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Rail Product Guide

Award winning composite solutions for railway stations including platforms, footbridges, end of platform gates, fencing and canopies.

Dura Platform 40 installed at Livingston South Station

Rail

Station Platforms & Associated Products

Unlocking the Power of Composites for the Rail Industry

© 2019 Dura Composites

About Us

1 www.duracomposites.com

Dura Composites is a leading supplier of composite products with over 23 years’ experience in delivering durable, performance-improving and cost-effective composite solutions to a wide range of industries.

We help companies of all sizes unlock the power of composites, and our client base includes businesses in the Industrial, Construction, Rail, Transport, Landscaping, Marine and Leisure sectors.

Our success is driven by our commitment to innovation and by empowering our staff to inspire, educate and problem-solve for customers.

In 2017, Dura Composites was awarded the Queen’s Award for Enterprise in recognition of our achievements at the forefront of composite material technology.

Dura Composites’ products are also available through a well-established global distribution network. Your local distributor can be found on our website.

Dura Composites Structural Stair Treads incorporate a number of ground-breaking features designed to reduce project costs and installation times.

2www.duracomposites.com

Our Expertise in CompositesComposites have been around since the 1930s, and were first developed for use within boat hulls, plane fuselages and wings. Today’s composites are used in a wide range of solutions from bridges to oil rigs and water slides to drum sets, and the design possibilities are vast.

using materials such as concrete can require long possessions and Road Rail Vehicles are required for the transportation of associated materials. Even when concrete is used, there is still no easy solution to fixing the problem of stepping distances between the train and the platform when subsidence means they have become out of gauge.

Dura Composites entered the Rail Industry with an award-winning platform solution in 2014 - the patented GRP Dura Platform. Since then the Dura Composites offering has evolved to include a wide range of industry-approved product solutions for the Rail Industry.

Dura are recognised as innovators and in 2017 we were awarded a prestigious Queen’s Award for Enterprise in recognition of our success in growing, innovating and championing the use of composite materials across the globe.

One of the most popular emerging composites of the past 40 years has been Glass Reinforced Plastic (or GRP), which is a resin-based composite that’s reinforced with a glass fibre. By contrast, fibre-reinforced plastic (FRP) is a plastic-based composite that is reinforced with any type of fibre, not necessarily glass, so the difference between FRP and GRP is essentially the type of fibre used. Dura Composites has a proven track record in supplying innovative GRP solutions for key rail infrastructure projects across the globe and has a range of value added services that help our clients unlock the power of composites for their projects.

It’s been almost 30 years since the first GRP composites were installed as part of Britain’s transport network within bridge structures, but the composite material innovation that the industry has seen since then has been staggering.The market for composites is growing rapidly as Rail asset owners reap the benefits that a low-maintenance, lightweight, non-conductive and robust alternative to traditional materials can have on the modernisation of ageing infrastructures.

With over 4.7 million rail journeys made in the UK every day, the stations where people start and end their journeys are a key focus for improvements to the passenger experience. Changes to rolling stock require longer platforms, and Victorian platform installations require replacement or refurbishment as they reach the end of their service life after more than a century of heavy use. Traditionally, remedial works

ContentsValue Added Services 3-4

Rail Product Selection Process 5

PTI Compliance 6

Station Platforms 7-8

The Evolution of Dura Platform 9-10

Dura Platform 40 11-12

Dura Platform 100 13-14

Dura Platform Options 15-16

Associated Station Products 17-18

Dura Dagger Boards 19-20

Dura Wall Lining & Soffit Panels 20

Footbridges, Stair Treads 21-24 & Landings

End of Platform Gates, 25-27Fences & Steps

Mounted Tactile Surfaces 28& Wayfinding

Technical Information 29-34

Silver Street Station

Please Note: All colour swatches and textures shown in this document are intended as a representation only and should not be considered as an exact colour match. We would always recommend ordering a free colour sample so you can assess colour suitability before placing your order. Dura Composites’ manufacturing process results in a high level of colour consistency although some variation in colour may be apparent across products from different production batches.

Dura Composites’ GRP Rail solutions are available through stock holdings, saving you valuable time when you need to get product to site. Same Day Despatch applies to in-stock standard items of up to 200 panels, ordered before 11am Monday to Friday – so you can order one day and install the next!*

Full Rail product solutions such as Stair Treads and Landings, Platform (40 and 100), End of Platform Gate Systems (all modular components) and Ballast Retention Systems are available from

the Dura Composites stock holding. We have one of the largest stock holdings of GRP profiles in the industry, including Angle, Channel, Beam, Box and Tube sections.

As well as the standard range, Dura Composites GRP profiles for the rail industry can be produced in a vast number of dimensions and are available in five different resin systems depending on the application (subject to extended lead times).

Material Availability & Same Day Despatch

*Same Day Despatch available on core in-stock items that do not require cutting or fabrication. To qualify, orders must be below 200 panels and be received and processed by 11am Monday to Friday. The vast majority of the country is covered by next working day delivery. However, there are a few outlying areas where this may not be possible. Check for service availability to your postcode area.

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www.duracomposites.com

What you get when you work with Dura Composites:

and our in-house CAD and Structural Engineering team can be utilised both for stand-alone design and as part of larger integrated design scheme.

Whatever your scenario, you can be confident that we’ll help ensure your project will meet the load performance and specification needed, otherwise we won’t supply it!

see the spec in action as well as make amendments on the fly, reducing the time it takes to get it perfect.

