A refurbishment project often begins with a walkthrough of a decades-old train. The seats may have lost their  comfort, or the door seals no longer close tightly. Panels rattle under vibration, and the materials behind them were never designed for today’s safety concerns.

Yet the frame is solid, and the operator’s goal is clear: extend service life while improving performance and compliance.

For design engineers, that means upgrading the materials inside these railcars to meet European modern standards like EN45545-2 without changing the structure or layout of the vehicle. It requires components that fit existing geometries, withstand years of service, and pass the tests that matter: flame spread, smoke density, and toxic gas emissions.

That is where CB Frost comes in. We combine globally trusted materials from Rogers Corporation with local engineering and fabrication expertise to help European refurbishment teams modernise existing fleets efficiently and confidently.

EN45545-2: Modern Standards for Legacy Fleets

EN45545-2 defines how materials must perform in the event of a fire. It categorizes applications by hazard levels (HL 1, HL 2, HL 3) and requirement sets (R 1–R 26) that apply to specific components such as interior panels, seating, and electrical insulation. Materials that achieve HL 3 performance automatically comply with HL 1 and HL 2, giving engineers flexibility and confidence across designs.

Rogers Corporation BISCO® silicones—including HT-800, BF-1000, and MF1®—are tested and approved to EN45545-2 with materials meeting several Requirement Sets R2, R3, R8, R9, R10, R19, R21, R22 and R23 at Hazard Level 3 (HL 3). These materials are trusted across Europe for seating, interior and exterior sealing, and insulation in refurbishment programs where compliance and long-term reliability are non-negotiable.

Technical Snapshot: BISCO® MF1® Silicone Foam

• Typical Applications: Seating, interior panels, cushioning, vibration isolation
• Standard: EN 45545-2 R19 and R21 (HL3 compliant for seating applications)
• Density: 80 – 112 kg/m³ (depending on grade MF1-35 to MF1-75)
• Compression Set: ≤ 1.5 % (ASTM D 1056, 22 h at 70 °C)
• Temperature Range: −55 °C to +200 °C
• Features: Excellent resilience, low smoke and toxicity, durable comfort over years of use

Designing for Long-Term Performance

Material selection determines how long an upgrade truly lasts. In older trains, foam cushions and rubber seals often degrade from heat, compression, and vibration. Over time, they lose recovery, allowing gaps to form or comfort to diminish.

Upgrading to engineered silicone foams solves these issues by maintaining flexibility, compression recovery, and stability even after years of continuous loading and temperature cycling.

• BISCO MF1 maintains comfort and resilience in seat cushioning and interior panels while meeting the strictest fire-safety standards
• BISCO® HT-800 offers stable compression and sealing for doors, roof mounts, and HVAC systems, helping prevent water ingress and noise transfer.
• BISCO® BF-1000 provides a lightweight, flame-retardant option for enclosures and insulation applications.

These materials perform across wide temperature ranges and resist environmental aging, helping operators extend maintenance intervals and lower total lifecycle cost.

Local Fabrication, Faster Turnaround

Refurbishment projects often run on tight schedules. Every additional week a train remains in the depot adds cost and disrupts operations. CB Frost supports these programs with UK-based converting and lamination capabilities, turning certified materials into ready-to-install parts within short lead times.

Our in-house team can reproduce existing parts, modify designs for fit, or laminate pressure-sensitive adhesives for easier assembly. Local stock of EN45545-2 compliant materials ensures that supply keeps pace with refurbishment timelines.

Global Materials. Local Expertise.

The Rogers and CB Frost & Co partnership gives European rail engineers the best of both worlds: Globally proven materials from Rogers —trusted by major OEMs and Tier 1 suppliers—and CB Frost’s local, responsive support to help implement them effectively.

Together, we simplify refurbishment programs, reduce lead times, and ensure that every component meets the highest standards for safety and reliability.

Extending railcar life is not only a matter of maintenance; it is an opportunity to upgrade performance and safety. Replacing outdated foams and seals with high-performance silicones helps fleets meet today’s standards while preparing for another decade of reliable service.

From seat cushions to HVAC seals, our material solutions are engineered for performance, fabricated locally, and built to last.

To discuss your rail needs or for assistance in material selection, talk to our knowledgeable sales team.