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Chugging through TN’s Integral Coach Factory, India’s oldest train-making facility

Chugging through TN’s Integral Coach Factory, India’s oldest train-making facility

What makes this coach manufacturing factory in Perambur so special? “Everyone travels by the coaches we’ve made, no?” points out an employee.
Down the history track

ICF was the brainchild of an Indo-Swiss collaboration - between the Government of India and the Swiss Car and Elevator Manufacturing Corporation Ltd., and its construction began in 1952.

ICF’s first milestone came in the year 1957 when the facility flagged off its 100th coach. The factory was initially just a shell manufacturing facility. Shankar, ICF’s PR head, explains that a shell is just the outer casing of a coach - like a skeleton. “The shells were then sent to the zonal railways. Seven years later, in 1962, a furnishing facility was inaugurated at ICF and we began furnishing the shells that were manufactured here,” he adds.


Photos courtesy: ICF

Integral Coach Factory is not the kind of place you can leisurely amble through. The place is abuzz with people welding joints, cutting through sheets, beating down metal, cranking giant conveyors and manoeuvring backhoe loaders with heavy and sharp metal objects.

Referred to as the Mecca of Coach Manufacturing facilities, the factory is spread across 511 acres and employs 11,000 workers today. “At one point, in the mid-80s, our task force was over 14,000,” says Shankar.

Those who have seen the factory grow search for words to describe its transformation. R Shanmugam, one of ICF’s oldest residents and employees, says, “I was born here. My father, P Raju, joined ICF in 1955 itself, so I’ve literally seen the landscape change. Earlier, when Anna Nagar was just about coming up in the vicinity, you could see the Anna Tower from here. You didn't even have to climb up tall buildings, it was plainly visible. Now I cannot believe my own eyes.”

Factory today

While factories can be a dull mix of blue, rust and grey, ICF breaks away from this stereotype with colourful murals on its walls, sculptures fashioned out of metal scraps and grassy patches wherever possible. Vinoth, a PR Inspector at ICF and our guide for the day, shares that ICF was given a facelift a few years ago. The manufacturing units too underwent transformations in the last few years. ICF also inaugurated a new spring shop in April this year.

“We also have an exhibition space for artists to conduct art shows. While we’ve got artists commissioned to work on these sculptures, our own employees have also designed a few. Those were appreciated by many. Our current GM encourages such initiatives,” he says with a smile. They have also rejuvenated the lake in the vicinity and the residential colonies have inaugurated multiple sports facilities.

How are coaches made?

Taking us through the giant coach-like Linke Hofmann Busch (LHB) unit, Shanmugam explains that initially the coaches were made using wood and mild steel, following which only mild steel was used.

“Right now, we’ve moved to making LHB stainless steel coaches. These are so much better and stainless steel has good corrosion resistance. You have to take into consideration the corrosion resistance of metal, mainly because...imagine! The train travels through different landscapes…From hottest and driest place to the coldest and rainiest parts of the country. These coaches will have to be corrosion resistant,” he explains.

An LHB coach has two main parts - the shell and the bogie. While the shell is the metal skeleton/frame of the coach, the bogie is the one on which the shell is mounted. The shell consists of the roof, underframe and side walls. The bogie houses the most crucial mechanism that keeps the train running - the wheels. “It is extremely important to check this mechanism before mounting the shell on the bogie. We have to make sure the brakes, the pins, the planks, the axle, the spring, the bearings, etc., function smoothly. Nothing can go wrong here,” explains Hameedudin, Senior Section Engineer at ICF.

While intense care is taken to beat down the shell’s frame (measurements are of supreme importance here), engineers are extra careful when it comes to the bogie. Weight tests, brake tests, etc., are done to make sure they’ve made the perfect bogie. The shell, now mounted on the bogie, is taken to the watershed where leak-test is done. Once the shell passes all the tests, it is then sent to the furnishing factory, where the coach is given its aesthetics.

And all this while coaches come in different types - sleeper class, First AC, Second AC, AC 3-tier, electric (EMU), MEMU, Kolkata metro and luxury coaches to name a few. ICF manufactures more than 170 varieties of coaches on the whole.

