RCF Kapurthala unveils prototypes of narrow gauge coaches for Kalka-Shimla Railway route

Ashesh Agrawal, general manager, RCF, who unveiled the coaches said that these coaches will be transported to Kalka for the second phase of extensive oscillation trials.  Based on the outcome of the trial, they will be planned to be put into service on the Kalka-Shimla route.

The RCF was entrusted with the project to design and manufacture a new narrow gauge rolling stock for Kalka-Shimla Railway (KSR).

The RCF will be manufacturing 30 such state-of-the-art narrow gauge panoramic coaches, including four AC Executive Chair Cars (12-seater), eight AC Chair Cars (24-seater), 13 non-AC Chair Cars (30-seater), and five Luggage Cars. These coaches have a lightweight shell with upgraded bogies and an improved air brake system.  They will have power windows and darkening vista glass in the upper classes, and slide windows in the second class for a panoramic wider view so that the passengers can experience the beauty of the mountains and valleys.

The coaches will also be equipped with modern safety features such as CCTVs and fire alarms, anti-UV coated window glasses, powered doors, heating/cooling package AC, linear concealed fans, linear LED lights, modular seating rail-mounted seats with flip backs, restaurant-type seating with luxury seats for Executive class, onboard mini pantry, luggage bins, inter-car gangway (vestibule) etc.

The project posed significant challenges for RCF as there was no digital data for modelling of narrow-gauge tracks for development and verification of coach designs which were developed around 1908, said a statement by RCF.

“Notwithstanding the above limitations, the RCF Design team worked tirelessly to recreate the required design inputs using the experience garnered over years of developing rolling stock designs for IR Broad Gauge system,” it said.

According to the Design team, the 3D models were created using the old blue print and sketches available at Kalka workshop.  These models were then used as the baseline for development of the new designs for modification of the bogies and development of all new shell superstructure and furnishing designs.

After the Railway Board gave the design approvals, two prototype shells of air-conditioned Chair Car and Luggage Car were manufactured in September 2022 which were rigorously tested by RDSO next month for static stress analysis at RCF.

In December last year, these two semi-furnished shells were transported by road to Kalka workshop and tested on the Kalka-Shimla route at speeds higher than the present sectional speed to determine the stability and ride quality. After successfully testing the shells under static and dynamic conditions, the RCF developed the interiors suiting the new design.