The PRM TSI as it is known (Persons with reduced mobility Technical Specification for Interoperability) came into force in July 2008 and applies to all trains used on the interoperable rail system: the major lines of the mainline rail system in the UK. 

PCC have developed the first fully certified PRM TSI compliant toilet module in the UK. The deadline for the UK compliance is Jan 2020:  every train must have one PRM compliant toilet. 

Whilst the latest fleets of rail vehicles are compliant with accessibility requirements and future new builds will be similarly compliant, older vehicles are subject to a refurbishment in order to meet the new PRM TSI legislation. 

The PCC “comfort zone” toilet module has been designed to allow an extensive range of vehicle upgrades to the PRM TSI standard from vehicles of class 156 proportion upwards with different interface fixings according to the train size. 

Hydro Aluminium Extrusion provided mill finished extrusions for the toilet modules which are then powder coated. 

Mark Isaac, Managing Director of PCC says “We wanted to source materials for the product as locally as possible and via the Internet we found that we had an aluminium extrusion company on our doorstep.”  

“We designed everything on CAD, adds Mark.  When the first order was delivered consistency from Hydro enabled it all to fit together “like a lego set”. 

We were very pleased with the quality of the  extrusions as well as the service that we were given.  

Time was of the essence and our Sales Manager at Hydro, Jim Purnell made sure our very short timescales were met, which was a big help”.  

Although the PCC toilet boasts the smallest footprint available, it also encompasses a 1500mm internal wheelchair turning circle. 

“An advantage of such a small footprint is that less seats are lost from the original train layout when the refit is carried out which obviously has a cost benefit,” explains Mark. 

The “Comfort Zone” toilet can either be supplied pre-built, or flat-packed for easy installation into existing rolling stock.  Other toilet modules in the market are supplied ready assembled and need to be dismantled before being for fit.  

The original design was modified as a result of product tests.  

“We set out with the idea that it had to be right for both the Rail Operator AND the rail passenger, so the original prototype has already been given a makeover” says Production Support Engineer, Sam Murcutt. 

We brought in a top design team to create a clean, fresh and modern feel about the unit as well adding additional facilities.” 

Each toilet module consists of nine aluminium extrusions to support the phenolic glass composite panels and aluminium honeycomb walls. 

“We specialize in glass reinforced phenolic composites which we make in house and use as our toilet module panels,” explains Mark, “not only because it is light in weight but it is also rail approved: meeting stringent fire, smoke and toxic fume requirements.” 

We buy in the aluminium honeycomb which makes up some of the structure.” 

Aluminium is an ideal material for this application as it is light in weight for easy installation but also very strong. It also has the potential to apply some very tough finishes such as powder coating that will withstand the rigorous demands of public spaces. 

“We have experimented and use various fixings to join the different materials together for optimum fit and function”, adds Sam.  

Where two honeycomb walls are connected the extrusion has “teeth”– called an “interference” fit.  A three finger extrusion connects three walls together. 

Where the toilet wall (aluminium honeycomb) meets the babychanging wall (phenolic) the extrusion has teeth on one side and then space to bond onto the phenolic with structural adhesive.  

The versatility of aluminium is also shown in the softer “T4” material which is bent round the edge of the toilet hatch. 

For Rail Engineers, ‘Comfort Zone’ ticks all the boxes. It is fully compliant and certified to meet PRM/TSI regulations and flat packed for easy installation. The facilities have been engineered so that servicing can be carried out in one operation, to save ongoing maintenance costs. 

The “Comfort Zone” was unveiled at Railway Interiors Expo 2011 in Cologne and caused a stir amongst visitors to the PCC stand.  Rail industry delegates recognized the product would help them in their challenge to become accessible and the exhibition order book reflected this.  

The Newport factory began gearing up since 2010 to begin production of the first nine units which will go into service this autumn.