26
BY: HILMAR BACKER FIRE PROTECTION OF ROLLING STOCK 2015 18-19 MARCH 2015 A JOURNEY OF COMBINING FIRE SAFETY AND DESIGN CRITERIA FOR ENGINEERING THERMOPLASTICS FOR RAILWAY INTERIORS
BY: HILMAR BACKER
October 2013
BY: HILMAR BACKER
FIRE PROTECTION OF ROLLING STOCK 2015
18-19 MARCH 2015
A JOURNEY OF COMBINING FIRE SAFETY AND DESIGN CRITERIA FOR ENGINEERING THERMOPLASTICS FOR RAILWAY INTERIORS
No. 1
CONTENT
ABOUT SABIC
INTRODUCTION
CASE STUDY: SEATING
CASE STUDY: LIGHTING
CASE STUDY: SIDE-WALL CLADDING
NEW SABIC DEVELOPMENTS
No. 2
We are one of the world’s leading manufacturers of chemicals, fertilizers, plastics, and
metals. Since our founding in 1976, we have achieved rapid global growth.
• 2nd largest global diversified chemical company*
• 88th largest public company in the world*
• $ 50.4 billion Sales Revenues in 2013
• $ 90.4 billion Total Assets in 2013
WE ARE SABIC
* Forbes 2012
STRATEGIC
BUSINESS UNITS:
• CHEMICALS
• PERFORMANCE CHEMICALS
• METALS
• FERTILIZERS
• POLYMERS
• INNOVATIVE PLASTICS
6
No. 3
Luggage racks
Transparent doors
and deviders
RAILWAY INTERIORS
Side-Walls / Ceilings
Anti-Grafitti
interiors panelsRail seat cover parts
Air-Ducting
Rail seats
Railway Lighting
Cable Trunking
Railway Connectors
Picture Source: All pictures used with customer permission
No. 4
NEW TECHNOLOGIES
Polymer
Functionalization
through additives
Filled FR
Polymer blends
LEXAN™ co-polymers
PRODUCT/PROCESS TECHNOLOGY
Fu
nctio
na
lity
Addition of new building blocks
yields PC co-polymer resins with
new properties
No. 5
NEW TECHNOLOGIES
NEW LEXAN™ CO-POLYMERS : • Stable and compact char formation
• Leading to very robust Heat release
and Smoke density results! (HL3)
STD. FR POLYCARBONATE OR
FR PC/ABS: • Loose & unstable char,
• Failing in Heat release & Smoke Density
NEW MINERAL FILLED FR PC/ABS: • More stable char formation,
• Improved HRR & Smoke density (HL2)
No. 6
SELECTING MATERIALS
Plastics FRP Metal
Cost + - + - + -
Noise Reduction + + + + - -
Design + + + -
Design complexity + + + -
In-colored (no paint) + + + - - -
Easy replacable + - +
Durability + + - + +
Safety + - + - + -
Regulation + - + + +
Customization + - + + + +
Repairability + - - +
Depends by application and specific material use.
No. 7
EXPERT TECHNICAL ASSISTANCE:
OUR SERVICE EXCELLENCE
Part design
Assembly design
Tooling design
Process design
Chemical compatibility data/testing
Adhesive selection and testing
Product development, specialized needs
Weathering testing/color technology support
Physical property testing/temperature extremes
Regrind analysis
Thermo-cycle testing
FEA support
Product/process development lab
Design, Development, Testing and Processing Support
CASE STUDY: SEATING
No. 9
MATERIAL DEVELOPMENT OF LEXANTM FST3403 RESIN
Final Part Mold Flow
Railway Regulation Co-Polymer Development
DOE‘s on burning behavior
In-house Fire TestingGrammer ICE-seating
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EN45545-2:2013
Picture Source: All pictures used with customer permission
No. 10
VALIDATION BY CUSTOMERS
Ease of installation Mechanical testing
Railway RegulationCo-Polymer Development
Engineering Design
Fire Testing
Final Part
Bombardier Mono-Rail
Mechanical requirements
Picture Source: All pictures used with customer permission
No. 11
ART TO PART EXAMPLE – RAILWAY SEAT
CUSTOMER CHALLENGE
• Bombardier was looking for a fresh new seating design for the seat banks of Sao Paulo’s Innovia rail
system.
• They were interested in a lightweight solution that would increase passenger comfort, durability and
sustainability.
