LHB coach bogies are 'corroding': Railway Board raises safety concerns as toilet leaks, salty air & even cleaning practices emerge as problems

The Railway Board has raised concerns over heavy corrosion in the bogies of Linke Hofmann Busch (LHB) passenger coaches, despite the use of corrosion-resistant materials and improved cleaning practices.

Senior railway engineers flagged the issue at a recent conference of principal chief mechanical engineers (PCMEs), where officials asked three major coach manufacturing units to examine the problem and suggest solutions.

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The units include Integral Coach Factory (ICF), Chennai; Rail Coach Factory (RCF), Kapurthala; and Modern Coach Factory (MCF), Rae Bareli.

“Heavy corrosion in LHB bogies is a cause of worry,” the minutes of the conference, compiled by the Railway Board, said.

Why is corrosion in LHB coach bogies a concern?

Railway officials have advised increased attention to the maintenance of both AC and non-AC LHB coaches, as corrosion in bogie components could pose a safety risk and increase maintenance requirements.

The issue has also prompted the Railway Board to ask zones to examine corrosion-prone components and sub-assemblies during scheduled maintenance.

Eastern Railway prepared a detailed report in March examining corrosion in LHB AC and non-AC coaches. The report included age-wise and component-wise analyses of corrosion.

LHB coach corrosion: Toilet areas emerge as a key concern

Experts examining the issue found that the proximity of structural components to lavatory areas is one of the major factors contributing to corrosion.

Water can seep through lavatory flooring or defective pipe fittings and reach the underframe of the coach. This can expose metal components to moisture and corrosive substances.

“Although bio-toilets are designed to treat waste, any accidental overflow or leakage of effluent - which is acidic and rich in chlorides - causes rapid corrosion of the trough floor, sole bars and headstock,” the Eastern Railway report said.

The report also identified cleaning practices, dents on steel surfaces and vinyl advertisement wrappers among the factors that can contribute to corrosion.

Coastal areas may accelerate LHB coach corrosion

Coaches operating in coastal regions face an additional challenge because of exposure to saline air.

“Coaches running in coastal regions are exposed to saline air. The high salt (NaCl) content acts as a powerful electrolyte, accelerating the electrochemical process of corrosion,” the experts said.

The presence of salt and moisture can accelerate the corrosion process, making preventive maintenance particularly important for coaches operating in coastal areas.

Railway Board asks zones to improve corrosion prevention

The experts recommended a combination of design, maintenance and operational measures to address corrosion in LHB coaches.

Railway zones have been advised to avoid aggressive chemicals and high-salinity or untreated water while washing coaches. Proper rinsing and drying after washing have also been recommended to prevent corrosive residues from remaining on metallic surfaces.

Officials have further been asked to ensure that drain holes, slots and passages in underframe and bogie areas remain free of blockages, helping prevent water from accumulating.

Improving existing corrosion-protection systems has also been suggested.

Railway safety: Zones told to inspect critical components

The Railway Ministry has asked all railway zones to review critical safety areas and follow the precautionary measures identified by experts.

The focus will be on components and sub-assemblies highlighted in the Eastern Railway report, particularly during scheduled maintenance.

The concerns come as Indian Railways continues to operate a large fleet of LHB coaches, which replaced older indigenous coach designs on many passenger services and were introduced to improve speed, safety and service life.

The Railway Board's latest direction places greater emphasis on identifying corrosion at an early stage and preventing damage to critical coach structures and bogie components.


Inputs from PTI