Once the product is designed, our professional staff can cut it into life, using precision tooling to perform straight lines, complex cuts, routing – whatever you need.

STANDARDDrawing on 20+ years’ experience Dura’s cutting team can cut to a 3mm tolerance.

SPECIALISTAlternatively, if you require a more specialised cutting service our team can help. We aim to optimise cuts per panel to ensure yield and panels are used in the most efficient way.

ROUTINGWe can router holes suitable for lifting eyes or for other requirements as specified.

If you’re a designer in rail infrastructure, we can help support your design services across all phases of the rail project lifecycle by providing detailed technical specifications for our award-winning product range.

We have an extensive library of previous projects which are approved and installed throughout the rail network

When you’re looking for product to fit a space, it’s vitally important that it meets your specification. Dura Composites specialist cutting team offer a full range of services to ensure that our product meets your requirements. From inception to realisation, we’ve got you covered!

Our 2D, 3D, and 4-axis CAD team are the best people to help you get a first impression of how you can utilise our Dura Composites products.

With hyper-detailed sketches and designs of your build, you’ll be able to

Design Support

Cutting – Standard & Specialist

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Our Dura Composites BIM Objects allow Network Rail, contractors and specifiers to see up-to-date, accurate data about Dura Composites products and to easily incorporate them into their overall design. Authored to the trusted NBS standard, each BIM Object details the various surface finishes, profiles,

sizes and colour options for each product, and provides specifiers and end clients with detailed information on how the products will perform during their expected lifecycle.

For further information and to see our BIM Object range of products, visit:

www.nationalbimlibrary.com and search Dura Composites.

Our expertise ensures we offer unique solutions to the challenges that railway surveys unearth. The 3D Point Cloud Survey uses laser points to capture existing infrastructure, allowing a seamless integration when modeling old with new. It can be used to establish if planned components could subsequently cause issues for follow on works and can eliminate the need for expensive and inefficient site visits.

With budgets under ever increasing scrutiny, it’s never been more vital to ensure that the solutions provided to the rail industry are both future proof and have a measurable impact on efficiency.

Dura Composites now offer a series of training sessions for designers and contractors to understand the technical

capabilities and install methodology of Dura products in a supportive and engaging environment. We can cater training sessions specifically to the requirements of your project. For more information please speak to a member of the Rail team.

Dura Composites’ Free Rail Infrastructure CPD is part of the RIBA Core Curriculum in the category of Design, Construction and Technology.

BIM Objects

3D Point Cloud Survey

CPD Training

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Rail Product Selection ProcessWe have a systematic approach to lifecycle management and can provide a range of information to support your Rail project - from design, construction and operation through to maintenance and sustainable demolition.

1. Design

3. Maintenance

2. Construction

4. Demolition

We can help support your design services across all phases of the rail project lifecycle by providing detailed technical specifications for our award-winning product range.

No replacing, re-painting or repairing and little or no maintenance expenditures.

On-site installation support can be provided for projects to ensure first-hand knowledge is available to installers to ensure the project is delivered within the allocated possession time.

End of life product can bereturned to Dura Composites for re-purposing, subject to terms and conditions.


From the overall appearance of the entryway to the anti-slip nature of the platform edge, the materials used in and around a station have a direct impact on helping to guide passengers through the station safely and effectively.

There are many risk factors associated with the PTI, including:

PTI Compliance

The passenger-train interface (PTI) has been an area of increasing focus for those operating in the rail sector in the past few years. Over the last five years, PTI accidents on the mainline network have resulted in, on average, 1,354 minor injuries, 51.6 major injuries and 3 fatalities per year and have led to the railway developing a PTI strategy for improving safety risk, operational performance and accessibility.

Dura Composites’ strategy for improving the passenger train interface has been to create market-leading composite solutions for the rail industry which are designed to reduce incidents and accidents through clever features such as anti-slip surfaces and height adjustable capabilities, and which can be installed efficiently and cost effectively across the network.

One such example has been the introduction of Dura Platform to help solve the problem of stepping distance issues between the train and the platform, commonly identified by ‘Mind the Gap’ notices and announcements commonly

heard at rail stations. The UK mainline network has just over 2,500 stations with 6,000 platforms, many of which are Victorian and reaching the end of their lifecycle, but rebuilding thousands of legacy platforms to comply with the standards required new stations is simply not realistic.

Dura Platform allows contractors to replace or overlay onto damaged or subsided platforms a low maintenance, modular, lightweight, height adjustable structure that enhances safety with anti-slip surface options, in-built water management, integral lines, integral lighting, snow melting capability and that has similar or lower overall project costs than concrete. Utilising Dura Platform to reduce the gap to comply with current standards improves the passenger experience both through reducing injuries and reducing the length of time needed to board and alight trains.


Legacy platforms that do not conform to the current standard Varied Rolling Stock, stepping

distances and heights Crowding on platforms within

stations An ageing population Distractions – the increase in use

and dependency on technology Improper footwear Weather Disability access

AFTER

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BEFORE

BEFORE

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✔

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Roydon Railway Station

Tulse Hill Railway Station

Roydon Railway Station

Station Platforms

After over a century of heavy use, many of the UK’s concrete train station platforms now require replacement as they reach the end of their service life. Traditionally concrete has been used, but works can require long possessions and are costly.

