Minimum Loading Standards for Coiled Metal Products in Closed Cars

Transcription

1 Closed Car Loading Guide Part 9 (formerly Pamphlet No. 23) Minimum Loading Standards for Coiled Metal Products in Closed Cars Approved August 26, 2014, by the Damage Prevention and Freight Claim Committee

2 Copyright 2014 by the Association of American Railroads (AAR) 425 Third Street SW Washington, DC All rights reserved, including the right to reproduce this book in any form. It is the AAR s intention that this publication be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the purchaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise made available to multiple users through any electronic distribution media including but not limited to a local area network or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and its authorized distributor(s) without written permission from the AAR.

3 Minimum Loading Standards for COILED METAL PRODUCTS IN CLOSED CARS (Supersedes Pamphlet No. 23, Published April 1995; Cancels G.I.S. Nos. 572, 589, 628, 635, 643, 653, 684, 685, 688, 717, 718, and 726 Issued: August 2014 Published by Transportation Technology Center, Inc DOT Road Pueblo, CO (Printed in U.S.A.) 2014

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5 TABLE OF CONTENTS Title Page 1.0 Introduction Overview Reference Documents Rail Transportation Environment Selection and Preparation of Car Overview Clearance at Side Bearing Loaded Cars Maximum Load Weight Distribution of Weight Lengthwise in Cars Distribution of Weight Crosswise in Cars Concentrated Weight Bulkhead Equipment Load Planning General Load Planning Packaging and Unitizing Steel Strapping Polyester Plastic Strapping (PET Strapping) High-Friction and Stretch-Rope Packaging Blocking and Bracing Materials Steel Strapping Lumber Friction Mats Polyethylene Foam Pads Web Strap Assemblies Controlled Floating Loads Unitized Coils on Rubber Mats Method Unitized Coils on Rubber Mats Method High-Capacity Bulkhead Doors with Contour Buffer Pads General Loading Information Single Layer Load in Two Rows Two Layer Loads in One or Two Rows Offset Pattern Coils with Stretch Rope Packaging Floor-Anchored Systems Floor-Anchored Straps Method Floor-Anchored Straps Method Floor-Anchored Straps Split Coils Coil Harness Kits Method Coil Harness Kits Method Closed Car Loading Guide Minimum Loading Standards for Coiled Metal Table of Contents i

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7 LIST OF FIGURES Figure 2.1 Concentrated floor loading card Figure 2.2 Distribution of weight lengthwise in car Figure 2.3 Bulkhead doors Figure 4.1 Typical coil packaging Figure 4.2 Coil packaging and stretch-film roping Figure 5.1 Contour polyethylene foam pads Figure 5.2 Web strap assembly Figure 6.1 Unitized coils on rubber mats Method 1, one row Figure 6.2 Unitized coils on rubber mats Method 1, two rows Figure 6.3 Unitized coils on rubber mats Method Figure 6.4 Unitized coils Method 2, guide rails Figure 7.1 Bulkhead doors with contour foam pads, single layer load Figure 7.2 Bracing for skids in doorway Figure 7.3 Coils loaded in two layers Figure 7.4 Coils loaded in two rows and two layers Figure 7.5 Coils loaded in a 1-1 offset pattern with bulkhead doors and contour pads Figure 7.6 Aluminum coils secured to skids with stretch-film ropes Figure 8.1 Floor-anchored straps Method Figure 8.2 Floor-anchored straps Method Figure in.-diameter coils on rubber mats with floor-anchored straps split coils Figure in.-diameter coils on rubber mats with floor-anchored straps split coils Figure 8.5 Coil harness kits Method Figure 8.6 Coil harness kits Method Closed Car Loading Guide Minimum Loading Standards for Coiled Metal List of Figures iii

8 LIST OF TABLES Table 2.1 Length of load versus percentage of stenciled load limit Table 2.2 Load weight as percentage of load limit Table 6.1 Masticated rubber mat specifications for Figure Table 6.2 Masticated rubber mat specifications for Figure Table 7.1 Rebonded rubber mat specifications for Figures 7.1, 7.3, and Table 8.1 Rebonded rubber mat specifications for Figure Table 8.2 Rebonded rubber mat specifications for Figure List of Tables iv Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

9 INTRODUCTION 1.0 INTRODUCTION 1.1 Overview The purpose of this guide is to relate basic good car loading procedures that have been developed through laboratory and field testing, engineering studies, and accumulated experience in rail transportation. Compliance with the Minimum Loading Standards contained herein will ensure conformance with Circular No. 42-K rules and provide adequate protection for lading from sources of damage in the normal railroad environment The general rules contained in Circular No. 42-K or supplements thereto issued by the AAR are formulated for the purpose of providing safe methods of loading boxcars and must be observed The loading rules and/or practices apply to shipments transported in the USA, Canada, and Mexico The loading methods in individual closed car loading publications issued by AAR s Damage Prevention and Loading Services are minimum standards that have been evaluated and approved by the AAR Damage Prevention and Freight Claim Committee. The minimum standards offer practical guidelines on the subjects covered. Because these are minimum standards, it may be necessary to supplement the methods in some instances Securement standards in AAR closed car loading publications are intended for safe transit of the railcar from origin to destination and for the prevention of lading and equipment damage. The standards do not address unloading practices Loading and bracing methods not currently approved may receive consideration for approval and publication under the Damage Prevention and Loading Services General Information Bulletin, No. 2, Procedures Governing Evaluation and Acceptance of New Closed Car Loading and Bracing Methods and Materials. Submit requests to Director, Damage Prevention and Loading Services, Association of American Railroads, Transportation Technology Center, Inc., DOT Road, Pueblo, CO CAUTION: Car rocking motion caused by lift equipment entering and/or exiting the railcar may cause unsupported packages or articles with a high center of gravity to fall to the floor. Minimize access to the car. Exercise caution when inside a partially loaded car. Lift operators should stay on lift equipment, whenever possible, while inside a partially loaded car. 1.2 Reference Documents Circular No. 42-K (or supplements thereto) General Rules Covering Loading of Carload Shipments of Commodities in Closed Cars These requirements must be observed in all closed car loading activities to ensure safe transit of the railcar from origin to destination, thereby eliminating hazard to railroad operation Circular No. 43-E (or supplements thereto) Rules Governing the Loading, Blocking, and Bracing of Freight in Closed Trailers and Containers for TOFC/COFC Service This publication contains the requirements covering loads in trailers or containers. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 1 1

