After a recent accident on Mumbai’s suburban railway that claimed four lives and injured six due to overcrowding, Indian Railways is planning to introduce newly designed non-AC trains with automatic doors. The move aims to improve commuter safety, with the first prototype expected by January 2026 following ventilation and design upgrades to prevent suffocation risks.
The Mumbai Suburban Railway—one of the world’s busiest urban transport networks—is set for a significant safety upgrade following another fatal overcrowding incident. In a response driven by commuter safety concerns, the Railway Board has announced that new non-air-conditioned trains will soon feature automatic door closure systems to prevent passengers from falling out during peak-hour rush. According to officials involved in the development, the Railway Ministry and senior Railway Board members held an emergency meeting with the Integral Coach Factory (ICF) in Chennai shortly after the tragedy. The consensus was clear: existing open-door non-AC trains pose a grave safety hazard and need an urgent redesign.
At present, Mumbai’s suburban network operates 250 train rakes, of which only 30 are air-conditioned. The remaining 220 non-AC rakes lack door-closing mechanisms, making them particularly dangerous during high-density travel periods. A single 12-coach non-AC train is designed to seat 1,200 passengers, with room for 1,800 standing. However, during what railway officials refer to as the “super dense crush load,” over 4,000 passengers squeeze into each train—more than double the safe limit. Officials revealed that earlier proposals to retrofit existing coaches with automatic doors were shelved due to severe ventilation concerns. In previous yard trials, closing doors led to a 2.5x increase in carbon dioxide levels inside coaches, creating discomfort and possible health risks for commuters.
To overcome this, ICF Chennai has now been tasked with designing an entirely new class of non-AC coaches that balance safety with airflow. These upgraded coaches will include three key design changes: louvred doors to allow air circulation, roof-mounted ventilation systems to pump in fresh air, and interconnecting vestibules between coaches that will enable passengers to move freely, helping to reduce uneven crowding. An official familiar with the design process confirmed that the prototype will be ready by November 2025. Following testing and approval by the Commissioner of Railway Safety, the train will be deployed for commuter feedback on the Mumbai network by January 2026. The prototype will undergo rigorous trials to evaluate both its technical performance and commuter response.
While the exact cost of the new trains will only be determined after ICF submits its final specifications, the cost of a standard non-AC train is currently estimated at ₹20–25 crore. These trains typically have a service life of 18 years. Given the scale of Mumbai’s railway operations, the financial implications could be substantial, though officials refrained from making any preliminary estimates. The development of new non-AC coaches comes alongside the ongoing manufacturing of 238 AC trains for Mumbai’s suburban network. However, with the majority of commuters still relying on non-AC services, the Railway Board has emphasised the importance of upgrading this category as well. Ensuring both affordability and safety has become a central challenge in India’s urban transport planning.
Transport experts said the decision represents a long-overdue shift towards safer public infrastructure. A former Railway Board member pointed out that between 2004 and 2024, more than 51,000 passengers died on Mumbai’s Central and Western suburban rail systems—mostly from overcrowding, falls, and track crossings. In 2023 and 2024 alone, the systems recorded nearly 5,000 fatalities combined. While recent safety measures have reduced the annual death toll, overcrowding remains a persistent and unresolved issue. According to transport planners, Mumbai’s trains operate at a density of 15 passengers per square metre during peak hours, which significantly exceeds international safety norms. Some experts warn that automatic doors, while necessary, may not function efficiently under such extreme conditions if crowd control measures are not also improved.
“Door automation is a welcome step, but it will not solve the deeper issue of commuter congestion unless paired with increased frequency, better scheduling, and last-mile connectivity,” said a Mumbai-based infrastructure expert who has advised on suburban transit projects. Moreover, behavioural challenges may hinder the effectiveness of the new system. It is common practice for Mumbai commuters to stand near doors even when space is available inside, especially on short-distance trips. Experts believe that commuter education campaigns and train staff sensitisation will be essential for the new door systems to work safely and efficiently.
Despite these concerns, the introduction of ventilated, auto-door-equipped non-AC trains marks a major leap forward in India’s urban mobility ecosystem. It reflects a growing recognition within Indian Railways that commuter safety must evolve in tandem with modern engineering and urban density. Officials say the 2026 rollout will act as a live test case for expanding similar upgrades across other high-density corridors in Indian cities. If successful, the prototype could pave the way for standardising automatic doors in all future non-AC trains—not just in Mumbai but across the country.
As India pushes for greener, safer, and more inclusive cities, the redesign of one of Mumbai’s most iconic public transport systems could become a defining moment in its journey towards sustainable urban living. For the millions who rely on these trains every day, this change promises not just comfort, but the most basic assurance of all—a safer ride home.
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