Thermoplastic Extrusion for the Rail Sector
EN 45545 fire safety, ESD protection and durability for rolling stock and infrastructure.
Thermoforming in the Rail Industry
At CANDEA Plastics we manufacture high-performance extruded sheets and profiles for the rail industry, where fire safety, electrostatic protection and extended service life are fundamental requirements. Our materials comply with EN 45545-2 at hazard levels HL2 and HL3, ensuring regulatory conformity for metro, tram and high-speed interiors.
From carriage interior panels to ETCS/ERTMS module enclosures, our formulations are engineered to withstand over 30 years of service under constant vibration, extreme thermal cycling and exposure to aggressive chemical agents. We work with operators, OEM manufacturers and Tier-1 suppliers to develop solutions that reduce weight, improve passive safety and simplify rolling stock maintenance.
- Weight Reduction (Lightweighting): Replacement of heavy metals and fiberglass with high-performance thermoplastics, contributing to energy efficiency and reduced track-and-wheel wear.
- Fire Compliance: Materials formulated to meet EN 45545-2 HL2/HL3 and NF F 16-101, eliminating regulatory uncertainty from the design phase.
- Extended Service Life: Formulations designed to maintain mechanical and aesthetic properties over 30+ years of continuous service, reducing maintenance and replacement costs.
Technical Challenges: Safety and Durability on Rails
Fire Safety (EN 45545-2)
The greatest challenge in rail interiors is passive fire safety. Materials must meet stringent fire behavior, smoke emission and toxicity requirements based on the vehicle's operational category, especially in tunnels and underground sections where evacuation is more complex.
- Our Solution: Flame-retardant thermoplastics formulated to comply with EN 45545-2 at hazard levels HL2 and HL3, as well as NF F 16-101 for the French market. Halogen-free flame retardant additives available as required.
- Benefit: Certifiable safety from the raw material. Materials ready to pass flame spread, oxygen index (LOI), smoke density and toxicity tests, accelerating final component certification.
ESD Protection for Signalling and Control (ETCS/ERTMS)
Next-generation signalling systems (ETCS/ERTMS) and traction control units rely on highly sensitive electronics. Electrostatic discharge generated by pantograph-catenary contact, high-speed air friction or passenger movement poses a real risk to these safety-critical components.
- Our Solution: Permanent conductive and dissipative compounds with controlled surface resistance in the range of 10⁵ to 10⁹ Ω/sq, engineered to protect electronic modules without interfering with GSM-R/FRMCS communication signals.
- Benefit: Reliable protection for balise housings, on-board ETCS modules, trackside signalling cabinets and PCB handling trays during maintenance.
Vibration and Chemical Resistance
Components in under-floor and technical areas are exposed to continuous vibration, ballast impacts, thermal cycling from -40 °C to +80 °C and direct contact with cleaning agents, hydraulic fluids and degreasers. The combination of these stresses accelerates degradation of materials not designed for this environment.
- Our Solution: High-impact polymers with excellent vibration fatigue resistance and chemically inert formulations against the most common railway fluids, including brake fluids, oils and industrial degreasers.
- Benefit: Under-floor components that maintain mechanical and dimensional integrity throughout the vehicle's service life (30+ years), minimizing unscheduled maintenance stops.
Technical Material Catalog for Rail
We develop formulations that balance fire safety, ESD protection and mechanical durability to cover every zone of rolling stock and rail infrastructure.
| Material Family | Key Properties | Typical Applications |
|---|---|---|
| Conductive ABS ESD | High impact resistance + permanent antistatic protection (10⁵–10⁹ Ω/sq). | ETCS module housings, passenger information displays, signalling cabinets. |
| Conductive PP ESD | Excellent chemical resistance + static dissipation + low weight. | Under-floor trays, cable trunking, traction equipment protections. |
| Flame-Retardant Polymers (FR) | EN 45545-2 HL2/HL3 compliance, low smoke and toxicity emissions. | Interior wall and ceiling panels, seat linings, decorative moldings. |
| UV Stabilized Materials | Resistance to solar radiation degradation + long-term color stability. | Exterior fairings, front-end panels (cab ends), bogie covers. |
| High-Impact Materials | Exceptional vibration fatigue resistance + low-temperature toughness (-40 °C). | Under-floor structural components, equipment mounts, ballast protection guards. |
CANDEA Materials for this sector
ABS ESD Conductivo CA-447
CA-447
Compuesto de acrilonitrilo-butadieno-estireno (ABS) con protección ESD permanente en el rango disipativo. Combina alta resistencia al impacto con excelente estabilidad dimensional y un amplio rango de temperatura, lo que lo hace ideal para la fabricación electrónica y para entornos industriales exigentes, y permite fabricar en cualquier color.
View all materialsHIPS ESD Conductivo CA-142
CA-142
Poliestireno de alto impacto (HIPS) con protección ESD conductiva y equilibrio mecánico mejorado. Ofrece módulo de flexión y estabilidad térmica superiores a los grados HIPS estándar, siendo la elección para bandejas de precisión y packaging de transporte reutilizable.
View all materialsPS-PE COEX ESD CA-226
CA-226
Mezcla de poliestireno y polietileno con protección ESD conductiva. Una solución económica que combina buen equilibrio mecánico con disipación electrostática fiable, diseñada para packaging electrónico de alto volumen y manipulación automatizada de componentes pudiéndose suministrar en cualquier color.
View all materialsApplications Across the Rail Value Chain
From in-line protection to final parts in the end product.
Passenger Interior
Safe and aesthetic solutions for the passenger environment in metro, tram and high-speed services. Materials that resist intensive use, frequent cleaning with aggressive agents and maintain their appearance for decades, meeting the highest fire safety standards.
- Wall panels, ceilings and interior partitions with EN 45545-2 compliance.
- Seat linings, armrests and fold-down trays.
- Lighting covers and hidden ventilation ducts.
Signalling & Control
Electrostatic protection for signalling electronics and next-generation train control systems. Materials that guarantee the integrity of ETCS/ERTMS modules, GSM-R communications and on-board diagnostic systems, essential for operational safety.
- Housings for on-board ETCS modules and traction control units.
- Trackside signalling cabinets and balise protections.
- ESD trays for PCB handling in maintenance workshops.
Exterior & Structure
High-performance materials for exterior and under-floor components that must withstand the harshest conditions: UV radiation, ballast impacts, continuous vibration and exposure to aggressive fluids over 30+ years of service.
- UV-stabilized exterior fairings and front-end panels.
- Vibration-resistant cable trunking and under-floor protections.
- Bogie covers and high-impact ballast protection guards.
Why choose CANDEA Plastics for Rail?
Beyond plastic extrusion, we are your partner in innovation and material development.
Guaranteed Regulatory Compliance: Materials formulated and tested to meet EN 45545-2 HL2/HL3, NF F 16-101 and European operator standards from the design phase.
Traceability and Batch Control: Exhaustive tracking of raw materials and production batches to facilitate IRIS (International Railway Industry Standard) audits and supplier certifications.
Custom Formulation: Ability to adjust color, texture and functional properties (ESD, FR, UV) to OEM or operator specifications, including corporate color matching.
Proven 30+ Year Durability: Formulations validated to maintain mechanical and aesthetic properties throughout the vehicle's service life, reducing total cost of ownership (TCO).
Prototyping and Short-Run Agility: Fast supply of smaller quantities for design phases, prototype certification and First Article Inspection (FAI) in rolling stock projects.
Ready to take your project to the next level?
Contact our experts to meet your technical and regulatory requirements.