Floating floors in rail cars Advantages 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. We get the raw material only from PU supplier and develop in R&D and Cellular product – mixed with sylomer and closed Sylodyn

Business areas products and material solutions Rail Heavy freight High-speed Urban transport Standard-gauge railway Light rail Sub ballast mats, sleeper mats, etc since from 40 years, isolation of building , interiors sky scrapers new York , in down town in tokoyo, 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. German railway station in Ulmn – harsh environment experience for 40 years

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 1990 – rail car Austrian company delivered to Baverio , main concept complete decoupling of floor to structure. 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 with elastic bearings Material advantage Benefit vibration isolation higher comfort decreased Life-Cycle-Costs reduction of secondary air-borne noise lower noise level inside rail car low creeping long 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 reduction in 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 polyurethane Sylomer® 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

Support of Getzner 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 screw compressors drivers cabin

References Metro Ultra-light-floor tram High speed train Vienna - Austria High speed train China Metro Bangkok - Thailand Commuter trains Germany Mainline trains UK DMRC - India 1 – seimens 2 bombardier 3 seimens 4 bombardier 5 hitachi 6

Internal and external statements 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. Rohs - Reach -

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 Baikerikar amit.baikerikar@getzner.com More curioues to know more on our solutions.