Success Story

Rogers Keeps Commuters Safe

Mass Transportation

Rogers BISCO® BF-1005 Foam Preventing Power Loss on Commuter Trains

Customer Problem

Commuters in major metro areas choose trains as their mode of transportation because commuter trains allow them to enjoy a safe, comfortable ride in addition to the benefit of not needing to brave the elements to drive through rain or snow. However, when train cars lose power, not only does it cause delays for the affected train and any cars caught behind it on the track but, even worse, trains without electrical power lose their ability to regulate the internal temperature of the cars.

If the train loses power in a tunnel during the summer, temperatures inside the car can reach 38°C (100°F). Equally as concerning, lost power in the winter months can result in passengers braving below freezing temperatures inside the cars.

A commuter train operator faced this challenge on a regular basis because their electrical panel, located on the external surface of the car, was failing. The extruded rubber gasket that filled the space between the electrical panel and the car was not holding up to the harsh weather conditions commuter trains endure. It hardened over time, producing gaps where wind, rain and sun damaged the electrical panel. The result was loss of power.

The Rogers Solution: BISCO® BF-1005 Foam

BISCO BF-1005 extra soft foam provided a solution for the commuter train operator by preventing damage from the elements that originated from a loose gasket between the electrical unit on the exterior of the train and the train car itself. The existing extruded rubber gasket was failing sooner than expected and the cost of replacing the gasket was prohibitive.

The compression set resistance (see description) of the BF-1005 made it the perfect solution to fill the space created by the inadequate seal provided by the extruded rubber gasket. The softness of the BF-1005 allowed it to easily fill the difficult geometries needed to maintain a good seal and keep the elements from shorting out the electrical panel. In addition, BF-1005 foams meet ASTM E162, ASTM E662 and SMP 800C for flame, smoke and toxicity requirements for trains, making it the clear solution for this customer.

An added benefit was the commuter train operator did not need to waste man hours removing the old, dried out rubber gasket before installing the BF-1005 foam. A Rogers Authorized Preferred Converter provided a precut peel and stick ready-to-use solution which saved the customer time and money on installation.


BISCO® BF-1005 foam maintained a seal between the two surfaces while also providing UV protection and superior durability, which means fewer repairs to the electrical panel.

Eliminating injury to maintenance workers is of deep concern to the operator, as is reducing incidences of power loss which cause discomfort to customers. When repairs on an electrical enclosure are called for, cars can potentially be out of service for three to five days, costing the car operator $5,000-$10,000. With car warranties averaging about ten years, the problem could recur three to five times, resulting in a substantial cost to the operator.

This makes the installation of BISCO® BF-1005 the smart choice to prevent electrical problems due to weather exposure caused by failing extruded rubber gasketing material.

View All Success Stories


Elastomeric Material Solutions

Find local representatives for personalized support.