10 INTRODUCTION 1.3 Rail Transportation Environment There are inherent characteristics of the rail environment that must be understood to recognize the need for many of the requirements identified in this publication Forces encountered within the rail vehicle are induced by shock and/or vibration. In most instances, the force is a complex result of both shock and vibration. Force input due to shock is mainly a result of impacts during switching and train slack action (run-in and run-out during train movement). Force input due to vibration is a result of the movement of the railcar s wheels on the rails. This vibration force can act either in a vertical or lateral plane. These forces are due to the movement of the car wheels on the rails, the truck geometry, rail joints, rail elasticity, nonuniformities of the rail and wheels, and overall track condition. When all these factors are acting on a rail vehicle, the resultant force is very complex The lading in a rail vehicle can also generate forces; for instance, in canned commodities, the metal cans can act as springs. For multilayer loads in the rail vehicle, any vertical force input in the bottom layers can be greatly amplified as it travels to the top layers. This is the transmissibility factor due to the harmonics of a particular stack or column of containers Uncontrolled movement and/or displacement of the lading in a rail vehicle can cause safety problems, equipment failure, damage, and unloading problems. The following minimum loading standards in conjunction with proper packaging will provide safe arrivals. 1 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

11 SELECTION AND PREPARATION OF CAR 2.0 SELECTION AND PREPARATION OF CAR 2.1 Overview Railroads are responsible for supplying cars that are clean and have sound roofs, sides, and square endwalls; smooth floors; and snug-fitting doors. Any exception is cause for rejection. Shippers are responsible for inspecting interiors of cars to see that they are suitable to carry lading safely and damage-free Before attempting to open the doors of any railcar, check to make sure that all hardware is intact so that the doors open safely. Check the door tracks to make sure they are equipped with stops on the ends so that the doors do not fall off when opened. It is critical to check locking bars and related hardware to make sure you can safely open plug doors. Make sure the doors are operating correctly before fully opening them. There is always the possibility that material or lading may be leaning against the inside doors or is applying pressure. Use extreme care when opening any type of railcar door to protect against injury Always check the car to see if water entry is possible. Make sure that the car is watertight. Look for light leaks or evidence of new or large amounts of rust, which may indicate recent water entry into the car. (Note to customers: Notify appropriate carriers immediately if railcars are received with water damage to ensure that the car is shopped and repaired before the car is used again.) Check the car floors for any holes or rough surfaces that may result in leakage or damage to the product If the car supplied is not suitable for loading and the shipper elects to load the car rather than reject it, it is the shipper s responsibility to properly prepare the car The loading methods illustrated in this guide have a proven track record of success in specific car types. Please note the type of car for which each method is used. Failure to use the proper loading method in the proper type of equipment will result in damage to the product and a dissatisfied customer (i.e., if a loading method is shown for use in a cushion equipped car, use that loading method only in cushion-equipped cars) Boxcars used for loading and transporting heavy concentrated weight (e.g., metal) must be inspected by the originating carrier (either before they are placed for loading or at loading point) for suitability to safely carry such loads to their destination When ordering boxcars for loading concentrated weights of heavy commodities, shippers are responsible for notifying serving carriers of the heavy-weight conditions and if the cars were not inspected by the originating carrier for these conditions Boxcars furnished for loading and transporting heavy concentrated weight (e.g., tin plate, copper anodes, lead ingots, cathodes, zinc slabs, spelters, and all other high-density commodities) must meet the following requirements: Cars must be stenciled 25K, 50K, 70K, or 80K adjacent to door opening, indicating floor loading capacity Wood floors must be 2¼ in. thick in sound condition supported by at least three metal floor stringers on each side of the center sill the full length of the car If equipped with sliding sill underframe, wood floors must be 2¼ in. thick in sound condition supported by at least two metal floor stringers on each side of the center sill the full length of the car. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 2 1

