Evolution of Freight Stock in Indian Railways

Indian Railways inherited freight carrying wagons from British era. Such wagons were four wheelers, vacuum braked, low axle load, low carrying capacity, low pay to tare ratio, low volumetric capacity, plain axle journal bearing, screw coupling freight stock.
It has been a long journey, post independence, in design and development of more efficient freight stock with eight wheeler bogie construction and migration from vacuum to air brake & screw coupling to center buffer coupler.
However, the inherited track along with its track side railway infrastructure continued to impose restriction on Max/Min Moving Dimension (MMD) profile and has not allowed wider wagons despite Broad Gauge track. Later, electrification with its over head infrastructure further imposed restriction in development of taller wagons. Now for greenfield construction of new lines viz. Dedicated Freight Corridors, a good opportunity is available for
re-defining MMD profile for Indian Railways.

1. EVOLUTION OF FREIGHT STOCK
ON
INDIAN RAILWAYS
&
MMD MODIFICATION
REQUIREMENTS
Om Prakash Chaube
Former Executive Director / Wagon
RDSO, Indian Railways
Oct. 2019

2. STATUS BEFORE 1947
•Design of freight stock provided by British consultancy
firms M/S Rendol,Palmer & Tritton
•25 types of commodity specific wagons
SNType of Wagon Commodity
14-Wheeler Open Wagon (O, OX,OH,OS,ON)Coal, Iron Ore etc.
24-Wheeler Covered Wagon (CR,CH, CA,
CMR, CE)
Food Grains, Jute,
Fertilizers, Cattle etc.
34-Wheel Tank Wagon (TO, TP, TM)Petroleum Products,
Molasses etc.
4Bogie Open Wagon (BO, BOC)Coal, Iron Ore etc.
5Bogie Covered Wagon (BCR) Food Grains etc.
6Bogie Well Wagon (BW, BWX, BWL, BWH)Industrial Equipment
7Other Wagons (BR, BVG)Rail Panel, Brake Van

3. Wagon Type Axle
load (t)
Pay
Load (t)
Tare
weight (t)
Pay to
tare ratio
O4-Wheeler
Open Wagon 16.3 22.29 10.312.16
OH4-Wheeler Open
High sided wagon 16.321.8810.722.04
OM4-Wheeler Open
Military Wagon16.321.9810.622.07
BOBogie Open
Wagon 16.344.9520.252.22
BOCBogie Open Coal
Wagon 16.345.1420.062.25
CR4-Wheeler
Covered Wagon 16.321.8310.772.02
OX4-Wheeler Open
Wagon, heavy 19.327.0711.532.34
CX4-Wheeler Heavy
Covered Wagon19.326.5612.042.20
SALIENT DESIGN FEATURES OF PRE INDEPENDENCE FREIGHT STOCK

4. FEATURES OF PRE INDEPENDENCE FREIGHT STOCK
•Low axle load (16.3 –19.3 tonnes)
•Low payload to tare weight ratio (2.02 to 2.34)
•Very less volume available for commodities
•Maximum 27 tonnes payload for 4-Wheeler
wagons
•Maximum 45 tonnes payload for bogie wagons
•Vacuum Brakes, Screw Coupling
•Plain Journal Bearing

5. DEVELOPMENTS IN FREIGHT STOCK (POST INDEPENDENCE)
Type Design by Axle
Load (t)
Pay
Load (t)
Tare
Weight (t)
Pay to
tare ratio
Comm
odity
BOBSM/s. ISW &
M/s. TALBOT
(Germany)22.9 65.18 26.422.4Iron Ore
BWS
(12
Wheels)
Hitachi 18.70132.9691.441.45Heavy
Machin
ery
BWTDeutsher
(East
Germany)
22.956.0435.561.57Heavy
Machin
ery
TBTCRDA,
Italy
16.2519.513.01.5Bitumen

6. RDSO ESTABLISHED IN 1957
•1958: BOX wagon designed for coal movement
on BG system
ØAxle load : 20.32 t, Payload of 56 tonnes
ØLength : 13.7m, 44 Nos. in one train
ØFitted with fabricated UIC bogie
ØVacuum brake system
ØCylindrical roller bearing in axle box
ØCenter Buffer Coupler/Transition Coupler
•1980:BOXNwagondesigned:Generalpurpose
wagon(A/L20.32t)withreducedlengthof10.7
mand58wagonsinonetrain,payload58.8t.

