1.1 - Rail Interior Component Assembly

Assembly of rail components manufactured by us is one of our core competencies. Our specialist team of trained technicians can undertake a variety of assembly processes to provide finished component assemblies including Luggage Stacks, Luggage Racks, Draught Screens and Ceiling Panels.

1.2 - Project Management

We understand the importance of being able to meet key project milestones whilst maintaining product quality. That is why we appoint Project Managers to any project regardless of size.

Our Project Managers control every aspect of the project life-cycle from design, engineering & validation and manufacture. This service includes leadership, planning, stakeholder management, control and successful delivery of projects on your behalf.

1.3 - Engineering Calculations & Simulation

We undertake engineering calculations and simulations to validate designs.

A Static Structural analyses of the design is completed in accordance with GM/RT 2100 Issue 5 and APTA PR-CS-S-018-13 Rev1. This is completed in-house using LSDYNA, Hyper works or ANSYS simulation software, and any reporting will be submitted with the simulation results to gauge the position for crash testing.

Using the same simulation software, a Dynamic and Static Structural analyses of the product is completed. In the simulation, we will simulate Structural Integrity and Injury Criteria using 95th% or 50th% Hybrid 111 RS instrumented dummies. These simulations are used to ensure our designs meet all requirements for crash testing. Reports are prepared for product approvals and for crash testing validation/setup.

1.4 - Fire Testing

Our work on both new and current rolling stock brings the need for fire testing of composite products.

We instruct recognised testing facilities to ensure our products consistenty meet the fire performance levels required by the following rolling stock standards:-

  • GMRT 2130 – Vehicle Fire, Safety & Evacuation
  • EN 45545-2 – Requirements for fire behaviour of materials and components
  • BS 6853 – Code of practice for UK fire precautions in the design and construction of passenger carrying trains
  • London Underground Limited (LUL) Number S1180 (Rolling Stock)
  • London Underground Limited (LUL) Number S1085 (Stations & Tunnels)
  • DIN 5510-2 Standard for German classification of materials fire behaviour
  • NF F 16-101 Standard for French selection of materials for railway rolling stock
  • US Federal Railroad Administration (FRA) requirements
  • UIC 564-2 Regulations relating to fire safety in passenger carrying railway vehicles
1.5 - Crash Testing

We have extensive experience organsing the full scope of Crash Testing, including:-

  • Generation of Crash Test Plan
  • Design and production of Crash Test Rig to mount either the car body or the products to be tested
  • Documentations (reports produced from simulation results) to validate the minimum number of testing required for the project
  • Crash Test management and set-up.
  • Crash Test Reports for Approvals
  • The tests are conducted using the Hybrid 111 RS fully instrumented dummy. All instrumentation is certified to ISO/IEC 017025:2005 which meets the requirements as set out in GM/RT 2100 Issue 5 and APTA PR-CS-S-018-13 Rev1. The sled facility we use has a deceleration type rig with bungees for accelerating the rig to around 100km/h. Once the sled reaches its target velocity it is decelerated through a controlled impact to reproduce the desired crash pulse.
  • We will then prepare all reporting for submission to NoBo
1.6 - Static Load Testing

Our qualified engineers conduct physical static load testing in-house using our specifically designed test rig, all in accordance with GM/RT 2100 Issue 5 and APTA PR-CS-S-018-13 Rev1.

All loadings are verified using a certified load gauge, and tests are recorded, photographed and videoed for reference. Formal Reports are generated and submitted for approval.

1.7 - Adhesion Testing

We have been working towards certification to DIN 6701-2 Adhesive Bonding of Railway Vehicles , a standard for ensuring quality bonding techniques are adopted in the manufacture of our products. We understand that periodic testing is required, and we work with certified test facilities to offer the following:-

  • Weiss Technik Climate Chamber
    • Low temperature testing to -40ºC
    • High temperature testing to +190ºC
    • Heat ageing
    • Thermal shock testing with fast ramp-uprate
  • Spec Climate Chamber
    • Low temperature testing to -40ºC
    • High temperature testing to +170ºC
    • Elevate humidity testing to 95% relative humidity
    • Fully cyclical climatic testing, long and short term
  • Alpha Ten Tenso Meter
    • Peel testing
    • Shear testing
    • Joint break test on rigid substrates
    • Peel speed from 1mm min-1 to 2000mm min-1
    • 1000N load fitted cell

 

