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Contents of Presentation Composite Solutions to the Fire Performance needs of Mass Transit • The changing demands demands of new fire standards standards in mass transit Geof Tippin Tipping g
DSM Compo Composite site Resins • Compos Composites ites with combustion combustion gases of low toxicity are favoured favoured
“Composites In Fire” 9 – 10 September 2003 Newcastle upon Tyne,
• Examp Examples les of low toxicity toxicity composites composites in railways
England
• Future opportunitie opportunitiess for composite composite growth in mass transit and other demanding fire scenarions
SOME RECENT RAIL DISASTERS
SOURCES OF FIRE Fire Type
King’s Cross Station King’
Frequency
Vandal Fires [interior ]
Eurotunnel
145
68
Electrical Faults [interior ]
8
4
Small Fires [interior ]
2
1
57
27
Electrical Faults [undercar undercar ]]
Kitzsteinshorn
Total
FST PROPERTIES OF MATERIALS (1970‘s)
Fire
(1980‘s)
212
(1990‘s)
Fire
Fire
SMOKE SMOKE
SMOKE SMOKE
TOXICITY
100
UK Fire Tests BS 476 Part 6 fire propagation
(Fire, Smoke and Toxicity Toxicity))
[%]
Part 7 surface spread of flame
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
German Railways Standard DIN 5510
• Focuses on reaction to fire and smoke generated
• It does not include any measurement of toxic gas emission
Epiradiateur
LONDON UNDERGROUND
‘THINK THE UNTHINKABLE’ UNTHINKABLE’ A train stopped in a tube and on fire
LUL Three Metre Cube Test
MATERIALS REQUIREMENTS
CATEGORIES OF TRAINS - BS6853
according to BS 6853:1999
Category Category Ia Trains which predominantly use tunnels
Interior vertical surfaces Test
Category Category Ib Trains which use tunnels, but infrequently
Parameter Ia
Ib
II
i (max)
6
6
nc
I (max)
12
12
Nc
BS 476 Pt. 7
Class
0
0
1
Smoke
A (ON) (max)
2.6
4.2
9.4
A (OFF)
3.9
6.3
14
R-Index (max)
1.0
1.6
3.6
BS 476 Pt. 6
Category Category II Trains Trains which run predominantly overground
• 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
Changing Fire Standards Push Composites Towards Those With Low Toxicity Combustion Gases 1960’s
• 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 Cone calorimeter
the recommendations are adopted by EC member states
Halogenated additives Antimony
1970’s Halogenated polymers
1980’s Gel coated systems
SMOKE SMOKE
Phenolic resin systems
1990’s into the millennium Specialised polymer backbone Aluminium trihydroxide filled systems Specialised additives e.g. APP Aliphatic monomer systems
TOXICITY
IMO Resolution A653 (16) Combustion Gases Maximum Concentrations
Fire Safe ATH Filled Polyester Composites -
Carbon Monoxide
1450 ppm
Hydrogen Chloride
600 ppm
Hydrogen Fluoride
600 ppm
Very low levels of smoke
Oxides of Nitrogen
350 ppm
Very low levels of toxic gas emission
Hydrogen Bromide
600 ppm
Very low heat output
Hydrogen Cyanide
140 ppm
Sulphur Dioxide
120 ppm
Pass BS 6853 category 1a
Excellent fire performance
Cone Calorimeter Comparison for Smoke and Carbon Monoxide Cone Calorimeter at 50 kW/m 2
Synolite 5 001-T-1 10 wt.% glass
Phenolic L aminate 30 wt.% glass 60 wt.% glass
300 phr ON-921 Ignition Time (s)
186
159
Heat Release (MJ/m2)
18.0
38.6
21.7
Smoke (m2/m2)
160
294
175
CO2 (kg/m2)
no dripping
==> low contribution to fire spread
154
1.51
2.30
1.03
(kg/m2)
0.05
0.38
0.36
CO2 / CO Ratio
30
6
3
CO
Advantages of halogen-free highly flame retardant polyester composites in fire situations:
low smoke development ==> visibility to reach emergency exits low toxic gases
==> passenger safety
low heat development
==> passenger safety
FABRICATION TECHNIQUES Hand Lay-up
Resin Injection
Examples of low toxicity composites in railways
Pultrusion
Compression Moulding
Hand Lay Up Applications
PULTRUSION APPLICATIONS Cable Trays
• Synolite 5001-T-1 specialised low viscosity aliphatic resin • Fire performance can be tailored to different fire specifications by varying the aluminium trihydroxide grade and level
Fire Resistant Profiles Frames for Fire-Proof Doors Ceilings
• Can meet the most severe fire standards up to BS 6853 class 1a
Grids and Floors
• Suitable for large, low volume components for example
Supporting Tubes for Tunnels
arc barriers, driver cabs, flash guards, internal panellin g and window frames
• Filled system can be used as a coloured gel coat
Manufacture by RTM
• Suited to medium volume applications such as • • • • • • •
Talent – light rail train – interior also uses ATH filled polyester composites
• Composite preferred to aluminium due to better surface profile
• Pultruded profiles top and bottom
• SMC panels middle
• Fire performance to DIN 5510 S4
• Internal panelling made from SMC
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
Transrapid – Sanghi Airport Express • Transrapid magnetic levitation train recently trialled in Shanghai
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
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
• 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
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 intumescent systems in passive fire protection systems and offshore applications
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
Composite Solutions to the Fire Performance needs of Mass Transit Geof Tipping
DSM Composite Resins
“Composites In Fire” 9 – 10 September 2003 Newcastle upon Tyne, England
• 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
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 pigmentable gel coat layer Good physical properties especially at lower filler loadings
FIRE SAFETY OF MATERIALS The Role of Aluminium Trihydroxide
Comparison of Physical Properties CSM hand lay up laminates
[Limiting Limiting Oxygen Index] Index]
100 B3
B2
B1
A2
DIN 4102
M3
M2
M1
M0
France (NFF 1616-101) Great Britain (BS 476 Pts 6&7)
