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Composites Enable Unified Solutions for

Savings Safety and Style in ExpandingRolling Stock Global Market

Thomas Johnson, Ashland Performance Materials

ll the studies point to the same

conclusion - passenger rail rider-

ship is up tremendously. The latestUNIFE (Association of the European Rail

Industry) report confirms this observa-

tion. UNIFE reports that rolling stock has

now reached some 50 million units

across 50 countries with an annual

growth rate of 2 - 2.5 percent annually.

Total market volume is currently projected

at 37 billion euros. Europe remains the

dominant market for rail coach procure-

ment with North America coming in sec-

ond, but the Asia-Pacific region is soon

expected to overtake North America as

the second largest consumer of coaches.

In the U.S., the APTA (American PublicTransportation Association) reports the

highest ridership numbers in more than

50 years. With the continuing high costs

Modar resin was used to make the aerodynamic front of this train.

of fuel, and congestion of roadways glob-

ally, it is easy to see why more people are

turning to rail as the single-best solution

in meeting todays transportation needs.

During the Bush administration, rail

projects were not high on the U.S.

agenda, and federal financing was not

readily available. Under the Obama ad-

ministration, however, interest in passen-

ger rail investment has increased

dramatically. Industrial Information Re-search (IIR) is currently tracking 90 rail

projects with a value exceeding $17 bil-

lion. Another $100 billion in new projects

are currently in various planning stages.

Going forward, it is anticipated that the

green movement will accelerate the use

of public transportation. In the U.S.,

greenhouse gases from transportation

currently represent a third of all emis-

sions. Research has shown that public

transportation can save up to 37 million

metric tons (MT) of CO2 annually. Thats

about the same as the emissions gener-

ated by the electricity consumed in five

million homes. Public transportation of-

fers an immediate alternative for individ-

uals looking to reduce energy

consumption, commuting expenses, and

their carbon footprint.

Weight is a paramount concern in

rolling stock, given the high cost of fuel.

Fuel costs for public transportation sys-tems have nearly doubled since 2004.

Fuel has risen from 6 per cent of operat-

ing budgets to 11 per cent today. Using

composites to reduce weight and im-

prove aerodynamics has long been

demonstrated to bring significant fuel

consumption reductions. Alstom, for ex-

ample reports a 15 per cent reduction in

fuel consumption, and some 70 MT

weight reduction on its AGV train, using

composites.

Composite materials, or glass rein-

forced plastics (GRP), are most com-

monly found in interior passenger coach

components. GRP enables the coach de-

signer to mould in multiple features, thus

reducing part assembly requirements,

labour and maintenance. Designers can

also mould in surface textures that deter

graffiti. Composites are used heavily in

ceiling and floor panels, front ends, side-

walls, window masks, luggage stowage,lavatories, kitchen and driver compart-

ment modules, and seating units.

Fire safety in rail applications is a criti-

cal concern. One of the best means to

satisfy this need is mandated FR (Fire

Resistance) norms and performance

standards. Ashland Performance Materi-

als, a commercial unit of Ashland Inc.

(NYSE: ASH), has developed a full line of

fire-resistant composite resins for use in

fabricating FR compliant components for

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A dining car interior features GRP

components for comfort and aesthetics

as well as safety

Mass transit interiors feature Modar

resin technology in maintenance panels

and flooring

Resins used in coach construction

protect travelers by featuring low smoke

and low flame potential.

the rail market. These products are most

commonly sold under the HETRON and

MODAR brand names. As an interna-

tional manufacturer and supplier to this

industry, Ashland has developed com-

mercial products that meet or exceed the

regulatory demands in nearly every cor-

ner of the world. Ashlands HETRON andMODAR resins find use in a wide variety

of fabrication processes - from hand lay-

up and pultrusion to sheet moulding com-

pounds to infusion.

Generally speaking, the EU and U.S.

have been developing their own individ-

ual FR norms since the 20th century. Oc-

casionally, one nation has adopted the

standards of another for expediency, or

because no local FR norm existed. The

end result has been a proliferation of FR

regulations for a multitude of applications

based upon a wide variety of FR test

methods. In particular, the EU has an ur-gent need to harmonise its FR standards.

The architectural and railway markets

have provided the initial focus for Euro-

pean FR standard harmonisation. Marine

FR requirements typically defer to the

world standards of the International Mar-

itime Organisation (IMO). In the architec-

tural market, the EU has recently

published EN 13501-2; the famous Euro-

classstandard. For the railway market,

the EU has established EN 45545 for Fire

Protection on Railway Vehicles.

Here is brief description of the EN

13501 for Construction Products:

There are seven Euroclasses: A1, A2,

B, C, and D & E; the most stringent is

A1:nocontribution to fire.For smokeemissions: S1, S2, S3; for droplets, d0,

d1, d2.

Products are classified by five tests.

Small Flame (ignitability)

pr EN ISO 11925-2.

Radiant Panel

pr EN ISO 9239-1.

Bomb Calorimeter

pr EN ISO 1716.

Single Burning Item

EN 13823.

Little Furnacepr

EN ISO 1182.

New Euroclasses will replace all exist-

ing national classifications. For example,

today in France, building materials that

carry the French classification M/F will be

reclassified according to the new Euro-

class standard. The following table dis-

plays a rough approximation of how the

new Euroclasses will line up with existing

national FR standards in France, Ger-

many, and the U.K.

Top performing thermoset glass rein-

forced plastic (GRP) composites can

likely achieve a rating of B / S2 / d0. By

their very nature, thermosets will not de-

velop a droplet rating above d0, how-

ever, their organic content generally

precludes an A classification for fire.

Composite materials remain a relativelynew technology in the rail market.

Their potential is most certainly under-

estimated.

Dramatic changes have occurred in

recent times. Railway infrastructure / net-

works and operating companies for

trains have been split (for instance in

France SNCF / Rseau Ferr de France

(RFF) -French Railways Network). Pub-

lic operators have been sold to private

companies. The train industry overall has

become considerably more concen-

trated, and major players have acquired

facilities all over Europe (e.g. Fiat Fer-rovia now belongs to Alstom). Trains are

now crossing national borders more and

more frequently. The EU commission is

looking to unravel the market protection-

ism afforded by the old national FR

norms. EN 45545 will be a key milestone

to unite disparate national FR standards

under a single umbrella.

At the same time, the rail industry is

growing at an unprecedented rate. And

whether you live in New York, London,

Shanghai or Mumbai, the demands are

much the same for fire protection in pas-

senger rail rolling stock. Comprehensive

FR technology from Ashland as found in

its HETRON and MODAR resins enables

composites to deliver fuel savings, aes-

thetic appearance, and public safety with-

out compromise in passenger rail

applications.

Contact information

NC stands for non combustible

For more information pleasevisit:www.ashland.com

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