12 SELECTION AND PREPARATION OF CAR If equipped with steel floors or special-type wooden flooring the full length of the car, the overall strength of the floor must be not less than that of a floor with three stringers as specified above Boxcar must be checked by the shipper to see that the floors and supporting structure are in good condition. If the shipper has any doubts concerning the condition of the car, the serving railroad should be contacted Shippers have the responsibility of attaching a concentrated floor loading card, shown in Figure 2.1, to the routing or placard board on each side of the boxcar loaded with metals with densities exceeding 400 lb/ft 3 and/or 800 lb/ft 2 floor-bearing area. Figure 2.1 Concentrated floor loading card Loads occupying less than the total floor space that could cause unbalanced distribution within the car must be secured to prevent movement. 2.2 Clearance at Side Bearing Loaded Cars For cars not equipped with constant-contact-type side bearings (zero clearance normal), clearance must be maintained at side bearings to permit free curvature of trucks. 2.3 Maximum Load Weight Load weight in the car must not exceed the load limit stenciled on the car Load weight on one truck must not exceed one-half of the load limit stenciled on the car. 2.4 Distribution of Weight Lengthwise in Cars For all boxcars, except for those with staggered double-doors built before 1966, the percentages of stenciled load limits shown in Figure 2.2 must not be exceeded for loads located between truck centers, measured to full length of the car, unless car owners have otherwise noted in the Official Railway Equipment Register. Figure 2.2 Distribution of weight lengthwise in car 2 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

13 SELECTION AND PREPARATION OF CAR For staggered double-door boxcars built before 1966, the percentages listed in Figure 2.2 are shown in Table 2.1: Table 2.1 Length of load versus percentage of stenciled load limit Length of Load 40 ft 50 ft 10 ft to 20 ft 40% 35% 20 ft 1 in. to 24 ft 45% 40% 24 ft 1 in. to truck centers 75% 75% Truck centers to full length of car 100% 100% If the maximum load is 40% of stenciled load limit, the provisions in paragraphs and would not apply Weight of material loaded in either end between truck centers and end of car must not exceed 15% of stenciled load limit for boxcars built before January 1, 1966, and 25% for cars built after January 1, When crosswise bearing pieces are used, the distance between the outside bearing pieces (center-to-center) must exceed the minimum distances specified in paragraphs and for that percentage of the stenciled load limit being loaded and be in sufficient number to ensure uniform distribution of lading on the car floor Bearing pieces lengthwise of the car, extending beyond the lading, may be used to spread weight distribution over a greater area. In such cases, Length of Bearing Pieces is substituted for Length of Load in paragraphs and Bearing pieces must be of suitable strength in relation to percentages stated and must be continuous and in sufficient number to ensure uniform distribution of lading on the car floor When the length of load is less than the distance between truck centers, and the load is not located in the center of the car, the center of load weight must not be nearer to either truck center than that shown in Table 2.2: Table 2.2 Load weight as percentage of load limit 2.5 Distribution of Weight Crosswise in Cars Inside Length of Car 50% of load limit or less Any place between truck centers 60% One-sixth distance between truck centers 66.6% One-fourth distance between truck centers 75% One-third distance between truck centers 87% Three-sevenths distance between truck centers 90% Nine-twentieths distance between truck centers The load must be located so that the weight along both sides of the car is approximately equal for the entire length of the load When the load is such that it cannot be placed to obtain equal distribution of weight crosswise of the car, use properly secured and suitable ballast to equalize the weight In boxcars, lading must be secured to prevent tipping or moving toward the sides of the car where the vacant space across the car exceeds a total of 12 in. between lading and car sides. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 2 3

14 SELECTION AND PREPARATION OF CAR 2.6 Concentrated Weight Observe the concentrated load restrictions stenciled on the side of the car adjacent to the doors; e.g., 50K and 75K. This indicates the maximum front axle load for lift trucks entering the railcar. 2.7 Bulkhead Equipment When cars are equipped with bulkhead doors, inspect the doors to determine if they can be moved safely, then move the doors to approximately where they will be located under load. Engage the locking mechanisms to make certain they are operational. Inspect for full extension all locking pins at the top and bottom of the bulkhead doors. Locking pins must penetrate the tracks a minimum of 1 2 in. Tapered locking pins must penetrate the tracks a minimum of 1 2 in. beyond the taper (see Figure 2.3). LOCKING PINS MUST PENETRATE THE FLOOR AND CEILING LOCKING TRACKS A MINIMUM OF 1/2 IN. MINIMUM 1/2 IN. Figure 2.3 Bulkhead doors The weight of cargo restrained by each bulkhead must not exceed one-half of the load limit stenciled on the car sides Examine all bulkhead doors before loading. This cannot be emphasized too strongly. Before moving a bulkhead door, inspect the overhead assembly to determine if it is in good condition so the door can be moved safely Inspect locking handles to determine if they function properly. Inspect locking pins to make sure they penetrate into the holes of the overhead and floor locking tracks. If locking pins do not penetrate, DO NOT LOAD After cargo is loaded, place the door squarely (straight up and down) and snugly against the load, and lock into place. If the face of the load is not flush, use filler material to make it flush. If the door s surface is not smooth, protect the product with fiberboard. 2 4 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

