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Dura-Core 1000 Composite Flooring


Dura-Core 1000 compression molded composite panel combines high strength fiberglass reinforced plastic (FRP) laminate skins with a lightweight thermoplastic foam core material. The panel exhibits excellent flame, smoke, and toxicity properties (FST). Engineered for use as a floor material in light transit rail car interiors, and multi-wheeled vehicle applications, the unique resin system meets stringent transit industry specifications for FST and is halogen free.

In addition to these best-practice safety standards, Dura-Core 1000's mechanical properties deliver significant energy efficiencies via its light weight core and additional cost-efficiency realized via Haysite's proprietary, one-step compression molding process vs. other methods such as vacuum infusion. In addressing the transit industries critical concern of flame/smoke generation and smoke toxicity, Dura-Core 1000 has been tested using the following ASTM (American Society of Testing and Materials) methods and provided excellent results.
  • ASTM E-162: Surface Flammability of Materials Using a Radiant Heat Energy Source.
  • ASTM E-662 : Specific Optical Density of Smoke Generated by Solid Materials.
  • BSS 7239: Toxic Gas Generation by Materials on Combustion.

    The product's proprietary skins are comprised of a flame retardant FRP material which meets the NYCTA (New York City Transit Authority) specification 64 for low FST and stringent mechanical properties. Whereas traditional plymetal flooring material is comprised of wood and metal weighing approximately 3.5 lbs. per sq. ft., Dura-Core 1000's composite weight is much lighter at 2.5 lbs. per sq. ft. This 28.6% weight reduction (SG=0.63), coupled with Haysite's unique compression molding process, offers viable energy savings and cost-efficiencies versus plymetal configurations.

    Dura-Core 1000 is fully compression molded in a sandwich core construction to ensure against any separation / delamination failure. The composite system's physical properties also offer excellent corrosion and chemical resistance; providing very low moisture absorption and excellent resistance to a variety of harsh weather environments.

    Current Standard Dura-Core 1000 Size Specifications Include:
  • Standard Sheet Sizes of 36 x 72, 48 x 60, 48 x 96 (inches)
  • Top/bottom rigid layers are .093 inch.125 inch and .165 inch thick
  • Thickness of .500 inch to 2.00 inch total thickness
  • Custom sheet sizes available to meet all applications

    Dura-Core 1000 has also been successfully tested for a small scale fire resistance to meet the ASTM E119 Flame Specification - the principal method to test the fire-resistance of a variety of flooring materials. The test implemented a mocked up portion of a rail car using a 4 inch x 6 inch specimen of Dura-Core 1000 to withstand flame under a time vs. temperature curve. The final testing results indicated that the specimen did not emit smoke and gasses hot enough to ignite cotton waste at any time during the exposure. Notably, the testing exposure time for Dura-Core 1000 was in excess of 40 minutes - over 2.5 times more than the standard required minimum time of 15 minutes, and significantly longer than the new projected standard of 30 minutes. In addition to also meeting the FST requirements of the NYCTA Specification 64, Dura-Core 1000 is designed to meet the required testing qualifications for new and retrofit applications for the Bay Area Rapid Transit District (BART), Bombardier, and Kawasaki.
    Haysite implements a unique molding process that saves time in production as all processing elements are completed in a one-step proprietary method. This processing advantage also provides the flexibility to manipulate the composite if necessary for intricate custom applications. This flexibility is essential to rail car designers. It provides them with the ability to strengthen the composite sheet in specific areas (interior/exterior) to meet higher design and mechanical requirements. Examples of this would include fiberglass close-outs on the edges or sides of the panel, as well as horizontal/vertical cut strips that can be fabricated into the molding to accommodate bolts, poles, stanchions, etc. Haysite is also exploring processing options that will incorporate decorative, durable, and skid-resistant finishes that can be incorporated on the panels to provide rail car designers with an entirely finished floor solution. In effect, this will eliminate the need for costly secondary installations for carpet, rubber mat, linoleum top covers, etc.
    (DURA-CORE 1000) Dura-Core 1000 Composite Flooring
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