Wagon Construction Overview

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Questions and Answers

What components connect the ends of a wagon with its sides?

Ventilators

Corner angles (correct)

Top copings

Side panels

What is the purpose of the anti bleeding device found in flap doors?

To enhance ventilation

To facilitate manual unloading

To prevent spillage (correct)

To strengthen the door structure

Which components are included in the construction of the ends of the wagon?

Swing doors and label holders

End panels and stanchions (correct)

Roof sheets and carlines

Retractable anchoring locks

What type of doors are commonly used for unloading in wagons?

Swing doors and flap doors Signup and view all the answers

What type of wagons have fixed or flexible ends and no side walls?

Flat/well wagons Signup and view all the answers

Which features do hopper wagons include in terms of their construction?

Side discharge/centre discharge doors Signup and view all the answers

In a covered wagon, what is used to enhance the roof's integrity?

Car lines Signup and view all the answers

What was the purpose of the retro fitment advised by Zonal Railways?

To address severe field issues in earlier versions of door assemblies. Signup and view all the answers

Which door design was determined to have performed with the least field problems in the trial?

Sliding door with top mounted rollers on guide channel. Signup and view all the answers

When was the bottom roller design for the sliding door developed?

August 2009 Signup and view all the answers

What document number was issued by RDSO for the retro fitment procedure in June 2010?

WD-10036-S-01/WD-06076-S-13 Signup and view all the answers

What is the primary method of operation for the door mechanism in most wagons?

Manually operated system Signup and view all the answers

What issue led to the need for modified locking arrangements in earlier door versions?

Severe field issues and performance feedback. Signup and view all the answers

Which of the following is NOT a common defect that necessitates attention in wagon bodies?

Cracking of the roof sheet Signup and view all the answers

What is a likely cause of corrosion on the wagon floor and roof sheets?

Moisture retention in clean areas Signup and view all the answers

Which damage is specifically caused by abnormal loads in a wagon?

Distortion or cracking of stanchions Signup and view all the answers

Which factor significantly contributes to the corrosion of wagon body components?

Inadequate painting and surface protection Signup and view all the answers

What is a common outcome of slackening rivets over time?

Weakening of the structure Signup and view all the answers

What condition can cause bulging of the ends of wagons?

Improperly secured consignments Signup and view all the answers

What type of wagons have a pneumatically operated door mechanism?

Special hopper wagons Signup and view all the answers

Which of the following does NOT contribute to the corrosion of wagon bodies?

Regular cleaning and maintenance Signup and view all the answers

What is the first step in applying a riveted patch in sickliness and ROH depots?

Examine and mark the area of the patch to be cut. Signup and view all the answers

Which repair method is effective for removing bulges in wagon ends without dismantling?

Using a hydraulic jack between two coupled wagons. Signup and view all the answers

What should be done if structural members are bulging by more than 25mm?

Straighten them without dismantling. Signup and view all the answers

What is the correct order for securing a riveted patch?

Mark rivet holes, drill, position, then secure with bolts. Signup and view all the answers

Why should bulging of body structural members be addressed?

It can cause infringements with maximum moving dimensions. Signup and view all the answers

What action is recommended if stanchions develop cracks?

Assess whether they can be repaired or need replacement. Signup and view all the answers

Before riveting a patch, what should be ensured regarding the riveting process?

The riveting is sound with concentric snap heads. Signup and view all the answers

What might cause damages to body structural members such as stanchions and carlines?

Improper packing and handling of loads. Signup and view all the answers

What should be the focus while straightening structural components?

Pull them into the correct position without dismantling. Signup and view all the answers

What type of packaging is crucial in preventing damage to structural members during transport?

Rigid and secure packing methods. Signup and view all the answers

What was the primary purpose of modifying the hinge in the design?

To improve door securing and eliminate rain water seepage Signup and view all the answers

In Design Modification-II, what feature replaced the existing long chainless cotters?