ICF Highlights

ICF also exports coaches to countries like Thailand, Burma, Taiwan, Zambia, Philippines, Tanzania, Uganda, Vietnam, Nigeria, Mozambique, Bangladesh, Angola and Sri Lanka. From manufacturing their 1000th coach in 1962, ICF churned out its 50,000th coach on July 6, 2015. Last year, 2017-2018, it set another record by manufacturing 2503 coaches (in 68 variants). “We plan to increase it to 3000 coaches this year,” beams Vinoth.

ICF also has an interesting line-up of projects in the pipeline. It recently rolled out a LHB 3-tier with continuous windows, giving AC coaches a swanky makeover. It also introduced the engine-less Train 18. “It will be almost on par with the European trains with a top speed of 160 km/hr,” explains Shankar.


It’s perhaps time bid adieu to the dusty maroon and inky blue trains we are so used to. Antyodaya Express could be its replacement. ICF rolled out the country’s first paintless train on Tamil New Year this year. The 22-coach LHB will be operated as an unreserved train for “superfast service” on dense routes at a speed of 120 kmph. They’ve also got plans for Train 20 with an aluminium car body.

Even five years ago, many would have marvelled at the idea of an exclusive women’s team. While ICF has always had women employees, they never formed an exclusive team. “Women have always done all kinds of engineering works along with men. Now, under the Mahila Shakti team, we’ve formed an exclusive women’s team of 30,” explains Charulatha, Senior Section Engineer/ Shop 20 (Sidewall section), over the heavy noise of metal clanking and machines whirring. The youngest employee in Mahila Shakti, that was formed in February this year, is 22 years old while the oldest is 55.

All aboard!

Trains may not be the most magical modes of transport now, but they demand a certain kind of admiration for they way in which they’ve survived, outliving most of their Industrial Revolution peers.

A train journey in India can be life changing and are sometimes the perfect way to get to know cities, people and landscapes. And train journeys have been prophetic - what if Gandhi never took the train?

Several pairs of hands work in unison to complete one coach. KN Babu, Secretary at ICF tells us that one LHB coach spends around 15 days in the shell unit and another 10 days in furnishing (if it’s a simple sleeper coach) before it can be sent out. "AC coaches take another week extra," he adds. Several thousand workers toil through 8 hours of their shift every day to help India move.

ICF was initially just a railways residential colony and locals always referred to it as the Perambur coach factory. Today, ICF has its own pin code and is filled with proud residents and employees who vouch for how extraordinary it is.

So what makes this coach manufacturing factory special? “Of course ICF is unique. Everyone travels by the coaches we’ve made, no?” shrugs Shanmugam.
 
Some more images from the Article:
Chugging through TN’s Integral Coach Factory, India’s oldest train-making facility

ICF_MAIN_IMAGE_1.jpg


14_Shri%20Babu%20Rajendra%20Prasad%2014.jpg


Gate%20Way%20to%20Shell%20Division-1955.jpg


ICF%20AREAL%20VIEW.JPG

Except first one, Image Credit: ICF
 
Indian Railways may have finally found the solution to its punctuality problem
The Indian Railways has decided to revamp its antiquated signalling system in phases to enhance safety and increase average speed of trains. The national transporter plans to introduce the new European Train Control System-2 (ETCS2) which will allow it to increase train speeds significantly and, as a result, run more trains with the same infrastructure, officials said.

The new technology allows trains to run in shorter blocks, which means trains can run on the same track with a minimum distance of just 500 metres between them. The first such signalling system will be installed on the highly congested Delhi-Mughalsarai section. Indian Railways expects companies such as Bombardier and Alstom to bid for the project, according to officials.

“At the recent Rail Board meeting, the 830-km Delhi-Mughalsarai section was identified for ETCS2 signalling. This will be carried out through a joint venture with Power Grid Corporation for signalling and with Railtel for communication.

Since the Delhi-Mughalsarai route has very high traffic density, modern signalling will help in decongestion,” said a railways ministry official, who did not wish to be identified. “Modern signalling will help reduce congestion in rail network and increase line capacity by 40-50%,” he said. The ability to run more trains on tracks will also help the railways improve its chequered record in terms of punctuality.

“It will eliminate train delays due to automated signalling and real-time information of train movements being made available, eliminating the need for manual data logging,” the official said.

