Polycarbonate and Polycarbonate Sheet for Railcar Seats Case Stu

Lighter, safer, stronger

Mumbai Railway System Upgrades Seating with Covestro Polycarbonate

With more than 6.5 million daily commuters, the Mumbai suburban railway system is the lifeline of the megalopolis. As part of a project to increase capacity, modernize and improve services, Mumbai Rail Vikas Corporation selected Integral Coach Factory to develop world-class railcars .

OEM: Integral Coach factory, Chennai – India 
Supplier: Covestro
Coverter: Airflow equipments (India) Pvt. Ltd, India
Industry: Mass transport/railways
Application: Passenger seatings
Product: Bayloy® FR 10 and Makrolon® FR 6557

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Integral Coach Factory determined that a lighter, safer and stronger material was needed to upgrade the existing wood composite seating. It turned to Covestro for high-performance materials to satisfy requirements for weight reduction, resistance to high compressive loads, compliance with flame standards and weathering and vandalism resistance, as well as good aesthetics.

Covestro material experts recommended Bayloy® FR 10 polycarbonate sheet for its high strength, durability, ability to handle high loads and vandalism resistance. The polycarbonate sheet meets the UL94 V-0 standard and NCD specifications for flame retardance and performs well under UV-light exposure and extreme temperatures. Bayloy® sheets also are available in several colors and textures, providing improved aesthetics.

For other railcars, Integral Coach Factory selected an injection-molded resin seat solution that offered an improved production cycle, better passenger comfort and higher performance. In this process, Makrolon® FR 6557 polycarbonate from Covestro is shot directly into an injection molding die, creating stable back rests and seats with more accurate dimensions and reduced wall thickness.

Makrolon® FR 6557 provides high mechanical strength, dimensional stability, weight reduction and meets the UL94 V-0 standard and NCD specifications for flame retardance.

The resin, produced in Covestro’s state-of-the-art Color Competence and Design Center in Greater Noida, India, is available in several colors.

Bayloy® FR 10

  • High impact resistance
  • Thermal stability
  • Classified in accordance with UL94 V-0
  • Fully recyclable

Makrolon® FR 6557

  • flame retardancy
  • Medium viscosity
  • UV stabilized
  • Easy release
  • UL 94V-0 rated at 3.0 mm
  • High mechanical strength
  • Processable via injection molding
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