As rail vehicles have limited, often crowded spaces, it is crucial to ensure that fire does not start easily, spread quickly, or release a significant amount of heat, smoke, or toxic gases to its surroundings. Assessing these properties according to the EN 45545-2 standard is compulsory throughout Europe to show that materials are suitable for use in trains, subways, and trams.
The correct EN 45545-2 testing procedure is determined based on material type and vehicle hazard level. The newest version of the standard specifies a total of 28 requirements (R1–R28) for different types of materials and components, while the hazard level (HL1–HL3) depends on the conditions under which the vehicle is operated. Higher hazard levels apply when evacuation is likely to be slow, for example, when trains have sleeping cars or are operated in tunnels.1
Measurlabs offers fire testing to meet EN 45545-2 requirements for all three hazard classes. The tests required for each product type are summarized below, but you can also just contact our experts for a quote tailored to your material.
Tests to meet EN 45545-2 requirements
The reaction-to-fire tests that must be performed to meet each of the 28 requirements specified in EN 45545-2 are listed in Table 1, along with examples of products the requirements apply to. More information on the individual tests is provided in a subsequent section.
Table 1: Tests to meet EN 45545-2 requirements
Requirement | Products subject to the requirement* | Tests required |
R1 | Interior surfaces (e.g., walls, ceiling panels), interior doors, insulation materials, luggage racks, window frames, curtains, downward table surfaces, trash cans, air ducts, information displays, non-listed interior products with exposed area > 0.2 m2 | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R2 | Limited surfaces (≤ 0.2 m2), upper table surfaces, toilet wash basins, water and air containers | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R3 | Strips (width ≤ 200 mm, separated from other strips by > 200 mm of R1-material) | ISO 5658-2**** EN ISO 5659-2 EN 17084 (Method 1) |
R4 | Light diffusers (e.g., polycarbonate diffusers, lamp coverings) | ISO 5658-2 EN ISO 11925-2 EN 17084 (Method 1) |
R5 | Air filter materials | EN ISO 11925-2 ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R6 | Passenger seat base and back shells (including coatings and coverings), all surfaces of non-upholstered seats (alternative to R18 and R21) | ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R7 | Interior and exterior surfaces of gangways, locomotive air ducts, exterior walls and floors, external design features, bogie structures, arc splash barrier materials, non-listed exterior products with exposed area > 0.2 m2 | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R8 | External roof structures (including paints and coatings), outer surfaces of water and air containers placed on the roof (R7-compliant materials are also compliant with R8) | EN ISO 9239-1 ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R9 | Wheel sets, brake discs, tyres, air suspension bags, flexible metal and rubber units | ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R10 | Interior structures and coverings, insulation materials (alternative to R1 or R28), floor composites and coverings (alternative to R28) | EN ISO 9239-1 EN ISO 5659-2 EN 17084 (Method 1) |
R11 | Type A arc-resistant electrical insulation materials | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R12 | Type B arc-resistant electrical insulation materials | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R13 | Brake resistor casings and heat shields | A1 rating according to EN 13501-1 (i.e., EN ISO 1182 and EN ISO 1716) |
R14 | Flammable insulation liquids | EN 60695-1-40 |
R15 | Interior cables** | EN 60332-1-2 EN 60332-3-24 EN 50305 EN 61034-2 |
R16 | Exterior cables** | EN 60332-1-2 EN 60332-3-24 EN 50305 EN 61034-2 |
R17 | External surfaces of the driver’s cab section | ISO 5658-2**** ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R18 | Complete passenger seats | EN 16989 |
R19 | Staff seat upholstery and supporting structures | ISO 5660-1 |
R20 | Bedclothes for couchettes and beds | EN ISO 12952-2 ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R21 | Upholstery for passenger seats, armrests, removable headrests, mattresses | ISO 5660-1 EN ISO 5659-2 EN 17084 (Method 1) |
R22 | Longitudinal interior window seals, door joints, and panel connections, interior supply line systems and high power devices, interior chokes, coils, pipes, and hoses, non-listed interior products with exposed area ≤ 0.2 m2 | EN ISO 4589-2 ISO 5659-2 EN 17084 (Method 2 or Method 1) |
R23 | Longitudinal exterior window seals, door joints, and panel connections, exterior supply line systems and high power devices, exterior chokes, coils, pipes, and hoses, non-listed exterior products with exposed area ≤ 0.2 m2 | EN ISO 4589-2 ISO 5659-2 EN 17084 (Method 2 or Method 1) |
R24*** | Printed circuit boards | EN ISO 4589-2 |
R25*** | Printed circuit boards | EN 60695-2-11 |
R26 | Printed circuit boards, small electrotechnical products, such as circuit breakers, contractors, switches, and fuses | EN 60695-11-10 |
R27 | Light diffuser and display screen cover | ISO 5658-2 EN ISO 11925-2 EN 17084 (Method 1) |
R28 | Interior structures and coverings, insulation materials (alternative to R1 or R10), floor composites (alternative to R10) | EN ISO 9239-1 EN ISO 5659-2 EN 17084 (Method 1) |
* The listed product types are examples, not a comprehensive list.
