Indian Railways is preparing to pilot the use of galvanised steel rails in coastal and high-humidity regions as part of efforts to curb corrosion and reduce the heavy cost of frequent track renewals, according to a report by Mint.

The proposed move could extend the life of tracks in corrosive environments from just two to three years to more than 12 years, despite a modest increase in upfront costs. The plan is being evaluated as an alternative to the nickel copper chromium (NCC) rails currently supplied by Steel Authority of India Ltd.

While NCC rails offer better durability than conventional rails, galvanised or zinc-coated rails are considered more effective in regions exposed to saline air, heavy rainfall and high humidity. In such areas, standard steel rails corrode rapidly, even though their average lifespan elsewhere is around 12 years.

“The cost could vary anywhere between 8 per cent and 20 per cent depending on the type of coating used, but if the rails last longer than conventional ones, the objective will be met,” V Shanker, former executive director (planning) at Indian Railways, was quoted as saying.

Indian Railways currently spends close to Rs 200 billion every year on track renewals, a figure that could fall significantly if corrosion-resistant rails perform as expected. Officials said galvanised rails are estimated to cost about Rs 84,000 per tonne, compared with around Rs 76,000 per tonne for conventional rails, but lifecycle savings are expected to outweigh the initial premium.

The Research Designs and Standards Organisation has already approved specifications for zinc thermal-sprayed rails, and the Railways may begin phased procurement of about 0.1 million tonnes. A pilot trial has already been conducted on the Vijayawada–Guntur section.

Experts have broadly welcomed the initiative, while highlighting technical challenges. Shanker noted that zinc coatings could potentially interfere with ultrasonic waves used to detect minor cracks in rails, though he expressed confidence that the Railways would address the issue. Others cautioned that the zinc layer may wear off at the rail head or be damaged during welding, underscoring the need for further trials.

Despite these concerns, Indian Railways sees corrosion-resistant rails as a key step towards building more resilient infrastructure, particularly as it continues to invest heavily in new lines, track doubling and gauge conversion projects across the country.