Navigating EN45545-2: Why Silicone is the Gold Standard for Rail Interiors
News
March 11, 2026
The CB Frost Guide to Hazard Levels, Fire Safety, and Material Selection for the Rail Industry. Passenger safety is at the centre of every design decision for the modern rail industry. Since the mandatory adoption of EN45545-2 (the European standard for fire protection on rail vehicles) across Europe in 2016,...
The CB Frost Guide to Hazard Levels, Fire Safety, and Material Selection for the Rail Industry.
Passenger safety is at the centre of every design decision for the modern rail industry. Since the mandatory adoption of EN45545-2 (the European standard for fire protection on rail vehicles) across Europe in 2016, gasket materials designed for the mass transit sector are a necessity.
For engineers designing interior applications for rolling stock, including HVAC systems, lighting enclosures, and doors seals, the challenge is finding a material with the necessary balance of mechanical durability and the strictest fire, smoke and toxicity standards required by EN45545-2. With this balance considered, high-performance grades of Silicone rubber, sponge and foam are the clear winner.
To ensure you are selecting the best suited materials for various sealing and cushioning applications within rail interiors, this guide explores why Silicone materials, including the Rogers BISCO® family and MF775 Silicone rubber, are outperforming other gasket materials when it comes to rail industry compliance.
Understanding EN45545-2 Hazard Levels
To select the right rail material for your application, it’s important to understand the classification system. EN45545-2 classifies rail vehicles based on the environment they operate in and the difficulty of evacuation, categorised into Hazard Levels.
- HL1 & HL2: Hazard Levels 1 and 2 typically apply to standard operation rail vehicles, such as trams or subways, where evacuation is generally straightforward.
- HL3: This is the strictest category, required for vehicles that operate in tunnels, or environments where evacuation is much more difficult.
The most important thing to remember is that compliance is mandatory. If your interior gasket material fails to meet the relevant EN45545-2 Hazard level for its use, then the entire rail carriage can fail compliance. At CB Frost, we supply Silicone grades specifically formulated to meet these rigorous HL3 requirements.
Silicone Rubber, Sponge and Foam for Rail Applications
The table below features our top Silicone rubber, sponge and foam grades commonly used for rail interiors, outlining their application suitability and compliance.
| Material Grade | Type | Common Applications | Compliance |
| Rogers BISCO® HT800 | Silicone Foam (Medium) | HVAC Seals, Enclosures, General Sealing | EN45545-2 (HL3), UL94 V-0, HF1 |
| Rogers BISCO® BF1000 | Silicone Foam (Extra Soft) | Low-Closure Force Door Seals, Gap Filling | EN45545-2 (HL3), BS 6853, UL94 V-0, HF1 |
| Rogers BISCO® BF2000 | Silicone Foam (Ultra Soft) | Vibration Isolation, LCD Gaskets | EN45545-2 (HL3), BS 6853, UL94 V-0, HF1 |
| MF775 Solid Silicone | Solid Rubber (60 Shore) | External Gaskets, Heavy-Duty Seals | EN45545-2 (HL3), LUL S1085 |
| MF1 Silicone | Silicone Foam | Seating Cushions, Gap Fillers | EN45545-2 (HL3) |
| CBF Sil-V0 | Silicone Sponge | LCD Gaskets, HVAC Seals, Door & Window Seals | EN45545-2 (HL3), UL94 V-0 |
Silicone or EPDM for Rail?
Since the introduction of EN45545-2, one of the most common questions we have been asked by Engineers designing new rail vehicles is whether they can use EPDM for its lower cost and weather resistance. Low Smoke Low Toxicity (LSLT) grades of EPDM are EN45545-2 (HL3) compliant and are well suited to some rail applications. However, Silicone rubbers are frequently preferred due to these three distinct advantages:
- Fire resistance: Silicone naturally self-extinguishes and does not release the toxic smoke associated with standard grades of EPDM or Neoprene. LSLT grades of EPDM are engineered specifically to prevent the release of toxic smoke.
