USSR USES PROGRESSIVE METHOD IN RAILROAD CAR REPAIRING

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00809A000700120329-2
• Release Decision: RIPPUB
• Original Classification: R
• Document Page Count: 8
• Document Creation Date: December 22, 2016
• Document Release Date: September 14, 2011
• Sequence Number: 329
• Publication Date: July 29, 1953
• Content Type: REPORT

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COUNTRY USSR DATE OF
INFORMATION 1925 - 1950
SUBJECT Economic; Technological - Railroad equipment -
LANGUAGE
HOW
PUBLISHED Book
WHERE
PUBLISHED Moscow
DATE
PUBLISHED 195D
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The repair of railroad cars by the progressive method was first introduced
in 1925 in the Tambov Car Repair Plant. Since then, it has been widely accepted
by Soviet car repair plants and repair yards.
A further development of the progressive method was the introduction of the
unit subassembly method, by which a defective unit is replaced by a repaired unit
xhich has been assembled previously on a special Sig or bench, and which then is
delivered to the proper position on the track were it is installed on the car.
This method was first introduced in 1948 in the Darnitsa Car Repair Plant in re-
conditioning two-axle boxcars.
The entire process of repairing a two-axle boxcar by the progressive method
is carried out in five positions. The car is completely stripped in the fix?st
position.' Except for the door yosts, which are left intact provided they need
not be replaced, all posts are removed. The roof of the car is removed by means
of abridge crane and placed on a special ,jig where it is repaired.
Zn the second position, the frame anti t;?~ end sills are repaired. The end
sills are removed from the car itself and re :fired on a bench, after which they
are again installed on the car as complete wits.
CLASSIFICATION~~RRIITTRyyESTRICTETTDZZ~~II~~
CENTRAL~INTELLIG~'ENC:Y REPORT
INFORMATION FROM
FOREIGN DOCUMENTS OR RADIO BROADCASTS CD NO.
Or nizatsi Vagonnovo Khozyaystva (Drganization of Railroad Cr.r Man-
agement , N. Z. Krivoru zdat, Moscow, 1950, pp 116-37,
Appendix tables 1 and 2
DATE D(ST.o29 Jul. 1953
NO. OF PAGES( 8
SUPPLEMENT TO
REPORT NO.
THIS IS UNEVALUATED INFORMATION
In the third position, the car is raised; ;.he wheels are replaced; the brake
gear and all accessories, the ,journal boxes, and tY,e bearings are. mounted; and
the liners and packing are installed.
In the fourth position, sides previously pre~ured and painted are attached
to the car, and the posts are riveted to the bra::'.et angles and end sills. Part
of the floor is laid.
STATE
ARMY
DISTRIBUTIC~Y
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In the fifth position, laying of the floor is completed. Abridge crane
fs used to place the repaired and painted roof an the car. After the poets are
riveted to the angles, the doors are hung on the sides. The automatic brakes
sire given a final testing and the foundat'on brake gear is regulated. Upon com-
pletion of this work, the car is delivered to the inspector.
A car remains in each position 4 hours; it takes 20 hours to recondition
a~txo-axle boxcar.
The capital repair of s four-axle freight car, which takes 32 hours, is
broken down into eight operations carried out by special crexs. A repaired
car leaves the track every 4 hours.
The methods employed by the Kanash Car Repair Plant in making capital re-
pairs on four-axle boxcars and those employed by the Moscow Car Repair Plant
imeni Voytovich in making capital repairs on four-axle passenger cars are ex-
amples of the progressive method of repairing cars.
In the case of boxcars, the wooden parts of the car and the roof are re-
moved completely in the first position. This includes the floor, the inside
lining, the molding, and +.he roof carline fillers. The metal posts and the
carlines are unbolted and, after the posts and roof' are removed, the body and
frame are cleaned of rust and mud.
In the second position, the car is stripped of its metal parts and the
rivets are removed. The worn-out metal parts of the frame, the doors, and the
trap doors are removed, the brake gear parts and the automatic brake are dis-
mantled, the bolts are loosened, and the rivets are cut out. If necessary, the
frame and body ar.~ straightened.
In the third position, the car is lifted either by an overhead crane ar
by electric ,jacks, and is placed on steel stands. The trucks are removed from
under the car and are sent to the truck shop for repairs. The draft gear and
automatic coupling equipment is disassembled completely, the center sill is re-
paired at the backs`.op, and the body center-plate is either repaired or replaced.
