Global Rolling Stock · leading rolling stock/railcar builders from such countries as Japan, EU,...
Transcript of Global Rolling Stock · leading rolling stock/railcar builders from such countries as Japan, EU,...
Global Rolling Stock
Car Builders are
exporting their cars to
more and more foreign
countries
The United States represents
a potential mass transit
growth market that has
leading rolling stock/railcar
builders from such countries
as Japan, EU, UK, South
Korea, China, Mexico,
Canada, and South America
bidding and winning new
transit railcar projects.
United States Fire Safety of
Passenger Railcars and
Locomotives are governed by
CFR Part 238.103, Appendix B.
This requires that all
passenger flooring used in the
vehicle design shall undergo
and pass an ASTM E-119 Floor
Fire Test (30 minute)
GENERALLY, THERE ARE TWO CARBODY
UNDERFRAME MATERIALS USED IN USA
ROLLING STOCK CONSTUCTION:
STEEL:
ALUMINUM:
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ASTM E-119 Fire Safety Compliance:
Actual Floors under 30 minute
E-119 test.
Composite
Floor Panels
Copyright © 2006 Milwaukee Composites Inc. All Rights Reserved.
Simulated
Passenger
Load
PASS REQUIREMENTS:
1. No drop –thru of any floor
structure
2. No increase above 139
degrees C from ambient.
3. No ignition of cotton cloth
samples
4. No Flame-Thru’s
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Southwest Research NFPA 130/ASTM
E-119 Floor Fire Test Cell (SAN ANTONIO, TEXAS)
Complete Floor
Assembly is
Mounted Above
Furnace
Gas Fired
Furnace
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This is a photograph
of one of the test
furnaces available to
Perform ASTM E-119
testing.
A REVIEW
of
SOME BASIC TESTING
OF ALUMINUM CARBODY
SUPPORT MEMBERS AND
UNDERSTRUCTURES.
Composite floor system being
Installed onto test chamber
support for an indicative
research test. The intention of
this test was to understand
how an aluminum I beam floor
joint support would behave in a
fire test with no carbody
underpan, or insulation or air
gap.
Fifteen minute (15) minute time
duration.
Furnace Ramp to Temperature
was to ASTM E-119
requirements.
Desired full temperature:
704 oC (1300oF)
Tested @ Southwest Research Institute: San
Antonio, TX
HEIGHT:
3 cm (8”)
WEB
thickness:
3.1 mm (0.125”)
FLANGE thickness:
4.7 mm (0.125”)
6061-T-6 ALUM I-BEAM
Significant Aluminum
I-beam deflection:
going molten @ 6’:39”
into the test.
Aluminum I-beam has
broken away from
aluminum car support
structure @ 6’:46”
into the test.
Small Scale Fire Test: Top
Surface After Test.
Composite floor structure
did not fall into furnace
despite aluminum I beam
failure.
Washington Metro Area Transit
Authority (WMATA) 6000 Car
Floor Structure.
• Aluminum Extruded Subfloor
• Aluminum Extruded Side
Sills
• 164 carsets in service since
2008
The Phenolic Composite Floor
Panels were mounted upon
Elastomeric Standoff Tapes
and then All Floor Panels Were
Riveted to The Aluminum
Extruded Profiles Beneath.
Fiberglass Insulation
Between Phenolic
Composite Floor Panel &
Aluminum, Approximately
19mm (0.75”) thick.
Phenolic Composite Floor
Panels:
19mm (0.75”) thick.
ASTM E119 FLAME SOURCE
The ASTM-E119 Test Agency
Concluded the WMATA 6000
Aluminum Car Structure with
passenger floor was rated
for Fifteen (15) minutes.
Determine Fire Performance of
A Small Scale Passenger Floor
Assembly, Non-loaded,
Supported By An Aluminum
Corrugated Understructure.
Tested @ EXOVA Warringtonfire
(United Kingdom)
Corrugated Aluminum
Fiberglass Insulation
19mm Composite Floor
Altro Floor Covering
Note: @ minute 23:00,
corrugated aluminum
understructure began
to melt away.