Dura Platform 40 &100

Dura Platform is a breakthrough composite product which solves all of these challenges and more in record time! Made from Glass Reinforced Plastic (GRP) which complies with Network Rail specifications, our composite station platform offer significant improvements over traditional alternatives such as concrete. It has been described as “game changing” by industry insiders and has won multiple awards.

Dura Platform is an excellent choice for both new build and refurbishment projects and is fast becoming a viable rival for traditional materials such as concrete, steel and tarmac.

Dura Platform can span up to an industry-leading 3.2m clear span and is capable of being man-handled, eliminating the need for costly RRVs or heavy lifting equipment. Its hidden fixing system minimises trip hazards, and the platform is also crankable to create an instant 1:40 fall to manage drainage.

Our latest innovation for Dura Platform includes the option of a solid surface on the 600mm plank which removes the need for longitudinal cover plates to cover the fixings and provides a uniform, aesthetically pleasing finish.

7 www.duracomposites.comwww.duracomposites.com

Key Benefits of Dura Platform

Saves TimeAs Dura Platform can be installed rapidly by skilled contractors, it requires fewer possessions compared to a conventional re-build approach and allows for work to be carried out at difficult locations where a more

traditional approach would be prohibitive.

Saves MoneyThe overall outlay cost is less than a traditional

re-build approach, and adjustments can be made quickly and easily to suit the requirements of future

rolling stock.

Dramatically Improved LifecycleDura Platform has a design life in excess of 60 years, making it a truly futureproof solution. There are many clever features of the product that allow it to be tailored

to the site conditions.

Low MaintenanceNot only is the composite surface incredibly low-

maintenance, but additions such as the yellow tactile integrated with the platform edge have practically

eliminated the ongoing cost of platform edge painting.

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Dura Platform 40, Marsden StationCredit: Network Rail Media Centre

V1 V2 V3.1Year: 2013Tulse Hill Station

Year: 2014Elephant and Castle Station

Year: 2015Needham Market Station

Product: Dura Slab Light (Single Skin)

In Brief: New innovation, Dura Slab (light) with a 5mm top plate skin, used to increase panel length and speed up installation, allowing for a recessed tactile.

Product: Dura Slab (Double Skin)

In Brief: Double-skinned version of Dura Slab installed at Elephant and Castle Station to help solve major stepping distance issues between the trains and the platform.

Product: Dura Platform 100 (Pultruded)

In Brief: First pultruded Dura Platform 100 installed in a record breaking 36 hours.

BEFORE

AFTER

BEFORE

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BEFORE

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The Evolution of Dura Platform

V6

V4V3.2 V5

Year: 2019Silver Street Station

Year: 2016New Hythe Station

Year: 2016Chestfield & Swalecliffe Station

Year: 2016East Croydon Station

Product: New Dura Platform 40 Surface with fixing cams


In Brief: Dura Platform 40 improvements implemented on platform 1 and 2 at New Hythe Station replacing rotting timber with a full GRP modular system.


In Brief: Dura Platform 100 selected for its spanning capabilities, overcoming a challenging 3.5m span on an existing substructure within tight possession times on site.

Product: Dura Platform 40 (Integral Heating)

In Brief: This busy non-terminal station in Croydon (East Croydon) saw the launch of the first ever GRP platform with integrated heating and edge lighting resulting in vast improvement to the PTI in all weather conditions.

In Brief: New Dura Platform 40 with improved surface and discreet fixing cams, was selected to replace the decaying timber substructure and platform, due to its lightweight modular design.

BEFORE

AFTER

BEFORE

AFTER

BEFORE

AFTER

BEFORE AFTER


The Evolution of Dura PlatformNot all GRP Platforms are equal.

Here’s why we’re different...


Dura Platform 40New discreet cams to improve aesthetics

Dura Platform panels are designed to interlock to minimise independent panel deflection.

SUITABLE FOROVERLAYS &RE-GAUGING

With a span of 1.5m per 5kN/m2 UDL.

Dura Platform 40, Silver Street Station

Patent Application No GB 18 19754.1

Patent No GB 2 523 381

Dura Platform 40 is ideal for use in scenarios where the substructure can be adapted to suit 1.5m centres. The key benefits of Dura Platform 40 are the cost, weight, and modular install methodology advantage.

Please contact a Dura representative on 01255 440291.

Solid surface on the 600mm plank, which removes the need of the longitudinal cover plates that historically covered 75% of the fixings on the platform

A more uniform, aesthetically pleasing finish

Design life of 60+ years

Reduced on-site fabrication (75% less cover plates to bond on site)

Improved heating distribution (if required as a feature)

Improved fire performance, tested in accordance with Network Rail Fire Safety Standards

Cost effective pricing for customers, due to manufacturing efficiencies

Key Benefits

AFTER

Livingston South Station

Livingston South railway station is one of two railway stations serving Livingston in West Lothian, Scotland. It is located on the Shotts Line, 14 miles west of Edinburgh Waverley on the way to Glasgow Central.

Livingston South station has become the first station in Scotland to install the patented composite fibreglass platform system solution, known as Dura Platform.

This award-winning design is a precision engineered product manufactured by a pultrusion process which complies with Network Rail specifications and offers significant improvements over traditional alternatives – including a dramatic reduction in possession time and sizeable overall project cost savings.

Dura Platform has been used to install over 12,000 sqm of platform since 2014, demonstrating its sustainability.