SABIC SUPPORT
• Design optimization – Montemeao was challenged to design for total cost of ownership
• Tool development assistance – tooling assistance was required to allow aesthetics
• Processing support – support was given to resolve any processing challenges
• Material certification – pass on Americas Railway standard NFPA-130
• Color recommendations – any color possible
• Static, dynamic and impact load testing – impact test and validation
CUSTOMER WINS
• A new, injection-molded seat the reduced manufacturing costs
• Up to 15% lighter, reducing CO2 emissions vs. thermoset processing
• End of life recyclability
• Ease of maintenance and replacement
Picture Source: All pictures used with customer permission
No. 12
RESULTS
Implementation at Bombardier Mono-Rail program in Sao Paolo
Picture Source: All pictures used with customer permission
No. 13
SABIC’S THERMOPLASTIC RESINS FOR THE RAILWAY SEATS
LEXAN
FST3403 Resin
CYCOLOY
CX7240 Resin
CYCOLOY
C6600 Resin
France NF F 16.101/102
Germany DIN-5510-2
France NF F 16.101/102
Germany DIN-5510-2
High Flow
EN45545-2 R6 / HL3
France NF F 16.101/102
Germany DIN-5510-2
Poland PN-K-02511
Americas NFPA-130
LEXAN
EXL9330 ResinFrance NF F 16.101/102
SA
BIC
RE
SIN
PO
RT
FO
LIO
LEXAN
FST3002 Resin
High Flow
EN 45545-2 R6 / HL2
NEW
PRODUCTS KEY FEATURES
OPAQUECYCOLOY™ PC/ABS
RESINS
LEXAN™ PC
RESINSOPAQUE
No. 14
LEXAN™ RESIN SOLUTIONS FROM SABIC
> LEXAN FST3002 RESIN
A PC COPOLYMER SOLUTION OFFERING:
> High-flow capabilities
> Easy design and production of large parts
> Consistent surfaces with no marks, grainage, stains or flow lines
> HL2 level of EN 45545 compliance for seating components such
as seat base and back shells and seating side panels
FOR INJECTION-MOLDED APPLICATIONS
NEW!EN 45545
COMPLIANT
R6 – HL2
CASE STUDY: LIGHTING
No. 16
VALIDATION WITH CUSTOMERS
Final Part by Elkamet
Customer validation
Railway Regulation Customer Needs Mapping
Mechanical behavior
EN45545 acc: class HL3-R4
Extrusion trials
• Transparency
• Diffusion
• Haze
• Transmission
• Etc.
Certification
Picture Source: All pictures used with customer permission
No. 17
SABIC’S THERMOPLASTICS FOR THE RAILWAY LIGHTING
EN45545-2 R4/HL3
NF F 16.101/102
DIN-5510-2
EN45545-2 R4 / HL3
SA
BIC
PO
RT
FO
LIO
PRODUCTS KEY FEATURES
EN45545-2 R4 /HL3
NF F 16.101/102
DIN-5510-2
LEXAN
2034 Resin
LEXAN
EX9332T Resin
LEXAN
FXD9332T Resin
NEWEXTRUSION
DIFFUSION
SATIN EFFECT
LEXAN™ PC
RESINS
EXTRUSION
TRANSPARENT
OPAL WHITE
EN45545-2 R4LEXAN
F2000 Sheet
EXTRUSION
TRANSPARENT
OPAL WHITE
LEXAN™ PC
SHEETS
No. 18
LEXAN™ RESIN SOLUTIONS FROM SABIC
> LEXAN FXD9332T and LEXAN EX9332T RESINS
COMPLIANT MATERAIL SOLUTIONS WITH EN 45545 AND
THE EU BUS STANDARD EU 95/28/EG.
> LEXAN FXD9332T is a new diffusive resin suitable for
creating covers for LED light sources as its inherent satin-
like surface texture helps to scatter light and eliminate hot
spots. The material is well suited to be used in profile
extrusion.
> LEXAN EX9332T is a transparent resin that offers high
transmission of 89% over a wavelength of 450-750 nm. It
is suitable for applications that require very bright LED
lighting. It has a narrow transparent variance
specification, eliminating strong color variation during a
production run, reducing lot-to-lot variations while helping
to increase manufacturing efficiency.
