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Toilet cabins for these trains were initially being produced at Alstom Germany. Alstom decided to subcontract the complete toilet cabin assembly. BFG was selected to supply complete assembled toilet cabins. Vacuum toilet was supplied by SEMCO Denmark. This was the first project for BFG in Rail Industry. BFG successfully completed the project which opened the door for BFG in the Rail Industry.

The Allegro service is operated using Sm6 trains built by Alstom, which are electric tilting pendolino trains, specially equipped to operate on both the Finnish and the Russian railway technical systems, which vary substantially. BFG International partnered with Alstom to supply fully integrated toilet cabins for this train, comprising a total of 24 Standard toilet cabins, 4 universal toilet cabins, and 4 staff toilet cabins. The toilet system also called for fire retardant polyethylene fresh water tanks which meet DIN 5510 fire propagation specifications. These were produced at BFG’s France facility and delivered ready for installation. The trains were assembled at Alstom’s Savigliano facility in Italy.

BFG International produced integrated toilet cabins for these trains at BFG China Facility. In addition to universal cabins, two types of Western toilet cabins were produced as well as 3 types of shower rooms. All parts, produced using a hand lamination process, comply with TB/T3237:2010 and DIN5510 fire and safety regulations. The under fairings comply with T3138:2010 regulations.

BFG International delivered toilet cabins, under fairings, and kitchen door panels for these trains. The toilet cabins were produced using a Resin Transfer Moulding (RTM) process, while the under fairings deployed a resin infusion bagging process. BFG International worked with a number of suppliers to develop a special resin for this project which would pass the stringent fire and smoke safety regulations. All parts comply with NFF 161-01 and T3138:2010 regulations. The under fairings comply with TB/T3237:2010 and DIN5510 regulations.

FRP front ends and interior panels, including window panels and door trimmings, for these trains were produced at NOMA Industrie, BFG International’s fully-owned subsidiary in France. The parts, manufactured using a hand lamination process, comply with NF F 16-101 fire safety regulations.

Part of the client’s requirements was a waste management system that involved a 400 litre tank for waste collection and 250 litre tank for greywater collection. BFG, in keeping with its reputation for looking at problems with fresh eyes, suggested a unique solution: a single underframe waste tank was devised with separators, resulting in considerable cost saving for the client. The successful completion of this project led to an extension order for the same client. BFG also worked with Hyundai Rotem on a project for Syrian Rail in 2008.

The rolling stock for this system will comprise 6 INNOVIA Monorail 300 trains with 2 cars each. As part of BFG’s strategic supplier partnership with Bombardier, it produced front ends and interior panels for these trains at its Bahrain facility. The integrated front ends were produced using phenolic composites and BFG’s patented Phencore material, which offers an excellent strength-to-weight ratio. BFG also engineered a unique nose cone opening mechanism for this project. The front ends were subject to standard TTP testing relevant to FST for painted phenolic samples, acoustic insulation, glass bonding. 50 types of FRP interior panels were also produced using a hand lamination process and painted as per the client’s aesthetic requirements. The panels comply with ASTM E 162 and E 662 fire safety regulations.

BFG carried out detailed design, manufacturing and installation of front masks, driver’s desks, interior panels, exterior cladding and seating for the Mumbai Monorail fleet. All components were produced to EN 45545 HL3 fire safety standards.

As part of its strategic supplier partnership with Bombardier, BFG International delivered FRP interior panels for these trains. 30 different types of panels were produced, including door pillars, side walls, and end walls, via a combination of resin transfer moulding (RTM) and hand lamination processes. All parts comply with NFPA-130 fire safety regulations.

Alstom will provide 34 Citadis Spirit light rail vehicles (LRVs) with 4 cars each for the project, which marks the entry of Alstom LRVs into the North American market. Citadis Spirit can operate in extreme cold weather and move at speeds of up to 100 km/h. Alstom has also won a 30-year maintenance contract for this project. As part of its strategic supplier relationship with Alstom, BFG provided front ends, driver cabs, and interior panels for these trains. 89 different types of panels went into each train: 5 for the front ends, 3 for roof arches, 7 for skirts, 13 for the driver desks, and 61 for the interiors. The front end posed a significant challenge, being a highly complex part with a metal structure embedded into the FRP. This was addressed by constructing a precise jig to place the FRP onto the metal structure. The part also underwent rigorous water tightness testing before delivery. The front ends, DD, boogie boxes, and end walls were produced using an open contact moulding process. The under-window panels, and door and window pillars used a resin transfer moulding (RTM) process. All parts comply with NF F 16-101 and Grid 3 fire safety standards.