- Temperature range: Silicone materials for the rail industry function effectively from -55°C to +200°C (and -60°C to +230°C for CBF Sil-V0), ensuring seals do not crack in freezing conditions or melt or deform in high temperatures.
- Compression set resistance: Materials like HT800 have excellent “memory”, which means they return to their original shape even after years of compression. This characteristic is essential for preventing rattling doors and drafty windows that can be an issue for aging rail carriages.
Common Rail Applications
Silicon rubber, foam and sponge materials are frequently used for rail applications including:
- Acoustic barriers
- Doors seals
- Gap fillers
- HVAC seals
- LCD and lighting enclosure gaskets
- Seating cushioning
- Smoke seals
- Vibration isolation
- Partitioning
Don’t Gamble with Rail Industry Compliance
When it comes to mass transit, you can’t gamble with compliance. The cost of a failed safety audit, or worse, a safety incident, far outweighs the cost difference between generic rubber and high performance Silicone engineered for the rail industry.
As a preferred converter of Rogers BISCO® materials for over 30 years, we have the materials and expertise to manufacture bespoke gaskets and seals through processes including cutting, extruding, moulding and fabrication.
Need help selecting the right grade of Silicone for your next rail project? Speak to our team today or browse our rubber, sponge and foam materials.
Keep up to date with the
latest CB Frost & Co news
When sourcing sealing solutions for your next engineering, manufacturing, or construction project, selecting the right material is critical. Make the wrong choice and you risk leaks, environmental damage, or system failure. For buyers and procurement managers, one of the most common dilemmas when specifying a seal is material selection, and deciding between a solid rubber […]
The rumble of rail industry innovation echoed around the UK this March, as the Rail Forum Rail Industry Technology Roadshow took to the roads. Spanning eight busy days, from the 10th to the 21st March, this one-of-a-kind event brought cutting-edge rail solutions directly to the heart of the industry, thanks to a state-of-the-art trailer, transformed […]
In high-volume manufacturing and assembly environments, the old cliche that time is money is completely true. Every minute saved on the production line translates directly into increased profitability and efficiency. While silicone sponge gaskets are already recognised for their superior sealing, temperature resistance, and durability, adding an adhesive backing transforms them from high-performance components into […]
In the world of industrial manufacturing and product design, there are certain materials and products that play pivotal roles yet seldom receive the spotlight they deserve. Among these, sponge rubber extrusions stand out as unsung heroes of vibration isolation and noise control in many different industries. Often hidden away in the crevices of machinery, buildings, […]
As a specialist in the supply and conversion of rubber, sponge and foam materials for an extensive range of industrial applications, we work hard to meet our customer requirements, and do what we can to adapt our products to improve their processes. For example, our adhesive laminating processes can be used to apply adhesive backing […]
At CB Frost, we stock, supply and convert a wide range of high-performance materials to meet the stringent requirements of the modern Railway industry. The materials used in the construction of rail carriages play a pivotal role in ensuring the safety, efficiency and longevity of the vehicles and carriages. As technical advancements continue to shape […]
Whilst silicone rubber is undeniably an extremely popular and versatile material for a wide range of applications, at CB frost & Co, our expertise and product range extends far beyond Silicone. As specialists in rubber and plastics manufacturing, we pride ourselves in supplying and converting a vast array of high-performance materials, tailored to meet the […]
Last month, we were at Derby Arena for this year’s Rolling Stock Networking show, the UK’s biggest annual international rail show. RSN 2024 featured 154 exhibitors, including CB Frost, and welcomed over 2,000 attendees from rail trade associations, passenger and freight train operating companies, manufacturers, technical equipment suppliers and services companies, amongst many other organisations […]
Over the decades, we have gained significant expertise in rubber moulding processes. With our extensive catalogue of materials, we supply moulded rubber parts in a range of commercial materials, along with industry specific grades, ensuring that our customers can choose the best material to suit their application. Our team is always on hand to help […]