Besides, the move will enhance safety on tracks. In 2017-18, 73 accidents had taken place on railway tracks. “Signalling will potentially eliminate human induced rail accidents to zero,” the official said. In a recent review meeting chaired by Prime Minister Narendra Modi, the railways was told to go for a signalling technology which was financially viable and indigenous.

The ministry official said that once the ETCS2 technology is tried on the Delhi-Mughalsarai section, foreign companies will be invited to set up the signalling equipment manufacturing plants in India.

“The European technology will be price competitive and in later stages we also plan to manufacture it locally under ‘Make in India’,” he said.
Indian Railways may have finally found the solution to its punctuality problem
 
Indian Railways to give trains Rajdhani Express type makeover; get set for a big surprise
Indian Railways has decided to refurbish coaches of 140 rakes, running on 132 (66 pairs) routes across the country, on the pattern of Rajdhani Express within a year, to provide the best facilities to travellers on these trains, said a DNA India report, which added that of the total, 11 rakes would be modified on 12 routes of Mumbai Central Railway, and 20 rakes on 14 routes of Mumbai Western Railway. Following the Railway Board's approval on April 3, meetings took place, and officials have reportedly started initial work from this month. "We want to provide amenities to passengers which they would enjoy only in trains like Rajdhani and Shatabdi. We have included these 140 rakes under 'Project Utkrisht'," R Gupta, Member Rolling Stock, Railway Board, who is the top official to decide on rakes and locomotives, told the DNA India.

The report citing sources said that Railway Board has chalked out modifications plan that will include vinyl wrapping of the coaches, equipping coaches with fire extinguishers, information posters, braille signage, changing of the torn seats and compressed cushioned seats. Further, the plan reportedly includes dustbins inside coaches, and adequate maintenance along with inspection in every two hours for on-board cleanliness.

A senior Railway official, however, told DNA India, "By June, we will start uploading Google sheet that shall be directly monitored by the Railway Board. All the 140 rakes will be refurbished at a cost of Rs 60 lakh each by March 2019."

The coaches of long distance trains are being replaced with LHB ones from those manufactured at Integral Coach Factory, said the report, adding that these LHB coaches are attached in premiere trains including Rajdhani and Shatabdi Express.

A senior CR official said, "The modification of both the trains will begin soon. Deccan Queen will be ready by August 15," adding that Modification work on the LTT-Madgaon double decker express will also complete by December 2018.

It may be noted that among the measures being taken for cleanliness include GPS tagged attendance of staff, cleaning of toilets every two hours, garbage bag in dustbins and its regular cleaning. While the coach interiors would have single colour rexine for seats and torn ones to be replaced, toilet indication would be provided in AC coaches besides having curtains and fire extinguishers inside these coaches.

The cleanliness of toilets would reportedly get a special attention and the measures include proper ventilation and auto janitor inside to avoid foul odour, improved flushing valves along with LED lights inside.
Indian Railways to give trains Rajdhani Express type makeover; get set for a big surprise
 
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The proposed track lies quite close to my house.
Recently a regional party Maharashtra Nav Nirman Sena instigated local farmers.
Thats btw is their tried and tested formula of making money out of big infra projects.
The biggest saboteurs of the industrial initiatives undertaken by this government are the SS & the MNS .
 
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Bullet train booster: Indian Railways to do a first along Mumbai-Nagpur Expressway; massive gains in offing
This bullet train boost will be a big help for the public going forward. Indian Railways has joined hands with the Ministry of Road Transport and Highways to twin a rail line along the proposed expressway between Mumbai and Nagpur -- a first such coordinated move to execute a transportation project. Both arms of the government will work together to put the project on the fast track with the aim of drastically cutting travel time on the busy route. "Spanish consultant Ineco has conducted a feasibility study on constructing a high-speed rail line along the proposed Mumbai-Nagpur Expressway and the reports are positive," a senior Railway Ministry official told IANS.

Ministry of Road Transport and Highways, which is already acquiring land for the proposed expressway, will keep the rail project in mind, he added. The elevated rail line could be built in the middle or along the proposed 800 km expressway depending on the ground situation, according to a feasibility report. The official said that twin tunnels and bridges can also be constructed to cross rivers and negotiate hilly areas in a coordinated way for road and rail traffic.

