SCOPE OF WORK

To develop a manufacturing process to deliver phenolic GRP drivers cab desks which met stringent fire and smoke criteria for Aventra rollingstock.

PROJECT OVERVIEW

Having worked as a Tier 1 supplier for draught screens on the Electrostar trains for Southern and Porterbrook, Tiderock was asked to evaluate plans for a driver cab desk assembly for the new Aventra trains, initially produced by Alstom to operate on the Elizabeth Line beneath London.

Our engineering team suggested modifications to moulded part shapes to improve manufacturing efficiency while maintaining part integrity and performance requirements. We also developed metalwork bonding, paint, and sub-assembly techniques to add value to the process. Notably, Tiderock delivered a complete manufacturing solution to provide a plug-and-play assembly, which significantly reduced the installation time required at Alstom’s facility.

Through the delivery of full First Article Inspection approval, tools were modified where necessary to provide parts that are easier to install within the driver cab and last longer in service. Paint techniques and standards were developed to ensure the highest quality parts are consistently produced and delivered, supported by a full suite of jigs and fixtures to guarantee repeatability.

Utilising the wealth of experience within our team, a low-formaldehyde phenolic GRP layup was refined to satisfy BS6853 criteria across infusion and hand-lay manufacturing processes. This later transitioned to the EN45545 HL2 standard, which our materials also exceed. By combining the advantages of raw materials processing with solid tooling and silicone bagging, we are able to manufacture complex geometries with ease.

The design and production of the Aventra driver cab desk has been highly successful, forming the basis of desks for London Overground and Greater Anglia. Tiderock now assists from the design phase through to the production of new designs for South Western Railway and West Midlands Trains. We also continue to manufacture other composite parts for rail applications, such as external panels, cab fronts, valances, internal panels, and lineside parts, using phenolic and polyester GRP that is fully EN45545-2 and HL2/3 compliant.

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