15 LOAD PLANNING 3.0 LOAD PLANNING 3.1 General Load Planning Load, block, or brace commodities tightly lengthwise and crosswise to eliminate all void spaces, which are primary reasons for damage. Take up any void spaces remaining in a car. Use blocking, fillers, and other suitable materials, and secure them in accordance with the methods outlined in this guide and other guides listed on the back cover of this book Load and secure lading to permit unloading from either side of the railcar, except when dimensions of individual units of freight prohibit unloading from either side of the car Inspect lading before loading car. Do not load damaged lading Evenly distribute the weight of loads from side-to-side and end-to-end in the car and to a uniform height of lading insofar as lading permits. Always center the units in the doorway area along the lengthwise centerline of the car Stow lading in a manner to prevent contact with doorposts Fill all lengthwise space with lading and with lading and filler material, or appropriately block and brace When there is a possibility of lading falling or rolling out of the doorway or coming in contact with sliding or plug-type side doors, protect openings with wood doorway protection, steel straps, or other material of sufficient strength and number, and adequately secure it Apply temporary bracing in partly loaded or unloaded cars that will be switched during the process of loading or unloading. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 3 1

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17 PACKAGING AND UNITIZING 4.0 PACKAGING AND UNITIZING 4.1 Securing Coils to Skids Secure platforms or skids to the coils with 1¼ in in. steel straps, 1¼ in in. polyester plastic strapping (PET strapping), or stretch film roping to restrict movement on the platform/skids during transit as indicated in specific loading methods. 4.2 Steel Strapping Unless otherwise specified, use a minimum 1¼ in in. steel straps on all coils.use two straps per coil, one lengthwise of the skid and one crosswise of the skid.place waterproof material around the coils. See Figure ¼ IN. STEEL STRAP CORNER PROTECTORS Figure 4.1 Typical coil packaging 4.3 Polyester Plastic Strapping (PET Strapping) Use a minimum 1¼ in in. Type IV PET straps on all coils.use two straps per coil, one lengthwise of the skid and one crosswise of the skid.place waterproof material around the coils The strap must have a minimum break strength a/ of 2,800 lb Seal the strap with a friction weld or heat-seal joint (sealless) with a joint strength of 2,100 lb (75% of minimum break strength) Strap must be clearly marked by the strap manufacturer with the strap I.D., spaced at 5 ft intervals (maximum) Ensure that straps are straight and not twisted before tensioning. NOTE: Protect PET strapping from contacting coil edges and other sharp areas. a/ See ASTM Standard D3950, Standard Specification for Strapping, Nonmetallic, for information on strapping type and grade and testing procedures. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 4 1

18 PACKAGING AND UNITIZING 4.4 High-Friction and Stretch-Rope Packaging Only the following method using high- friction layers and stretch-film roping has been evaluated and found acceptable for this loading method: Alcoa, Inc., packaging patents U.S. No. 5,918,745, U.S. No.6,125,612, Canada No.2,277,514), as shown in Figure 4.2. PIZZA TOP 250 LB TEST, WVBC MICHELMAN COATED, MSDS LABELED, 2 IN. DIAMETER BELLYBAND 20 IN. WIDE, 2 MIL POLY WITH ALCOA LABELING FINISHED PACKAGE ALCOA COIL CUT HERE STRIP (APPLIED AT SLITTERS) VAPOR WRAP 150 GAUGE, BLOWN, 50%, FIVE LAYERS, HEAVY TACKIFIER ABRASIVE-RESISTANT INNER LAYER 9-MIL POLY WITH > = 1.0 COEFFICIENT OF FRICTION, BOTH SIDES 60 IN. OR 50 IN. WIDE, PARTIALLY APPLIED AT SLITTERS SKID WRAP 250 GAUGE, CAST 200%, HIGH FTL, 650 LB TENSION AT CORNERS, FIVE TO EIGHT ROPES, LOW COEFFICIENT OF FRICTION FRICTION DECK PAD METHOD 9 MIL HIGH-COEFFICIENT POLY (>1,0) TO ~1/2 IN. STANDARD 140 G/FT 2 DENSITY SHODDY PAD SKID ROPE NOTCHES, STANDARD 48 IN. AND 40 IN. WIDE, 1 IN. INCREMENTS Figure 4.2 Coil packaging and stretch-film roping See General Information Bulletin No. 8, Practical Guidelines for Stretch Film Roping of Steel Coils Shipped Eye Vertical in Boxcar and Intermodal Shipments, for additional information. 4 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

19 BLOCKING AND BRACING MATERIALS 5.0 BLOCKING AND BRACING MATERIALS 5.1 Steel Strapping Use the proper combination of steel straps, seals, sealing tools, notches, or crimps to provide a minimum breaking strength of 4,725 lb and 75% joint efficiency for all doorway protection straps Use metal protectors, such as corner guards or plates, sufficient to provide a suitable radius to protect straps at all points on lading having sharp edges and/or sharp corners Use tensioning and sealing equipment properly. Check the tools periodically to ensure their efficiency More detailed information regarding steel strapping is available in the Closed Car Loading Guide, Part 1, (formerly Pamphlet No. 14), Minimum Loading Standards for Freight in General Purpose Boxcars. NOTE: For the latest updates of approved strapping, go to the TTCI Web site at Lumber For more detailed information regarding wood and nailing, refer to the Closed Car Loading Guide, Part 1 (formerly Pamphlet No. 14), Minimum Loading Standards for Freight in General Purpose Boxcars or AAR Open Top Loading Rules Manual, Section 1, Appendix D, Material Mechanical Properties. 5.3 Friction Mats Friction mats are used between freight and the railcar and between layers of freight to increase resistance to lateral and longitudinal movement. For freight loading applications, friction mats are most commonly manufactured from either masticated or rebonded rubber, in thicknesses up to ¼ in. Use friction mats as specified in specific loading methods Do not use rubber mats that have been torn or in any way damaged. 5.4 Polyethylene Foam Pads Pads are typically 54 in. high by 24 in. wide and 3¼ in. thick at the center of the pad. The polyethylene pads have a density of 4 lb/ft 3. See Figure 5.1. Do not score or perforate the pads. CONTOURED ON BOTH SIDES FOR USE BETWEEN COILS TYPE A TYPE B CONTOURED ON ONE SIDE ONLY FOR USE BETWEEN COILS AND END WALL OR BULKHEAD Figure 5.1 Contour polyethylene foam pads Type A: For use between coils. Contoured on each side with two 8-in.-long ¾-in.-diameter plastic tubing legs capped off with 1-in. rubber cane tips inserted at the bottom of each side to elevate the pad above the adjacent deck boards. Type B: For use between coils and the endwall or bulkhead. Contoured on one side only. Place flat side against endwall or bulkhead. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 5 1