Small chainless cotters Signup and view all the answers

Where was the tower-bolt positioned in Design Modification-II?

Outside the door Signup and view all the answers

What was one of the main benefits of the hinge modification mentioned?

Elimination of the possibility of door hitting Signup and view all the answers

What did the swing bolt in the latest design help achieve?

Increased security of the door Signup and view all the answers

How many small chainless cotters were provided in the latest design modification?

Two Signup and view all the answers

What issue was addressed by eliminating the gap between the door and the side wall?

Preventing rain water seepage Signup and view all the answers

Which modification occurred in June 2010?

Replacement of cotters and bolt positioning Signup and view all the answers

What was a key feature of the hinged door modification?

An outer view door locking arrangement Signup and view all the answers

What aspect of the original design was improved regarding the door-securing mechanism?

Modified to hinge and secure better Signup and view all the answers

What is the required action if the area to be patched extends beyond 260 mm from the floor height?

Use two standard patches of 5 mm thickness or a single special patch of 5 mm thickness and 520 mm width. Signup and view all the answers

For two or more adjacent panels requiring patching, what is the coverage requirement for the special patch?

It must extend from stanchion to stanchion. Signup and view all the answers

What should be the thickness of the plate for BCN/BCNA wagons for the end and sides?

3.15 mm Signup and view all the answers

What should be referred to for detailed instructions on panel patching for BOXN wagons?

RDSO Drg.No.WD-94047-S-1. Signup and view all the answers

What is the specified thickness of the plate for the roof of BCN/BCNA wagons?

1.6 mm Signup and view all the answers

What is the thickness of the standard patches used for BOXN wagons?

5 mm Signup and view all the answers

What is the minimum expected length of a special patch when repairing adjacent panels?

Must extend from stanchion to stanchion. Signup and view all the answers

What is the material used for the side wall in BOXNR wagons compared to BOXN wagons?

Stainless Steel Signup and view all the answers

How many side stanchions are provided in BOXNR wagons as opposed to BOXN wagons?

9 Signup and view all the answers

What is the thickness of the door plate in BOXNR wagons?

4 mm Signup and view all the answers

What change occurred in the inside height of the side wall when upgrading from BOXN to BOXNR?

Increased to 2127 mm Signup and view all the answers

Which of the following features is NOT present in BOXNR wagons as described?

Mild steel side sheets Signup and view all the answers

What is the primary reason for avoiding riveted patches in workshops?

They are not suitable for all types of repairs. Signup and view all the answers

Which method is recommended for straightening bulging structural members without dismantling?

Pulling into position with a chain and screw coupling. Signup and view all the answers

What should be checked before applying a riveted patch?

The alignment of mating edges. Signup and view all the answers

What specific condition of structural members necessitates intervention?

Bulging exceeding 25mm. Signup and view all the answers

Which step is NOT part of the procedure for applying a riveted patch?

Inspecting the original structure for cracks. Signup and view all the answers

What adverse situation may lead to damages in stanchions and carlines?

Excessive shunting impacts. Signup and view all the answers

What is an effective method to remove bulges from wagon ends?

Using hydraulic jacks between coupled wagons. Signup and view all the answers

What is a critical requirement for riveting a patch in position?

Rivet holes must be properly aligned. Signup and view all the answers

What action should be taken when stanchions develop cracks?

Assess and repair as necessary. Signup and view all the answers

What is the first action in the repair of bulged structural members?

Assess the severity of bulging. Signup and view all the answers

What is the minimum required number of rivets to secure a patch that is attached by riveting?

8 rivets Signup and view all the answers

What is the maximum allowable pitch distance for rivets when securing a patch?

90 mm Signup and view all the answers

Which thickness should standard patches ideally have to match the damaged panel?

The same as the damaged panel Signup and view all the answers

What should be done to patches before storage and application?

Surface cleaning and two coats of zinc chromate primer Signup and view all the answers

What material thickness should be used for packing if the old panel is badly corroded?

