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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.

As part of its strategic supplier partnership with Bombardier Transportation, BFG produced front ends and interiors for these trains at XXX and delivered them via to Bombardier’s facility at Dandenong for final assembly. The fully integrated impact-resistant front ends enjoyed the high performance from BFG’s patented phenolic material. In addition to standard TTP testing relevant for FST for phenolic samples and structural testing, the parts also underwent ballistic tests to ensure compliance with the client’s requirements. 65 types of interior panels were developed for the project, including driver desks, camera covers, end wall lockers, hood panels, door pillars, and PID assembly. The parts, produced using a hand lamination process, comply with BS 476 Part 7 and BS 6853 Annex D.8.4 fire safety requirements. All parts were finished using PPG paint system.

As part of its strategic supplier partnership with Bombardier Transportation, BFG produced high performance FRP interior panels for these trains. Over 50 types of panels were developed, including door pillar panels, bogie box, and floor panels. The floor bonding systems and the corridor panels posed a significant challenge in this project, which BFG addressed by building an exact replica of the train interiors to understand and resolve functional issues. A combination of resin transfer moulding (RTM) and hand lamination processes were deployed to produce the parts, which all comply with NF F 16-101 fire safety specifications.

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.

The network operator, Berliner Verkehrsbetriebe (BVG), signed an agreement with Bombardier Transportation to supply 20 Series HK trains of four cars each. The trains, which run at a maximum speed of 60 km/h, were produced at Bombardier’s facility at Hennigsdorf, Germany. As part of its strategic supplier partnership with Bombardier Transportation, BFG produced FRP interior panels for these trains at XXXX. 36 types of panels were produced, including side wall panels, door side panels, end cover panels, and door gear panels. All parts, which were produced using a hand lamination process, comply with DIN 5510 fire safety requirements.

The Budapest Metro uses three types of rolling stock, including two types of Metropolis trainsets produced by Alstom: AM5-M2, which are five-car sets, and AM4-M4, which are four-car sets. As part of its strategic supplier relationship with Alstom, BFG produced 60 driver desks for this project at ATMC Industrie, BFG’s wholly owned subsidiary in France. The parts were manufactured using a contact moulding process and comply with French NF F 16-101 fire safety standards.

As part of its strategic supplier relationship with Alstom, BFG delivered interiors parts for 3 cars between 2014 and 2015. This comprised 12 different types of door pillar panels and under seat boxes, which were produced at BFG India using LRTM (Light Resin Transfer Moulding) and hand lamination processes. All parts complied with NF F 16-101 and Grid 3 fire safety standards. An early design flaw, which placed a very sharp radius at the hatch corners, resulted in cracks in the gel coat along the corners. BFG addressed the issue by proactively producing different trial parts and testing them as per Alstom Transportation’s stringent requirements before dispatching them. Final assembly of the trains took place in France.

BFG supplied FRP interior panels and driver’s cab components for the Chennai Metro fleet, manufactured in fire retardant polyester resin with gelcoat and painted finish. The scope included side walls, central ceilings, lateral ceilings, gangway partitions, cab partitions and driver’s cab. BFG engineers addressed the challenges of integrating FRP parts with metal parts by proposing bespoke jigs and fixtures. The first contract of 32 trainsets (4-car trains) was completed successfully in March 2019, followed by a 10-trainset extension order in May 2019.

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.

BFG partnered with Alstom between 2008 and 2018 to deliver interiors and front ends for over 300 Citadis trams. BFG’s systems are perfectly integrated with Alstom for seamless product development and delivery. Alstom had been manufacturing parts for the Citadis in France and Spain for a decade before looking further afield and approaching BFG. Initially the project was mostly a repeated design order with very little design input from BFG; however, BFG was able to improve the overall efficiency of the process to such a level as to offer very competitive pricing. BFG introduced multi-cavity moulds for the LRTM process to accommodate the smaller size and weight of the Citadis parts, which meant that BFG could quickly meet the higher production requirements of the Citadis by taking multiple parts from each pull from the mould. BFG delivers the front end to Alstom completely equipped, thereby cutting down time on the production line. Eventually BFG also produced its own patented new generation design for the Citadis. BFG’s local presence in France facilitates the close working relationship with Alstom and allows for the seamless exchange of technical knowhow, ensuring compliance to the requirements. Alstom ramped up production of the Citadis between 2011 and 2012, and to meet the increased demand BFG transferred the project from BFG Bahrain to BFG Philippines where up to 15 trains a month were turned out. Today 80 percent of the X02 Platform is manufactured by ATMC, BFG’s French site. Final assembly of the Citadis takes place in La Rochelle, France, and Barcelona, Spain. Unparalleled efficiency An enduring relationship

Alstom was one of a consortium of train builders commissioned to build the first generation of Civia trains in 2002. In 2006 Alstom received an order for 40 third-generation trains, known as Civia III. BFG, as part of its strategic supplier partnership with Alstom, provided interior panels and train front ends. All parts were manufactured using a hand lamination process at BFG’s facility in Bahrain. The front ends comply with NF F 16-101 fire safety regulations, and all interiors parts meet UNE 23-727 and F3 requirements, as per NF F 16-101 standards.