20 BLOCKING AND BRACING MATERIALS 5.5 Web Strap Assemblies Web strap assemblies are anchored to the car floor using T-hooks inserted into anchor plates or sidewalls with wall anchor clips. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb or as specified in a specific loading method. Tensioning ratchets are located near the sidewall. See Figure 5.2. NOTES: 1. WEBBING MATERIAL: POLYESTER COLOR: SEE COLOR SCHEDULE 2. ASSEMBLY BREAKING STRENGTH: 18,000 20,000 LB 3. ASSEMBLY WORKING LOAD LIMIT: 6,500 LB 4. EXTRA 16 IN. NECESSARY FOR TWO WRAPS AROUND DRUM Figure 5.2 Web strap assembly 5 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

21 CONTROLLED FLOATING LOADS 6.0 CONTROLLED FLOATING LOADS 6.1 Unitized Coils on Rubber Mats Method This loading method is suitable for coils loaded in one or two rows in each end of the car. See Figures 6.1 and 6.2. UNCRIMPED SEAL STEEL UNITIZING STRAP, 2 IN IN. 30 IN. LUMBER, 2 IN. 6 IN. MINIMUM UPRIGHT, 2 IN. 6 IN. RUBBER MAT, 12 IN. WIDE Figure 6.1 Unitized coils on rubber mats Method 1, one row STEEL UNITIZING STRAP, 2 IN IN. LUMBER, 2 IN. 6 IN. MINIMUM 30 IN. UPRIGHT, 2 IN. 6 IN. RUBBER MAT, 12 IN. WIDE Figure 6.2 Unitized coils on rubber mats Method 1, two rows Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 6 1

22 CONTROLLED FLOATING LOADS Use only cushion-equipped boxcars for this loading method Use this method to load metal coils on platforms/skids with the eye vertical. Secure coils to the platforms/skids with 1¼ in in. steel straps to prevent movement on the platform/skids during transit Prior to loading, place a 12-in.-wide strip of rubber mat down the center of the car. The mat must run from the end of the car to a minimum of 48 in. beyond the doorway end of each row of coils. See Figure Specifications for the masticated rubber mats are shown in Table 6.1: Table 6.1 Masticated rubber mat specifications for Figure 6.1 Property Standard Specification Thickness 0.25 in. Density ASTM D grams/in. 3 Tensile ASTM D psi Tear ASTM D624, Die B 410 ppi (pores per inch) Durometer Hardness ASTM D676, 80 (Shore A) Nail 2 in. 6 in. lumber on top of each side of the rubber mat with minimum 20d nails, one every 12 in. The lumber should extend from the end of the car to 48 in. past the front of the load Load coils down the center of the car as shown in Figure Encircle all coils in each row with one 2 in in. steel strap lengthwise of the car Use 2 in. 6 in. lumber uprights as a buffer between the coils and the 2 in. unitizing strap. The height of the uprights should be 24 in. minimum or within 3 in. of the height of the coils if the coil is less than 24 in. high. Uprights should be nailed to the top 2 in. 6 in. The top 2 in. 6 in. should be 30 in. long minimum When the density of the product and space for loading permits, place lading a minimum of 30 in. from the endwall of the car Place one 2 in. strap seal (uncrimped) under the coil packaging band and around the unitizing strap to maintain strap alignment Tension and seal unitizing straps per manufacturers instructions. 6 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

23 CONTROLLED FLOATING LOADS 6.2 Unitized Coils on Rubber Mats Method Use only cushion-equipped boxcars for this loading method Use this method to load metal coils on platforms/skids with the eye vertical. Secure coils to the platforms/skids with 1¼- in in. steel straps to prevent movement on the platform/skids during transit Load the coils in two rows in each end of the car starting approximately 30 in. from each endwall. The rubber mats extend from the endwalls of the boxcar to 30 in. beyond the doorway end of the coil unit in each end of the car and are not secured to the car floor. Use one continuous rubber mat at each location, if possible. The outside skid runners of each skid are located on the rubber mats. See Figure ¼ IN. STEEL UNITIZING STRAPS RUBBER MATS 1¼ IN. STEEL UNITIZING STRAPS PACKAGE STRAPS (TYPICAL) Figure 6.3 Unitized coils on rubber mats Method The rubber mats are 1 ft wide and in. (3 mm) thick Specifications for the masticated rubber mats are shown in Table 6.2: Table 6.2 Masticated rubber mat specifications for Figure 6.3 Property Standard Specification Thickness in. Specific Gravity ASTM D Tensile ASTM D412, Die A, Min 435 psi Tear ASTM D624, Die B, Min 85 ppi (pores per inch) Hardness ASTM D2240, Shore A 65 ± 5 Coefficient of Friction TAPPI TB 160M Unitize the coils using 1 ¼ in in. steel straps passed through the eye of the coils. Each coil is unitized with the adjacent coils lengthwise and crosswise of it and diagonally opposite of it, as shown in Figure 6.3. The lengthwise and diagonal unitizing straps run under the deck boards of the skids. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 6 3

