Safety apparels for painting include Goggles, Helmet, and Gum shoes along with Air compressor plant with spray gun.

Silicon carbide water proof paper of grade nos. 120, 220, 320 & 400 are used for painting work.

Lettering brushes include flat brushes nos. 1 to 12, round brushes nos. 1 to 12, and stencil brushes.

The following legends should be stenciled on battery box covers: Make, Type, Specific gravity (at full charge) corrected to temperature, Cell watered on, Cell examined on.

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

All lettering on coaches should be according to the sizes prescribed in the marking diagrams as per RDSO drawing number CSC-1728.

Laminated panels should be polished with silicon paste or similar suitable polish to restore luster and provide a protective coating.

If FRP windows are very dirty, they should be removed and cleaned with oxalic acid.

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.

Window glasses should be cleaned well and all paint marks should be removed before the coach is turned out after POH.

All standard schedule charts, signs, etc., should be stenciled/painted or screen printing as prescribed in drawing.

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

Air dry time of individual coat of Polyurethane Enamel should be minimum 8 hours.

The second coat of full gloss Polyurethane Enamel is applied to a cumulative DFT of 70 microns minimum.

The first coat of full gloss Polyurethane Enamel is applied to DFT of 35 microns minimum.

Wipe the entire surface of coach body with soft cotton clothes before applying Ist coat of full gloss Polyurethane Enamel.

Allow 8 hours of air dry time for Polyurethane surfacer and then do wet flattening with emery paper of grade 280.

Polyurethane surfacer is applied to a DFT of 60 microns minimum.

A coat of Polyurethane surfacer is applied by trolley mounted airless painting equipment to a DFT of 60 microns minimum.

Remove the dust accumulated over the surface by jet water and let it force dry.

In case of wet flattening, emery paper of grade 280 should be used.

Dry flattening is done by pneumatic sander machine with 150 grade emery paper.

Allowable air dry time of individual putty coat should be minimum 8 hours.

The total DFT of both putty coats is approximately 600 microns (first coat 300 micron + second coat 300 micron).

The first coat of unsaturated polyester base knifing stopper putty has DFT of 300 microns.

Two coats of unsaturated polyester base knifing stopper putty (two pack) as per M&C/PCN/100/2018: Chapter-III are applied.

Apply zinc phosphate primer (two pack system) to a cumulative DFT of 85 microns.

Where facilities exist, the entire coach body should be sand blasted and the primer coat of zinc phosphate primer should be applied by spray/brush immediately thereafter.

One coat of Eco-friendly water based Etch primer of DFT 25 microns is applied after cleaning the surface properly.

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

Level up the surface imperfections over welded joints with light weight body filler (MDTS 176 rev. 04) and after 2 hours of air dry time, do dry flattening.

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

The entire surface should be applied with a suitable paint remover and the old paint scraped off.

Paint Schedule 'A' is for complete repainting when old paint is removed to bare metal, and Paint Schedule 'C' is for touch-up when general paint condition is good.

RCF Drg. no. LW83100 (Ref. Doc. no. PLW0960) gives the exterior colour scheme of the coaches.

After the coach body is fully repaired and flooring work completed, it should be swept and cleaned of all dust, shavings, etc., before placing in the Paint shop.

The LHB painting procedure has 14 steps from Surface Preparation to De-masking as listed in the document.

Alkyd painting system is less durable, has low gloss and colour retention, less resistance to salty atmosphere and UV rays, and requires frequent repainting, increasing effective cost.

LHB coaches use the Epoxy-Polyester-Polyurethane painting system as per RCF specifications.

The four painting systems mentioned are: Alkyd-Alkyd-Alkyd system, Epoxy-Epoxy-Alkyd system, Epoxy-Epoxy-Polyurethane system, and Epoxy-Polyester-Polyurethane system (used for LHB coaches).