While the feasibility report is being examined by the Railways officials concerned, the Spanish team is set to make a detailed presentation, including on the financial aspect, to the public transporter shortly to take the ambitious project further. According to the study, travel time will be drastically reduced for both road and train travellers as the expressway will be fully access-controlled while the elevated rail track will ensure an uninterrupted high-speed train journey.

Land acquisition is a serious problem and many rail projects, including the ambitious Dedicated Freight Corridor, have been delayed due to land-related issues. The Mumbai-Ahmedabad high-speed rail corridor is also facing the same problem. Incidentally, the improved road network in the country has taken a toll on the Railways` business on shorter routes and the national transporter is making a concerted effort to wean away goods and passenger traffic from roads and increase its share.

"It`s a new way of executing the project faster, as the combined efforts to acquire land will ease a major burden for both ministries and pave the way for speedy execution," the oficial said. The Mumbai-Nagpur section is part of the proposed high speed rail corridor between Howrah and Mumbai, the diamond quadrilateral rail project.
Bullet train booster: Indian Railways to do a first along Mumbai-Nagpur Expressway; massive gains in offing
 
Kerala: Battery-run cars deployed at 9 railway stations
There is good news for elderly and physically-challenged persons arriving at railway stations as they can avail the facility of battery operated cars to move to platforms from main entrance. The Southern Railways has tied up with Maini Material Movements Pvt Ltd (MMM) to operate buggies at Ernakulam Junction (ERS), Thiruvananthapuram (TVC), Thrissur (TCR), Kollam Jn (QLN), Kottayam (KTYM), Alappuzha (ALP), Guruvayur (GUV), Nagercoil Jn and Kanniyakumari (CAPE).

An amount of Rs 30 will be charged per head per trip in main stations like TVC, QLN, KTYM, ERS and TCR while the ticket rate will be Rs 40 in all other stations. Three cars will be deployed in Ernakulam and Thiruvananthapuram. "There will be an option at the IRCTC website to book the buggy service in advance while booking train tickets," said Ernakulam Station Director R Harikrishnan while launching the services at Ernakulam Junction station.

Only computerised hand held machine is used for doling out tickets and the service is provided round the clock. Also a dedicated mobile number (for instance 9008031998 at Ernakulam Junction) has been provided for enabling commuters to avail the facility quickly. "The cart driver should have a valid Light Motor Vehicle licence and ID card and should not work for more than 10 hours on a stretch," an official said.

Though the first buggy service was introduced at Ernakulam Junction station in January 2016 after the alumni of St Teresa's college donated one for the benefit for senior citizens, it was however discontinued soon. We'd to discontinue it soon as the railway rules didn't permit the crossing of such vehicles over tracks. In effect a commuter can't be taken to platform No 2, 3, 4 and five. Now the railway board has cleared its operation to other platforms and removed the track crossing restriction," the officer said.
Kerala: Battery-run cars deployed at 9 railway stations
 
World’s tallest girder railway bridge is being built in North-East! 10 facts that will leave you awestruck
Building an Indian Railways network that reaches and connects the seven sister states of North-East has always been acknowledged as a daunting and challenging task. But, to be able to build the world’s tallest girder railway bridge in the Himalayan ranges, is truly a remarkable feat. Come 2019, this dream project of Indian Railways will turn into a reality. Called Bridge No 164, the world’s tallest girder railway bridge, will have a pier height of 141 metres. That’s almost twice as high as Qutab Minar! At present, Europe’s Mala-Rijeka viaduct is the world’s highest at 139 metres. The tallest girder bridge is part of the upcoming 111-kilometres long Jiribam-Tupul-Imphal railway line. The ambitious railway line upto Tupul is expected to be complete by 2020, while the tallest girder railway bridge will be ready by June 2019, says Saibaba, Chief Engineer Construction, Northeast Frontier Railway (NFR). In an interaction with Financial Express Online, he said that the best international practises are being used for the construction of the crucial bridge. We take a look at some interesting details about the world’s tallest rail girder bridge and the Jiribam–Tupul–Imphal railway line:

1. Bridge No.164 is being built across the valley of river Ijai near Noney and has been designed to take a maximum train speed of 120 kmph.

2. The bridge will also help in crucial freight movement. According to Indian Railways, the bridge is designed to carry up to 25 ton axle-load freight trains as well.