Bombardier was commissioned to deliver 75 new, high performance electrical multiple unit (EMU) trains of 6 carriages each, which will operate across the entire South East Queensland rail network, a distance of over 800 km. The design is based on the Adelaide Metro A-City Class 4000 Electric Multiple Units. Bombardier’s scope includes the fleet design, manufacture, and maintenance of the QNGR. As a strategic supplier to Bombardier, BFG International produced FRP interior panels and front ends for these trains at its facilities in Bahrain (2 train sets) and India (75 train sets). The integrated phenolic front ends have anti-ballistic properties and undergo rigorous ballistic and FEA testing, as well as bonding pull load and mechanical tests. As a strategic supplier to Bombardier, BFG International produced FRP interior panels and front ends for these trains at its facilities in Bahrain (2 train sets) and India (75 train sets). The integrated phenolic front ends have anti-ballistic properties and undergo rigorous ballistic and FEA testing, as well as bonding pull load and mechanical tests. Around 75 types of panels were produced for the interiors, using a combination of vacuum bagging and hand lamination processes. All structural brackets were laminated to avoid A1 bonding issues. BFG International worked with Akzonoble & PPG paint systems to comply with the client’s requirements for isocynate-free paint. All parts comply with BS 6853 1B fire safety regulations.

Also known as Expresso Tiradentes, the new line is also serving as an extension of metro line 2 of the Companhia do Metropolitano de São Paulo (CMSP / São Paulo Metro).The monorail system will reduce travel time between the two destinations from two hours to 50 minutes benefiting 500,000 passengers a day. BFG Supplied complete equipped front end and interiors for this project. For Monorail weight of the panels must be kept as low as possible since monorail operates on rubber wheel which has limited load carrying capacity. BFG developed special laminate with 3D core which has very high stiffness and low weight. These panels are complying to ASTM standard for fire & smoke and mechanical properties.

BFG International manufactured integrated toilet cabins for these trains at its Bahrain facility. The toilet systems comprise stainless steel undercarriage wastewater tank, a greywater system with a 5-litre capacity, and TEMVAC vacuum toilet system. BFG engineers built a prototype to address the challenges of fitting all the required features, such as baby changing table, sliding doors, wash basins, etc, into the limited space available. A total of 64 standard toilet cabins and 12 crew cabins were produced. All parts, produced using a contact moulding process, comply with NF F 161-01 fire safety regulations.

This project marked another milestone for BFG, being the first major rail interiors project completed by the Group, and which would eventually lead to many more similar projects in the future. The SM4 units were initially ordered from CAF in Spain, but later license built by French train builder Alstom, with whom BFG enjoys a strategic partnership as a preferred supplier. BFG entered this project at a crisis point in April 2003. The previous supplier had failed to meet the requirement and the entire project was critically delayed. Not only was the timeline extremely tight, but the scope of the work was larger and more varied than any of BFG’s previous experience. It would be the first time BFG took on a major rail interiors project, and there were no design drawings available to work from. Nonetheless BFG rose to the challenge and turned it around in record time. By May it was ready for First Article Inspection (FAI) and by June it was ready to make deliveries. The challenges posed by the project required flawless coordination between BFG and Alstom to fast-track approvals and minimise delays. At the time BFG did not have the robotics technology it has today, and so all the required tools were made by hand. The panels were manufactured at BFG Bahrain and delivered to Alstom for final assembly at its plant in Reichshoffen. In an unprecedented move, BFG also placed its own engineers at Reichshoffen to install the panels onto the trains. Although BFG’s internationally recognised standards, aesthetic finish, and cost competitiveness were all assets, the most important factor was the Group’s level of responsiveness and willingness to cooperate with the customer to deliver a satisfactory result. BFG also holds the capability to draw expertise from a wide variety of industries and is not constrained by the rigid hierarchical organisational structures that its competitors have. Race against time Innovative Manoeuvres A Trustworthy Partner

The trains feature a ThermoEfficient Climatisation System for reduced energy consumption, on-board restaurant and family zones, generous seating in first and second classes, and large luggage, bike and ski racks, and can travel at a top speed of 200 km/h. As part of its strategic supplier partnership with Bombardier, BFG International produced sanitation units for these trains at its BFG Bahrain facility. The integrated toilet cabins comprise polyethylene fresh water tanks and a Dowald vacuum system. The toilet cabin panels were produced using a combination of hand lamination and resin transfer moulding (RTM) processes, and all parts comply with DIN 5510-1 and DIN 5510-2 fire safety regulations.

