Rail-ready composites

What looks like a three-dimensional, single-cast component on the sides of trams from the Flexity range from Bombardier, consists of pultruded GRP elements with glued-on end caps, which have been milled, glued, primed and painted. Optionally, the 656 mm wide roof panel can also be manufactured with a glued-on bracket. It has fire protection in accordance with NF F 16-101 and DIN 5510. For new projects, we also meet fire protection requirements in accordance with EN 45545.

Bombardier designed the M5000 tram as a high-floor tram specially for use in Manchester. The spoiler consists of a solid stainless steel frame with a glued-on GRP profile. The profile was milled on modern CNC machines at TC, glued to the frame, primed and painted with a special 2K-PUR metallic paint. It is manufactured in different lengths and designs. It has fire protection in accordance with BS 6853. For new projects, we meet fire protection requirements in accordance with EN 45545.

The high-capacity, double-decker local trains developed by Siemens are fitted with an interior deck system from TC. All of the components – middle deck, low-floor and high-floor haunches, inner side deck and cold air duct – are based on GRP pultruded profiles.

TC supplied side panel casing components for the TALENT local train, manufactured by Bombardier Transportation in Talbot. These components were manufactured on the basis of nine different pultruded profiles. All of the components – the GRP profiles and other components made of SMC pressed parts, EPDM covers, stainless steel and aluminium components – were designed, machined and bonded together at TC. This meant that the customer was supplied with ready-to-paint finished parts.

The various systems are based on pultruded profiles made of glass fibre-reinforced plastic produced by Exel Composites in Belgium. For the air ducting system, the fire protection properties of the GRP profiles were set in such a way as to meet the requirements in accordance with EN 45545.

Following the development of the interior deck system for the Desiro ML Mittelrheinbahn and the Desiro ML Brüssel at TC and its subsequent delivery, the interior deck system for the Desiro ÖBB is now being manufactured at TC. The various systems are based on pultruded profiles made of glass fibre-reinforced plastic produced by Exel Composites in Belgium.

Having developed and manufactured the airflow system for the Desiro ML Mittelrheinbahn and the Desiro ML Brussels, TC is now also producing the airflow system for the Desiro ÖBB. The respective systems are based on pultruded profiles made of fibre glass-reinforced plastic. For the air ducting system, the fire protection properties of the GRP profiles were set in such a way as to meet the requirements in accordance with EN 45545.

For the Sprinter Lighttrain made by Bombardier, stainless steel sliding blocks were glued into the GRP profiles (A2 bonding) for high rigidity. Vertical tear resistance of 2,772 N was required for every single adhesive bond. This requirement was far surpassed in practice.

The roof panel, which has the appearance of a 3-dimensional component from a single cast, consists of pultruded GRP profiles and 3D moulded parts, partly combined with stainless steel components. 3D-printed components may also be used.