Note: Recall that @ minute 23:00, aluminum began to
melt away, and now the entire aluminum understructure
is gone. The pink glowing material is the residual
fiberglass insulation previously within the corrugated
aluminum profiles.
The Phenolic
Composite Floor
Panel’s Bottom
Fiberglass &
Charred Balsa
Core Is All That
Remains.
A REVIEW
of
SOME BASIC TESTING
OF STEEL CARBODY SUPPORT
MEMBERS AND
UNDERSTRUCTURES.
TYPICAL STEEL (Stainless Steel) Carbody
UNDERFRAME WITH UNSUPPORTED
SPANS.
TYPICAL STAINLESS STEEL
UNDERFRAME FLOOR ASSEMBLY for
ASTM E-119 Thirty (30) Minute Fire Test.
Some Carbuilders use just a
single section of insulation
above the steel underpan, with
approximately 3 to 4 inches of
air as an insulation gap.
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Thermocouples are
arranged throughout
the top of the floor test
specimen
Complete Railcar Floor is Mounted on the
Actual Carbody Underframe Assembly
and is Mounted Above Furnace
NEW YORK CITY
TRANSIT
R-160
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All floor loading
specified by the transit
agency must be
simulated during the fire
test. Cinder blocks are
used to provide the
loads at specific
locations.
Tested @ National Gypsum Fire
Chamber (Buffalo, NY)
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At least three (3) cable
holes through the floor
must be tested.
Exposed side showing cable holes
through the car floor assembly.
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Fire Nozzles as they
look through the
viewing window of the
ASTM E-119 Furnace
during testing.
R-160 PASSED Thirty (30) Minute
Fire Test.
View Through furnace
window just after test is
completed showing red-
hot steel underframe.
EXPERIENCE GAINED with FIRE TESTING
USING ALUMINUM and STAINLESS STEEL
CARBODY COMPONENTS &
UNDERSTRUCTURES: Stainless steel car bodies utilizing an
underpan, and an insulation between the bottom of the floor panel and above the underpan has an excellent chance of passing an ASTM E-119, 30 minute test.
Aluminum carbody understructures, directly exposed to the fire source beneath the car during ASTM E-119 testing will have difficulties passing an ASTM E-119, 30 minute fire test.
During ASTM E-119, 30 minute testing, the entire fire platform assembly tends to deflect and skew, especially around minute 15 and beyond. Underpan assemblies tend to open caused by high heat stress allowing the direct flame source to access the bottom of the passenger floor panel. This can cause delta T failure.
Any air-gap that is part of any aluminum or steel underframe fire test platform assembly will cause a flame-through and should carefully be inspected and corrected before testing begins. Air-gaps cause fire test failure.
Special attention should be paid to the penetrations going through the test floor platform assembly. All penetrations should be properly sealed with fire stop compounds to prevent flame-through.
Most test authorities will highly scrutinize various coatings (fire preventive coatings such as intumescent blends, ablative layers) applied to the carbody underpan and underfloor assemblies to prevent heat build-up during ASTM E-119 testing. The concern appears to be rooted in that coatings may wear away during a thirty (30) year car expected service life, thus compromising passenger safety during a fire event.
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GLOBAL
ROLLING STOCK
CARBUILDERS: • Using New Materials
• Steel & Aluminum Underfloor
The Industry Needs Constant
SUPPLIER/CARBUILDER/
TRANSIT AUTHORITY
TEAMWORK
PASSENGER
SAFETY
IS IMPROVED
CONTINUOUS
IMPROVMENT
REQUIRED TO MEET
ASTM E-119
FIRE SAFETY
STANDARDS
Our Industry Goal for All USA Rolling Stock/Car
Construction: Secure an ASTM E-119
Fire Test “PASS” For All Car Designs.
SUPPLIERS MUST
CONTINUE TO DEVELOP
MORE IMPROVED FIRE
COMPLIANT PRODUCTS &
SERVICES