[The gremlin] Water ingress is a hot topic in vehicle manufacturing due to the severity of the issues that can arise from it. These can include; increasing the weight of the vehicle, corrosion of metal components, rotting of plywood flooring, mould and bacteria build up and legal issues with passengers being exposed to slippery floors. Legionella Bacteria are commonly spread through airborne water droplets in vehicle air conditioning systems so it is imperative that water does not enter the systems of the vehicles in the first place.
[The solution] All of our products go through rigorous testing during development stages to make sure that each product has high adhesion, durability and minimal water absorption properties, helping to prevent water ingress. We support our customers by getting involved at the design process enabling the customer to pick the right product for the right application. We also support our customers in training their operatives to prevent water ingress issues caused by incorrect processes and poor joint design.
[The outcome] Water ingress is dealt with proactively rather than retrospectively; avoiding time consuming and expensive repair work after the vehicle is in service. With the technical training provided by Forgeway, our customers can follow the correct bonding processes for their specific application to prevent issues from arising.
[The gremlin] Customers using new light weight composite flooring materials as an alternative to heavy plywood have experienced issues when bonding the traditional vinyl floor covering. Owing to the porous characteristics of the new generation composites it was necessary to use consolidating primers to achieve adhesion to the composite flooring. Not only did this increase production time; primers are also known to have health and safety implications for operatives. Manufacturers were also having issues with debonding when the subjected to temperature variation and constant passenger traffic.
[The solution] Pyrok 9142 was used to bond vinyl flooring to the porous sub-floor without the use of a primer.
[The outcome] This reduced production time, removed health issues associated with primers and eradicated problems associated with debonding.
[The gremlin] Electrification of vehicles is throwing up a problem few thought about – noise. Without the sound of the engine to cancel out other noises; vehicle road noise, road debris and water impact are becoming a focus in the industry as operators demand a solution. A customer wanted a solution to reduce and cancel the excessive sound transmission from stones and water hitting the bottom of the bus.
[The solution] Forgeway developed Formoa 760 a sprayable coating that protects the underside of the bus from stone chips and water noise. Formoa 760-AC is a coating that also contains and anti-corrosive additive that protects the underside of the vehicle from corrosion. This is especially helpful in colder or coastal climates where there may be a higher amount of grit (rock salt) on the roads during winter or high air salinity. Coastal regions can see an increase in corrosion by up to five times that of inland areas
[The outcome] This has resulted in reducing the noise by over 7 decibels in some cases. The additional benefit of the reduction in corrosion on the underside of the bus increases the safety of the vehicle and avoids expensive warranty claims.