FOR LED LIGHTING APPLICATIONS
NEW!EN 45545
COMPLIANT
R4 – HL3
CASE STUDY: SIDE-WALLS
No. 20
MATERIAL DEVELOPMENT
Color options Thermoforming
Railway RegulationCo-Polymer Development
Staining / Anti-Grafitti Norm testing
Fire Testing
Scratch performance
Picture Source: All pictures used with customer permission
Interiors side-wall
No. 21
PRODUCTS KEY FEATURES
ULT
EM
™ &
LE
XA
N™
SH
EE
TS
SABIC’S THERMOPLASTIC SHEETS FOR THE RAILWAY INTERIORS
PEI
PC/ABS BLEND
PC
ULTEM™
R16SG29 Sheet
LEXAN™
H6000 Sheet
LEXAN™
F6000 Sheet
LEXAN™ MARGARD™
MR5FR Sheet
LEXAN™
F2000 Sheet
LEXAN™
H6500 Sheet
High Modulus
Meet EN45545
Meet EN45545
Clear & Opal White
Fulfilling DIN5510
NF F 31-112 (G1) Anti-graffiti
DIN 5510 & US - NFPA 130
High Modulus
Both Side
Coated Sheet
High Modulus
M1 F1 2-5mm, Meet EN 45545
OPAQUE
OPAQUE
LEXAN™
H6200 Sheet GERMAN DIN 5510
M1 F2
OPAQUE
PC CO-POLYMER LEXAN™
XHR6200 Sheet Meet EN 45545OPAQUE
LEXAN™
KH6200 Sheet
NF F 31-112 (G1) Anti-graffiti
DIN 5510
LEXAN™
KH6500 Sheet
LEXAN™
H6200M Sheet
NEW
NEW
NEW
TRANSPARENT
No. 22
LEXAN™ SHEET SOLUTIONS FROM SABIC
> LEXAN KH6500 SHEET
A PC/ABS SOLUTION OFFERING:
> Graffiti resistance - French NF F 31-112 (G1) anti-graffiti norm
> Environmentally responsible non-chlorinated and non-brominated
fire safety - German DIN 5510-2:2009
> Compliance with U.S. fire regulations > NFPA 130 - Fixed Guideway Transit and Passenger Rail Systems
> ASTM E162 - Surface Flammability of Materials Using a Radiant Heat Energy Source
> ASTM E662 - Specific Optical Density of Smoke Generated by Solid Materials
> ASTM E1354 - Heat and Visible Smoke Release Rates for Materials and Products Using an
Oxygen Consumption Calorimeter
> SMP 800C - Toxic gas sampling and analytical procedures
> Easy manufacturing and thermoforming
> Low gloss aesthetics after thermoforming
> Durability, high stiffness and impact resistance
> Lightweight and design freedom
> POTENTIAL APPLICATIONS: Railway interior seats and
tables, walls and other large rail interior parts
ROBUST, LOW GLOSS PRODUCT FOR ANTI - GRAFFITI
NEW!GERMAN DIN
US NORM
COMPLIANT
No. 23
LEXAN™ SHEET SOLUTIONS FROM SABIC
> LEXAN KH6200 SHEET
A PC/ABS SOLUTION OFFERING:
> Graffiti resistance - French NF F 31-112 (G1) anti-graffiti norm
> Environmentally responsible non-chlorinated and non-brominated
fire safety - German DIN 5510-2:2009
> Durability and impact resistance
> Lightweight
> Easy manufacturing
> Lower system cost
> Design freedom
> POTENTIAL APPLICATIONS: Rail carriage interior walls, rail interior panels, window
frames, interior ceiling and other large rail interior parts
COST EFFICIENT PRODUCT SOLUTION FOR ANTI - GRAFFITI
NEW!GERMAN DIN
COMPLIANT
No. 24
CONTACTS
Hilmar Backer
Industry Marketing Manager
Mass Transportation
SABIC
Plasticslaan 1
PO Box 117
4600 AC Bergen op Zoom
Stephan Plomp
Industry Marketing Manager
Railway Interiors
SABIC
Plasticslaan 1
4612 PX Bergen op Zoom
The Netherlands
www.sabic.com
Torben Kempers
Regulatory Expert
Mass Transportation
SABIC
Plasticslaan 1
4612 PX Bergen op Zoom
The Netherlands
www.sabic.com
No. 25
DISCLAIMER
DISCLAIMER: THE MATERIALS, PRODUCTS AND SERVICES OF SAUDI BASIC INDUSTRIES CORPORATION
(SABIC) OR ITS SUBSIDIARIES OR AFFILIATES (“SELLER”) ARE SOLD SUBJECT TO SELLER’S STANDARD
CONDITIONS OF SALE, WHICH ARE AVAILABLE UPON REQUEST. INFORMATION AND RECOMMENDATIONS
CONTAINED IN THIS DOCUMENT ARE GIVEN IN GOOD FAITH. HOWEVER, SELLER MAKES NO EXPRESS OR
IMPLIED REPRESENTATION, WARRANTY OR GUARANTEE (i) THAT ANY RESULTS DESCRIBED IN THIS
DOCUMENT WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY
OF ANY DESIGN OR APPLICATION INCORPORATING SELLER’S MATERIALS, PRODUCTS, SERVICES OR
RECOMMENDATIONS. UNLESS OTHERWISE PROVIDED IN SELLER’S STANDARD CONDITIONS OF SALE, SELLER
SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS, PRODUCTS,
SERVICES OR RECOMMENDATIONS DESCRIBED IN THIS DOCUMENT. Each user is responsible for making its own
determination as to the suitability of Seller’s materials, products, services or recommendations for the user’s particular use
through appropriate end-use and other testing and analysis. Nothing in any document or oral statement shall be deemed to
alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a
writing signed by Seller. Statements by Seller concerning a possible use of any material, product, service or design do not,
are not intended to, and should not be construed to grant any license under any patent or other intellectual property right of
Seller or as a recommendation for the use of any material, product, service or design in a manner that infringes any patent
or other intellectual property right.
SABIC and brands marked with ™ are trademarks of SABIC or its subsidiaries or affiliates.
© 2013 Saudi Basic Industries Corporation (SABIC). All Rights Reserved.
† Any brands, products or services of other companies referenced in this document are the trademarks, service marks
and/or trade names of their respective holders.