7. BOXN WAGON
•Fitted with twin pipe air brake system.
•Sealed cartridge taper roller bearing (CTRB).
•Cast steel “Casnub” bogie.
•High capacity draft gear.
•High tensile centre buffer coupler.
•Payload of one goods train (BOXN) 3410 tonnes
against 2467 tonnes of one BOX train.
•Gross Train load 4714 t (BOXN); 3576 t (BOX)

8. OTHER WAGONS
•BCNA Wagon designed for
ØFertilizer
ØFood grains
ØCement
•Tank Wagon (BTPN/BTPGLN) for Petroleum/LPG.
•BTFLN –Tank Wagon –330 Nos. –U/F, Sole bar/ centre sill less
•Flat wagon (BRNA) for carrying rails, steel plates, coils.
•BOBRN Wagons : Hopper wagon for coal.

9. CONSTRAINTS
(Axle Load, Speed, Unloading/Loading)
•Axle load restricted to 20.3t
ØTrack / Bridge Restrictions/TLD
•To reduce speed differential between freight and
passenger trains.
ØHigh sapeed (100 kmph) wagons introduced.
•Tipplers -a constraint
•Covered wagon –Manual Head loading.

10. BRIDGE STANDARDS
A/L(t)TLD (t/m)
•BGML (1926 )22.97.67
•RBG (1975)22.97.67
•MBG (1987)258.25
(BOXNHL = 8.35)
•25 T (2008)
(HMLoading)
259.33
•DFC32.512.13

11. TIPPLERS INSTALLED AT PRESENT
S.No.Max. height of wagon
tippler from rail level
which tippler can handle
No. of tipplers
TotalCapacityNos.
13225 mm
(BOXN height)
8280t/90t
100t/105t
110t
120t
62
16
4
Nil
23450 mm
(BOXNHA height)
580t/90t
100t/105t
110t
120t
Nil
5
Nil
Nil
33735 mm15680t/90t
100t/105t
110t
120t
40
99
15
2
243
These 243 tipplers are installed at 156 unloading points.

12. PATTERN OF RICE LOADING IN BCNA
WAGON AT FCI/BARABANKI

13. PATTERN OF FERTILIZER LOADING IN BCNA
WAGON AT INDOGULF/JAGDISHPUR

14. Further Developments
•1998 : BOXNHA wagon designed for 22.1 t (Coal )
and 23.5 tonnes axle load (Iron Ore) –Speed 100 KMPH
•BOXNCR: Open wagon with Stainless Steel body for
minimizing corrosion
•BOXNHS: BOXN wagon fitted with bogies fit for 100
KMPH
•BOST: For steel coils and coal
•BFNS: For HR/CR Coils
•BLCA/BLCB: Container Flat wagon

15. •BOXNLW: Cold rolled formed sections & stainless steel
body
•BOXNAL,BOBRNAL: Aluminum wagon with reduced
tare weight
•Above new designs of wagons suitable for 100 KMPH
•Composition Brake Blocks (CBB) introduced in place of
C.I. Brake blocks
•Material –MS=IS2062(CU Brg.), Corten = IRSM-41,
S/S = IRSM-44 (mkt =409 M)
Further Developments (continued..)

16. BOGIE MOUNTED BRAKE SYSTEM
•Improved reliability of air brake system
•Enables introduction of tubs in design of wagons
•Higher height consignment can be carried as well type
configuration possible.
•Centre sill less design of wagon possible with
reduction in tare weight.

17. BOXN TYPE WAGON FOR IRON ORE & COAL
TypeofBOXNwagon
Type of wagonsApproximate holding as
on 31.3.05 (VU)
Type of wagonApproximate holding as
on 31.3.05 (VU)
BOXN
H-3233mm
W-3200mm
V-56.29m3
Tare-22.9t
69141BOXNHA
(22.1t A/L coal
23.5t A/L iron ore)
H-3450mm
W-3200mm
V-62.80 m3
Tare-23.17t
5 rakes
BOXNLW
(stainless steel + CRF)
H-3263mm
W-3250mm
V-58.84m3
Tare-20.4t
NILBOXNAL
(Aluminum Body)
H-3341mm
W-3250mm
V-61.09 m3
Tare-18.26t
NIL
•BOXNLW –Under production
•BOXNAL –P.O. to be placed by Railway Board.