WHY DURA PLATFORM 40?Dura Platform 40 is suitable to enable the re-gauging of existing platforms to meet PTI requirements by overlaying onto existing structures, or for extension and refurbishment of steel and concrete trestle systems. This innovative modular system is an approved product on Network Rails infrastructure list and meets specifications for composite platforms – spanning up to 1.5m.

This product was selected due to the fact it can be moved into position without heavy equipment, reducing cost and overall installation time.


As part of Network Rail’s £3.5m redevelopment of Livingston South Station, the modular lightweight system of Dura Platform 40 was the perfect solution thanks to its rapid install capabilities. This meant that despite just a 10-day blockade both platforms were demolished and replaced, delivering a wider platform and extension by 28m. Dura Platform’s non-conductive surface contributed to the platform compliance for the electrification of the railway and new 6 carriage trains that will be introduced on the route.

BEFORE

PTIFriendly

Four ManLift

MinimalPassengerDisruption

Concealed Fixings

Non Sparking

Dura Platform 40 - Case Study


Dura Platform 100Exceeds 33 minute burn time as specified by BS476 Part 20 and 21 (1985). With a span of 3.2m per 5kN/m2 UDL.

New discreet cams to improve aesthetics

Dura Platform 100 at Needham Market Station

Dura Platform 100 is ideal for use in Station scenarios where the substructure cannot be altered and the requirement is to span up to 3.2m within the 5kN/m2 loading.

Solid surface on the 600mm plank, which removes the need of the longitudinal cover plates that historically covered 75% of the fixings on the platform

A more uniform, aesthetically pleasing finish

Design life of 60+ years

Reduced on-site fabrication (75% less cover plates to bond on site)

Improved heating distribution (if required as a feature)

Improved fire performance, tested in accordance with Network Rail Fire Safety Standards

Cost effective pricing for customers, due to manufacturing efficiencies

Dura Platform panels are designed to interlock to minimise independent panel deflection.


SUITABLE FORNEW BUILDS &EXTENSIONS

Key Benefits


Patent No GB 2 523 381

AFTER

BEFORE

Needham Market

The radical award-winning Dura Platform design is a precision engineered GRP product manufactured by pultrusion process which complies with National Rail specifications and offers significant improvements over traditional alternatives – including a dramatic reduction in possession time and sizeable overall project cost savings.

WHY DURA PLATFORM 100?Dura Platform has a host of revolutionary features and allows contractors to replace or overlay onto damaged or subsided platforms a low maintenance, modular, lightweight, height adjustable structure that enhances safety with anti-slip surface options, in-built water management, integral lines, optional integral lighting and snow melting capability, all with similar or lower overall project costs than concrete.

Commenting on the installation of Dura Platform at Needham Market, which took just 36 hours, Simone Bailey, Asset Management Director at Greater Anglia said;

“We are always looking to improve stations for the customers and communities we serve. This innovative approach delivers a better platform for passengers, which is durable, more cost effective and quicker and easier to install”.

Needham Market is a railway station situated in the East of England, operated by Greater Anglia. In spring of 2015, the previous concrete platform at Platform 2 was replaced with a new composite fibreglass platform solution known as Dura Platform.


SavesTime

SavesMoney

MinimalPassengerDisruption

Concealed Fixings

Non Sparking

Dura Platform 100 - Case Study

“


There are a range of options which can be specified for both Dura Platform 40 and 100, such as fully integrated tactile recesses, illumination of the coper and integrated heating to remove frost & ice build up.

Dura Platform Options

Lighting and integrated system to remove frost and ice build-up at East Croydon Station

Image courtesy of Hammond (ecs) ltd

Available in both single or double lighting strips in white, blue or other colours, the Dura Platform LEDs present no trip hazard. Safe and visible, the LED strips are low maintenance, have low overall running costs and have an instant aesthetic impact, making platforms appear lighter and brighter.

Lighting Options


Snow and ice can cause serious problems for the railways. Drifting snow from platforms and embankments can coat the electrified rail, preventing trains from drawing power and blocking lines and snow and ice on platforms can delay passengers and cause painful trips and falls.

Traditional methods of snow and ice removal by station operators such as manual sweeping and salting or chemical de-icing are labour-intensive,

have limited effectiveness and cause accelerated corrosion and deterioration of the platform and support structures.

Dura Platform can be specified with an integral heating system to keep platforms free of snow and ice in extreme weather conditions.

Dura Composites’ innovative Platform Heating System removes the need for cost-intensive snow and ice clearing, whilst at the same time increasing platform safety for station users.

Dura Platform has been developed with an extremely hard wearing anti-slip finish as standard, in an attractive dark grey colour which suits all station environments. The surface is easy to maintain and over-achieves on Network Rails anti-slip specification in both wet and dry conditions. To discuss alternative surface options please contact your Dura representative.

Dura Composites trash and debris screens can be easily added to help reduce debris build up under the platform structure which could become a fire hazard.

Made from our high strength, but low weight Dura Grating and Dura Profile, they are suitable for both new build and platform refurbishments, and also help assist with rodent control.

Heating Options

Surface Treatments

Trash/Debris Screens

Debris Screens at Needham Market Station

Dura Platform’s integral heating system melts snow and ice in minutes

Associated Station Products

Dura Composites combines a deep understanding of the needs of the Rail industry with years of design innovation and product development expertise to provide an unrivalled passenger experience.

Dagger Boards, Pedestrian Footbridges, Stair Treads, Landings, End of Platform Gates, Fences and Steps

Our ancillary station products include lightweight, durable composite dagger boards, which achieve EN13501 Class B - s1 d0 fire rating.