24 CONTROLLED FLOATING LOADS Use guide rails and backup cleats of minimum 2 in. 4 in. lumber along the sidewalls to maintain longitudinal alignment of the units. Guide rails extend from the endwall to a minimum of 30 in. past the doorway end of the unit in each end of the car. Secure the guide rail to the car floor using 4 in. nails, one every 18 in. in a staggered pattern. Use backup cleats extending from the guide rails to the car sidewalls, one every 4 ft, secured with a minimum of two 4 in. nails. The guide rails are not secured on top of the rubber mats. See Figure 6.4. GUIDE RAIL, 2 IN. 4 IN. LUMBER MINIMUM BACKUP CLEATS, 2 IN. 4 IN. LUMBER MINIMUM Figure 6.4 Unitized coils Method 2, guide rails 6 4 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

25 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS 7.0 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS 7.1 General Loading Information Use only cushion-equipped boxcars with high-capacity bulkhead doors For this loading method, use multilayer contour polyethylene foam (polyfoam) pads between coils of aluminum and at the end of each row of coils between the end coil and the endwall and bulkhead. See Figure Use core plugs, minimum 1½ in. thick, in the eye at the top of each coil. Also use core plugs in the eye at the bottom of each coil to help prevent edge damage at the eye of the coil. Use is optional Use 1¼ in in. steel straps on all coils loaded with this method. Use two straps per coil, one lengthwise of the skid and one crosswise of the skid. Place waterproof material around the coils Examine all bulkhead doors before loading. Before moving bulkhead doors, inspect the overhead assembly to verify that the mechanism is in good condition so that the doors can be moved safely. Check to make sure that the locking handles function and that locking pins are operating properly and penetrate sufficiently into the overhead and floor locking tracks. Before loading, move bulkhead unit or units beyond the doorway of the car to facilitate loading in the opposite end Use only heavy-duty bulkhead doors when loading coiled metal products. These types of doors are extra-heavily constructed and have three pins in four locations Securely tape Type B polyethylene foam filler pad(s) to each endwall for contact and to provide protection between the endwall and adjacent coil. Position the pad so that the flat side of the filler is placed against the endwall and the contoured side is placed against the adjacent coil Position double-contoured Type A polyethylene foam filler pads between each coil. Elevate pads above the height of the adjacent deck boards by lengths of plastic tubing capped with 1 in. rubber cane tips Securely tape an appropriate foam filler pad to the last coil loaded so that the contoured side of the filler is placed against the coil and the flat side is placed against the bulkhead doors After the car is loaded, place the bulkhead doors squarely and snugly against the load and lock into place. Check again to ensure that locking pins penetrate holes in floor and overhead tracks. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 7 1

26 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS 7.2 Single Layer Load in Two Rows For this method, load all coils in the car with skid runners parallel to the sidewalls. Place the first coils against the endwall and sidewall with remaining space left down the center of the car. Load all other coils in line with the first coils, again with the space left down the center of the car. See Figure 7.1. POLYFOAM CONTOUR PADS USED BETWEEN COILS AND AT ENDS OF ROWS EXTRA HEAVY DUTY BULKHEAD HAS THREE PINS AT EACH OF FOUR LOCATIONS CROSSWISE BLOCKING, 12 IN. MINIMUM SEE FIGURE 7.2 Figure 7.1 Bulkhead doors with contour foam pads, single layer load Use floor blocking or welded guide rails to maintain row alignment and to prevent cross-car movement. Use back-up cleats, minimum of 12 in. long, secured by three 4 in. nails. Place floor blocking against skid runners and perpendicular to the skid runners. Use of floor blocking is mandatory whenever the crosswise void exceeds 12 in Ensure that the bulkhead is straight across the car and that bulkhead doors are pushed tightly against the load. 7 2 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

27 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS If rows of coils extend into the doorway area of the car and skid runners are perpendicular to the car walls, use parallel guide rails (2 in. 4 in.) down the center of the car in the doorway area, nailed to the floor against the ends of the skids. Nail additional pieces to skid platforms to unitize them and to act as doorway protection. See Figure 7.2. ALTERNATIVE FLOOR BLOCKING; LUMBER, LAMINATED, TWO 2 IN. 6 IN. PIECES CORE PLUG SEE PARAGRAPH LUMBER NAILED TO SKID PLATFORMS LUMBER, 2 IN. 4 IN. Figure 7.2 Bracing for skids in doorway Use two steel straps, minimum 1¼ in in. or equivalent, across the doorway as an alternative to the lumber pieces nailed to the skid platforms. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 7 3

