The complete sequence includes: Garnet Blasting/Etch Primer, Epoxy Primer, Light Weight Body Filler, 1st & 2nd coat Putty, Putty Rub Down & NC Application, NC Rub Down & Surfacer, Surfacer Rub Down & 1st Top coat, Masking & Rub Down & 2nd Top coat.

Annexure 8C specifies application areas: Full Exterior & Full Interior, Side Walls, End walls, UF & Roof, End Wall Side Walls Joints, Sole Bar Joint, Roof Bearer Joints, Door Corners, Turn Under, etc.

First step: Cleaning with soap solution or any other cleaning solution, wash thoroughly with water, touch up damaged portion with primer recommended under A schedule.

First step: Remove old paint through various methods and level up surface imperfections by body filler (MDTS 176 rev. 04) and do dry flattening with sand paper of Grade P-80.

Cleaning brushes for LP sheets with soda ash are specifically mentioned for cleaning laminated plastic sheets.

The four types of scrapers mentioned are: Shave tukes, Triangular, Semi circular, and Diagonal.

Round brushes of sizes nos. 1/0, 2/0, 3/0 & 4/0 are used for painting work.

Flat brushes of sizes 25 mm, 38 mm, 50 mm, 63 mm, 75 mm, and 100 mm are used for painting work.

Tools and Plant for painting should be as per RDSO CMI No. RDSO/2013/CG/CMI-01.

Carrying capacity of OCV's should be marked to the nearest tones up to one decimal place above actual capacity.

Transportation code applicable to the type of coach as per appendix 'B' of IRCA Conference Rule part IV should be marked on coaches.

Return date showing the month and year in which the coach is required to be returned to the owning railway workshop for POH should be stenciled on the left side of end panel.

Anti-telescopic coach end walls should be marked with yellow stripes as per sketch no. 77356.

For wooden batten seats, sand paper smoothly, apply a coat of filler, sand entire surface smoothly, and repaint with a coat of full gloss Polyurethane Enamel.

The laminated plastic seats or moulded seats of synthetic materials require no painting. These items should be cleaned thoroughly with soap solution or suitable detergent.

FRP windows should be painted with polyurethane paints to RDSO specification no. M&C/PCN/100/2013 Chapter-V.

If paint on mouldings has deteriorated or become thick, remove completely by paint remover, wash thoroughly, allow to dry, repaint with epoxy zinc phosphate primer followed by two coats of full gloss Polyurethane Enamel.

Applicable specification and documents for interior painting are Dy. CME/D's technical specification no MDTS094 RCF No. MD22151 dated 16.03.2011.

RCF Doc. No. PLW0961 covers tools, machinery, consumables, precautions, and procedure for two component high build elastified paint application on interior of shell.

After primer dries, it should be putted, then a coat of Polyurethane surfacer applied, followed by two coats of Polyurethane Enamel as per paragraphs 8.4g to 8.4k.

In Schedule 'C', primer is applied by brush at the places where metal surface is visible after scraping off loose and damaged paint.

In Schedule 'C', a coat of Epoxy zinc phosphate primer to DFT of 60 Microns is applied by brush at places where metal surface is visible.

Cobalt blue RAL 5013 is used along with golden yellow No. 356 IS:5-94 for standard lettering on coaches.

Standard lettering should be done with golden yellow color No. 356 IS: 5-94 and cobalt blue RAL 5013.

After applying second coat, check DFT and glossiness value whether it is up to the mark else revise the operations.

RCF Doc. No. PLW0960 covers tools, machinery, drawings, consumables, precautions, and procedure for full gloss Polyurethane Enamel (two pack) application on shell.

Allow 8 hours of air dry time after Polyurethane surfacer application, then do wet flattening with emery paper of grade 280.

RCF Doc. No. PLW0958 covers tools, machinery, consumables, precautions, and procedure for surfacer application on shell.

Remove the dust accumulated over the surface by jet water and let it force dry before applying Polyurethane surfacer.

Dry flattening is done by pneumatic sander machine consisting of 150 grade emery paper (in case of wet flattening emery paper of grade 280 should be used).

Apply two coats of unsaturated polyester base knifing stopper putty to a DFT of first coat 300 micron and total DFT of both coats will be 600 microns approximately.

RCF Doc. No. PLW0954 covers tools, machinery, consumables, precautions, and procedure for Unsaturated polyester base knifing stopper putty application on shell.

RCF Doc. No. PLW0952 covers preparation of epoxy based zinc phosphate primer, precautions during application, and procedure for application on exterior and interior surfaces.

Option 1: Apply one coat of Eco-friendly water based Etch primer of DFT 25 microns. Option 2: Where facilities exist, sand blast the entire coach body and apply epoxy zinc phosphate primer immediately.

After applying light weight body filler, allow 2 hours of air dry time, then dry flattening should be done with sand paper of Grade P-80.

Light weight body filler as per MDTS 176 rev. 04 is used to level up surface imperfections over welded joints.

After paint removal, the coach surface shall be swabbed with petroleum hydrocarbon solvent to IS:1745-78 to remove all traces of paint remover.

If extensive corrosion repair necessitates removal of old paint to bare metal, follow Paint Schedule 'A'. If general condition of paint is good, follow Paint Schedule 'C' for touch-up work.

The six disadvantages are: Less durable, Low Gloss & Colour retention, Less resistance to salty atmosphere, Less resistance to ultra-violet rays, Require frequent re-painting, Increases effective cost of painting.

The evolution of painting systems: Alkyd-Alkyd-Alkyd (oldest, used in ICF), followed by Epoxy-Epoxy-Alkyd (earlier in RCF for ICF), then Epoxy-Epoxy-PU (RCF for ICF), and finally Epoxy-Polyester-PU (current for LHB coaches).