** No further testing is needed if cables already satisfy the fire safety requirements specified in EN 50306, EN 50264, or EN 50382.
*** Either one of these requirements, or R26, can be chosen for circuit boards.
**** If flaming droplets are observed, the EN ISO 11925-2 test is also required.
Overview of selected EN 45545-2 tests
The parameters assessed with some of the most commonly required EN 45545-2 tests are summarized below:
ISO 5658-2: Lateral flame spread test measures critical flux at extinguishment (CFE). A minimum limit from 13 kW/m−2 to 40 kW/m−2 is applied, depending on the product type and corresponding requirement.
ISO 5660-1: Cone calorimeter test measures heat release, smoke production, and mass loss rate. Maximum limits are applied to the maximum average rate of heat emission (MARHE), measured in kW/m−2.
ISO 5659-2: Single-chamber test measures optical density and toxicity of smoke emissions. Parameters for which EN 45545-2 sets limits are optical density after four minutes (Ds(4)), maximum optical density (Dsmax.) observed during the 10-minute test, and the cumulative value of specific optical densities during the first four minutes (VOF4).
EN ISO 11925-2: Ignitability test with a small flame measures flame spread and formation of flaming droplets. Flame spread on applicable products must not exceed 150 mm within 60 seconds, and flaming droplets must not be formed.
EN ISO 9239-1: Reaction to fire tests for flooring measure the critical heat flux at extinguishment (CHF) in kW/m−2, for which minimum requirements apply.
EN ISO 4589-2: Oxygen index (OI) test measures the minimum oxygen content of an oxygen-nitrogen mixture that is required to sustain burning. An OI of at least 28% is required for HL1 and HL2 materials, while the OI for HL3 materials must be at least 32%.
EN 17084 toxicity tests measure the toxicity potential of combustion products. Method 1 corresponds to the area-based smoke chamber test described in EN ISO 5659-2 and is used to determine the conventional index of toxicity for listed products (CITG). Method 2 is based on the tube furnace test described in NF X 70-100-2 and is followed to determine the conventional index of toxicity for non-listed products (CITNLP).
When is testing not needed?
According to EN 45545-2, materials already classified as A1 according to the EN 13501-1 standard do not require further testing. Similarly, non-combustible materials listed in Commission Decision 96/603/EC, such as mineral wool, cement, and glass, can be used in railway applications without being tested.2
Some tests can also be omitted when materials have been previously classified as A2 – s1, d0. Such materials only require a toxic emissions test (where CIT<0.75) to comply with EN 45545-2.
All fire testing services in one place
Measurlabs provides accredited fire testing services to support compliance with EN 45545-2 for all hazard levels and material types, with expert support for determining the correct testing procedure. We can also assist with the required documentation, such as the Fire Certificate Inventory List (FCIL).
In addition to railway materials, we offer a wide range of fire tests for construction products according to EN 13501-1 and other relevant standards. Do not hesitate to contact us for more information or a quote for your company’s material.
References
1 As of the time of writing, the most recent version of the standard is EN 45545-2:2020+A1:2023. The main changes compared to EN 45545-2:2013+A1:2015 include the addition of two requirements (R27 and R28), the replacement of ISO/TR 9705-2 with EN 16989 for testing complete seats, and a reference to EN 17084 for toxicity tests.
2 See the consolidated version of Commission Decision 96/603/EC for the full list of non-combustible materials.