Floating floors in rail carsAdvantages and benefits of elastic floor bearings

made of high tech PU

International Conference on Rail Coach Interiors

09th to 10th of October 2015, New Delhi

Company facts

300 employees worldwide Production based in Austria Sales offices in Germany, France, USA,

Japan, China, India and Jordan Production of approx. 7000 tons of

high-tech PUR material per year Sales 2014: EUR 70.3 Mio. Export rate > ø86% Brands: Sylomer® and Sylodyn®

Core competence:

More than 40 years of experience with vibration isolation and noise reduction within railway superstructure an embedded bearing of buildings.

Business areas

Rail-Heavy freight-High-speed-Urban transport-Standard-gauge railway-Light rail

Construction-Elastic shielding of buildings-Foundation bedding-Timber construction-Impact noise

Industry– Machine bearing– Buildings– Rolling stock– Customer-specific products and material solutions

From track superstructure into rolling stock vehicles

Getzner Polyurethane elastomers (Sylomer® and Sylodyn®) are used since decades in track superstructure. The excellent material properties like

resistance against environmental impact and aging

excellent creep resistant behaviour proven long life

made it easy for Getzner to transfer the materials from rough superstructure conditions into the „safer environment“ of rolling stock vehicles.

Long term reference

Sub-ballast mats for high-speed line

Hannover-Würzburg, DB AG

installed in year 1988 refurbished after 27 years because of

change of ballast approx. 384.000.000 t load changes

since installation external material test from technical

university in Munich

Material properties are still conforming the original specification and data sheet.

Floating floor concept

Main target:

Decoupling floor construction of car body with elastic polyurethane stripes floating floor concept

Main benefits

Floating floor concepts have become very popular.

Depending on the solution and construction the main advantages are:

Reduction of noise level inside waggon higher comfort

Reduction of floor height reduction of complete waggon height, less cost and better

aerodynamic Reduction of weight

lower embeded power consumption during usage

in combination with

Reduction of vibration

this is the part of PU elastic elements from Getzner.

Sylomer® stripes mounted in a new metro car

Coaches for DMRC

Sylomer® useage in a repair workshop

Sylomer® stripes bonded underneath floor panel

Who benefits?

Passengers Railway operators Rail car manufactures

Advantages of floating floors withelastic bearings

Material advantage Benefit

vibration isolation higher comfortdecreased Life-Cycle-Costs

reduction of secondary air-borne noise

lower noise level inside rail car

low creepinglong life time

no cracks in seals longer service intervals

high efficiency at working load

reduction of floor height better aerodynamic

lightweight material lower energy consumption

no loss of material properties when prestressed

tolerance compensation during installation

flame retardant fire safety norms complied

easy cutting and bonding easy installation

Why using an PU elastic bearing?

• Compared to other materials (rubber, silicone) an elastic bearing (like Sylomer® or Sylodyn®) can achieve a significant noise reduction (depending on floor construction).

Elastic material gets softer as it reachs the dynamic load range

Excellent Creep resisitance

Higher damping causes better acoustic performance

Noise reductionin rail cars

The noise reduction of a floating floor is depending on

floor underlayment (polyurethane, rubber-metal-compound, silicone) thickness and width of stripes (e-modulus dependancy) floor panel (wood, composite, aluminium-honeycomb) floor covering

Possible noise improvment :

replacing rubber solutions 2 dB(A) to 7 dB(A) replacing a rigid connection up to 12 dB(A)

The tests for structure borne noise and vibration

reduction need to be designed for a specific project

Can an elastic polyurethane comply fire safety in trains?

The 2012 launched and new developed Sylomer® FR grade (fire retardant) can!

These materials are tested / conform EN 45545-2 for usage in floors.

R10 (formerly R9) – Floor composite (floor substrate and covering) R22 (formerly R23) – Interior (not listed materials)

The EN 45545-2 is finally replacing all local norms (DIN 5510-2, BS 6853, NF F 16-101) in March 2016.

Flame retardant polyurethaneSylomer® FR

• Certifications conform:

Norm: Classification:

EN 45545-2 HL 3 (Hazard level)

DIN 5510-2 S4, SR2, ST2

NF F 16-101 M3/F2

NFPA 130- ASTM E 662- ASTM E 648- ASTM E 1354

passed

JRMA passed

Support ofGetzner Werkstoffe

material selection conform indicated load cases (empty car, traffic load, max. load)

support in optimal strip positioning

calculation of deflection and natural frequency for different load cases

bonding recommendation

internal load testings

chemical resistance testings

partnerships with floor panel, profile manufactures and rail coach manufacturers

Areas of Applications - other than Passenger cabins

Steel coil

bearings

Decoupling of

HVAC units

Bearing of

sanitary cabins

Cabin bearing in

measuring vehicles

Decoupling of

screw compressorsBearing of

drivers cabin

References

Ultra-light-floor tramVienna - Austria

High speed trainChina

MetroBangkok - Thailand

Commuter trains GermanyMainline trains

UKMetro

DMRC - India

Internal and externalstatements

Getzner can offer statements regarding

ROHS and REACH confirmation VOC freedom freedom of halogenated flame retardants freedom of softening agents

From Deutsche Bahn AG we are listed as Q1 supplier since years.

Thank you for your attention

The success of our partners is our passion: offering the best technology in the world to deliver cost-effectiveness and reliability.

Thomas Gamsjegar thomas.gamsjegar@getzner

Amit Baikerikaramit.baikerikar@getzner.com