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.

Alstom built the XCC trains at its plant in Salzgitter, Germany. As part of its strategic supplier relationship with Alstom, BFG produced 310 integrated toilet cabins for these trains at its Bahrain facility. Each cabin is fitted with a 2-litre grey water system, a polyethylene internal waste water tank, and EVAC vacuum toilet system. In all, 30 types of FRP panels were manufactured for each toilet cabin. This particular project demanded internal and external finishes on a single panel, so the interiors received a gel-coated finish and the external side received a painted finish. All parts, which were produced using a contact moulding process, comply with DIN 5510-2 fire safety regulations.

As part of its strategic supplier partnership with Bombardier, BFG produces standard and universal toilet cabins for these trains at XXX. The toilet cabins comprise of polyethylene undercarriage tanks with a capacity of 242 litres for fresh water and 157 litres for wastewater. A compact vacuum toilet system produced by EVAC is also integrated. BFG uses its patented Phenolic material for these toilet cabins, affording them a superior strength-to-weight ratio. All parts, produced using a hand lamination process, comply with RVAR specifications for toilet cabins and BS 6853 fire safety regulations.

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.

A landmark project for BFG India, the Kochi Metro programme saw full development completed in a short span of 6–8 months. BFG delivered front ends, sidewalls, seating, driver desks, cab partitions and end gangways for the entire 25-trainset fleet, all manufactured in fire retardant polyester resin with gelcoat and paint finish using Hand Layup and LRTM processes.

KZ8A is a broad gauge electric freight locomotive developed by Alstom for KTZ. It is among the most powerful in the world, capable of hauling 9000 tonne freight trains at a maximum speed of 120 km/h. As part of its strategic supplier relationship with Alstom, BFG produced 90 kits of DRP front fairings and roof fairings, using a vacuum infusion process, which complied with NF F 16-101 fire safety regulations. BFG also produced driver cabs, comprising driver desks and cab covers for these locomotives, using a contact moulding process. The driver desks and cab covers were fully compliant with NF F 16-101 and GHOST fire safety regulations. All parts were produced at BFG's French facilities, NOMA Composites and ATMC Industrie.

As part of its strategic supplier relationship with Alstom, BFG produced front ends for these trains at ATMC Industry, BFG’s wholly owned subsidiary in France. The parts, which were produced using a contact moulding process, comply with NF F 16-101 fire safety standards.

As part of its strategic supplier partnership with Bombardier Transportation, BFG International produced 100 universal toilet cabins with door systems for these trains. The polyester gel coated toilet cabins are fitted with manual curved door systems and a compact vacuum toilet system. They comply with UIC and DIN 5510-2 fire and safety regulations.

Alstom supplied a total of 35 trains to the Merval fleet: 27 single-deck multiple-car X’Trapolis 100 train sets, and 8 single-deck multiple-car X’Trapolis Modular train sets. As part of its strategic supplier relationship with Alstom, BFG delivered GRP driver desks and skirts for 27 train sets. The parts were produced by NOMA Composites, a fully owned subsidiary of BFG in France, using a contact moulding process. All parts were compliant with NF F 16-101 fire safety standards.

BFG, who enjoys a strategic partnership agreement with both Bombardier Transportation and Alstom, produced FRP interior panels for these trains at its Bahrain facility. A combination of light resin transfer moulding (LRTM) and hand lamination processes was deployed to produce the panels, which included door pillars, armrests, and under-seat cases. They were finished with a gel coat and painted as per the client’s aesthetic requirements. BFG also produced anti-ballistic front ends for these trains at ATMC Industrie, its wholly owned subsidiary in France, using a hand lamination process. The parts, which comply with NF F 16-101, Category A1, Grid 3 fire safety regulations, underwent standard TTP testing relevant to FST for gel-coated polyester samples. They also passed Metro France’s stringent quality control processes.

As part of its strategic supplier partnership with Bombardier Transportation, BFG built 100 standard and 100 universal toilet cabins for these trains. The fully integrated cabins comprise polyethylene freshwater tanks, compact vacuum toilet systems, straight or curved automatic door systems, and amenities such as baby changing tables. The use of BFG’s patented phenolic material for the toilet cabins gives them superior a strength-to-weight ratio, while the gel coat finish adds durability. The RVAR compliant toilet cabins pass BS 6853 Cat 1B fire safety regulations.

