In a significant move to combat track corrosion and reduce long-term maintenance costs, the Indian Railways is gearing up to pilot the use of galvanized steel rails in coastal and high-humidity regions. According to sources familiar with the development, this initiative could extend the lifespan of tracks in these challenging environments by more than four times.
The Corrosion Challenge and a Metallic Solution
Regular steel rails in coastal areas and zones with high rainfall and humidity typically last only 2 to 3 years before succumbing to severe rust and requiring renewal. In contrast, the same rails in less corrosive environments can serve for about 12 years. The national transporter spends a staggering ₹20,000 crore annually on track renewals, a substantial portion of which is attributed to corrosion-related wear and tear in coastal belts.
The proposed solution involves using galvanized rails or thermal-sprayed zinc rails. While the initial procurement cost is higher—approximately ₹84,000 per tonne compared to ₹76,000 per tonne for normal steel rails, marking a 10% premium—the lifecycle cost promises massive savings. The protective zinc coating is expected to boost track life in corrosive zones from the current 3 years to over 12 years.
Phased Procurement and Technical Considerations
The Railways' research wing, the Research Designs and Standards Organisation (RDSO), has already approved standards for zinc thermal-sprayed steel rails. Based on this, the Railways is planning a phased procurement of about 1 lakh tonnes of the treated steel. A small-scale pilot has already been conducted on the Vijayawada-Guntur section to study the performance of rust-free rails.
However, experts have flagged potential technical hurdles that require thorough testing. A key concern is whether the zinc coating might interfere with ultrasonic waves used by crack-detection sensors to identify flaws in the tracks. V. Shanker, former executive director of planning for Railways, acknowledged this issue but expressed confidence that solutions would be found.
Furthermore, some engineers question the durability of the coating under operational stress. Shubhranshu, former chief of the Rail Wheel Plant in Bela, noted that the zinc layer on the rail's top running surface might wear out within days of train operations, and welding during installation could also strip the coating. He suggested exploring special anti-corrosion paints used in marine environments like oil rigs and called for more comprehensive feasibility studies.
Broader Infrastructure and Cost-Benefit Outlook
Beyond renewals, these corrosion-resistant rails could also be deployed for new line projects, track doubling, and gauge conversion—all key focus areas in the Railways' capital expenditure plan. For the fiscal year 2025-26 (FY26), the Railways allocated ₹32,235 crore for new lines, ₹32,000 crore for track doubling, and ₹4,550 crore for gauge conversion out of a total capex of ₹2.65 trillion.
The move is also seen as an alternative to the nickel copper chromium (NCC) rails currently produced by the state-owned Steel Authority of India Ltd (SAIL). SAIL's Bhilai Steel Plant has been supplying these high-performance rails for demanding applications like Vande Bharat Express trains and heavy-haul corridors.
Industry advocates like Rahul Sharma, director-India of the International Zinc Association, emphasize that the benefits of using galvanized rails in high-corrosion areas far outweigh the modest increase in initial cost. Former Railways member of engineering, M.K. Gupta, echoed this, stating that preventing corrosion ensures better track availability for operations, which automatically drives down lifecycle costs.
As of Thursday, January 11, 2026, queries sent to the railway ministry regarding the pilot had not been answered. The initiative marks a proactive step by Indian Railways to leverage material science for enhancing infrastructure durability and achieving substantial fiscal savings in the long run.
