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Composite Solutions to the Fire Performance needs of Mass Transit
Geof Tipping DSM Composite Resins
“Composites In Fire”9 – 10 September 2003Newcastle upon Tyne,
England
Contents of Presentation
• The changing demands of new fire standards in mass transit
• Composites with combustion gases of low toxicity are favoured
• Examples of low toxicity composites in railways
• Future opportunities for composite growth in mass transit and other demanding fire scenarions
SOME RECENT RAIL DISASTERSSOME RECENT RAIL DISASTERS
KingKing’’s Cross Stations Cross Station
EurotunnelEurotunnel
KitzsteinshornKitzsteinshorn
SOURCES OF FIRESOURCES OF FIREFire TypeFire Type FrequencyFrequency [%][%]
Vandal FiresVandal Fires [[interiorinterior]] 145145 6868
Electrical Faults Electrical Faults [[interiorinterior] ] 8 8 44
Small Small FiresFires [[interiorinterior] ] 22 11
Electrical Faults Electrical Faults [[undercarundercar]] 5757 2727
TotalTotal 212 100212 100
FST PROPERTIES OF MATERIALSFST PROPERTIES OF MATERIALS(Fire, Smoke and (Fire, Smoke and ToxicityToxicity))
(1970‘s) (1980‘s) (1990‘s)
TOXICITY
SMOKESMOKE SMOKESMOKE
Fire FireFire
UK Fire Tests BS 476
Part 6 fire propagation Part 7 surface spread of flame
2
French Railways Fire Tests – NFF 16-101
• Combines reaction to fire Epiradiateur NF P 92-501 [M ratings] with smoke and toxicity NFX 70-100 [F ratings]
• The M & F rating required is dependent on the type of rolling stock and the component location
Epiradiateur
German Railways Standard DIN 5510
• Focuses on reaction to fire and smoke generated
• It does not include any measurement of toxic gas emission
LONDON UNDERGROUNDLONDON UNDERGROUND LUL Three Metre Cube Test
‘‘THINK THE UNTHINKABLETHINK THE UNTHINKABLE’’
A A train stoppedtrain stopped in a tube and on firein a tube and on fire
3
CATEGORIES OF TRAINSCATEGORIES OF TRAINS -- BS6853BS6853Category Category IaIaTrains which predominantly use tunnelsTrains which predominantly use tunnels
Category Category IbIbTrains which use tunnels, but Trains which use tunnels, but infrequentlyinfrequently
Category IICategory IITrains which run predominantly Trains which run predominantly overgroundoverground
Test Parameter
Ia Ib IIBS 476 Pt. 6 i (max) 6 6 nc
I (max) 12 12 NcBS 476 Pt. 7 Class 0 0 1Smoke A (ON) (max) 2.6 4.2 9.4
A (OFF) 3.9 6.3 14Toxicity R-Index (max) 1.0 1.6 3.6
MATERIALS REQUIREMENTSMATERIALS REQUIREMENTSaccording to BS 6853:1999according to BS 6853:1999
Interior vertical surfacesInterior vertical surfaces
TOXICITYTOXICITYRR--IndexIndex
GASES IDLH values (mg/m3)BS 6853 NFX 70-100
Carbon dioxide 73.000 90.000Carbon monoxide 1.400 1.750Hydrogen fluoride 25 17Hydrogen chloride 76 150Hydrogen bromide 101 170Hydrogen cyanide 56 55Nitrogen dioxide 38 -Sulphur dioxide 270 260
FIRESTARR – “Fire Protection on Railway Vehicles”
• EC project to develop new European standard prEN 45545
• Considered fire initiation, time to flashover, time to loss of visibility and time to lethal conditions for passengers
• For structural , furniture and electrical railway parts performance has been compared to existing national tests
FIRESTARR – “Fire Protection on Railway Vehicles”
• Strong contenders include:• NBS smoke chamber at
50kW/m² heat flux with toxic gas emission following IMO criteria
• Cone Calorimeter at 50kW/m² heat flux for heat release
• It will be several years before the recommendations are adopted by EC member statesCone calorimeter
Changing Fire Standards Push Composites Towards Those With Low Toxicity Combustion Gases 1960’s
Halogenated additives
Antimony1970’s
Halogenated polymers
1980’s
Gel coated systems
Phenolic resin systems
1990’s into the millennium
Specialised polymer backbone
Aluminium trihydroxide filled systems
Specialised additives e.g. APP
Aliphatic monomer systems
SMOKESMOKE
TOXICITY
4
Fire Safe ATH Filled Polyester Composites -
Pass BS 6853 category 1a
Very low levels of smoke
Very low levels of toxic gas emission
Very low heat output
Excellent fire performance
IMO Resolution A653 (16) Combustion GasesMaximum Concentrations
120 ppmSulphur Dioxide
140 ppmHydrogen Cyanide
600 ppmHydrogen Bromide
350 ppmOxides of Nitrogen
600 ppmHydrogen Fluoride
600 ppmHydrogen Chloride
1450 ppmCarbon Monoxide
Cone Calorimeter Comparison for Smoke and Carbon Monoxide
Cone Calorimeter at 50 kW/m2
Synolite 5001-T-1 Phenolic Laminate10 wt.% glass 30 wt.% glass 60 wt.% glass
300 phr ON-921
Ignition Time (s) 186 159 154
Heat Release (MJ/m2) 18.0 38.6 21.7
Smoke (m2/m2) 160 294 175
CO2 (kg/m2) 1.51 2.30 1.03
CO (kg/m2) 0.05 0.38 0.36
CO2 / CO Ratio 30 6 3
Advantages of halogen-free highly flame retardant polyester composites in fire situations:
no dripping ==> low contribution to fire spread
