Roof panels for the Flexity tram in Palermo, Italy
What looks like a threedimensional, singlecast component on the sides of trams from the Flexity range from Bombardier, consists of pultruded GRP elements with gluedon end caps, which have been milled, glued, primed and painted. Optionally, the 656 mm wide roof panel can also be manufactured with a gluedon bracket. It has fire protection in accordance with NF F 16101 and DIN 5510. For new projects, we also meet fire protection requirements in accordance with EN 45545.
Spoiler for the M5000 tram in Manchester, UK
Bombardier designed the M5000 tram as a highfloor tram specially for use in Manchester. The spoiler consists of a solid stainless steel frame with a gluedon GRP profile. The profile was milled on modern CNC machines at TC, glued to the frame, primed and painted with a special 2KPUR metallic paint. It is manufactured in different lengths and designs. It has fire protection in accordance with BS 6853. For new projects, we meet fire protection requirements in accordance with EN 45545.
Interior deck system for the RheinRuhr Express (RRX)
The highcapacity, doubledecker local trains developed by Siemens are fitted with an interior deck system from TC. All of the components – middle deck, lowfloor and highfloor haunches, inner side deck and cold air duct – are based on GRP pultruded profiles.
Airflow system for the Desiro ML/ÖBB, Austria
Having developed and manufactured the airflow system for the Desiro ML Mittelrheinbahn and the Desiro ML Brussels, TC is now also producing the airflow system for the Desiro ÖBB. The respective systems are based on pultruded profiles made of fibre glassreinforced plastic. For the air ducting system, the fire protection properties of the GRP profiles were set in such a way as to meet the requirements in accordance with EN 45545.
Roof panels for the Sprinter Lighttrain in the Netherlands. For the Sprinter Lighttrain made by Bombardier, stainless steel sliding blocks were glued into the GRP profiles (A2 bonding) for high rigidity. Vertical tear resistance of 2,772 N was required for every single adhesive bond. This requirement was far surpassed in practice. The roof panel, which has the appearance of a 3dimensional component from a single cast, consists of pultruded GRP profiles and 3D moulded parts, partly combined with stainless steel components. 3Dprinted components may also be used.
Interior deck system for the Desiro ML
Following the development of the interior deck system for the Desiro ML Mittelrheinbahn and the Desiro ML Brüssel at TC and its subsequent delivery, the interior deck system for the Desiro ÖBB is now being manufactured at TC. The various systems are based on pultruded profiles made of glass fibrereinforced plastic produced by Exel Composites in Belgium.
External casing components for urban buses and longdistance coaches
For many years, we have been developing casing components for the exterior of buses and railway vehicles here at TC. One advantage of GRP profiles is that we can produce different component lengths based on just one tool. This increases flexibility in design. The components are based on a profile made of glass fibrereinforced plastic, which we process in our CNCcontrolled milling machines to produce
precisioncut parts for e.g. wheel arches, indicators and maintenance covers. We can also install reinforcements or addon parts at the same time if required.
The side walls of urban and overland buses are put under major strain by the daytoday demands placed on them stone chipping, scratches and minor and major accidents quickly cause damage to the thinwalled metal sheets found in older models. What's more, in some cases the effects of weather and chemicals such as deicing salts and cleaning products can lead to unsightly signs of corrosion, which can damage the image of the bus company among its customers. This makes repairs and touchups necessary.
As noncorrosive plating is not always available for older vehicles, TC manufactures side walls made of glass fibrereinforced plastic that are suitable for all such models and makes, and provide an optimal and durable alternative to older metallic plating.
Corner and plugin profiles and seat support covers
TC products aren’t always apparent at first glance. They often resolve problems in complex assemblies. For instance, they are used to meet the need for a component that has good thermal insulation properties, but is also lightweight and has a high mechanical load capacity.
Providing solutions with composite materials
Lightweight yet high rigidity and strength
Good thermal insulation
Freedom in design for customised shapes
Highquality, paintable surfaces
Undercuts can be created in the profile
Universal for radio waves
Roof rim for trams in Karlsruhe
When manufacturing and attaching the roof rim for trams in Karlsruhe, it was particularly important to ensure that the adhesive bond was secure. These dualsystem vehicles, which are manufactured by Bombardier, can reach speeds of up to 100 km/h. The GRP roof rim was attached to the vehicle body using an invisible aluminium bracket. The adhesive bonds between the aluminium and GRP were applied in accordance with DIN 6701, Class A1, and thoroughly tested in conjunction with the Fraunhofer Institut. FEM calculations demonstrate the permanent durability ofthe adhesive bond.