5 mm thick material Signup and view all the answers

What is the purpose of retaining the 2.5 mm thick old panel sheet during repairs?

To ensure structural integrity Signup and view all the answers

What is one requirement when welding patches?

The area of patch must be examined and marked Signup and view all the answers

What is the consequence of using a patch smaller than 100 mm on any side?

It is not permitted Signup and view all the answers

What action should be taken for a patch to be approved for stock in shops?

They should be cleaned and primed Signup and view all the answers

What must be done to prevent jamming of flap door hinges due to warpage?

Take down and straighten distorted or bulged doors. Signup and view all the answers

Which of the following actions is NOT recommended for maintaining wagon doors?

Allowing sagging doors to remain without adjustment. Signup and view all the answers

What is the primary purpose of introducing graphite grease in wagon doors?

To ensure the effective movement of hinges and sliding parts. Signup and view all the answers

What issue did Design Modification-I in June 2009 aim to eliminate?

The gap between the side wall and the door. Signup and view all the answers

What aspect should be ensured regarding hopper wagon doors?

They must close without leaving any gap between components. Signup and view all the answers

What must be checked and rectified in addition to repairing the doors?

Anti-bleeding devices and rain protection angles. Signup and view all the answers

What modifications were made in the Design Modification-II?

Elimination of gaps between the door and side wall. Signup and view all the answers

Which condition could result in inadequate overlap and sagging doors?

Installation of worn out hinges. Signup and view all the answers

Which component's malfunction could lead to issues in operating hopper wagon doors?

The chute plate. Signup and view all the answers

Which procedure is recommended for damaged or bent door stanchions?

Straighten the stanchions for proper door functioning. Signup and view all the answers

Study Notes

Introduction

Wagon body is the superstructure attached to the underframe.
It includes sides and ends, with supporting structures like stanchions, copings, roof structures, carlines, roof sheets, hoppers, tank barrels, cladding, doors, door fittings, operating handles, louvers, cleats, handles, hooks, footsteps, and hand brake wheels.

General Construction of Open Wagons

Sides: Made of side panels and stanchions attached to the underframe by crib angles and stanchions. Includes top copings, intermediate copings (if any), doors, door fittings, hand holds, tarpaulin cleats, and label holders.
Ends: Similar in construction to sides, consisting of end panels, stanchions, top copings, and intermediate copings. Attached to underframe by end floor angles, corner angles, and stanchions. Corner angles connect ends to sides; open wagons have reinforcing angles and corner pressings at the corner top.
Doors: Each side has a door for manual unloading. Hinged at the bottom with locking by chainless cotter at the top. BOXN wagons have two locking bolts per door to prevent slipping of the chainless cotter during tippling.

General Construction of Covered Wagons

Sides: Similar to open wagons with side panels, stanchions, top copings, doors, and fittings.
Ends: Similar construction to sides, with additional intermediate copings in some cases.
Roof: Roofs are made of thinner sheets compared to body sides and end panels.
Doors: Each side has swing doors at the top and flap doors at the bottom, hinged at the bottom with anti-bleeding devices.

General Construction of Flat and Well Wagons

Ends: Flat/well wagons lack side walls and roofs. The superstructure consists of either fixed or flexible ends, attached to underframe via stanchions, side attachment plates, and crib angles.
Side Stanchions: Flexible in some cases, attached to the sole bar through brackets; support brackets are also provided in rail wagons and well wagons; container flat wagons may have retractable anchoring locks.

General Construction of Hopper Wagons

Sides: Made of side panels and stanchions, attached to the underframe. Includes top copings, side stiffeners, doors (if side discharge), and label holders.
Ends: Similar to other wagons, consisting of end panels, stanchions, and end top copings; corner angles connect sides and ends.
Doors: Hopper wagons are fitted with either side or center discharge doors; operated manually by a bevel wheel and worm wheel connected to a hand wheel. Some special hopper wagons may have pneumatic operation.

