Paul Wartenweiler, BU Manager Composites, Walter Mäder AG, Switzerland

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1 EN Composite Systems 1) Requirements and Conclusions from more than 35 EN Projects 2) Increased Productivity through Mäder Total EN System Approach Warsaw, Paul Wartenweiler, BU Manager Composites, Walter Mäder AG, Switzerland s2

2 Mäder Composite Production Sites Total capacity tons at 2 places, China in transfer Mäder Composites Mäder Composites France Killwangen (Zürich) Sorgues (Avignon) Alkyd and modified Alkyds (S, WB, HS) saturated and unsaturated Polyester UV curing resins and gelcoats Additives Formulated resins und gelcoats

3 Mäder Coatings is a leading Supplier in Europe for Railway / Mass Transit Coatings

4 Flame retardant Systems for easy processing: more than 35 References for EN ALSTOM ICNG

5 EN Composite Systems 1) Requirements and Conclusions from more than 35 EN Projects

6 Experiences / Challenges of EN 45545

7 T02 - DIN EN ISO Smoke Generation Inside R1: DS4 Outside R17 DS max!

8 CEN TS Performance with / without Coating Toxic Gases Smoke Density VOF4 Smoke Density DS 4 Heat Release becomes a HL2 System when painted HL 3 HL NUVOVERN AQUA Primer + Topcoat NUVOPOL Gelcoat int. on GIRALITHE DITRA XP 1200 Spread of Flame 20 HL3 HL2 HL1

9 Intumescent Gelcoat High fire protection trough intumescent effect: Mäder Composites passed first EN tests in 2009

10 Fire Retardant Gelcoats, Important Points Intumescent Gelcoats (EN 45545) Not every intumescent gel coat is resistant to humidity / some only for inside It is well known from Intumescent Paints

11 Fire Retardant Gelcoats, Important Points Intumescent Gelcoats (EN 45545) Not every intumescent gel coat is resistant to humidity / some only for inside Intumescent gel coats which work are much more expensive Depending from supplier thickness up to mm

12 Some hints / Sandwiches Avoid Composite Design Dead Lock with EN (Gelcoat up to 1 mm!)

13 Closed Mould processing of fire retetardant resins

14 Closed Mould Basics Influence of Glass / Permeability

15 High Composite Evaluation costs for single Projects to meet EN Specifications and other Specs.: Change of mentality in the industry: -All from one supplier -All Composite elements specified: STANDARTISATION -Stringent Tests What happend?

16 >> Exploding costs, delays in executions Change of mentality in the industry: -All from one supplier to reduce risks and responsibility -All Composite elements specified: STANDARTISATION -Stringent Tests first of EN and Water resistance And >> (good, water proof) EN gelcoats are much more expensive than DIN 5510 etc >> whole manufacturing chaine must be better controlled

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18 Water Resistance of Mäder Intumescent Gel Coats Test: Mäder intumescent gel coat TGP after 10 day in humidity chamber ( 40 C / 100 % rel. F. )

19 Water Resistance of Intumescent Gel Coats Test result: Mäder intumescent gel coat TG > after storage 1 year outside (no coating) No bubbles

20 Bombardier Flexity II 2012 Example of coated GRP passing EN45545 HL 2, R1

21 EN Experiences EN Projects, many with water based coatings Bombardier Flexity II Blackpool Bombardier Flexity II Goldcoast Australia Intumescent Gel Coat NUVOPOL Water based Primer Water based Topcoat Bombardier Flexity II De Ljin Bombardier TRAXX 3 several Projects On going Bombardier S-Bahn Hamburg Siemens Desiro RRX Intumescent Gel Coat NUVOPOL 37-03/05 Solvent Based Primer Water based Base Coat Water based Topcoat 20 days KK test passed

22 Avoid Bubble Problems with Intumescent Gelcoats Some hints use suitable Gel Coat, pass KK test.. handle/ work in normal/ dry condition > take measures when not cure, post cure acc. plan apply in plant primer

23 EN Composite Systems 2) Increased Productivity through Mäder Total EN System Approach

24 Mäder Total EN UP Solutions Gelcoats, Resins and Coatings from one Supplier

25 Mäder Gel Coats fluences658-2 for Spray Spread and Brush of flameapplication: proven EN and Water Resistance Performance NUVOPOL Gelcoat Can be used without paint Chemical/water resistance In most colors available Faster gelling Lower costs Experience since 2012 NUVOPOL Gelcoat (A) NUVOPOL Gelcoat Very low smoke values: compensates smoke from coatings No auto-demoulding on large parts (front masks, nacelles) Can be laminated next morning HL 3 in colored gelcoat with XP Flexibel

26 Resins Proven Systems for EN Hand Lamination There are several resins (with different ATH loading) with EN certificates available However it turned out customers prefer the highest filled resin, giving most security in passing e.g.the smoke tests also with coatings in border line designs/applications and to avoid to have several products on stock Giralithe Ditra GL XP, highest flame retardancy, easy processing is the core product for hand laminated HL 3 HL 2 HL 1 composites

27 Resins Proven Systems for EN RTM / RTM light, Vacuum Infusion (to achieve given thickness) Giralithe Ditra GL XP is available in 2 low viscosity grades with excellent flow and wetting properties Giralithe Ditra GL XP white 3010, highest flame retardancy, easy processing pre-accelerated Giralithe Ditra GL grey 3100, highest flame retardancy, easy processing not pre-accelerated To achieve high flow rates and to avoid excessiv smoke special RTM mats have to be used: Mader Composites provides the full range of adapted fiber products

28 Proven Systems for EN Resins Vacuum infusion, High Fiber content NUVOCRYL FR G NUVOCRYL FR G is the core product for vacuum infusion for HL 3 HL 2 HL 1 composites

29 Improve further the Productivity Vacuum Infusion RTM light UV curing of Gelcoats

30 Vacuum Infusion Technologies for Railway and M.T.

31 Vacuum Infusion Technologies for Railway and M.T.

32 Mäder High Strength (HS) Concept, also for large Parts Comparison Hand Laminat versus Infusion of Train Front CASE: 10 sqm, single skin, 6 mm (HL) Hand lay up Weight/m2 Infusion Weight/m2 kg kg Gelcoat Lam. Glas % / 31% % / 67% Resin Total / m Total Front 172 kg 87 kg (49 % weight saving)

33 (Painted) Composites with Mäder Gel Coat, Resins and Coating pass EN HL 2 (R 17) Front Head by Infusion

34 (Painted) Composites with Mäder Gel Coat, Resins and Coating pass EN HL 2 (R 17) Infusion

35 (Painted) Composites with Mäder Gel Coat, Resins and Coating pass EN HL 2 (R 17)

36 Resin Transfer Moulding (RTM) RTM Production Bombardier S- Bahn Hamburg painted Composites pass EN HL2 Key Points: Short production cycles High, constant quality Lower part costs

37 RTM light RTMlight Production ALSTOM METRO Sidney Window Frames pass EN HL2 Key Points: Short production cycles High, constant quality Lower part costs

38 FDT Know How is also used for

39 Training by Mäder Composites

40 Summary Mäder Total EN Solutions: Paints, Gelcoats and Resins combined with innovative Manufactoring Methods 1) Training on EN ) Mäder Total EN Solutions 3) Training on Processing like RTMlight, Infusion, Quality Control etc Processing needs for Vacuum Infusion Processing, RTM Light RTM