We also design and supply award winning footbridge treads and landings, end of platform gates and fencing. Read on to discover more...

17 www.duracomposites.comwww.duracomposites.com

Key Benefits of our Station Products

Saving TimeLow weight for fast construction in time tight projects,

easy to man handle and move on site, don’t need heavy lifting equipment.

StrengthPound for pound stronger than steel, wood and

aluminium, and will not shear. Under weight it will deflect, so understanding load requirements is key.

Dramatically Improved LifecycleOur accessories are able to survive, especially

in harsh environments, will not rust orrot or react to air born chemicals.

Low MaintenanceNot only is the composite surface itself incredibly low-

maintenance, but it does not need to be painted, or treated yearly.

Fire ResistantOur composite product solutions are manufactured to meet or exceed the Fire Safety Standards set by

Network Rail, depending on the location of the product in a station environment (structural or non-structural).

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Dura Composites’ composite dagger boards are the ideal replacement material for timber in railway station canopy fascias.

Made from durable composite material with a Class B fire rating in accordance with BS EN 13501, Dura Composites Dagger Boards mimic the appearance of traditional wooden valance boards but are simple to install and require virtually no maintenance over their 50 year design life.

Dagger boards have been common at UK stations since the late 1850s, and primarily served the practical function of removing water from the canopy and reducing weather-inflicted damage such as rot, thereby preventing deterioration of the canopy itself. In addition to their practical functions, daggerboards were recognised as having positive decorative and aesthetic qualities and were produced in a range of intricate designs.

However they are traditionally made from timber which requires extensive maintenance due to weathering, which can cause considerable disruption to passengers

and station operators as rotten or warped boards normally need replacing in situ – leading to station platform closures.

Dura Composites can help you Unlock the Power of Composites for your station canopy or fascia project. Dura Dagger Boards come in a range of attractive profiles, all of which are non-conductive and require minimal maintenance over their long lifecycle – eliminating the need for repainting or replacing damaged or rotted sections at height and saving time and money on site.

Dura Dagger Boards

FastInstall

LowMaintenance

Lightweight


Dura Composites’ 19mm composite dagger boards mimic the appearance of traditional timber valance boards, but are lighter, simpler to install and require virtually no maintenance over their long design life.

Utilising the same composite material design as our market-leading station platform Dura Dagger Boards, the panels have an attractive woodgrain effect finish which mimics traditional timber detailing but is more robust and requires significantly less maintenance over time.

Our patent pending design achieves a market-leading fire rating of B-s1,d0 in accordance with European Standards EN-13501-1 and provides both decorative and functional benefits. The

shaping of the boards helps to keep passengers dry whilst

maintaining natural light and ventilation within the canopy.

Our footbridge cladding and canopy soffit panels combine strength, durability and minimal maintenance allowing them to be used in a variety of station footbridge or platform applications either externally or internally as attractive panelling, soffits and fascias.

The composite panels are incredibly lightweight and meet the requirements of BS EN 13501, allowing for footbridge parapets to be enclosed with less risk to passengers thanks to the Class B fire rating.

Dura Wall Lining & Soffit Panels are ideally suited to modular footbridge designs with differing span arrangements that can be modified for each unique location.

The material can also be used to replace worn timber soffit details under station canopies to give a modern clean look to the canopy whilst concealing the unsightly structure underneath. The lower weight nature of the composite means that panels can be quickly and easily removed if the substructure requires inspection or remedial works.

Dura Dagger Boards

Dura Wall Lining & Soffit Panels

Station Exterior & Platform Canopies

Station Footbridge Walls & Ceilings

BS 476 Part 7

Class 1

ACHIEVES B-s1, d0 IN

ACCORDANCE WITH

EN - 13501


Attractive, woodgrain finish without the maintenance

Patent Application No. GB 19 05176.2 Top and middle trims

BEFORE: Timber footbridge cladding

panels in need of repair

AFTER: All the look of wood, but none of the maintenance


Overlay solutions with gritted plate covers on to timber are not a safe and long lasting solution, accelerating the degradation of the timber substructure which is dangerous for both the public and maintenance staff. Dura’s structural stair tread solutions offer a safe and viable alternative with a design life of 60+ years!

Pedestrian Footbridges, Stair Treads & Landings


Dura Composites offer newly developed full systems to speed up install times and reduce costs, possessions and bridge closures, thereby limiting disruption to end users. The Dura systems made from GRP are lightweight, high strength, anti-slip, non-corrosive and non-conductive and overcome all of the problems normally associated with the use of traditional materials such as wood, steel and concrete.

Where previous composite treads on the market have been limited in span capabilities, Dura Composites has the ability to span up to 2.1m clear open span, achieving the required 5kN/m2 at L/300 deflection and meaning that additional supports can be avoided in most scenarios.

The NEW Dura Slab Structural Stair Tread design can be specified with built-in risers, speeding up the install process whilst increasing safety, particularly in scenarios where bridge treads are located near overhead lines or are replacing open risers.

Also included is a very slight fall to assist in the prevention of water pooling which can lead to problems with ice in the winter months. No heavy lifting equipment is needed as all panels can be easily manhandled even in full stock lengths. *For cut orders, please contact our sales team.