18. BOXNHL-22.9 t AXLE LOAD WAGON
•Designed in 2005.[Extra Length = 250mm, TLD = 8.35 t/m ;
BOXN (20.32 t A/L = 7.58 t/m TLD]
•To be introduced universally on IR track in 2006.
•Designed for 100 KMPH speed potential.
•Low tare weight (20.6 t). S/S Body
•Higher payload to tare weight ratio (3.4).
•Suitable for Coal and Iron ore traffic.
•Payload of one train (58 wagons) 4118 tonnes against
3410 tonnes for BOXN Wagon.
•Gross Load of one train (58 wagons) 5313 tonnes against
4714 tonnes for BOXN Wagon.

19. BOXNHL WAGON 22.9 t A/L
FeatureBOXNBOXNHL
Axle Load20.3 t22.9 t
Gross Load81.28 t91.6t
Wagon Length10.713m10.963m
TLD7.67t/m8.35t/m
Tare Weight22.88t20.6t
Wagon length over
coupler face
10.713m10.963m
Pay Load58.4t71.0t (density 1.15t/m3 +heap )
Pay load to tare ratio2.553.45

20. BOXNHL WAGON 22.9 t A/L
FeatureBOXNBOXNHL
Gross load of train4714t5313t
Pay load of 58 wagons3387t4118t
Volumetric Capacity56.29m359.19m3
Train Length621m636m
Speed75/80, 100100 KMPH Potential
Number of Doors64
CRF Section, Stainless Steel construction, Height 3225
(same as BOXN), Width 3250 (BOXN width 3200)

21. COMPARISON WITHOTHER RAILROADS
CountryMaximum Axle
load (tonnes)
Payload to tare
weight ratio
Australia406.4
USA365.7
South Africa264.0
INDIA
BOXN20.32.6
BOXNLW20.32.9
BOXNAL20.33.4
BOXNHL22.93.4

22. COMPARISON (CONTINUED)
•Piggy Back system (Ro-Ro)
•Double stack containers
•Auto-racks (for transportation of cars)
•Mechanized loading/unloading
•Use of Rotary Couplers
•Special wagons for finished steel
consignment
•Special wagons for petroleum products-
center sill less design.

23. Features USA Wagon BOXNLWBOXNAL
Length over
coupler
16180 mm10713mm10713mm
Length inside 14559mm 9784mm9784mm
Width outside 3196mm 3250mm3250mm
Width inside 3175mm 3022mm3022mm
Height from R/L3835mm3263mm3341mm
Tare 17.6t20.4 t18.2t
Payload 112.2 t60.8t63.0t
Gross rail load 129.7 t 81.2t81.2t
Volume with heap138 Cu m64 Cu m66 Cu m
Pay to tare ratio6.42.93.4

24. FUTURE CHALLENGES/CONSTRAINTS FOR IR
•Target: 1000 Million tonnes of originating loading
•Higher axle load (25t/30t) wagons with higher pay to
tare ratio
•Introduction of track friendly bogies
•Large scale introduction of Stainless Steel/Aluminum
wagons
•Introduction of double stack container services
•Commodity specific wagons
a)Ro-Rob)Autoracks
c)Efficient wagons for petroleum product.
d)Bulk carries for fertilizer, food grains, fly ash, cement.
e)Sliding roof multiple purpose wagons.

25. FUTURE CHALLENGES/CONSTRAINTS
(CONTD.)
•Introduction of advance warning systems
ØHot Box Detector
ØTrackside Acoustic Bearing Detection System
ØTruck (Bogie) Performance Detector
ØWheel Flat Detector

26. SCHEDULE OF MAXIMUM MOVING
DIMENSIONS
•Limits efforts to increase throughput of freight trains
and Multi-modal operations
•First issued in 1922
•Amendment in 1929 to provide necessary clearances
for electric traction equipments (OHE).
•New profile adapted in 1981 for goods stock:
ØWidth of MMD for goods wagons increased
from 3200mm to 3250mm.
ØCenter height increased from 4115mm to
4265mm.
ØSide height increased from 3505 mm to 3735
mm.