In addition, we offer powder coat and wet paint testing:-

  • Dry thickness film tests to the following standards – ASTM B 499, ASTM D 7091, ASTM E 376, BS 559, EN 13523-1, ISO 2360, ISO 2808-12, ISO 2808-7C, ISO 2808 7D, JIS K 5600-1-7, NF T30-124, ISO 2178
  • Paint adhesion tests to the following standards – ASTM D 3359-B, BS 3900-E6, ECCA T6, EN 13523-6, ISO 2409, ISO 2409, ISO 16276-2, JIS K 5600-5-6, NF T30-038
1.8 - Accreditations

Quality is at the core of our business, and this is evidenced by our commitment to the accreditations we hold.  We are certified to:-

  • ISO 9001:2015
  • International Rail Industry Standard TS 22163
  • EN 15085-2 CWRVC Welding of Railway Vehiles and Components
  • Working to DIN 6701 Adhesive Bonding of Railway Vehicles and Parts.
2.1 - Scope of Supply

We are a global supplier of rolling stock interior products including:-

  • Fixed – Cantilever – Folding – Sliding Table Assemblies
  • Luggage Stacks
  • Luggage Racks
  • Bodyside – Window – Ceiling Panels
  • Bicycle Racks
  • Draught Screens
  • Partitions
  • Grab Poles
  • Perch Seats
  • Catering Units
  • Flooring
  • Toilet Module Components.
2.2 - HL3 Polyurethane Edging System

In order to remain at the forefront of rail interior component manufacture, we have developed our own fire rated polyurethane edging system compliant to EN 45545-2:2013+A12015 meeting requirements set R22 and R23 for Hazard Levels HL1, HL2 and HL3.

This system goes beyond standard Technical requirements of HL2 and opens its use to all categories of vehicles including Underground, Double Decker, Sleeper and High Speed trains.

2.3 - PET Foam

Polyethylene Terephthalate (PET) foams are the newest structural core materials in the composite industry. Lightweight and high mechanical strength, in conjunction with residual flexibility and maximum service life, it makes it an ideal product for the rail industry.

Using PET foam, we have developed a composite material for flooring, tables and other interior products, which is compliant to EN 45545-2:2013+A12015 meeting requirements set R1, R2 and R10 for Hazard Levels HL1, HL2 and HL3.

The PET foam we use is made from 100% post consumer PET materials (mainly recycled beverage bottles) and offers a 40% weight saving over traditional composite boards such as plywood, whilst boasting longer life cycles due to higher impact resistance and pull out strengths.

2.4 - Wireless Charging

Rolling stock relies heavily on digital and mobile app technology including infotainment, mobile ticketing, and information relating to onward travel. There is a now a signficant requirement for on-board charging. Existing “Power to Seat” solutions on rolling stock currently take the form of a standard 3 pin plug and or USB.

Partnering with Aircharge, global wireless charging leaders, we have developed the rail sector’s first fully compliant sub-mounted or surface mounted Wireless Charger and Power Supply Unit tested to the following standards:

  • GM/RT 2100 Issue 5 Design for Interior Crash Worthiness
  • EN 50155 Rolling Stock Electronic EQT
  • EN50121-3-2 Electromagnetic Compatibility
  • EN 62233 Measurement for Electromagnetic Fields
  • Other general certifications – CE, IP55, FCC, QI
  • Safety Test Certificate IEC 60950-1
2.5 - Glass Panel PIS Screen

Partnering with OSG, global leaders in glass fabrication, we now offer products featuring digital displays using glass embedded LED screens.

Our products, incoroporating ScreeneX, can transform conventional Draught Screens, Partitions, Luggage Stacks, Tables & Windows into something far more valuable – a way of communicating and or promoting with your passengers.

2.6 - Reaction Injection Moulding

Reaction Injection Moulding (RIM) is the result of a reaction between isocyanate and polyol as they are injected into a closed mould at low pressure. The two components are mixed together as they flow into the mould as a low viscosity liquid and the reaction, which increases the temperature and the pressure at the surface of the tool, forms the polyurethane part in the tool cavity.

We are increasingly specifying RIM parts as a more repetitve and cost effective alternative to GRP (Glass Reinforced Plastic), and because this process is conducted in-house, we are able to maintain control of product from tooling design through to manufacture.

Our RIM parts have a Shore hardness of 80D (hard), and can be supplied primed, painted or surface treated with graphics to simulate various textures.

2.7 - Metalwork Welded to EN 15085

We offer both MIG and TIG welding from our dedicated precision metal fabrication facility.

In July 2018, we became one of only a handful of UK companies to be certified to EN 15085-2 demonstrating our competence for control of welding quality in the production of railway vehicles and components.

Certification for Welding of Railway Vehicles and Components (CWRVC) is being increasingly referenced by rolling stock manufacturers as a pre-requisite for those companies supplying components, assemblies and fabrications.