Universal Accessible Toilet (UAT) modules
Aluminium honeycomb composite panels, which are lightweight and strong, are an extremely beneficial material to use in rolling stock. They not only reduce weight and increase fuel efficiency, but are also easy to install and maintain
BCP has been designing and manufacturing aluminium honeycomb composite panels and structures for over 30 years and is experienced in working with several prime contractors in rolling stock.
With a unique combination of properties, composite panels are an ideal material for internal train components. Aluminium honeycomb composite panels are used in a wide variety of refurbished and new build rolling stock applications including galleys, universally accessible toilet modules, housing atlas style aisle carts and meal containers, luggage racks, table tops, baby changing tables, doors, gangway panels, cabin dividers, floor, and ceiling panels. Aside from supplying standard panels, BCP also work with clients in the rail industry helping to develop new products and build prototypes.
Most recently BCP, who manufacture all products from their Cambridgeshire based factory, has supplied curved panels for walls and doors for Universal Accessible Toilet (UAT) modules. The UAT has been designed to comply with PRM-TSI requirements and can be easily modified in size to accommodate different configurations including non-wheelchair installations. A composite panel manufactured by BCP comprises of honeycomb core sandwiched in between two aluminium alloy skins. The layers of the panel are bonded together with an extremely strong engineering adhesive and pressed together until the adhesive cures (cold cure and hot cure available). The result is a complete composite panel, which can be supplied in both flat and curved formats. Panels can be painted in customer colours or finished with a high-pressure laminate for a durable and visually appealing finish in the train operating company’s brand RAL, and impregnated with an anti-bacterial surface
where required. The laminate is impact, abrasion and surface wear resistant, as well as water resistant, making it ideal for washroom environments. It is also available in a flame-retardant grade, necessary for compliance with rail industry standard EN45545-2 for fire safety.
BCP is certified to the ISO 14001:2015 Environmental Management System with all the waste aluminium and steel from production being collected and recycled. The BCP team has extensive experience in the manufacture of a variety of train infrastructure and interior products, and the multi-disciplined team of engineers offer expertise in consultancy, design, simulation, prototyping, and full-scale production. The company also has inhouse design, development and testing expertise, including an on-site test laboratory for aluminium honeycomb structures and is committed to working with the rail industry.
BCP aluminium honeycomb composite panels
The core used in BCP’s panels is produced by its sister brand, Corex Honeycomb – the UK’s only manufacturer of high-quality aluminium honeycomb – with many tonnes already used in parts made for the rail industry through European manufacturers. The Corex Honeycomb range can be supplied in a variety of forms including expanded or unexpanded, full blocks or cut slices, perforated or unperforated, corrosion treated or untreated, using Aluminium Alloy Grade 3003 or 5052. The core, which is fabricated using a complex manufacturing process, is available in a choice of cell sizes.
Aside from their lightweight and durable properties, there are several benefits of using aluminium honeycomb composite panels for train infrastructure and interior products. They have a longer lifetime than wood, lower energy consumption (reduced weight is the key advantage to saving energy), lower maintenance and refurbishment costs, and require less rework due to tighter tolerances. They are also easier to install, with a better whole life cost compared to alternatives.
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