HVAC systems play an important role in ensuring safe and comfortable passenger travel on trains. The efficiency of these systems can hinge on the integrity of seemingly minor components such as air ducts and pipes—corrosion within these systems can lead to a wide range of issues, including reduced airflow, temperature inconsistencies and other system inefficiencies. These problems don’t just affect passenger comfort; they can lead to costly repairs. This is why the right material selection is essential when it comes to insulation for rail HVAC system components. Armaflex® Rail SD foam is proven to be a highly effective material for preventing the corrosion of air ducts and pipes.

Rail vehicles often operate in harsh environments, with ductwork and pipework exposed to a range of elements that can lead to corrosion. 

• Temperature fluctuations and condensation: When warm, moist air comes into contact with cooler surfaces within a HVAC system, this can result in a build up of condensation, particularly on cooling coils, duct walls, elbows, fittings, and flanges, which can lead to corrosion.
• Humidity: High levels of moisture in the air of enclosed spaces such as rail carriages can be a catalyst for corrosion of HVAC components.
• Airborne contaminants: Dust, dirt and other airborne particles can deposit on HVAC components as air is circulated. These particles can absorb moisture, which can lead to corrosion of key components.
• Chemical exposure: When chemically aggressive cleaning agents are used in rail vehicles and carriages, they can contribute to corrosion of metallic HVAC components over time.

This corrosion can lead to the rust, pitting, and weakening of essential components, ultimately impacting the performance and lifespan of the entire system. This is where the unique properties of Rail SD foam come into play.

Rail SD Foam and Thermal Insulation

Armaflex® Rail SD is a closed cell foam material, designed specifically for thermal insulation in the rail industry. Primarily known for its innovative moisture resistance, Rail SD foam is inherently suited to insulation applications for HVAC pipework and ductwork, creating a protective barrier against the elements that commonly lead to corrosion and degradation of components.

Featuring a closed cell structure, and built in vapour barrier, Rail SD significantly limits water absorption, helping prevent moisture from coming into contact with the metal surfaces of HVAC systems, which helps reduce the risk of corrosion. 

As well as creating an effective barrier against moisture, the thermal insulation properties of Rail SD play a key role in preventing condensation. By helping to maintain a more consistent surface temperature of HVAC components, Rail SD foam applications minimise the temperature differentials that cause moisture to form on duct and pipe surfaces. The combination of preventing external moisture ingress and mitigating internal condensation, and preventing the build up of mould and mildew, provides a strong defence against the degradation of HVAC components, and contributes to improved air quality within rail carriages.

EN45545-2 Compliance

Rail SD is compliant with EN45545-2, the European Standard for fire safety in railway vehicles, which adds another essential layer of protection. These extremely stringent regulations ensure that insulation materials feature key properties including low flammability, limited smoke emission, and minimal release of toxic gases in the event that they come into contact with fire.

Whilst EN45545-2 regulations are focused on fire safety, the durability and material integrity needed to meet these standards contributes to a greater resistance to overall environmental degradation, helping to aid the longevity of HVAC systems.

Armaflex® Rail SD Sheeting and Tubing

At CB Frost & Co, we can provide Rail SD sheeting and Rail SD tubing in a range of lengths and thicknesses, as well as converting Rail SD material into a range of bespoke products, including die-cut gaskets, washers and fabrications for insulation and protection of air ducts and pipes, and air conditioning units, to prevent corrosion and condensation.

Material Selection for Rail HVAC Systems

If you are considering insulation materials for protecting air ducts and pipework within HVAC systems for rail vehicles, then Rail SD foam provides an effective solution. By minimising moisture absorption and condensation build up, it helps safeguard the structural integrity and overall performance of HVAC and systems, ensuring reduced maintenance needs, increased efficiency, and ultimately a longer lifespan for rail vehicles. 

To discuss your needs, talk to our experienced sales team today, or to buy Rail SD sheeting directly, visit our online shop.