28 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS 7.3 Two Layer Loads in One or Two Rows For this method, load all coils into the car with skid runners parallel to the sidewalls. Load large-diameter coils with the first stack placed against each endwall centered in the car. Load all other coils in line with the first stack, again down the center of the car. See Figure 7.3. HIGH-CAPACITY BULKHEAD DOORS 1¼ IN. STEEL UNITIZING STRAPS OR EQUIVALENT POLYFOAM CONTOUR PADS REBONDED RUBBER MATS PLACED BETWEEN BOTTOM COILS AND SECOND LAYER SKIDS 2 IN. 6 IN. GUIDE RAILS Figure 7.3 Coils loaded in two layers 7 4 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

29 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS If the diameter and weight of the coils allow loading of two rows in each end of the car, load the first coils against each endwall and sidewall with remaining void space left down the center of the car. Load all other coils in line with the first stacks, again with the void space down the center of the car. See Figure 7.4. POLYFOAM CONTOUR PADS 1¼ IN. STEEL UNITIZING STRAPS OR EQUIVALENT HIGH-CAPACITY BULKHEAD DOORS Figure 7.4 Coils loaded in two rows and two layers REBONDED RUBBER MATS PLACED BETWEEN BOTTOM COILS AND SECOND LAYER SKIDS Unitize the second layer of coils in each stack to the first layer of coils with two 1¼ in in. steel straps, one parallel to the skid runners and the second perpendicular to the first. Center both unitizing straps on the coils. Locate the unitizing straps directly over the package straps and apply through slots or grooves in skid runners used for package straps Optional: Use rebonded rubber mats between the first layer coils and second layer skids (under the second layer skid) to provide protection for first layer coils and to further minimize shifting of second layer skids on top of the coils. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 7 5

30 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS Specifications for the rebonded rubber mats are shown in Table 7.1: Table 7.1 Rebonded rubber mat specifications for Figures 7.1, 7.3, and 7.4 Property Standard Specification Thickness 3 mm (0.125 in.) Density ASTM D lb/ft 3 Tensile ASTM D psi Tear ASTM D624, Die C 73 ppi (pores per inch) Elongation at break ASTM D % Compression Set B ASTM D (25% Deflection, 158 F/22 hours) Compression Set (Foam) ASTM D (50% Deflection, 158 F/22 hours) Compression Properties ASTM F36A 100 psi 19% 400 psi 52% Coefficient of Friction ASTM D1894 Wet: Dry: Use floor blocking to maintain row alignment and to prevent cross-car movement. When a single row is loaded in the end of the car, nail one 2 in. 6 in. guide rail on each side of the center skid runner. Secure them with 4 in. nails spaced no more than 18 in. apart. When two rows are loaded in the end of the car, use back-up cleats, minimum 12 in. long, placed perpendicular to and against the skid runners. Use of floor blocking is mandatory whenever crosswise void exceeds 12 in After the car is loaded, place the bulkhead doors squarely and snugly against the load and lock into place. Check again to ensure that the locking pins penetrate the holes in the floor and overhead tracks. 7 6 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

31 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS Offset Pattern For this method, use multilayer contour polyethylene foam pads between coils of aluminum and between the coils and the car endwalls, sidewalls, and bulkhead. See Figure Use 1¼ in in. steel straps on all coils loaded using this method. Use two straps per coil, one lengthwise of the skid and one crosswise of the skid. Place waterproof material around the coils Load coils in a 1-1offset pattern, as shown in Figure 7.5. Position skid runners lengthwise of the car. Place polyethylene foam pads as shown in Figure 7.5. Use a wooden void filler constructed from hardwood lumber or pallets to fill the void at the endwall or bulkhead where the coil is not immediately adjacent to the endwall or bulkhead. Use wood void fillers of approximately the same height as the adjacent coil. Use a buffer sheet, such as multiwall corrugated fiberboard, between the wood filler and the coil alongside it to prevent the filler from contacting the coil. NOTE: Marks on the outer surface of the coil may result from the pressure of the contour pads against the coils. Shippers should evaluate this condition before using this loading method. BUFFER SHEETS CONTOUR POLYETHYLENE FOAM PADS WOOD VOID FILLER CONTOUR POLYETHYLENE FOAM PADS BUFFER SHEETS Figure 7.5 Coils loaded in a 1-1 offset pattern with bulkhead doors and contour pads 7.5 Coils with Stretch Rope Packaging Use only cushion-equipped boxcars with high-capacity bulkhead doors and welded steel floor guide rails For this method, use multilayer contour polyethylene foam pads between coils of aluminum and at the end of each row of coils between the end coil and the endwall and bulkhead. See Figure Secure all skids loaded by this method with high-friction packaging layers and stretch-film ropes to minimize coil movement on the skids during transit. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 7 7