3. The Jiribam–Tupul–Imphal railway line cuts across the lower Himalayan ranges necessitating series of tunnels through the hills and tall bridges across the deep valleys. The line will connect Manipur’s state capital Imphal to Jiribam which is on the western-most boundary of the state. Jiribam is an area that adjoins the Cachar district of Assam. As of now Manipur’s capital Imphal has no railway connectivity.

4. Area prone to earthquakes: Brige No. 164 is located in Seismic Zone-V, making it highly vunerable to earthquakes. According to project in-charge Saibaba, a “site-specific design spectrum had been developed to ensure long-term stability of the bridge.” State-of-the-art techniques will be used to also check landslides due to heavy rains or earthquakes. All these techniques are being used for the first time in the North-East.

5. Wind speed: Studies have been conducted to analyse the stability and safety of the bridge under the maximum design wind speed of 241 kmph and the bridge is being built accordingly. Also, the entire Northeast area receives very heavy rainfall for almost 6 months in a year. According to Indian Railways officials that FE Online spoke to, the general soil profile is shale which is “most undesirable” for bridges of this magnitude. Hence the biggest challenge in building the bridge is to ensure sustainability against the extremities of nature.

6. The final cost of the bridge is assessed to be around Rs 400 crore including the safety work. The cost of the complete project upto Imphal is expected to be around Rs 13,800 crore.

7. Protection against terrorist attacks: The railway line and the bridge are being built despite several threats from militant outfits operating in the area. This bridge will be provided 24×7 security cover with personnel posted exclusively at the site. Additionally, surveillance of the bridge through CCTVs and remote monitoring by instruments and sensors is also being considered to ensure the safety. According to Indian Railways, at the conceptual stage an advisory group concluded that public assets are unlikely to be a target for militant outfits. Hence unlike the upcoming Chenab bridge, this one will not be blast-proof.

8. A dedicated laboratory with equipment and manpower has been set up by Indian Railways has at the bridge site to test and pass all the material that goes into the making of the bridge. Expertise of outside institutes is also being taken for double-checking of the quality control systems. The health and in-service performance of the bridge is proposed to be monitored by using sensors fixed to the bridge at critical locations. The sensors also record climatic features like wind speed.

9. Expertise: Three IITs (Kanpur, Roorkee and Guwahati) and NIT/ Silchar are also associated with this ambitious Indian Railways project by way of technical support and proof-checking of designs to make the bridge cost-efficient and sustainable.

10. At 10.54 kilometres, the Jiribam-Tupul-Imphal railway link will also boast of one of the longest railway tunnels on the Indian Railways network. In a first, the longest tunnel in the North-East will also have a service tunnel alongside with connection to the main tunnel at intermittent points. This will help in both maintenancew work and situations of emergency. According to Indian Railways officials, all tunnels on the railway link are in advanced stages of completion. For tunneling work, state-of-the-art NATM (New Austrian Tunneling Method) is being used.
World’s tallest girder railway bridge is being built in North-East! 10 facts that will leave you awestruck
 
दिल्ली से हरियाणा-राजस्थान सीमा तक दौड़ेगी हाई स्पीड ट्रेन, RRTS प्रोजेक्ट को हरी झंडी
हरियाणा सरकार ने दिल्ली के सराय काले खां से हरियाणा-राजस्थान सीमा तक हाई-स्पीड रेल नेटवर्क स्थापित करने के लिए रीजनल रैपिड ट्रांजिट सिस्टम्स (आरआरटीएस) परियोजना को हरी झंडी दे दी है. हरियाणा के मुख्यमंत्री मनोहर लाल खट्टर की अध्यक्षता में चंडीगढ़ में शनिवार को आयोजित बैठक में इसके अलावा कई अन्य निर्णय लिए गए. केंद्रीय योजना राज्यमंत्री राव इंद्रजीत सिंह भी इस बैठक में मौजूद थे. मुख्यमंत्री ने कहा कि इन जन-परिवहन योजनाओं से दक्षिण हरियाणा और विशेष रूप से गुरुग्राम में विकास और निवेश को नई रफ्तार मिलेगी.