Dura Slab Structural Stair Treads

Temporary Solution: Previous Dura Dura Slab Timber Treads Solution Moulded Structural Treads with Covers Grating & Plate & Landings (Now Obsolete)

GRP Materials & Delivery £3,850 £23,500 £18,950

Plate to close rise mats/labour £2,000 £2,000 Not required

Adhesives / Fixings £1,500 £1,500 £250

New Timber treads/landing £11,999 - Not required

Approx. Install Cost £29,000 £29,000 £29,000

NR Fire rating approval BS 476 No No YesPart 7 Class 1 & Part 20 & 21

Supplied by Dura Composites Yes No Yes

Lead Time from Point of Order 3-5 days Unknown 2-3 days (if in stock)*

Up to a 25 Year Warranty with Dura No No YesComposites, with a 60+ year Design life

TOTALS £48,349 £56,000 £47,950


PROS: Single unit construction with no

maintenance required. Structural anti-slip solution designed for the long term.

CONS: Contractor may have limited experience

with GRP.

PROS: Quick non-structural fix for individual damaged treads

CONS: Bonded surface will lift within a short time frame and limited footfall, so will require remedial

work & maintenance

PROS: Timber is readily available

CONS: Requires regular maintenance and costly

refurbishment

Pros & cons of various approaches:

How Dura Slab Structural Stair Treads Stack Up

Against the Competition:Example of a footbridge refurbishment featuring 50 Treads and 3 Landing Areas

HIGHSTRENGTH

& ANTI-SLIPSURFACE

ACHIEVES BS 476 PART 7

CLASS 1



The Dura Slab Structural Stair Tread finishes flush against the Dura Slab Structural Landing

Dura Slab Structural Landings Working in conjunction with the NEW Dura Slab Structural Treads, Dura Composites offer landing panels which can span up to 2m clear span (50mm thick option), achieving 5kN/m2 at L/300 deflection or up to 3.2m (using the 100mm option). Both reduce or eliminate the need for additional supports to break spans down, providing huge advantages over other composite solutions on the market.

Dura Slab Structural Landings are designed as a modular system, allowing the contractor huge flexibility both at the design stage and on site.

The anti-slip surface caters for all types of footwear and so is ideal for passenger environments.

The need for less or no alterations to the sub structure also dramatically reduces the install time, number of possessions and overall disruption to the end user.

Again, no heavy lifting equipment is needed as all panels can be easily manhandled even in full stock lengths.


HIGHSTRENGTH

& ANTI-SLIPSURFACE

ACHIEVES BS 476 PART 7

CLASS 1

Dura Slab Structural Stair Tread Dura Slab Structural Landing

AFTER

Great Bentley Station

IN BRIEFThe footbridge at the station was badly in need of refurbishment due to dangerous rotting wooden stair treads. Working in partnership with Greater Anglia, the team at Dura Composites developed the award-winning Dura Slab Structural Stair Tread and Landings which are made from high-strength Glass Reinforced Plastic (GRP) and incorporate a number of ground-breaking features designed to reduce project costs and installation times.

The refurbishment work at Great Bentley comprised bridge deck and tread replacements over the full span of the bridge, and the treads and landings were easily fixed into position thanks to their single unit construction.

Notable details include a built-in riser for rapid installation and an in-built fall to assist with drainage and reduce pooling on stair surfaces.

Commenting on the installation at Great Bentley, Simone Bailey Asset Management Director at Abellio Greater Anglia said;

“We are delighted with the results at Great Bentley which demonstrates our continued commitment to improving stations. The original footbridge featured 12- inch by 4-inch hardwood timber which was badly degraded.

Anti-slip covers had been applied as a temporary solution to prolong the life of the bridge, but this temporary fix simply accelerated the degradation of the timber beneath.

In working with Dura Composites to develop the 65mm Dura Slab Structural Stair Tread, we were able to employ a lightweight, durable, robust and easy to install anti-slip GRP composite solution which incorporated a built in fall to push water away from the steel structure underneath prolonging the life of the footbridge for passengers for many years to come.”

First opened in 1866, Great Bentley train station is on the Great Eastern Main Line in the East of England. The station has two platforms and is managed by Greater Anglia.

BEFORE

Dura Slab Structural Stair Treads - Case Study


Network Rail

Compliant

Fast Install Times

LowMaintenance

Anti-SlipSurface

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Dura Composites’ End of Platform gates and fencing have been developed as an alternative to steel due to their non-conductive properties, making them extremely suitable for electrified rail environments. Made from strong but lightweight GRP, they can be used for a wide range of station applications such as end of platform gates, platform perimeter fencing and screening of electrical works.

End of Platform Gates & Fences

Corrosion resistant Secure UV stable Lightweight Non Conductive Long Lasting

No painting, staining or maintenance Meets safety standards Retains colour and strength Easy to assemble and transport Suitable for use in high voltage areas 25 Year Warranty / +60yr Life Span

Railway car parks Pedestrian walkways Increase parapet heights End Gates for platforms Screening for electrical cabinets Litter guards

Applications Features Benefits


We can supply self-closing gates to complement our handrail systems. Gates are provided with spring assembly and can be hinged to an adjoining handrail stanchion or bolted to a suitable fixing plate.

Weighing up to 80% less than steel and 30% less than aluminium, they offer equivalent performance for considerably less weight.

This results in major savings including lower installation costs due to more economical transportation, handling and on-site positioning.

As well as fully fabricated non-corrosive and non-conductive single unit GRP end of platform steps we can also supply in component or flat pack kit form ready for quick assembly on-site.

