLE LOAD=20.32t SPRING CONFG.:14(O),14(I),4(S)
PAY LOAD =55.78t FRICTION SNUBBED
SPEED=100(E),100(L) DAMPING(METALLIC)

BOSTHS
BOGIE: 22HS
SPRING CONFG.:12(O),12(I),4(S)
FRICTION SNUBBED DAMPING(METALLIC)
 BOXNR
AXLE LOAD=22.9t
PAY LOAD =70.4t
SPEED=100(E),60(L)

BOXNR
BOGIE:22NLB
SPRING CONFG.:12(O),8(I),4(S)
FRICTION SNUBBED
DAMPING(METALLIC)
UPGRADED REHAB WITH SS
AXLE LOAD=20.32t AND MICRO ALLOYED BODY
PAY LOAD =58.75t
SPEED=80(E),75(L)

BOXN
BOGIE: 22NLB
SPRING CONFG.:12(O),8(I),4(S)
FRICTION SNUBBED DAMPING(METALLIC)
 BOXNRHS
AXLE LOAD=22.9t
PAY LOAD =70.4t
SPEED=100(E),60(L)

BOXNR
BOGIE:22HS
SPRING CONFG.:14(O),12(I),4(S)
FRICTION SNUBBED
DAMPING(METALLIC)
UPGRADED REHAB WITH SS
AXLE LOAD=20.32t AND MICRO ALLOYED BODY
PAY LOAD =58.75t
SPEED=100(E),100(L)

BOXNHS
BOGIE: 22HS
SPRING CONFG.:14(O),12(I),4(S)
FRICTION SNUBBED DAMPING(METALLIC)