Indian Railways recently announced their plans to induct aluminium-bodied passenger trains on a mass scale. They plan to order 100 Vande Bharat train sets to be made in India. This is a significant step in their ambitious rail modernization program. It will mark the first time Indian Railways demonstrates the technological capability to manufacture and operate aluminium body passenger trains in India. This move followed the induction of the first all-aluminium freight rakes in October 2022.
The advantages of aluminium coaches are myriad. By most metrics, aluminium trains are a significant upgrade, whether it is in speed, capacity, life cycle cost, efficiency, emissions reductions, safety, comfort or recyclability. They even offer an aesthetic improvement, as they do not rust and thus look good as new after years of use.
The induction will initially proceed with 100 Vande Bharat rakes as a pilot but will eventually ramp up to 100,000 in the coming years if all goes well. The aluminium trains offer a different cost structure, 35% more expensive to manufacture but offering significant operating cost reductions and a 10-year longer lifespan. This means that total lifecycle costs are significantly lower.
Benefits of aluminium-bodied Vande Bharat trains
There will be a big jump in speed. Aluminium Vande Bharat trains are designed to run at 200 Kmph compared to the 160 Kmph of the current steel trains. However, due to old track infrastructure, they will initially be limited to 130 Kmph until track upgradation can be done. This is done out of safety concerns to prevent derailments.
The environmental benefits will be huge as well. Switching to aluminium bodies is estimated to save more than 1500 tonnes of carbon emissions a year per train. Add to this the fact that aluminium is recyclable, which uses a fraction of the energy of primary production, and the potential environmental benefits are significant. This will go a long way in helping India achieve emissions reduction goals under the Paris Agreement.
The durability and crashworthiness of aluminium coaches also make them a preferred option for passenger trains, as they can absorb impacts without crumpling much better. Additionally, the recyclability of aluminium trains means that they have a resale value of around 80%.
In Europe and Japan, aluminium body coaches make up the lion’s market share due to their benefits. With the current project, India is all set to join the ranks of the top railway networks in the world. Vande Bharat trains are already a big hit with travellers, and the new aluminium body upgrades will only reinforce that popularity.
Aluminium coaches are just part of an enormous railway overhaul
The project is estimated to cost around INR 30,000 crore. Technical bids have been submitted by France’s Alstom and Swiss giant Stadler in conjunction with Medha Servo. The project will be a giant leap forward in upgrading India’s manufacturing prowess and is part of the enormous railway rehaul underway.
Another aspect of this rehaul is the electrification program. This electrification program, the largest in the world, should be done before 2024 ends, improving train speed and efficiency even further. Gone are the days of coal and diesel engines spewing black smoke all over the countryside! The combination of aluminium bodies, electrification and renewables means that soon Indian Railways will be one of the most future-ready and efficient in the world.