Nature of Repairs Required in Wagon Body

Wagons may need repairs due to corrosion of panels, floor plates, and roof sheets; puncturing of panels, bulging of ends (from shifting loads), tearing of panels, shearing of rivets (from severe impacts), and corrosion of floor angles. Wear, tear, weakening of welded joints (loss of weld metal), damage to door hinges and fittings, distortion or cracking of stanchions or other structural members, damages due to improper clamping on tipplers.

Corrosion in Wagon Body

Corrosion results from water logging in crevices; contact with corrosive consignments (salt, fertilizers); spillage of corrosive fluids, or escape of corrosive vapors. Inadequate painting or surface preparation can also contribute to corrosion.

Anticorrosive Measures

Maintains wagon cleanliness.
Thorough surface preparation and painting for major maintenance.
Careful attention to surfaces in repairs.
Use of Stainless Steel for new/rehab.

Rejectable Defects

Inspection carried out in sicklines and workshops according to IRCA Part III Rules.

Repairs in Sicklines and ROH Depot

Panel Patching: For damaged areas, use standard patches of specific dimensions (given in table). For areas extending over 260 mm from the floor, using double patches or single large patches is recommended.
Procedure for Welded Patches: Instructions on cutting, placing, and welding patches, with attention given to details like packing, rivets, and overlaps.

Repairs to Bulged Ends

Bulges can often be removed without dismantling using a hydraulic jack placed between wagons.

Repairs to Body Structural Members

Usually due to rough handling, heavy shunting, or shifting of loads.
Often needs to be straightened without dismantling using chains.
Possible repairs include spot heating, cooling.
Severe damages may require welding.

Water Tightening of Wagons

All uncovered areas must be made watertight using sealing compound, especially before the monsoon season.

Repairs to Doors and Door Fittings

Common defects include distortion (from mishandling), jamming of hinges, inadequate overlap between door flaps, and damage to gravity cotters, hooks, or hasps.
Addressing these involves straightening, replacing hinges, adjusting clearances, and checking and repairing anti-bleeding/rain protection devices

Repairs to Doors and Door Fittings (for BCNHL Wagons)

Details on modified door designs for BCNHL wagons, including new roller designs for improved operation, addressing issues like rain water seepage.

Retrofitable Sliding Doors

Two-part design supported at the bottom and pivoted for lateral movement; suitable for older BCNHL wagons; accommodates loading from the side; uses multiple rollers for easier operation.

Cleaning, Surface Preparation and Painting

Cleaning procedures for effectively preventing rust, providing a suitable surface for adhesion.
Prime coats, and finishing coats for complete paint job. -Cleaning procedures for effectively preventing rust, providing a suitable surface for adhesion.
Prime coats, and finishing coats for complete paint job.

Repairs and Maintenance in Workshops During POH and NPOH

Detailed procedures for painting.
Specific procedures for lettering, punching of wagon particulars, preparing of PR plates, and measuring tare weights.

Important Precautions During Welding

Precautions for safe and effective welding, including load content checks, presence of flammable materials, steam cleaning and testing before welding when possible.

Important DO's and DON'Ts

Guidelines for properly installing and utilizing these tools for welding.
List of what to do and what NOT to do, in terms of installing and using the tools.

New Wagon Numbering Scheme

New numbering system for efficiency in monitoring and tracking wagons, including codes for different wagon types, owning railways, year of manufacture, and individual wagon numbers. This includes multiple detailed subsections for specific wagon types and codes.

Description of Work

Brief description on procedures for upgrading BOXN wagons to BOXNR and maintenance, repair and operational considerations.

Lock Bolts

Lock bolts are important for repairs and maintenance; methods for proper installation are provided. Includes details on lock bolt pin, collar, installation tools, and the benefits of lock bolts.

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Description

This quiz delves into the components and general construction of open wagons, highlighting the structural elements that comprise their body, including sides, ends, and doors. Explore the details of how these elements are assembled and function together to create the wagon's superstructure.