As the global leading enterprise in rail transit equipment manufacturing, CRRC (China Railway Rolling Stock Corporation) has long faced persistent wall operation and maintenance pain points across its multiple production bases, including frequent collisions from heavy manufacturing equipment, industrial dust accumulation, and insufficient safety protection levels in special production zones. This wall protection upgrading project covers multiple core production campuses under CRRC, including Dalian Locomotive & Rolling Stock Co., Ltd., Lanzhou Locomotive Works, and Yongji Electric Motor Co., Ltd. Customized protection solutions are developed based on the scenario characteristics of different workshops, realizing a full-dimensional upgrading of factory walls from basic wear resistance to enhanced safety protection in special areas, which fully meets the strict environmental requirements for high-end rail transit equipment manufacturing.

Project Background

The welding workshops, final assembly workshops and material transfer passages in CRRC's production campuses have been operating under high load for a long time. The original ordinary latex paint walls suffered from large-area paint peeling and dents within less than half a year due to frequent scratches from heavy locomotive components during transfer. Walls around welding stations were covered with welding slag and metal dust, which could hardly be completely removed by conventional cleaning methods. In some special areas storing flammable and explosive materials, the original wall protection level failed to meet the latest national work safety specifications. Meanwhile, the exterior walls of the factory campuses, exposed to industrial dust and drastic temperature changes for a long time, developed problems such as coating cracking, water seepage and peeling, which not only damaged the overall industrial image of the factory, but also brought hidden risks to production safety.

Implementation of Customized Protection Solutions

The project team designed a layered and classified wall protection system tailored to the production characteristics of different CRRC campuses: For high-frequency collision areas such as final assembly workshops and material transfer passages, high-toughness industrial-grade anti-collision wall panels are adopted. With high-strength galvanized steel as the base and a special anti-corrosion wear-resistant industrial coating on the surface, the system can withstand direct impacts from heavy transfer forklifts and locomotive components, delivering an impact resistance more than 8 times that of ordinary walls. The surface is also treated with anti-static technology to avoid the adsorption and accumulation of metal dust. For special production areas such as welding and painting workshops, thermal insulation explosion-relief wall systems that meet national explosion-proof safety standards are installed. Using lightweight qualified explosion-relief panels, the system not only meets the basic wall protection requirements, but also safely releases pressure along the preset path in case of emergencies, fully complying with the high-risk area protection requirements in CRRC's work safety management system. For the exterior walls of the factory campuses, long-term energy-saving exterior wall protection coatings that meet the centralized procurement standards of CRRC Science Park are selected. Balancing excellent industrial weather resistance and green energy-saving properties, the coating can withstand extreme temperatures ranging from -40℃ to 70℃ without fading or cracking after long-term use. It also reduces the overall energy consumption of the buildings, which is in line with CRRC's green factory construction goals under the "Dual Carbon" strategy. For special wall requirements in radiation testing workshops, an integrated wall solution with customized lead protection lining is developed. Without damaging the original building structure, the solution achieves dual functions of radiation safety protection and physical anti-collision, fully meeting the scenario requirements of non-destructive testing for rail transit components.

Project Implementation and Safety Control

The entire construction process strictly followed the safety management specifications of CRRC's production sites. A "staggered peak and zoned operation" mode was adopted to completely separate construction hours from production peak hours. All construction personnel entering the site passed CRRC's special safety training, and the "two-person inspection, site clearance on the same day" system was implemented throughout the process, which did not cause any disruption to the normal locomotive production and delivery schedule. Meanwhile, the project was integrated with CRRC's self-developed "Anwang" AI intelligent monitoring system, where status monitoring nodes were embedded in key wall protection areas to realize real-time digital management and control of wall protection conditions. The system automatically triggers an alert once abnormal collision damage is detected, improving the efficiency of hidden danger investigation for walls by more than 70%.

Project Outcomes

Two years after the project was delivered and put into use, the wall operation and maintenance cost across CRRC's campuses has been reduced by 82% compared with that before the renovation. The wall repainting work, which used to be required twice a year, now only needs overall maintenance after more than 5 years. The wall protection level in special explosion-proof areas successfully passed the special inspection by the emergency management department, fully meeting the construction requirements of CRRC's "Five Standardizations and One Core" work safety culture system. The renovated walls not only maintain a neat and unified industrial appearance all the time, but also build a solid safety line for the high-precision manufacturing of rail transit equipment from three dimensions: physical protection, safety enhancement and digital management and control. This project has become a benchmark case for wall protection upgrading in China's heavy manufacturing sector, providing a replicable practical experience for safety renovation of industrial factories across the whole industry. </doc_start> If you need to adjust professional terminology, add more campus-specific details or optimize the format for international business presentations, you can put forward further requirements.（