New all-in-one solution offers fire protection for more sustainable rail parts
Scott Bader and SAERTEX have developed composite technologies capable of a 40% weight reduction versus steel train panels. In certain use cases the resulting systems are also shown to reduce the carbon footprint of parts by 77%[1].
Working together to meet rail OEMs’ environmental needs, while delivering enhanced passenger safety, the exploration of multi-material solutions has led to Crestafire LEO – a fully characterised suite of composite systems suitable for application by a closed mould process to make a wide variety of interior and exterior parts, from flooring through to front-ends.
“Combining Scott Bader’s fire safety expertise with SAERTEX’s specialism in mechanical performance has enabled us to devise new and improved ways to arrive at lighter, more efficient, environmentally desirable and exceptionally safe alternatives to metal and hand-laminated components,” explains Elena Romanova, Global Market Manager for Land Transport at Scott Bader.
“From roofs and side panels through to more complex shapes to fabricate, such as the pilot, Crestafire LEO’s combination of gelcoat, resin, reinforcement and core materials balances cost, structural performance and weight reduction concerns. Usually, it’s more challenging to meet fire safety standards with thinner components – especially when paint is applied – but this system is proven to pass the most stringent of standards and, coupled with its mechanical properties, is highly viable for other modes of land transportation too.”
The Crestafire LEO system comprises Scott Baser’s Crestafire resins and gelcoats infused with SAERTEX’s glass non-crimp fabrics (NCF) to deliver optimum performance. Significant weight savings are achieved because bringing these into an all-in-one solution leads to an 85% reduction in resin consumption, compared to hand layup processes. Ongoing research and development is now focused on achieving similar performance levels when combined with Scott Bader’s 100% bio-based resin, which is already being implemented for semi-structural uses, such as rail flooring.
“Each manufacturer has different requirements and each part of the train demands a certain profile in terms of thickness and mechanical properties. What we can provide is proof of concept that gives those involved in train construction confidence that our combined solutions can withstand the most demanding conditions,” says Steven Bakker, Commercial Director at SAERTEX.
“What’s more, having done some of that necessary groundwork ourselves we can be part of fast-tracking innovation by enabling technical teams to focus on implementing materials that are proven to work together, rather than finding complementary solutions to put to the test.”
Crestafire LEO Systems meet Europe’s EN45545-2 HL3 standards for fire, smoke and toxicity (FST) for the infusion of structural composites, as well as interior and exterior rail parts and front-ends.
Scott Bader and Saertex will be hosting a webinar covering Crestafire LEO systems and practical applications of proven solutions from rail OEMs and Tier 1 suppliers. Further updates to follow.
[1] Source: DACOMAT project indicates GWP of VE-Resin 5,97 kgCO2/kg* and Glass fabric 2,16 kgCO2/kg*
