Total EN 45545 Solutions for Flame retardant Composites Gelcoats, UP-Resins and Coatings from one Company www.madercomposites.com / en45545 EN 45545 For HL, Vacuum Infusion and RTM light
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
-
Total EN 45545 Solutions for Flame retardant Composites
Gelcoats, UP-Resins and Coatings from one Company
www.madercomposites.com / en45545
EN 45545
For HL,
Vacuum Infusion
and RTM light
-
Walter Mäder AG, Composites | madercomposites.com
Flame retardant Systems for easy processing EN 45545
AlstomSydney Metro
Bombardier S-BahnHamburg
Bombardier TraxxGermany
Siemens HC RRXXXXXXXX
Stadler Giruno EC 250XXXXXXX
Bombardier /Hitachi Rail ZefiroXXXXXXX
Bombardier Flexity II Basel
BT-4882 Flexity IIBlackpool
AlstomRiyadh Metro
Stadler Dosto S-BahnZürich
Bombardier Flexity IIAustralia
Bombardier Regio2NXXXXXXX
More than
35 References
1
1 5 9
2 6 10
3 7 11
4 8 12
8
9
5
24
116
712
10
3
Quality and Service for EN 45545Composites since 2012
EN 45545 Conclusion / Elements for Success
Knowledge EN Standard and Requirements
“State of the Art”, Materials and Processing
Early Project Collaboration
Double Check Feasibility / Proof of Concept
Conzept– Design– Production- method– Materials
Proof of Concept– FST Tests– Processing
CompositesProduction– SOPs
Coating /Finishing
Handling
Composites acc. to
EN 45545
Supp
ort A
ctiv
ities
Prim
ary
Act
iviti
es
NUVOPOL Gelcoat 37–03– Best in class water resistance– In most colors available (with anti- graffiti clear coat recommended)– 0,7–0,9 mm application– Faster tack-free– Lower costs– Experience since 2012
Water resistant painted intumescent Gelcoat since 2012 in operation for front masks and interiors passing EN45545 HL 2 R1 and R17
Bombardier Flexity IIBlackpool
Bombardier Flexity IIGoldcoast Australia
Bombardier Flexity IIDe Ljin
Bombardier TRAXX 3several Projects
NUVOPOL Gelcoat 37–05– No auto-demoulding on large parts, even at high temperatures: Vacuum Infusion or HL the next day possible
– Very low smoke values: compensates smoke from coatings– 0,8–1,0 mm application– HL3 R1 in colored gelcoat– Flexibel– Experience since 2014
Part 1: Continous condensation
18–23 oCRaum-temperatur
Part 2: Method for using samples in condensation water climates
T = 38 oC(49 oC / 60 oC)
T = 40 oC
Condensed water test DIN EN ISO 6270Coating materials – Determination of resistance to moisture
Humidity ResistanceAll Mäder Gelcoats / painted composites are tested according DIN EN ISO 6270-1 for 10 days inside and 20 days outside “no bubbles”
Water Resistance: Best in Class!
NUVOPOL Gelcoat 37–03, not coated passes over 20 days, coated over 40 days
Alstom Metro Riyadh, Front Cups produced in India / Dubai
Intumescent Gel Coat NUVOPOL 37-03Water based PrimerWater based Topcoat
On going
Customer training in Switzerland
EN 45545 Projects, with water based coatings2012 2017
NUVOPOL Topcoat 37–40– HL 2 R1 fire protection with only 0,3 mm thickness– Excellent UV-protection– Ceramified– Anti graffiti– Reduced weight and thickness of composites
Mäder gives with a dedicated team full training and service to OEM’s and composite makers
2 Walter Mäder AG, Composites | madercomposites.com 3
-
Walter Mäder AG, Composites | madercomposites.com
Total EN 45545 Solutions for Flame retardant Composites
Gelcoats, UP-Resins and Coatings from one Companymaderco
mposites.com
/ EN45545
(SB) Solvent based
(WB) Water based
Outside
Inside
Coat
ing
Opt
ions
Inside Outside
Single CoatPrimer
Top Coat
Primer PrimerBase CoatClear Coat
Primer
Base Coat
Top Coat Clear Coat
Primer (SB) ARTHANE 51 FR ETOKAT Grund FR ETOKAT Grund FR ARTHANE 51 FR ETOKAT Grund FR ETOKAT Grund FR
Base Coat (SB) ARTHANE 101
Base Coat (WB) NUVOVERN AQUAHYDRO BASE
CL 381 / NUVOVERN AQUA RAPID
Clear or Top Coat (SB) BARNIZ ARTHANE AG ARTHANE 251 NUVOVERN DS 10:1 BARNIZ ARTHANE AG
Clear or Top Coat NUVOVERN AQUA DS NUVOVERN AQUA NUVOVERN AQUA
Gel Coat NUVOPOL 37-03 TGP / NUVOPOL 37-03 TGP (A) / NUVOPOL 37-05 TGP
Proc
essi
ng O
ptio
ns
Hand Lamination
Resins GIRALITHE DITRA 2109–10 XP / GIRALITHE DITRA 2109-11 XP
Fiber Content 25–35 % by w.