TruClose Hinges

Dura Profile WFB

Dura Grating 13mm Standard

8mm floorclearance to allow for foot plate.

HIGHSTRENGTH

& ANTI-SLIPSURFACE

Our end-of-platform steps are made from high strength, GRP pultruded sections and are a lightweight solution which can be installed rapidly to keep the station operating smoothly.

End of Platform Steps

Balfour Beatty Rail

One area in which Dura Composites has been instrumental in helping deliver safety improvements is in the design and supply of GRP fencing, end of platform gates and anti-trespass guards to stop members of the public accessing the operational train line from the station.

In 2018, Dura Composites was approached by Balfour Beatty Rail who had been contracted by Network Rail to design and build the end of platform gates at 41 stations across Surrey and the south of England.

Although a basic design had been conceived, no detailed site surveys had been conducted. On viewing the proposed design, the Dura Composites Rail Team saw some major opportunities for design and material improvements that would help drive efficiencies and improve safety for those working on the railway and ultimately the travelling public.

Working with Alexandre Polícia, Senior Engineer at Balfour Beatty, the Dura Composites Structural Engineering and CAD team devised a new modular design utilising our market-leading GRP Dura

Profile and Dura Grating components that not only exceeded the required specified crowd loading requirements, but that also was not dependent on individual site survey reports from each station location which would have slowed down deployment and installation.

All Dura Composites Rail product designs take into account the entire asset lifecycle, from design, construction and installation through to renewal and disposal, thanks to the level of detailed information that Dura Composites is able to provide about its GRP product range.

A new station or a major refurbishment provides an opportunity to incorporate best practice into the station design – and Dura Composites is proud to have played a key role in improving safety measures over the past five years since establishing itself as a key part of the rail supply chain by working directly with clients right across the supply chain.

End of Platform Gates & Fencing - Case Study


“

Commenting on their experience, Alexandre Polícia, Senior Engineer at Balfour Beatty

“Dura Composites’ robust End of Platform Gate and Fencing was devised with speed of production and installation in mind and far exceeded our expectations. Dura Composites were helpful and professional, delivering an enhanced designed that was far more appropriate for the project than the initial design and that was fabricated and delivered on time and to the agreed budget. We won’t hesitate in coming to Dura Composites to deploy this new design for future station projects”.


Dura Composites recommends the market leading tactile solution from Viztek Ltd. Viztek are the only company in the UK that both manufacture and install surface mounted tactile paving, providing a one stop shop. When combined with Dura Composites’ platform, footbridge and walkway products, the tactiles offer an ideal solution for navigation and disability routes.

Mounted Tactile Surface and Wayfinding


Tactiles, with their raised dots or stripes, provide both warning and information to vision-impaired people to help make the station environment more accessible. They provide a good contrast in colour with the surrounding flooring area to assist visually impaired people to understand that they should proceed with caution.

“Key Benefits High Slip Resistance Levels Speedy Installation 10-15 Year Design Life No Noise Pollution During Installation No Mechanical Fixings Hard Wearing Recycled Materials Rail Approved

“Our innovative surface mounted tactile products work seamlessly with composite GRP solutions such as the Dura Platform to create a safe, visible and cost-effective navigation aid”.

Chris Elliott - Managing Director


Technical InformationDura Composites has invested heavily in real world testing for your peace of mind. We believe that decisions on which composite products to use for your specific rail project scenarios should be based on facts - not guesses or theories. We provide a raft of technical information to help ensure maximum safety for your rail infrastructure project. Please contact your Dura Representative on +44 1255 440291 for more information. Dura Platform 100,

Needham Market Station

Dura ‘s Product time



Network Rail standard time



Dura Station Platform

Type 40 &100

Dura Structural Stair Tread

Type 50, Dark Grey

Dura Footbridge/ Dura Slab

Type 50, Dark Grey

33 mins 33 mins

47 mins

20 mins 20 mins 20 mins

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165mm

105mm Dura Composites

Test Result

455mm 710mm

Non-Structural Materials

Dura Slab Stair Tread Covers

Dura Grating

Dura Handrailing

Dura Embankment Staircases

Dura Fencing

Structural Materials

Station PlatformType 40 and 100

Dura Slab Type 50, Dark Grey

Dura Slab Stair Tread 65

CLASS 1 CLASS 2 CLASS 3 CLASS 4

OtherManufacturers

Exceeds TestLimits for

Classification

Fire Safety StandardsNetwork Rail projects are obligated to use products that meet British and European Fire Safety Standards. Dura Composites is a supplier of composite products for the rail industry, meeting or exceeding the Fire Safety Standards set by Network Rail.

Flame Spread Test

BS476-7, Class:

Method of test to determine the classification of the surface spread of flame of products.

Burn Time & Load Bearing TestingBS476 20/21:

Method for determining the fire resistance and load bearing strength of an element.

When selecting materials for a rail project, it is important to understand how fire performance standards work and what they mean for your rail project.


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Fire Safety Compliancy Guide for Structural Materials (Evacuation Route)

Network Rail TQ-51_R - Appendix A: Specification & Testing Requirements for GRP (Glass Reinforced Plastic).

Rail Application Compliant Network Rail Installed BS476-7 Class 1 BS EN 13501 BS476-20/21 (Asset Type/System) Dura Products Example / EN13501 B, s2, d0 (Note-2 ,3 ,4)

BS EN 13501: European harmonised

test, taking into consideration:

combustibility, smoke production, flaming droplets or particles, burn time and flame

spread.

