Biocomposite Rail Carriage Door

TRB and Composites Evolution joined forces to meet the ever-growing demand for greener materials in the rolling stock industry.

Biocomposite Rail Carriage Door

Let’s set the scene…

TRB has over 40 years experience in the design and manufacture of high-quality rail interiors, door leaves and detrainment systems. In response to an ever growing demand and – gap in the rolling stock market – for greener, more energy efficient materials the award winning rail carriage door leaf project was born.

The result…

An innovative, biocomposite carriage door which not only meets the most stringent fire, smoke and toxicity requirements (comfortably!), but also delivers a 35% weight saving when compared to a bonded aluminium door… and all of this for a comparable cost!

Lyndon Newman, Chief Engineer for TRB commented: “We are extremely pleased with the overall performance data for the new biocomposite carbon fibre prepreg sandwich panel system, in particular the FST specifications achieved. In the 30 years I have been in the industry I have never seen such impressive fire performance test results for a non-phenolic based thermoset system, achieving the BS standard so comfortably. The Evopreg PFC bio-resin prepreg has fire retardant properties greater than phenolics, plus excellent temperature and chemical resistance.”

Lyndon went on to say: “We initially developed this biocomposite product for rail door leaves, but it could be used for other mass transport interior applications. We have brought aerospace prepreg technology to our rail customers and can now offer them a truly ‘green’ material design option that is 35% lighter than a bonded Aluminium door at a comparable cost.”

The details…

The TRB biocomposite door leaf is a sandwich construction consisting of carbon fibre-reinforced Evopreg PFC prepreg facing either side of a 100% recycled polymer foam core. It has a 40 year life cycle expectancy, is more robust than its aluminium equivalent, has superior fatigue resistance and low maintenance costs. Due to the significant weight reduction, the composite door leaf requires a less heavy duty door operating system and provides a number of cost saving benefits to rail operators, such as: reduced energy consumption per journey and less track wear and tear.


What our client said...

We are extremely pleased with the overall performance data for the new biocomposite carbon fibre prepreg sandwich panel system, in particular the FST specifications achieved.

Lyndon Newman, Chief Engineer, TRB Lightweight Structures

External Links

TRB Lightweight Structures


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In the 30 years I have been in the industry I have never seen such impressive fire performance test results for a non-phenolic based thermoset system