Innovative Solutions for Transport

The primary business focus of TRB Lightweight Structures has traditionally been the rail sector, but the company has proven its versatility and adaptability by branching out into hybrid and electric vehicles, medical devices, and more

It is constantly developing lighter and more sustainable materials for use across various markets, and these new solutions are now being widely applied to rolling stock. TRB Lightweight Structures Ltd. (TRB), based in Huntingdon, Cambridgeshire, is a leading tier 1 manufacturing and engineering company, offering comprehensive conceptto-delivery and rolling stock refurbishment services using its in-house production, engineering and laboratory testing facilities. The company has been working with the rail industry for more than 40 years, designing and manufacturing a wide range of interior and exterior components for both new build and refurbished rolling stock, including flooring, doors, partitions, galleys and storage units.

TRB is proud of its strong reputation as an International Railway Industry Standard (IRIS)-approved supplier of engineered parts and complete systems to leading train builders worldwide, including Hitachi, Alstom and CAF. The company is also DIN 6701 certified, and registered and approved by the Railway Industry Supplier Qualification Scheme (RISQS).

One of TRB’s core strengths is its capacity to develop, test and validate innovative lightweight metal and composite materials, which can be supplied to original equipment manufacturers (OEMs) as either individual components or fully assembled, ready-toinstall units. In recent years, the company has continued to research and manufacture a range of lightweight structural components based on more environmentally friendly materials for use in different sectors.

Promoting sustainability

The 2016 Paris Agreement to reduce CO2 emissions has resulted in numerous mergers, collaborations and major capital investments by the global transport industry to develop hybrid and electric vehicles. Transport companies have therefore been placed under pressure to rapidly adapt their manufacturing processes in order to stay in line with ever-changing legislation, as well as the public’s demand for cleaner modes of transport. TRB believes that advanced composites are a crucial part of this move towards greener travel, as they make rolling stock lighter, faster, more energy efficient and cheaper to maintain. TRB’s ultimate strategic goal – which is central to its business ethos – is to help reduce overall transport emissions by offering OEMs lightweight alternatives based on sustainable materials.

Advanced composites for the rail industry

TRB’s design and materials processing capabilities now include a broad selection of alternative lightweight composite materials for the rail sector – such as modified epoxy glass prepreg, fire retardant foam cores and select thermoplastic materials – that comply with the latest and most stringent fire, smoke and toxicity guidelines detailed in EN 45545. The company’s main production facility in Huntingdon is also DIN 6701 (Parts 1-4) A1 type certified for the bonding of safety-critical rail vehicle parts. Switching to bonding where possible eliminates the need for many fixings – further reducing weight, while improving assembly productivity and reducing overall production costs – and this comprehensive certification allows the construction of bonded rail vehicle products under any of the four DIN 6701 A1-3 and Z type classifications. This includes safety-critical products requiring A1 approval for applications where part failure during use risks endangering passengers, and TRB currently manufactures and supplies emergency detrainment door systems, driver cab doors and passenger exit doors.

Weight and cost-saving rail projects

TRB works in close partnership with its rail customers to continually devise new designs that minimise weight, reduce maintenance, repair and overhaul (MRO) costs, and improve safety. This service covers a wide range of potential applications, with past projects including the development of a new lightweight composite antenna cover for Hitachi and Alstom Transport, and the reverse engineering of a stiffer and lighter coupler hatch for the West Coast Pendolino.

TRB is also proud to have been working closely with Transport Design International (TDI) over the last few years to develop the composite bodyshell design of the Revolution VLR (Very Light Rail), which was launched in early 2022. The brief for this project was to create a lighter vehicle with reduced energy consumption, while still maintaining the same structural strength and adhering closely to both industry safety standards and governmental decarbonisation goals. To achieve these aims, TRB and TDI together developed modular wall panels composed of moulded carbon fibre laminates with a recycled foam core. The partnership also employed a unique polyfurfuryl alcohol (PFA) bioresin – a sustainable alternative to the commonly used phenolic resins. The Revolution VLR is 40 per cent lighter than the equivalent traditional heavy rail vehicles, with reduced energy consumption and CO2 emissions.

Giving train refurbishment an overhaul

TRB has extensive experience in the refurbishment of rolling stock, providing high quality, lightweight solutions for a number of common problems. This knowledge and expertise covers everything necessary for refurbishing doors, internal partitions, floors and roofs, including a detailed survey and quote, reverseengineering and finishing specific parts to meet customer needs. The company’s expertise covers everything from assessment and reverse engineering of components to improving maintenance efficiency, all while reducing the overall cost of components. TRB’s comprehensive service offering comprises all manner of processes to ensure that refurbished products stand up to the demanding rail environments. This includes stripping down panels, replacing worn materials – such as handles and rubber trims – fixing water ingress problems, filling dents repainting, and a host of additional services, all tailored to precisely meet each customer’s particular needs.

Future-proofing the rail industry

TRB has made major strategic investments to grow its capabilities, while also running continuous improvement programmes across the business to increase efficiency, reduce costs, and raise quality even higher. Looking forward, the TRB management team plans to make further strategic investments and establish additional partnerships with specialist technology providers that complement its capabilities. Richard Holland, Managing Director of TRB, explained: ‘We will continue to invest in product innovations and technologies to provide end-to-end manufacturing and refurbishment services across all transport sectors. We are dedicated to meeting the dynamic needs of this vital industry, and to supporting sustainability goals by further developing our repertoire of environmentally friendly materials.’

The clear aim is for TRB to continue to grow by focusing on providing its customers with complete solutions that meet their evolving needs, and by responding directly to the growing global socio-economic pressure for greener, more sustainable products.

Tel: 01480 588050

Email: sales@trbls.com

Visit: trbls.com/rail