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.

BFG International supplied anti-ballistic FRP front ends for these trains. The parts, produced using a hand lamination process at ATMC Industrie, BFG’s fully-owned subsidiary in France, comply with DIN 5510 fire safety regulations.

As part of its strategic supplier partnership with Bombardier Transportation, BFG International produced FRP parts, including interiors, front ends, and driver cabs, for these trains at its facility in Bahrain and India. The front ends are crafted from BFG’s patented phenolic material, which gives them superior strength-to-weight ratio. Over 165 types of panels were developed for this project, using a contact moulding process. All parts comply with BS-6853 fire safety regulations.

NTV ordered 25 Alstom Automotrice à grande vitesse (AGV) trainsets with 11 cars each in January 2008. Alstom built 17 of these at its plant at La Rochelle, France, and eight at Savigliano, Italy. As part of its strategic supplier relationship with Alstom Transportation, BFG produced 50 kits of driver desks and cabs at ATMC Industrie, its fully owned subsidiary in France. BFG also produced 50 sets of interior panels for the trains at NOMA Composites, its facility at La Rochelle, France. The driver desks and cabs were produced from fire retardant polyester using a contact moulding process. The interior panels, which included window panels with coat hooks and sun shades, passenger car step covers, and ceiling covers, used a combination of compression moulding and pultrusion processes. All parts comply with NF F 16-101 and UNI fire safety standards.

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.

In 2009 it became the first network to use the second generation Prima II electric locomotives built by Alstom. These trains are suitable for passenger and freight transportation and have operating speeds of up to 200 km/h. As part of its strategic supplier relationship with Alstom Transportation, BFG delivered high performance driver desks for these trains. The parts, which were made using a hand lamination process, were produced by NOMA Composites, BFG’s fully owned subsidiary in France. All parts comply with NF F 16-101 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.

As part of its strategic supplier partnership with both train builders, BFG International produced polyester screen covers for the MI09 trains at NOMA, its fully owned subsidiary in France. The parts, manufactured using a contact moulding process, comply with NF F 16-101 fire safety regulations.

FRP interior panels and driver desks were produced for these trains by BFG International at its Bahrain facility. The phenolic panels, which included door pillars, gangway ends, corner shelves, and window panels, were manufactured using a hand lamination process with a painted finish and comply with M1 F3 fire safety regulations. The driver desks comply with M1 F1 regulations. The project also required an anti-graffiti coating on all panels.

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.

As part of its strategic supplier relationship with Alstom, BFG produced 113 universal toilet cabins and 113 standard toilet cabins for these trains at BFG Bahrain. The polyester gel coated universal toilet cabins were fitted with automatic straight door systems, compact vacuum toilet systems, and polyethylene fresh and waste water tanks with tank frames. The standard toilet cabins comprised of the same parts but with hinged door systems. All parts, produced using a contact moulding process, comply with NF F 16-101 fire propagation specifications as well as UIC regulations for toilet cabins.

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

<p>BFG Partnered in developing complete train interior toilet cabin etc for this project. First train was designed, manufactured and installed by BFG in record 9 months. In all, 400 types of FRP panels were manufactured for complete train. To achieve aesthetic criteria set for the project, panel with multiple colour were produced and assembled.</p>

As part of its strategic supplier partnership with Bombardier Transportation, BFG produced sophisticated FRP front ends for these trains at NOMA Composites, its fully owned subsidiary in France. The parts, which have anti-ballistic properties, were produced using an infusion process, and comply with EN 45-545 fire safety regulations.

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 partnership agreement with Bombardier Transportation, BFG International produced FRP interiors for these trains. A total of 50 types of panels were delivered, including front ends, side wall panels, draft screens, and seat under covers. A special RTM (Resin Transfer Moulding) process was developed to inject MODAR resin to laminate the panels. All parts comply with ASTM E162, E662, and E1354 regulations for fire and safety.

As part of its strategic partnership agreement with Bombardier Transportation, BFG International produced integrated toilet cabins for these trains. The toilet cabins comprise internal polyethylene freshwater and wastewater tanks, a 250-litre grey water system, and EVAC vacuum toilets. Nearly 60 types of Phencore panels were developed for this project. Phencore, an advanced sandwich composite invented and trademarked by BFG takes the form of a robust phenolic skinned panel with a honeycomb Nomex core, and delivers high levels of flame resistance – and significant weight benefits – in a flexible, customisable form. All cabin interiors are finished with an anti-graffiti coating system and are compliant with EN 45545 fire safety regulations.

BFG International is pleased to announce the dispatch of the first front end module for Alstom's flagship TGV 2020 highspeed train project.

Composite train front ends by BFG International.

Integrated toilet cabins for trains by BFG.

Train waste management systems by BFG.