low smoke development ==> visibility to reach emergency exits
low toxic gases ==> passenger safety
low heat development ==> passenger safety
Examples of low toxicity composites in railways
FABRICATION TECHNIQUESHand Lay-up Resin Injection
Pultrusion
Compression Moulding
5
Hand Lay Up Applications
• Synolite 5001-T-1 specialised low viscosity aliphatic resin
• Fire performance can be tailored to different fire specifications by varying the aluminium trihydroxidegrade and level
• Can meet the most severe fire standards up to BS 6853 class 1a
• Suitable for large, low volume components for example arc barriers, driver cabs, flash guards, internal panelling and window frames
• Filled system can be used as a coloured gel coat
PULTRUSION APPLICATIONS
Cable Trays
Fire Resistant Profiles
Frames for Fire-Proof Doors
Ceilings
Grids and Floors
Supporting Tubes for Tunnels
Manufacture by RTM
• Suited to medium volume applications such as• Railway seats• Dado rails• Window surrounds• Drivers cabs• Arc barriers• Arc shields• Flash guards
• Fire performance can be tailored by the choice and loading of aluminium trihydroxide or APP
• System can be used as a pigmented gel coat
Manufacture by Compression Mouldingusing Sheet Moulding Compound
• Suited to large volume applications such as• Railway seats• Interior panelling• Ceilings• Bulkheads
• Formulae can meet BS 6853 1b
Case Study: Arc Barriers for LULwhere aluminium trihydroxide filled
polyester replaced asbestos
Case Study: Central Line Train Arc barriers based on Synolite 5001-T-1
6
EurostarEurostar emerging from the Channel emerging from the Channel TunnelTunnel
Case Study: Eurostar Components
Case Study: Network South East Train with flash guard panels installed
Case Study: Gel Coated Flash GuardsNow with several years of proven service
Case Study: Electrostar Train Gel Coated Dado Rail Manufactured for the Electrostar Train
7
Interior of the Electrostar with Composite Components
Deutsche Bahn AG
Interregio interiorwith SMC-parts:•luggage rack•seat shells•wall panels
S-Bahn Berlin
52 SMC inner parts •side panels•ceiling panels•door side cover•cover above door
Connection area of Regioswinger
Talent - light rail train - exterior uses aluminium trihydrate filled composites
• Composite preferred to aluminium due to better surface profile
• Pultruded profiles top and bottom
• SMC panels middle
Talent – light rail train – interior also uses ATH filled polyester composites
• Fire performance to DIN 5510 S4
• Internal panelling made from SMC
8
Chapman Seat
• Manufactured by Chapman Transport Systems for Chiltern Railways
• Moulded in Menzolit UK’s SMC Flomat 2950 series conforming to BS 6853 Category 2
• Category 1b SMC is also available
Desiro UK 450
• First of 132 trains ordered by British South West Trains
• SMC conforming to BS 6853 Category 2 chosen due to light weight and excellent mechanical properties
• Moulded painted parts include window frames, door and partition panels
Transrapid – Sanghi Airport Express
• Transrapid magnetic levitation train recently trialled in Shanghai
• Components include window surrounds and air conditioning ducts
• Moulded in specialised ATH filled low smoke polyester by hand lay up
• Conforming to DIN 5510 standard
Future opportunities for composite growth in mass transit
• Part two of Euronorm pr EN45545 will include ISO 5658-2 for flame spread, ISO 5659-2 for smoke opacity and gas analysis and ISO 5660-1 for heat release
• The categories, as in BS 6853, are based on risk assessment and will be more demanding than many existing fire tests with heat fluxes of 50kW/m²
• Specialised polyester systems filled with ATH perform well at these high heat fluxes and can meet the high IMO standards for low toxicity combustion gases
IMO approved grade Synolite 5001-W-1:
Conforms to IMO Res Msc61 [67] FTP Code Annex Part 2 Is used in the manufacture of cabins and bathrooms
Future opportunities for composite growth in mass transit and other demanding fire scenarios
• Definitely in railways under the existing and new proposed norms specialised polyester ATH/APP filled systems can meet the highest fire standards
• Significant opportunities exist in other mass transit markets such as marine
• Moving from reaction to fire applications into fire resistance there is significant potential for sandwich construction in conjunction with insulation materials in mass transit
• There is further potential for intumescentsystems in passive fire protection systems and offshore applications
9
Concluding Remarks
• Fire safe polyester composites can meet the most stringent demands for fire performance in railway applications
• Designing for fire safety is made easy by using specialised polyester resin systems with aluminium trihydroxide and other specialised additives.
