Railway safety involves a large number of standards and regulations in different areas. These also include fire protection in rolling stock, where EN 45545-2 plays a key role. This standard is part of the set of European standards developed to ensure fire safety in railway vehicles.

Why is EN 45545-2 so important?

EN 45545-2:2013 regulates the fire performance of materials and components in railway vehicles. This standard sets out clear and strict requirements that materials must meet to ensure the safety of passengers and staff in the event of fire.

EN 45545-2 is classified according to the various levels of risk associated with their design and operation:

  • HL1: Lowest risk level
  • HL2: Intermediate risk level
  • HL3: Highest risk level

And the factors influencing the classification of the hazard level are:

  • Kilometres travelled in tunnels: vehicles operating in long tunnels have a higher risk, which raises their classification to HL2 or HL3.
  • Automation: Automated (driverless) trains have stricter requirements due to the lack of trained personnel on board to manage emergencies.
  • Vehicle design: Trains that are double-decker or have sleeping compartments are considered more ‘dangerous’.
  • Operational categories: There are several operational categories based on the type of route (underground, elevated structures, etc.), directly affecting the risk assessment.

 

Thus, meeting the HL3 classification means that the material has passed rigorous tests for flammability, flame spread, density and smoke toxicity, and is reserved for vehicles operating in high-risk scenarios such as long tunnels, night trains or driverless trains. Choosing a material that complies with this EN 45545 HL3

standard ensures you comply with regulations and standards knowing that you are using the highest quality and safest products available on the market. As is the case with some grades of Plastazote® foams with flame retardant additive.

Plastazote® LD 15 FM ALU: The Foam that meets the EN 45545-2 standard.

Plastazote® LD 15 FM ALU is a product that ZFoam has been using successfully for more than ten years. This closed cell cross-linked polyethylene foam, manufactured by nitrogen injection, incorporates flame retardant additives to improve its fire resistance and is designed to offer exceptional performance in demanding applications

What makes it so special?

  • Lightweight: With a density of 15 kg/m³, it is easy to manage, highly efficient and makes it the lightest polyolefin foam on the market.
  • Closed cell structure: It does not absorb water, which makes it an ideal choice for humid environments and at risk of condensation, especially in locations where the temperature difference between the inside and outside of the carriage is extremely high. It is the perfect product for climates with extreme temperatures, whether in summer or winter.
  • Superior thermal insulation: A thermal conductivity of only 0.037 W/mK ensures efficient temperature control and allows for optimal design when calculating insulation thicknesses.
  • Chemical-free: Produced without foam residues (VOC), ensuring a healthier indoor environment.
  • Easy adaptability to curved surfaces: Lightweight and elastic material. Ideal for projects with complex geometries.
  • Excellent cutting and machining properties: Allows precise customisation for various applications.
  • Chemical resistance: Resistant to most oils, solvents, acids and alkalis.
  • Durability: Weather resistant and with good UV stability.
  • Halogen Free Versions: HF (Halogen Free) versions are available with all the features described above.

And when it comes to safety, Plastazote® LD 15 FM ALU is certified for performance:

  • R1* (indoor surfaces): Classified at levels HL1, HL2 and HL3.
  • R10* (ceilings): Meets the highest requirements, also in HL1, HL2 and HL3.

(*) Certifications available in the full range of thincknesses.

 

EN 45545-2 Standard

 

Where is Plastazote® LD 15 FM ALU used?

These are some of its applications in the railway sector:

  • Interior Surfaces: Used in ceilings, walls and floors as primary thermal and acoustic insulation.
  • HVAC ducts: Insulation in heating, ventilation and air conditioning systems.

and beyond Rail

In addition to the all-important railway sector, some variants of AZOTE® foams also excel in other sectors thanks to their versatility and performance:

  • Shipbuilding: Lightweight, fire-resistant materials that defy the harshest conditions.
  • Industrial air conditioning: Insulation that optimises energy efficiency.
  • Automotive: Used for thermal and acoustic insulation in door panels, roofs and engine components.
  • Aerospace: Used in aircraft interiors and insulation of electrical components.
  • Electronics: Ideal for encapsulating sensitive components.
  • Sports equipment: Used in body protectors and thermal clothing due to their light weight and insulation capacity.
  • Medical applications: Used in medical equipment and furniture requiring thermal control and flame-retardant properties.

Why choose ZFoam products

Choosing ZFoam means choosing solutions that comply with the most demanding regulations, but it also means choosing the most efficient and advanced products on the market.

Our technical team works closely to understand the needs and offer the necessary support for each project. We are a dependable partner, committed to innovation, quality and safety.

All certificates and other documentation for these materials are available on request from our sales department.

Do not hesitate to contact us!