27. SCHEDULE OF MAXIMUM MOVING
DIMENSIONS (Continued..)
•Revised MMD prescribed in 2004 :
ØTop width at centre height increased from 610
mm to 1520 mm
ØMaximum width of 3155mm near platform level-
Unaltered
ØMaximum width of wagon 3250mm above
platform level-Unaltered
ØIn BOBRN –3500 mm width permitted with
restrictions

29. Considerations For New MMD
•Height of Double Stack 9 ½’ containers will govern
the height of MMD (2896 x 2= 5792)
•This will cover height of 3tier AAR Auto Racks
(5400 mm)
•Width at top will be governed by Auto Rack width
(3,000mm)
•For Ro-Ro operation, height of 4760 mm above
floor level is required (NHAI tunnel height-4760 mm)
•Above are for New Corridor; Delhi-HWH-Mumbai
•For coal, existing MMD only for interoperability

30. Consideration For New MMD (Contd.)
•For Open Coal Wagon
-Interoperability,existing MMD to use, 1000 dia wheel
-Doors needed for manual unloading,tub ruled out
-Heap permitted
-Maximum Dimension which can be used:-
ØWidth O/S =3500 mm (BOBRN)
ØLength O/S=10713 mm (BOXN)
-Height works out from R/L = 3885 (BOBRN height
3735mm, P/F cover height 4115mm)

31. Considerations For New MMD (ctd..)
-Numbers of Wagons per train = 58
-Wagon Pay Load=96 tonnes, Gross Load= 120 t,
Tare=24t
-Train Pay Load = 5600t, Gross load= 7000t
-TLD=11.2 t/m (<12t/m)
-At TLD = 12.0 t/m, side height at BOBRN width reaches
4110mm-hits COP at Platform
-Suitable tipplers will be needed for increased
height,width & gross load.
-For interoperability, bridges will need examination as
universal TLD is 8.355 only.

32. WHY LONGER LOOP LENGTH & NEW MMD
Comparison of existing coal wagon in US & India
58 wagon trainTrain of 686m loop length
CountryUSIndia (BOXN)USIndia
(BOXN)
Nos. of wagon58583858
Train length939m*621m615m621m
Tare weight of rake1021t1328t669t1328t
Pay load6508t3213t4267t**3213t
Nos. of bogie/rake11611676116
No. of wheel set/rake232232152232
No. of bearing/rake464464304464
* Wagon of higher pay to tare ratio in advanced Railways are longer than IR wagons.
**In BOXNHL (22.9t A/L), pay load is already 4118t.

33. WHY LONGER LOOP LENGTH & MORE HEIGHT
•Thecoalthroughputof58wagoninUSis102%higherthanIndia.But,
toachievethisweneedalooplengthofmorethan1000m.
•InexistinglooplengthofIR,38UStypewagonscancarry32.8%more
coalthan58IRwagonwithlessmaintenancecostof20wagons(40
bogies,80wheelsetsand160axlebearings).
•Costofarakewillalsobelessduetolessnumberofbogies,wheelset
andaxlebearings.ButtoachievethisweneedhigherheightinMMD.
•Forhigherpaytotareweight,morethroughputandlessmaintenance
cost,wagonlengthandheightshouldbemore.Hence,longerloop
lengthandmorerelaxedMMD.
•Forlowertareweightandmorepayload,forcesonstructuralmembers
shouldbeless,whichcanbeachievedbyreducingbrakingforce.But
brakingdistanceswillbehigher.

34. WHY MORE WIDTH
•IndianRailwayhasBG(1676mm)systemandwider
stockcanbeusedprovidedwiderMMDpermitsit.
Baggedconsignmentsbeingflexiblefrom
loading/unloadingpointofview,canbeloadedmore
manually.
•Infuture,dependinguponavailabilityoftechnology,in
awagonofapproximately5000mmwidetworowsof
smallcarscanbeloadedatleastonlowestdeck.This
willincreasethecapacityoftrilevelautocarrack,rake
bynearly33%.

36. THANK YOU