यह बताया गया कि आरआरटीएस परियोजना का मार्ग पुरानी दिल्ली रोड के साथ-साथ गुरुग्राम के लेफ्टिनेंट अतुल कटारिया चौक तक इलेवेटेड होगा, इसके बाद सिग्नेचर टॉवर चौक तक यह जाएगा. फिर नेशनल हाइवे-48 के पास से गुजरते हुए राजीव चौक पहुंचेगा. उसके बाद खिड़कीदौला तक यह अंडरग्राउंड मार्ग होगा. उसके बाद यह आईएमटी मानेसर तक होते हुए एनएच (राष्ट्रीय राजमार्ग) के साथ-साथ घारूहेरा, रेवाड़ी और बावल तक जाएगा और राजस्थान सीमा पर समाप्त होगा. इस हाई-स्पीड रेल की औसत स्पीड 100 किलोमीटर प्रति घंटा होगी.

पहले चरण में खर्च होंगे 2500 करोड़ रुपये
इस परियोजना के पहले चरण की लागत करीब 25,000 करोड़ रुपये होगी. इस परियोजना को एनसीआर ट्रांसपोर्ट कार्प (एनसीआरटीसी) चलाएगी, जो उत्तर प्रदेश, हरियाणा, राजस्थान और दिल्ली राष्ट्रीय राजधानी क्षेत्र का संयुक्त उद्यम है. इससे दक्षिणी हरियाणा से दिल्ली तक रोजाना आने-जाने वाले यात्रियों को काफी राहत मिलेगी. एनसीआरटीसी तीन महीनों में विस्तृत परियोजना रिपोर्ट (डीपीआर) रिपोर्ट तैयार करेगा और 31 मार्च 2019 तक काम शुरू होने की उम्मीद है.
दिल्ली से हरियाणा-राजस्थान सीमा तक दौड़ेगी हाई स्पीड ट्रेन, RRTS प्रोजेक्ट को हरी झंडी
 
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JSPL to Adani Logistics, private sector bigwigs join Railways wagon scheme
The opening up of private investment in general-purpose wagons (GPWS) by the railways has invoked interest from at least eight big companies. These are from cement, steel, iron ore and aluminium sectors.

The scheme of allowing firms to own wagons, of the fleet of Indian Railways, is likely to attract more investors. State-run Coal India (CIL), too, is set to join, with likely orders of Rs 20 billion, for around 500 rakes.

The eight companies —JSW Cement, Jindal Steel and Power, Adani Logistics, Gallantt Ispat, Adhunik Metaliks, Rashmi Cement, Orissa Metaliks, and Orissa Manganese and Minerals —have so far submitted Expression of Interests (EoIs) for around 50 rakes.

This should bring in investment of around Rs 10 billion. “CIL, Tata Steel, UltraTech Cement and Vedanta, too, are expected to submit EoIs soon. This has happened within a month since the scheme was launched,” said Mohammed Jamshed, member (traffic) of the Railway Board.

Currently, the railways through its Indian Railway Finance Corporation (IRFC) arm leases out general purpose vehicles on a rental scheme. The new scheme allows companies to put in funds in wagons that could move multiple commodities.

There were earlier schemes for private investment in special wagons and container train operators (Liberalised Wagon Investment Scheme, Wagon Leasing Scheme, Automobile Freight Train Operator Scheme and Special Freight Train Operator Scheme). This programme will permit companies to have their own wagons in colours designed by them. The routes will be specified.

In addition, the railways have already placed orders for 40,000 wagons, including car carriers. “This will mean Rs 160 billion investment and provide adequate capacity for the railways in the coming years,” said Jamshed.

With rising demand and competition from the road sector, the railways was struggling to serve consumers with a wagon fleet of about 250,000. The new move is to have adequate general purpose wagons, to meet the expected rise in demand following the launch of Dedicated Freight Corridors (DFCs).

A DFC will use longer wagons of 25-tonne axle load capacity, compared to the existing 22.9-tonne axle load. The former will cost around Rs 2.5 million and latter costs around Rs 2 million.

In the general purpose wagon scheme, corporates will get 10 per cent rebate on the base freight for 15 years, for carrying each commodity. However, the rebate will not be more than the lease charge IRFC now gets from the railways. The scheme was launched on April 26. With the largest freight consumer, CIL, expected to join, the scheme might see investments over Rs 100 billion.

Though the railways planned to acquire around 12,000 wagons in 2017-18, it finally added 7,120. For the current financial year, it has set a target of adding another 12,000 wagons.
JSPL to Adani Logistics, private sector bigwigs join Railways wagon scheme