fr materials for railway applications and compliancy to the … · 2018. 5. 25. · our know-how...

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FR materials for railway applications and compliancy to the European standard

1

Alix LE SUEUR

Challenges and opportunities in a context of regulatory framework changes

Warsaw - 15th May 2018CREPIM – Your fire safety is our duty

Content

• Introduction

• Standard evolution

• What does it imply?

• FR strategy

• Target market and regulations

• Fire scenario?

• Work diagram

• CREPIM’s success stories

2CREPIM – Your fire safety is our duty Warsaw - 15th May 2018

CREPIM

3Warsaw - 15th May 2018CREPIM – Your fire safety is our duty

IntroductionStandard Evolution

FR StrategySuccess Stories

CREPIM• Location: north of France

• Created in 1994, CREPIM belongs to the Top 5 fire laboratories in EU

• 4 services

Development department

Testing department

Certification department

Training department

• A team of 20 people and 1500 m2 arededicated to fire properties studyand improvement


Our Expertise

• ISO 17025, 77-1, 2 & 3 COFRAC accredited since 1999

• SNCF/RATP recognition since 2003

I and F classifications

NF EN 45545-2 + A1 : 2016

• Notified laboratory (Euroclasses) since 2009

• Laboratory accredited for issuing M classification reports since 2010

• Laboratory certified CRT since 2007

• COFRAC ISO 45011 accreditation since 2013


Why CREPIM ?

• We can accompany you through the issues and challenges of normative changes and evolutions

• We, as a certified, accredited and independent laboratory, can evaluate reaction to fire and fire resistance performances.

• We can train you so that you can apprehend the evolution of the regulations serenely

• We can develop with you fire-retarded products tailored to your markets

Identification of the tough

elements of the certification

process

Helpingcompaniesanticipatechanges

Formulate new materials

Access to markets through

certification


Quality

Flexibility

Reactivity

Standard Evolution


What does it imply?



The stakes

• Evolution of fire models in railway applications :

• New thermal stress levels

• New equipment to assess reaction to fire

• New parameters taken into account

8

National scale European scale

Flame spread F

Ignitability I

Smoke SToxicity T

Flame spread F

Ignitability I

Smoke SToxicity T

Rate of heat release R


Fire proofing strategy




Fire scenario

10

EN 45545-2

EN 45545-3


Retarding fire Resisting fire

How to adapt a fireproofing strategy


Application field

Target market

Required properties

Regulation - Tests to pass

Cost

Fireproofing

strategyMaterial :

Plastics + additives

Final product

Conception

Environmental

Toxicological concerns

Maintaining key

properties

How to adapt a fire-proofing strategy


Fire proofing strategy

Maintaining the other

key properties

Material: plastics & additives

Final product

conception


CREPIM’s success stories



Vertical and horizontal downward facing interior surfaces


Required compliancy


EN 45545-2 R1 (small and medium scale tests)

Requirement StandardParameter and

unitMax or

MinHL1 HL2 HL3

R1

ISO 5658-2(50kW/m²)

CFE (kW/m²) Min 20 20 20

ISO 5660-1 (50kW/m²)

MAHRE (kW/m²) Max - 90 60

ISO 5659-2 (50kW/m²)

Ds(4) (a.u.) Max 600 300 150

VOF4 (min) Max 1200 600 300

CITG (a.u.) Max 1.2 0.9 0.75

• Most of commonly used composites don’t comply with the EN 45545-2 standard : 50 kW/m²

• ISO 5658-2: Vertical radiant panel very difficult to pass

• ISO 5660: Heat released rate taken into account

• ISO 5659-2: Low smoke density criterion

State of the art

Top /Gel coat

Thermoplastic or thermoset

reinforced resin

Fire retardant strategy

to comply with EU std

Fire retardedTop/Gel coat

Mineral fillers or additives

promotingintumescence


Need to think over the whole fireproofing strategy

Our feedback – Fire proofing plastics

0

2

4

6

8

10Toxicité

Opacité

Propagation deflamme

Diminution dudébit calorifique

Efficacité / Tauxde charge

Hydroxyde métallique

• Examples

• Aluminium hydroxide

• Magnesium hydroxide

• Boehmite

• Synergists

• Zinc hydrostannate

• Zinc stannate

• Zinc borate

• Nanoclay


Toxicity

Smoke density

Flame spread

Effectiveness/

loading rate

Reducing the

heat output

Metallic hydroxides

• Fireblock unsaturated polyester

Development of fire retarded unsaturated polyester based resins

(Norsodyne) and gelcoats (Polycor) :

• Halogen free

• Based on intumescence phenomenon

• Won the 2011 JEC Innovation award

Polynt Composites project

R1 HL3 according to EN

45545-2


Electrical applications


Required compliancy


EN 45545-2 : R22 to R26 (small scale tests)

Requirement Standard Parameter and unit Max or Min HL1 HL2 HL3

R22

EN ISO 4589-2 Oxygen index (%) Min 28 28 32

ISO 5659-2 (25 kW/m²) Dsmax (a.u.) Max 600 300 150

NF X 70-100-1 and 2 (600°C) CITNLP(a.u.) Max 1.2 0.9 0.75

R23

EN ISO 4589-2 Oxygen index (%) Min 28 28 32

ISO 5659-2 (25 kW/m²) Dsmax (a.u.) Max - 600 300

NF X 70-100-1 and 2 (600°C) CITNLP(a.u.) Max - 1.8 1.5

R24 EN ISO 4589-2 Oxygen index (%) Min 28 28 32

R25 EN 60695-2-11 Glow wire temperature (°C) Min 850 850 850

R26 EN 60695-11-10 Vertical small flame Min V0 V0 V0

Amphenol Air LB project

• Development of a new fire retarded thermoplastic resin

dedicated to railway E&E applications:

