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.
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.
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.
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:-
We have extensive experience organsing the full scope of Crash Testing, including:-
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.
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:-
In addition, we offer powder coat and wet paint testing:-
Quality is at the core of our business, and this is evidenced by our commitment to the accreditations we hold. We are certified to:-
We are a global supplier of rolling stock interior products including:-
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.
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.
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:
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.
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.
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.