A Public Private Partnership was established between Downer EDI Rail and Hitachi to design, manufacture and commission the trains. The stainless steel train bodies were partially constructed by Changchun Railway Vehicles in China before being shipped to Downer EDI’s Cardiff Locomotive Workshops facility for final assembly, testing and commissioning. BFG International produced FRP interiors for these trains at its facility in the Philippines. 136 types of panels were produced using hand lamination and resin transfer moulding processes. All parts comply with EN-45545 fire safety regulations.

As part of its strategic supplier partnership with Alstom, BFG International produced fully integrated toilet cabins for these trains. The toilet systems comprise internal polyethylene waste water tanks, a 2-litre greywater system, and EVAC vacuum toilet system. A contact moulding process was used to produce the parts, with a gel-coated finish for internal surfaces and painted finish for external surfaces. All parts comply with DIN 5510-2 fire safety regulations.

In October 2013 the Passenger Rail Agency of South Africa (PRASA) and Gibela signed a contract for the supply of 600 X’Trapolis Mega commuter trains of 6 cars each over a period of 10 years. The contract also includes the construction of a local manufacturing facility in Dunnottar, 50 km east of Johannesburg. The project is valued at around €4bn and is one of the biggest in rail transport worldwide. The first 20 trains will be produced at Alstom’s Lapa plant in Brazil, after which the site at Dunnotar will produce the remaining 580 trains. Alstom’s French sites in Ornans, Tarbes, Le Creusot, Reichshoffen, Villeurbanne and Saint-Ouen will also be involved in the project as well as the sites in Sesto in Italy and Charleroi in Belgium.

BFG engineered and fabricated a structural primary roofing system for the Haramain High Speed Rail Station at King Abdullah Economic City in Saudi Arabia. Working with Foster+Partners as architects and Dar Al Handasah as engineering consultants, BFG delivered an innovative composite roofing solution using a unique and proprietary high productivity manufacturing process. The lightweight yet structurally robust FRP roof panels were designed to withstand the extreme Saudi climate while providing a landmark architectural statement for this critical transport hub.

BFG Architecture delivered primary structural roofing systems and building facades for three of Doha Metro’s red line stations: Economic Zone, Al Wakra, and Ras Abu Fontas. A total of 39,108 sqm of FRP panels were delivered for the project, which were constructed at BFG Architecture’s facility in Bahrain and shipped to Doha for assembly. Unique geometric patterns were developed for each station, making each one a recognisable landmark along the city’s newly laid metro lines. This meant that separate tools had to be produced for each station. In addition, most surfaces were curved, which added another challenge to the tooling and manufacturing process. BFG Architecture’s tooling experts and designers delivered seamless FRP facades which will withstand the coming decades with little to no maintenance. To add to the organic feel of the stations, the Qatar Rail authorities requested a natural sandstone finish for the facades. BFG Architecture developed a custom sandstone finish based on the unique colour signature of the Qatari desert, and the result is a building which feels natural and organic and looks at home with its surroundings.

17 trainsets for Deutsche Bahn. Front End, Cab linings, Driver desk, Stair Linings, Vestibule and Hand rails. Alstom Transport, 2023-2027.

100 trainsets with front end for Danish State Railways (DSB). Alstom Transport, 2023-2027.

BFG International supplies composite front ends for the ICNG (Intercity New Generation) trains operated by NS, the national railway of the Netherlands. Manufactured by Alstom Transport, these next-generation intercity trains feature advanced composite front end components.

BFG International supplied 130 vacuum toilet cabins — both unisex toilet rooms (UTR) and accessible toilet rooms (ATR) — for the Caltrans bi-level passenger rail cars manufactured by Nippon Sharyo Manufacturing, LLC for the California Department of Transportation.

Diversified composites manufacturer BFG International has officially opened a new manufacturing facility in Ekurhuleni, South Africa, to supply fiberglass components for railway projects.

34,000m² of complete structural roofing for the Haramain High Speed Railway terminal. 1,848 FRP roof panels.

BFG composites for rolling stock, rail interiors, front ends and sanitary cabins.

Composite rail interiors by BFG International.

BFG systems integration for rail sanitary cabins.

Use of composites in the rail and transportation sector.