• REACH compliant fire retardant solution

• Terminal blocks

• Harsh climatic environment : -60°C to 100 °C

• High fire properties and low smoke/low toxicity


R22 HL3 according to

EN 45545-2

Our feedback – Fire proofing plastics

0

2

4

6

8

10Toxicité

Opacité

Propagation deflamme

Diminution dudébit calorifique

Efficacité / Tauxde charge

Hydroxyde métallique

Dérivé halogéné

• Examples

• Polybrominated diphenyl ethers (PBDEs)

• Hexabromocyclododecane (HBCD)

• Bromophenol

• Chlorinated phosphate esters

• Synergists

• Antimony oxide

• Zinc borate


Toxicity

Smoke density

Flame spread

Effectiveness/

loading rate

Metallic hydroxides

Halogen derivatives

Reducing the

heat output

Train seats


Regulatory evolution for train seats

• Back and base shell (R5-HL3)

Fire reaction MAHRE < 60 kW/m²

Smoke opacity Ds4 < 150 and

VOF4 < 300 min

Smoke toxicity CITg < 0,75

• Upholstery (R21-HL3)

Fire reaction

Smoke density and toxicity

Integrity

• Complete seat test (annexes A and B)

Vandalism test

Fire test on vandalised seat

European harmonised

standard – EN 45545-2

Update

• Each component separately

Fire reaction M1

Smoke opacity and toxicity

F4

• Complete seat test (UIC 564-2,

appendix 13)

Seat must self extinguish

after 10min max.

No flaming droplets

Former national French

standard - NF F 16 101


Train seats


EN 45545-2 : R18 (full scale seat test)

& R21 (small scale tests)

Requirement StandardParameter and

unitMax or

MinHL1 HL2 HL3

R18 ISO/TR 9705-2MAHRE (kW) Max 75 50 20

HRR peak (kW) Max 350 350 350

R21

ISO 5660-1 (25kW/m²)

MAHRE (kW/m²) Max 75 50 50

ISO 5659-2 (25kW/m²)

Dsmax. (a.u.) Max 300 300 200

CITG (a.u.) Max 1.2 0.9 0.75

• Most commonly used systems (textile covering + interlayers + foam) don’t comply with the EN 45545-2

• Whole seat assembly tested

• Heat released rate taken into account

• Vandalised seat tested

Need to think over the whole fireproofing strategy

Train seats – state of the art

Textile covering

Interlayers

Foam

Heat resistant non-woven para-aramid

Neat PU foam or graphited

FR textilePET FR

OrPET + FR back coating

Heat resistant non-woven para-aramid

(possible to forego it)

Neat foam or foam + back coating

compliant with

National std

adaptation needed to

comply with EU std

“all in one” FR textile

covering


• ENSCL/CREPIM/ENSAIT• EU funded

Development of a new textile covering based on :

• PET

• Metal phosphinate

• Polysilsesquioxane nanofiller (act as a synergist with FR system)

INTUMAT project


Cone calorimeter test at 50 kW/m²

Sample at 25 mm from the radiant heat sourceCone calorimeter test at 50 kW/m²

Sample at 25 mm from the radiant heat source

• Double advantage of the textile developed

• Fire retardant properties and foam protection

• Vandalism resistant HOW ? fabric is weaved with technical core-wrapped yarns PET-FR/p-aramid (Friction spinning process)

Warp

Weft

WarpW

eft

After vandalization test

Train seats


Front Back

• Results

• New textile developed successfully passes the whole testing process for seats

Small scale test : R21 HL3

Large scale test on vandalised seat: R18 HL3

Train seats

ISO 5660-1 (25kW/m²) ISO 5659-2 + IRTF

Name Ignition time (s)HRR peak(kW/m²)

THR (MJ/m²) TSV (m²)Residual

weight (%)MAHRE (kW/m²)

CIT (4min CIT (8min) Ds max

First assembly 122 223.1 97.6 6.01 18.5 103.1 0.03 0.18 555

Final assembly 148 126.1 6.0 1.3 91.1 24.0 0.01 0.01 86.8

HL3 - - - - - 50 0,75 200

EN 45545-2 Appendix A et B

Nom Vandalism Residual weight (%) THR (MJ) HRR peak (kW) MAHRE (kW)

Final assembly Not possible 99.7 2.35 2.60 8.4

HL3 - - - 350 20


• With the evolution of standards, we need to increase our level of expertise

• So why choose CREPIM?

• We have fully integrated part 2 and 3 of the EN 45545

• We are part of standardisation committees so we are capable of anticipating the evolution of the tests and of the requirements’ criteria

• We are all chemists

• Better understanding of the relationship between a material’s nature and its reaction to fire

• Capable of interpreting results in terms of chemical degradation

• We are experienced in implementing and characterising materials

• We have networks and privileged links with FR suppliers and outsourcers


Conclusion

How we can help you?

• Define your need and target for the material regarding fire safety and the system as a whole – EN 45545 parts 1 to 3

• Define the fire scenario

• Measure and analyse the current material’s performances

• Innovation : implementation of technological roadmap

• New FR systems

• New resin

• New assembly

• Make the link between FR performances and cost effectiveness


THANK YOU FOR YOUR ATTENTIONDo you have any questions?


Alix LE SUEUR

+33 (0)3 21 61 64 [email protected]

mailto:[email protected]

fr materials for railway applications and compliancy to the … · 2018. 5. 25. · our know-how...

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