By having a supply of previously repaired trucks on hand at this position, the
Kanash Car Repair Plant is able to saintain a continuous and uninterrupted re-
pair schedule. Cars can be placed on trucks 2 hours after being lifted from
their original trucks.
The fourth position involves welding, riveting, and erecting work. In
addition, the brake equipment is mounted.
Both the fifth and sixth positions involve carpentry and erecting work.
The fifth position includes the laying of the floor, the insta'lation of the
lining and molding, the hanging of doors, and the placing of draft gears and
automatic couplers. As part of the sixth operation, the lining is bolted, the
automatic brakes are tested, and a selected spot is painted for stenciling.
About 1,000 bolts and nuts are necessary t~: install the floor and lining in a
'four-axle boxcar. In this position there is c scaffola which is raised and
lowered b; .moans of an electric motor, to facilitate l:ne work.
The principal work done in the seventh position is the laying of the roof
on the car and the .painting of the sides, the body, and the roof. To facilitate
the roof work, there is a special scaffola along the entire length of the car.
This scaffold is 3,100 millimeters from the top of the track rail and G00 milli-
meters from roof level. All preparatory roof wo-~ is done on this scaffold.
In the eighth position, the car is painted for tl-c? second time, ie sten-
ciled, and is completed for delivery to the inspe^t.:- :f the Minisiry of Rail-
ways.
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The following table gives a schedule of capital repairs on a four-axle
boxcar repaired by the progressive method. It lists the various operations end
the skills involved, the number of workers in the crew, the time it takes to
carry out specified repairs, and the man-hours involved in each operation and
postiien.
Time
Number of Involved Man-
Workers hours) Hours
First Position
Lift car, place on benches; Fitters 2 0.25 0.5
roll trucks out
Remove friction draft gear
Remove doors, hatch covers,
stringers, coupler handles,
door rails
Dismount hand sad automatic
brake
Replace body center plate
'nnd side bearings
Fit and rivet around center
pin, center-sill and plate,
and coupling
Remove and fit parts with
acetylene torch; perform gas
welding work
Replace, removed trucks; drop
car on trucks
Repair frame by fitting and
riveting
Iristnll brake cylinder;
assemble brake gear
Third Position
Repair body by fitting and
riveting
Perform electrical welding
work on body
Brake-equipment
fitier
1
4
4
Fitters
2
4
$
Boileramiths
~Riveters7]
4
4
16
Welder
1
4
4 {
Fitters
2
0.25
1
0.5
Boilersmiths
2
4
4o y
8
Reamer
Brake-equipment
1
2
4
4
4
8
fitters
20
Boilersmiths
welders
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2
2
4
4
8
8
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Third Position
Install door guides, door Fitters
rails, and stringers
Assemble friction draft gear "
Assemble air pipes and brake Brake-equipment
equipment fitters
Time
Humber of Involved Maa-
Workers hours Hours
Fourth Position
Paint vnderframe and poets; Carpenters 8 4 32
lay floor; install side,
front, and rear end lining;
install carllne Pilfers, door
posts, cornice, and roof lin-
ing
Fifth Position
Bore holes and bolt lining and
floor
Hang and fit doors and hatches
Sirth Position
Teat automatic crake with car
inspector
Cover roof xi.th sheet iron
and install chimney flashing
Prepare car for painting by
application of filler
Seventh Position
Apply first coat of paint to
car
Dry car in paint-drying shed
Psighth Position
Apply second coat of paint
Dry car
Carpenters
$
4 32
Fitters
2
4 8
Brake-equipment
fitter
1
4 4
Roofers
2
i
4 8
Painters
2
2 4
STAT
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Time
Number of Involved Man-
Workere hours) Hours
Eighth Position
Stencil car and deliver to Painters p 1 2
inspector
Prepare and load compressorless 2 2 4
paint tank for future work
The repair of passenger cars by the progressive method involves a great
many complications, but the experiences of the more advanced car repairing enter-
prises, such as the Moscow Car Repair Plant imeni Voytovich, clearly shox that
this method is both possible and economical. Capital repairs on passenger care
are carried out in seven positions at this enterprise. Six of these positions
are located in the erection department and the seventh is in the paint shed.
In the first position, a passenger car is stripped completely. The draft
gear, the hand and automatic brakes, and the metal sides are removed; the
xooden parts of the body, the heating system, the water pipes, and the internal
fixtures are all d'sassembled; and the roof is removed from the car. A ,fib crane
is located in this position to remove the heating apparatus and to transport
heavy components. To facilitate the work, this position is also equipped with
e three-tier movable scaffold.