• Flexibility in design and through colour is facilitated by the wide range of manufacturing techniques available to produce cosmetic finishes where required
• Passenger safety is ensured due to the difficult-to-ignite composite materials and the exceptionally low smoke and low toxic gases which may be generated
Composite Solutions to the Fire Performance needs of Mass Transit
Geof Tipping DSM Composite Resins
“Composites In Fire”9 – 10 September 2003Newcastle upon Tyne,
England
What are Fire Safe Polyester Composites?
• Three components in the composite • Specialised aliphatic polyester resins• Aluminium trihydroxide fire retardant filler• Glass reinforcement
• Different methods of manufacture to suit the shape, size and number of components needed
Fire Safe Polyester Composites are through pigmentable in a wide range of colours
Can be used as a pigmentablegel coat layer
Good physical properties especially at lower filler loadings
FIRE RETARDANT EFFECT OF ALUMINIUM TRIHYDROXIDE
Heat
> 200 oC
2Al(OH)3 Al2O3 + 3H2O
Replaces substrateAbsorbs heat
Produces steamDilutes O2 atmosphere
Adsorbs smoke particles
Retains particle form
10
FIRE SAFETY OF MATERIALSFIRE SAFETY OF MATERIALSThe RoleThe Role of Aluminium of Aluminium TrihydroxideTrihydroxide
[[Limiting OxygenLimiting Oxygen Index]Index]
00
2020
4040
6060
8080
100100
300300200200100100 400400
Class 1
B 3 B 2 B 1 A 2
M 3 M 2 M 1 M 0
Class 2 Class 0
S 3 S 4 S 5
DIN 4102DIN 4102
FranceFrance(NFF 16(NFF 16--101)101)
Great Great BritainBritain(BS 476 (BS 476 PtsPts 6&7)6&7)GermanyGermany(DIN 5510)(DIN 5510)
MARTINAL ONMARTINAL ON--921 921 FillingFilling Level (Level (phrphr))GlassGlass--ReinforcedReinforced Polyester (25% Glass)Polyester (25% Glass)
% O
% O
22
Comparison of Physical PropertiesCSM hand lay up laminates
Resin type 5001-T-1 5001-T-1 5001-T-1 Phenolic
ON 921 phr 300 150 - -
ON 901 phr - - 150 -
Glass % 11 20 17 30
Flexural strength [MPa]
92 136 147 101
Flexural modulus [GPa]
12.3 8.5 8.5 4.6
Specific gravity
2.0 1.8 1.8 1.5
Synolite 5011-R-1 - Martinal ON 901 Pultrudate
Mechanical Properties 150 phr ON 901 Result
Flexural Strength 1020 MPa
Flexural Modulus 32 GPa
Impact Strength 52 kJ/m2
FST Properties 130 phr 150 phr 170 phr
M M1 M1 M1
F - F0 -
R - 1.3 -
R value measured on phenolic pultrudate 5.1
New Low Smoke Resin Especially Designed for Pultrusion Applications
• Synolite 5011-R-1 is a special halogen-free fire retardant polyester in methyl methacrylate
• Specifically designed for pultrusion, Synolite 5011-R-1 can be highly filled with aluminium trihydroxide e.g. Martinal ON 901
• This high reactivity resin and particle shape of the filler enables fast pull speeds on pultrusion lines to be achieved