RTM light / RTM
Resins GIRALITHE DITRA 2109-10 XP white 3010 / GIRALITHE DITRA 2109-10 grey 3100
Fiber Content 20–40 % by w.
Infusion
ResinsNUVOCRYL FR 60-60 G / NUVOCRYL FR 60-90 G
GIRALITHE DITRA 2109-10 XP white 3010 / GIRALITHE DITRA 2109-10 grey 3100
Fiber Content 40 % up to 65 % by w. for high strength application / 50 % weight saving
Test
s
PerformanceHumidity Resistance DIN EN ISO 6270-1
passed
EN 45545-2 HL 2
Anti Graffiti yes yes yes yes
Gelcoat The choice of the gelcoat depends on various factors: Please ask for specific recommendation
NUVOPOL 37-03 TGPGelcoat thickness: 0,7–0,9 mm
NUVOPOL 37-03 TGP (A) and 37-05 TGP Gelcoat thickness: 0,8–1,0 mm
EN 45545 (R1, R17, R7, R8…)Depending thickness, sandwich, coating and manufacturing methodes
Some Mäder Coating Options for Mäder EN 45545 Composites … for Hand Lamination, RTM light and Vacuum Infusion Processes
4 Walter Mäder AG, Composites | madercomposites.com 5
-
Walter Mäder AG, Composites | madercomposites.com
Vacuum Infusion for EN 45545 Composites
Alstom ETR 675
Toilet Floor
Also for Structural Applica- tions: NUVOCRYL FR 60-60 G with up to 65% glass content with NUVOFIBER BIAX / QUADRIAX
Vacuum Infusion System Gelcoat NUVOPOL 37-05 TGP Resin NUVOCRYL FR 60-60 G
Glass Quadriax Up to 50% lighter weight!
Also for inside applications for lower weight, better, constant quality and strength Vacuum Infusion System Various options depending on mechanical strength
Preparation with Glass and Peel-Ply Infusion Start and after 4 Minutes Low cost approach for lower strength requirements with GIRALITHE DITRA 2109-10 XP white 3010
Locomotive Front Mask
RTM Light System for EN 45545 Interiors and Exteriors
It is not Hand Lami-nation or SMC:
For many interior composites the RTM / RTM light
method is more cost efficient and has shorter lead time
RTM Light SystemGelcoat NUVOPOL
37-05 TGP Resin GIRALITHE
DITRA 2109-10 XPwhite 3010
Sandwich Front MaskRTM Light System, Gelcoat NUVOPOL 37-05 TGP Resin GIRALITHE DITRA 2109-10 XP grey 3100 Gel-, curing time adjustable to process
Front Mask AIREX/3AC
RTM Light SystemGelcoat NUVOPOL 37-05 TGPResin GIRALITHE DITRA 2109-10 XP, grey 3100Gel-, curing time adjustable
RTM Light SystemGelcoat NUVOPOL 37-05 TGP
Resin GIRALITHE DITRA 2109-10 XP white 3010Pre-accelerated for fast molding
Alstom Metro Sydney Interior Cap Lining
Bombardier S-Bahn Hamburg
Pc. Part Cost Lower Cost Higher Cost
Volume High Low
Sq. FtGeometry
Large/Complicated40 000 2000
Quantity
50
Small /Simple10
200
500
Labor Automation Labor Intensive
Higher Cost Lower CostTooling Cost
SMC VARTM / RTMLRTM
Open Mold
6 Walter Mäder AG, Composites | madercomposites.com 7
CASE 2: 10 sqm, single skin, 6 mm (HL)
Hand lay up Infusion
Weight / m2 Weight / m2
kg kg
Gelcoat 0,80 0,80
Lam. Glas 5,00 30 % / 31 % 5,00 60 % / 67 %
Resin 11,00 2,50
Total / m2 16,80 8,30
Total Front 168 kg 83 kg
Comparison Hand Laminat versus Infusion of Train Front
49 %
-
Walter Mäder AG, CompositesIndustriestrasse 1CH-8956 KillwangenTel. +41 56 417 85 55Fax +41 56 401 67 [email protected]
Bhimrajka Mäder184-B, Maker Tower ‚E’, 18th FloorCuffe Parade Mumbai – 400 005, Indiawww.bhimrajkamader.com
Mäder Composites FranceZI du Fournalet117 avenue de FrèresLumières CS 20111 SORGUESTél. +33 4 90 39 36 00Fax +33 4 90 39 51 30www.madercomposites.com
Mäder China5001, Shuangzhu Road NorthJiading industry Zone201815 Shanghai CHINA
Please contact
us for further
information abou
t
EN 45545.
Version 9 / 18
Related Documents