In the second position, the body of 'the car is separated from the under-
frame. The underframe and trucks are rolled out from under the body, the under-
frame is raised, and the trucks are changed. Work is performed on the body, the
frame is repaired, the draft gear is installed, the underframe is lowered on
trucks previously repaired in the truck shop, and the body is attached to the
underframe. The heating apparatus is installed. A car remains in this position
2 days.
In the third positign, work on the body is completed. Work is done also
on the heating arrangement, and the body is inspected by the inspector. A car
remains in this position 2 days.
In the fourth position, where the car also remains 2 days, the metal aide
aheecs are reinforced, the assembly of the heating equipment is completed, the
doors are installed, the furniture is repaired and assembled, and the exterior
of the car is cleaned and primed for painting.
In the fifth position, the interior trimming is completed. The windox
frames are installed, locks and door hand_'es are attach,~d, electric light fix-
tures are connected, and automatic brakes are tested. Following this, the in-
terior of the car is cleaned and primed for painting. The exterior is given a
second and third application of ground coat. A car remains in this position
2 days.
A car also remains 2 days in the sixth posiL_un, where work is done on the
roof, the platform lights and tail gates are installed, the interior is given
s second and third application of ground coat, and :t.e sxterior is rubbed.
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STAT
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In the seventh position, in which a car remains 5 days, all the paint work,
interior and exterior, is completed and the car is lettered. The interior of
the car is given two applications of paint and a touch-up fob; the exterior ie
given two applications of paint and an application of lacquer.
The ordinary layover time for a four-axle passenger car undergoing capi-
tal repairs is. established ~s 16 one-shift work days.
The following table gives a schedule of capital repairs made on a Pour-axle
hard-seat passenger car. It li^ta the various operation: and the skills involved,
the number of workers in the crew, the time it takes to carry out specified re-
pairs, and the nan-hours involved is each operation.
First Position
Disassemble rails and tail
gates
Disassemble head and auto-
matic brakes
Disassemble automatic coup-
ling apparatus an3 buffers
Disassemble window frames
Disassemble door locks
Disassemble electrical
equipment
Disassemble water pipes and
lavatories
Remove exterior metal sheets
Remove vestibule and interior
doors
Disassemble roof and venti-
lators
Disassemble heating equip-
ment
Disassemble interior
furnishings
Remove body from frame
Place body on stands, roll
out trucks
Repair under frame
Time
Number of Involved Man-
Skille Workers hours) Hours
Fitters
2
2
4
~~
2
4
8
~~
2
2
4
Carpenters
2
8
16
Fitters
2
3
6
Electricians
2
4
8
Fitters
p
6
~
Straighteners
2
8
16
Carpenters
2
8
16
Roofers
4
8
32
Steam pipe-fitters
5
8
40
Carpenters
4
4
16
Bodymen
2
2
4
Fitters
2
1
2
Fitters, welders
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4
8
32
STAT
awl
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I
STAT
Roll trucks back under
Yrame, lover body oa trucks,
sad ad~nst trucks
Install automatic coupling
apparatus and buffers
Second Position
Dismantle exterior wooden
face boards
Dismantle floor and interior
lining
Replace floor and interior
lining
Replace exterior wo.,3en face
boards
Replace exterior sheet metal
Assemble heating equipment
Install interior furnishings
Adjust vestibule doors
Install guard rails and tail
gates
Third Position
Cover roof and assemble
ventilators
Assemble crater pipes and
lavatories
Install window frames
Install electrical
equipment
Hang and fit doors
Install door locks
Time
Dumber of Involved 1~Yni-
Workers hours Hours
Fitters
2
2
4
Bodymen
4
6
5
20
Carpenters
6
5
8
30
48
Bodymen
"
6
4
8
8
48
Straighteners
12
8
32
96
Steam pipe-fitters
3
14
42
Carpenters
2
12
24
"
2
4
8
Fitters
2
4
$
Roofers
6
5
3p
Fitters
2
8
16
Carpenters
3
12
36
Electricians
2
8
16
Carpenters
2
8
16
Fitters
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RESTRIGfiID
1
4
4
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Fourth Position
Apply second coat of paint
to roof
Paint running gear
Rub and prime sides of
exterior
Apply paint to sides of in-
terior, second coat
Apply fixol Lfinishing varnish T7
to sides of exterior, first
coat
Touch up and lacquer sides of
interior
Apply fixol to sides of ex-
terior, second coat
Paint floor, second coat
Turn car over to inspector
of Ministry of Railways
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2
8
16
2
8
16
5
8
40
2
8
16
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