Berger’s contribution for longer durability of Indian Railway coaches

Berger Paints bags award at Rail Analysis 4th Innovation & Excellence Summit 2023, New Delhi. Sanjay Chowdhury, Vice president & Business Head, and S Ravichandran, Chief manager (T&D), Berger Paints India – Protecton elucidate on the role of the company in ensuring durability of coaches in Indian Railways. Railways are one of the major consumers of paints in the industry and they have always worked on setting higher standards by improving the bench mark of quality requirements. But again, we always remember the age-old synthetic enamel painting system (IS2074, IS110, IS 5083, IS 5862, IS 8662), that were adopted by all Railways Coach manufacturers for their exterior application of trains and the challenges faced for the environment in which it is placed was so challenging that Railways looked for alternatives and high performance products. Berger-Protecton took the lead, and it was through ICF Chennai in the years 2002-03 that the first painting of epoxy-polyurethanes was undertaken as a trial on Jansatabdi coaches and observed for frequent inspections for a period of 18 months to evaluate and record the performance. Southern Railways had placed these coaches on regular run and those coaches with newer coating systems from various leading paint manufacturers were placed for comparative performance analysis. It is happy to recollect the final observation of coaches #2623 and 2707; it is clear that Berger's product was doing well in terms of corrosion free performance and the general gloss retention is satisfactory in comparison to others. Berger-Protecton are the leaders in protective coating in India and we continue to strive and keep the honour of customers pride by ensuring corrosion free protection of their assets by constant interaction continued improvisation and enhancing with advanced protective coatings from R&D stage-manufacturing-supply-execution-inspection. What factors contributed towards Berger to be a recipient of this prestigious award? Berger Paints were recognised for the contribution to Indian Railway for providing innovative solution in the sector of cleaning, painting, and coating of coaches. The continued innovation and upgradation of painting system offered by Berger Paints, resulted in excellent performance in terms of durability and extended life which helped Railways in reduction of frequency of painting cycle resulting in sizable savings for the Indian Railways. How is this coating solution unique? The coating system currently used comes with low VOC which helped Railways to reduce the impact of solvent on environment. Berger-Protecton has coated many Rajdhani and other coaches in the last couple of years by adopting good painting practices as per international standards. How long did Berger work with Railways to take this award? Berger Paints with its presence in India for last hundred years have been patronised by railways for decades together. However, with the advancement of paint technologies, initiatives were taken by Berger-Protecton team with the ICF in early 2000. During the period from 2002 to 2004 sampling work was done at ICF for painting coaches with new coating system. Among various rail coach manufacturers ICF being the change innovator took up this proposal of Epoxy PU coating systems and issued a trial order to Berger Paints for two Janshatabdi coaches that were field tested for 2 years observing and monitoring the performance. This documentation and excellent comparative performance over four other competitors paved way to making it to the RDSO standards under the PPN series which is currently practiced for all new coaches and maintenance coaches painting. What other new technology are you promoting with Railways currently? It is also a great pride to state that Berger-Protecton are the first to introduce Fluoropolymer coatings on FIAT Bogie of VANDE BHARAT as per JIS Japanese technology with approval of RDSO (Research Designs & Standards Organisation) to providing excellent corrosion and weather resistance. Berger-Protecton continues to keep working closely with the research wing of RDSO to implement advanced coating system of international standards. Successful Trails were conducted at Titagarh Wagons for BOXNHL WAGON and proved for the value addition offered in terms of quality (improved drying and overcoating interval) as well as on reduced consumption. Berger-Protecton also takes pride in the India’s first Vertical lift Railway Sea Bridge connecting the mainland of India with Rameswaram Island. This state-of-the-art bridge will be the country's first vertical lift railway sea bridge and is expected to be completed by March 2023. The sea bridge is being executed by Rail Vikas Nigam Limited (RVNL) at a cost of Rs 535 crores that replaces the old bridge constructed in 1914. Berger has supplied a special epoxy primer for the zinc metallised steel structures that are top coated with Fluoro Polymer for the 4700 MT tons of steel used in this bridge. This special top coat shall give protection from the most aggressive marine corrosion and also ensure to sustain the gloss for decades reducing the need for frequent maintenance painting interventions.