häwa GmbH

Information about:

Deutsche Bahn Projects

häwa GmbH

• Certification according to DIN EN 15085 (welding)

• Certification according to BN 918 340 (powder-coating)

• Strength certificates

Prerequisites for the processing of orders from Deutsche Bahn AG

häwa GmbH

These standards describe the welding process of metallic materialsused for the manufacture and maintenance of railway vehicles andcomponents.

They specify the quality requirements and certification of weldingmanufacturers to define a uniform manufacture and repair procedure.

Regulation for the welding of railway vehicles andcomponents according to DIN EN 15085 Parts 1 to 5

häwa GmbH

Description Certification level (CL)

Applies to welding manufacturers producing railway vehicles orcomponents with welds of the weld performance classes CP A to CP D. Certification level L 2 to CL 4 is included.

CL 1

Applies to welding manufacturers producing railway vehicle componentswith welds of the weld performance classes CP C2 to CP D.Welding procedure specifications including welds of the weldperformance class CP C1, if these welds are examined according to weldperformance class CT1, EN 15085-5:2007, table 1.Certification level CL 4 is only included for CL 2 or CL 3-classified components.

CL 2

Applies to welding manufacturers producing railway vehicle componentswith welds of weld performance class CP D.

CL 3

Applies to companies which do not perform welding operations, but design, or purchase & assemble or purchase & resell railway vehiclesand components. Certification not required for welded componentsaccording to CL 3.

CL 4

DIN EN 15085-2 defines four certification levels (CL 1 to 4)

häwa GmbH

Certification level Allocation of partsLevel CL 2 Construction, modification and repair of pressureless containers without

particular test pressure, for example: • Storage containers for non-hazardous substances• Other shipping containersConstruction, modification and repair of railway components, forexample: • Interior fitting for passenger trains (partition panels, walls, doors, panellings) • Support frames for internal equipment (electrical, air-conditioning andair systems) • Driving cab equipment• WC-components and water tanks with fittings• Sliding walls in the vehicle (incl. slide rails)• Brake pipe supports

• Non-self-supporting tool boxes below the base frame (withoutsupporting frame)

• Gearboxes and consoles for handbrake operation• Footboards, handles (incl. handrails in the entrance area) and

railings in the railway vehicle area

Our cabinets and enclosures are used in locomotivesand transport vehicles. Here, the customer requirescertification level CL 2 from the manufacturer

häwa GmbH

Level CL 3 Construction, modification and repair of simple attachments for railway vehicles, for example: •Cranks and levers for various operations•Stop plates

• Tool boxes and cabinets in railway vehicles (including gearboxes and consolesfor manual operation, without supporting frame)

• Sign holders• Wheellocks• Cover for freight car (tank car heat protection) • Footboards, handles, railings in railway vehiclesConstruction, modification and repair of common supply parts for railway vehicles,

for example: • Seat frames, window frames, ventilation grilles

Certification level CL 2 includes automatically all lowerlevels. Thus, our production is also CL 3-approved

häwa GmbH

The certification applies to the construction and manufacture ofcomponents and assemblies and to the following materials:

• Carbon steels up to tensile strength 275 N/mm², e.g. DC01

• Stainless steels, e.g. 1.4301

• Non-hardening aluminium alloys, e.g. AlMg3

Currently, all orders to be processed according toEN 15085 are produced by our CL2-certified manufacturer Schimscha

häwa GmbH

Deutsche Bahn AG requires that distributors must be also certified.

Standard CL 4 applies to these companies.

Level CL 4 This certification level applies to companies which do not performwelding operations butu designu purchase and assemblewelded components and assemblies.

Since häwa and the manufacurer Schimscha are twoindependent companies, häwa shall be considered asdistributor

häwa GmbH

• The responsible welding supervisor for häwa isAlex Wagenleitner

• Thus he is contractually bound to häwa and listed in the häwa organigram

• He is working in the production facility in Ravenstein-Erlenbach

häwa is certified accoring to standard CL 4 sinceDecember 2013

häwa GmbH

häwa GmbH

• DB requires BN 918 340 approved/certified coating systems

• Sample sheet metal plates with a 1-coat and 2-coat finish weresuccessfully tested by a DB-authorized testing institute. Both coatingsystems are suitable for indoor applications.

• The test includes a bullet impact test, a condensed-water test, a saltspray test, resistance to detergents etc.

• The test report is sent together with an application for qualification tothe Deutsche Bahn which will issue then a certification with a 5-year validity.

Paint specifications for Deutsche Bahn products

häwa GmbH

häwa GmbH

• In addition to the welding certificates, the customer may also requirea cabinet strength certificate.

• A proof of strength can be performed analytically via the Finite Element Method (FEM) or in a practice test via a vibration test.

• The customer defines the test type at his own expense.

• These costs are shown separately in the offer or the order.

• In this field, we cooperate with the company “Invenio“.

Proof of strength

häwa GmbH

Requirements e.g.:Proof of strength according toEN 12663-1

Static load cases:

Longitudinal acceleration: ± 3.0 g

Lateral acceleration: ± 1.0 g

Vertical acceleration: ± 1.0 g

Example of a FEM calculation

häwa GmbH

Enclosure for the driver's cab of a shunter

W = 1,204 mmH = 929 mmD = 493 mm

Current projects

häwa GmbH

Enclosure with continuous hole profile for flexible installation offittings, with two galvanizedswing frames.Removable side panels.

Former suppliers: Rittal, Dessauer

Current projects

häwa GmbH

Modular cabinets in various sizes for tunnel rescue trains

Current projects

häwa GmbH

Modular cabinet:

W = 600 mmH = 1,100 mmD = 600 mm

With mounting plate19“ mounting railsRoof-mounted ventilatorBottom cable entry plate

Current projects

häwa GmbH

Modular cabinet:

W = 600 mmH = 900 mmD = 600 mm

With mounting plate19“ mounting railsRoof-mounted ventilatorBottom cable entry plate

Current projects

häwa GmbH

Modular cabinet:

W = 600 mmH = 1,800 mmD = 600 mm

With mounting plate19“ mounting railsRoof-mounted ventilatorBottom cable entry plate

Current projects

häwa GmbH

Free-standing cabinets in various sizes for tunnel rescue trains, e.g.

W = 1,200 mmH = 1,800 mmD = 600 mm

Current projects

häwa GmbH

Double doors with weldedcenter bar and mountingplatesTop cable entry plate

Current projects

häwa GmbH

• The welding certification EN 15085 does not exclusively apply to theDeutsche Bahn but also to other railway companies (e.g. ÖBB, SBB)

• Furthermore, this certification is also required from manufacturers ofroller coasters or transport systems (rail vehicles) etc.

• The EN 15085 standard is valid throughout Europe

Welding certification validity

häwa GmbH

For any further information or question,

please contact

Alex Wagenleitner

häwa GmbH