Load bearing and structural station materials that may form an evacuation route in a railway station.

Compliancy tests for composite products used on Network Rail Stations Flame Spread Classification Test Burn Time Testing

Industry Standard - For Fire ResistanceFire Safety Tests - UK & European Recognised

RIS 7700 INS (Note-1)

Applicable Network Rail Specification / Standard

BS476-7 Class 1: Vertical test method

for solid plates, measuring the

travelling distance of the burn down the length of the plate.

BS476-20: Method for determining the fire resistance of

an element

BS476-21: Method for testing the fire

resistance of a load bearing element

Platform -Composite Overlays

Platform - Composite

Overlays Free Spanning

Footbridges -Bridge Deck

Dura Platform

Dura Platform

Dura Slab

Dura Structural Stair Treads

Footbridges / Stairs -

Structural Stair Treads & Risers

Notes (applies to both tables)

Notes 1 - RIS 7700 INS requires that material should be non-combustible where practicable and perform no worse than existing material. Building regulation requirement defines combustible and non-combustible material. For platforms it is agreed that Steel,Tarmac and Concrete is non-combustible. It does not add to the fire load.

Notes 2 - The acceptance criteria shall be minimum 20 minutes with BS476 20/21 test conditions (i.e. Test loading, Temperature and Deflections etc).

Notes 3 - Indicative test with actual test loading and deflection criteria as per BS476-20/21 may be acceptable with Network Rail Fire

Engineer’s written approval. This situation might arise when the test takes place in a smaller furnace (& not 4m x 3m as required by BS476 20/21). For example for platform overlays maximum span might be limited to 1500mm.

Notes 4 - T est loading shall be defined by the designer in accordance with respective Network Rail standards. Refer Appendix B of Form A :- Modular Platform System - GRP

Notes 5 - For roof application other than walkway access the Fire Engineer must be consulted for further instructions.

RIS 7700 INS


Fire Safety Compliancy Guide for Structural Materials (Non-Evacuation Route)

Network Rail TQ-51_R - Appendix A: Specification & Testing Requirements for GRP (Glass Reinforced Plastic).

Rail Application Compliant Network Rail BS EN 13501 (Asset Type/System) Dura Products Installed Example B, s2, d0

BS EN 13501: European harmonised test, taking into

consideration: combustibility, smoke production, flaming droplets or particles, burn

time and flame spread.

Non structural station materials that do not usually form part of a platform evacuation route in a railway station.

Compliancy tests for composite products used on Network Rail Stations Flame Spread Strength Test RIS 7700 INS (Note-1)

Fire Safety Tests - UK & European Recognised Applicable Network Rail Specification / Standard

BS476-7 Class 2: Vertical test method for solid plates,

measuring the travelling distance of the burn down

the length of plate.

Public Evacuation / Non Public - Embankment

Staircase StructuralStair Treads

Dura Slab Stair Tread Covers

Dura Grating

Dura Handrailing

Dura Grating

Dura Grating

Dura Fencing

Dura Embankment Staircases

Fencing

DaggerBoard

Footbridges / Stairs -Stair Tread & Nosing Covers ✔

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Non-Public Roof Walkways / Canopies

/ Walkways

Handrail(Public &

Non-Public)

Public /Non-Public - Grating

Non-Public TracksideWalkways

BS 476 Part 7 Class 2

BS 476 Part 7 Class 1

RIS 7700 INS (Note-1)


Dura Composites conducts live load testing in conjunction with theoretical data modelling using state-of-the-art software and hardware to ensure the longest possible lifecycle.

Load Performance

Achieves a clear span of 3200mm with a 5kN UDL at L/300 deflection.Weight per m2 = 50.45kgs Approx. m2

Achieves a clear span of 1500mm with a 5kN UDL at L/300 deflection.Weight per m2 = 35.55kgs / Approx. m2

Platform 100

Demonstration of theoretical data

modelling

Platform 40


The 4s rubber slider test imitates the heel of a shoe or foot to determine the level of slip resistance. The 4s slider test method is specially designed to replicate everyday

footwear across a surface. The four S’s stands for:

The 4s slider test should not be confused with the pendulum 5s slider or TRL (Transport Road Laboratory) test, which is designed for testing slip resistance on a roading surface.

The results gained from a 5s slider/TRL test are significantly higher than the 4s slider test. The 4s slider test can be relied upon in a court of law where a personal injury claim may have been made. This test measures the floors slip resistance values against the recommended health and safety minimum value of ‘36’ and proves to insurance companies, slip accident claimants (genuine or fraudulent), and personal injury lawyers, that a safe floor environment has been provided.

Slip ResistanceDura Platform (40 and 100) achieves above a 55PVT value in both wet and dry conditions.

4S Slider Explained

STANDARD4S = SHOE SOLE SIMULATOR

Anti-Slip Resistance

UV Fade ResistanceDura Composites conducted an accelerated 5000 hour UV weathering test, to ensure the product is suitable for harsh UV environments in terms of load

performance and colour stability.

May 2020

Head Office

Dura Composites LtdDura House, Telford RoadClacton On SeaEssex, CO15 4LPUnited Kingdom

Tel: +44 (0)1255 440291Email: [email protected]

www.duracomposites.com

Rail

Due to our policy of continual improvement we reserve the right to change specifications at all times without prior notice.

© 2019 Dura Composites

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