EN 45545 compliant grades for E&E railway components by BASF

Last update on May 11, 2026

Meeting the fire safety requirements of the European railway standard EN 45545 presents a recurring qualification challenge for manufacturers of electrical and electronic rail components – particularly in selecting materials that comply across multiple hazard levels and application categories without triggering repeated approval cycles.

A range of Ultramid® and Ultradur® grades from BASF Engineering Plastics has been tested and classified under this standard, covering the application groups most relevant to rail vehicle construction.

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Halogen-free flame-retardant systems

The EN 45545 standard defines a tiered framework of Hazard Levels – HL 1 to HL 3 – aimed at reducing the probability of fire ignition, slowing flame propagation, and limiting smoke and toxic gas emissions. The underlying objective is to preserve sufficient evacuation time for passengers and personnel in emergency conditions. For manufacturers working on application groups R22, R24, R25, and R34, BASF reports that qualifying grades are available within the Ultramid® and Ultradur® portfolio.

 

The flame-retardant systems integrated into these grades are based on nitrogen/phosphorus intumescent chemistry as well as magnesium hydroxide both halogen-free alternatives to chlorine- and bromine-based systems. According to BASF, this formulation approach also limits the potential for secondary corrosive damage from smoke gases, a relevant consideration for enclosed rail environments. The grades are distributed across flame-retardant classes FR30, FR40, and FR72.

 

One aspect of the EN 45545 testing protocol that may simplify the qualification process is its color-independence: once a grade is certified, all color variants are covered without requiring additional approval. Wall thickness coverage is handled through defined minimum and maximum thicknesses during testing, which BASF indicates provides additional design flexibility for OEMs and processors.

Compliant grades

The current EN 45545 classification reports cover a broad range of grades across both the Ultramid® and Ultradur® families, including:

 

 

You can review the full technical specifications of BASF's products and compare available grades directly in the Master Catalog of Plastics.

 

Image credits: BASF

Source
BASF