32 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS Use only heavy-duty bulkheads intended for this commodity with this loading method Weld steel floor guide rails parallel to sidewalls to ease positioning of skids For this method, use aluminum coils on skids with the eye vertical. The aluminum coils used during testing weighed approximately 28,000 lb. Secure skids to the coils with high-friction packaging layers and stretch-film ropes to minimize coil movement on the skids during transit Load all coils in the car with skid runners parallel to the sidewalls. Load the coils beginning at one endwall down the centerline of the car with the outside skid runners positioned adjacent to welded floor guide rails to minimize any potential lateral shifting, as shown in Figure 7.6. TYPE A CONTOUR PADS TYPE B CONTOUR PADS WELDED GUIDE RAILS WELDED GUIDE RAILS FRICTION METHOD 9 MIL HIGH-COEFFICIENT OF FRICTION POLY (>1.0) TO ~ ½ IN. STANDARD 140 G/FT 2 DENSITY SHODDY PAD. SHODDY PAD STAPLED TO TOP SKID RUNNERS, BETWEEN DECK BOARDS. SKID ROPING 650 LB TOTAL TENSION FORCE/CORNER (APPROXIMATELY EIGHT ROPES/CORNER) FOR 400 LB SKID. TENSION PROPORTIONAL TO SKID WEIGHT. POLYETHYLENE FOAM PADS TYPE A TYPICAL 54 IN. 24 IN. 3¼ FT PADS WITH TWO EACH, 8 IN. ¾ IN. PLASTIC TUBING LEGS CAPPED OFF WITH 1 IN. RUBBER CANE TIPS. TYPE B PADS ARE TAPED TO END WALLS AND TO BULKHEAD COILS. Figure 7.6 Aluminum coils secured to skids with stretch-film ropes Continue to load the remaining skids down the centerline of the one end of the car while maintaining proper load balance within load limits Place the bulkhead door squarely and snugly against the foam pad/coil combination in the loaded end of the car and lock in place. Check that locking pins penetrate the holes in the floor and overhead tracks Repeat the loading process for the opposite end of the car. If the car is equipped with more than two bulkhead doors, position and secure the unused bulkhead door(s) tight to a bulkhead door already secured in one end of the car and lock into place. 7 8 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

33 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 7 9

34 HIGH-CAPACITY BULKHEAD DOORS WITH CONTOUR BUFFER PADS 7 10 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

35 FLOOR-ANCHORED SYSTEMS 8.0 FLOOR-ANCHORED SYSTEMS 8.1 Floor-Anchored Straps Method Use only cushion-equipped boxcars for this loading method Use this method to load metal coils on platforms/skids with the eye vertical. Secure coils to the platforms/skids with 1¼ in in. steel straps to prevent movement on the platform/skids during transit. See Figure 8.1. COILS CENTERED IN BOXCAR COILS STAGGERED IN BOXCAR NOTE: COILS MAY MOVE SLIGHTLY TOWARD CENTER OF CAR IN TRANSIT SIDE VIEW Figure 8.1 Floor-anchored straps Method Load coils either down the center of the car or staggered, as shown in Figure 8.1. Place coils on 4 ft. 4 ft rebonded rubber mats, minimum in. thick. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 8 1

36 FLOOR-ANCHORED SYSTEMS A rebonded rubber mat with the specifications shown in Table 8.1 was used during testing: Anchor each coil using two 4-in.-wide web strap assemblies. Place two strap assemblies around the front and rear of each coil at the base of the coil. Use a 6 ft 6 in. nylon wear sleeve on each strap where the straps contact the coils. Anchor web straps into the floor by inserting T-hooks into the anchor plates. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 24,000 lb. Tensioning ratchets are located near the sidewall Ensure that straps are straight and not twisted before tensioning. 8.2 Floor-Anchored Straps Method 2 Table 8.1 Rebonded rubber mat specifications for Figure 8.1 Property Standard Specification Thickness 3 mm (0.125 in.) Density ASTM D lb/ft 3 Tensile ASTM D psi Tear ASTM D624, Die C 50 ppi (pores per inch) Elongation at break ASTM D % Hardness ASTM D2240 Shore A (porous) Compression Set B ASTM D (25% Deflection, 158 F/22 hours) Compression Set (Foam) ASTM D (50% Deflection, 158 F/22 hours) Compression Properties ASTM F36A 100 psi 15-25% 200 psi 30-40% 300 psi 40-50% 400 psi 45-55% Coefficient of Friction ASTM D1894 Wet: Dry: Use only cushion-equipped boxcars with anchor plates for this loading method Use this method to load metal coils on platforms/skids with the eye vertical. Secure coils to the platforms/skids with 1¼ in in. steel straps or an equivalent stretch-film roping method to prevent movement on the platforms/skids during transit. See Figure 8.2. FOAM PADS, AS REQUIRED RUBBER MAT UNDER EACH OUTSIDE RUNNER Figure 8.2 Floor-anchored straps Method Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

37 FLOOR-ANCHORED SYSTEMS Place 7 in. 48 in. rubber mats, minimum in. thick, on the car floor to contact outside skid runners when positioned. A rebonded rubber mat with the specifications shown in Table 8.2 was used during testing: Load coil/platform units down the center of the car as shown in Figure 7.3 while maintaining proper load balance within load limits. Utilize a sufficient number of web strap assemblies, as required by the loading pattern. Do not secure more than two series of coil/platform units in tandem Securely tape in place foam separator pads of appropriate thickness between coils and between coils and endwalls when the platform is larger than the coil diameter. Laminated polyethylene foam pads measuring 2 in. 6 in. 24 in. (4 6 lb/ft 3 density) were used as separators during testing Anchor each single coil and/or tandem combination using two 4-in.-wide web strap assemblies. Place a strap assembly around the front and rear of each single unit application at the base of the coil. Place two strap assemblies at the base of the doorward coil in a series application. Anchor web straps into the floor by inserting T-hooks into the anchor plates. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb. Tension straps using ratchets located near the sidewall Ensure that straps are straight and not twisted before tensioning. 8.3 Floor-Anchored Straps Split Coils Table 8.2 Rebonded rubber mat specifications for Figure 8.2 Property Standard Rebonded Rubber Sheet Thickness 1/4 in. Tensile ASTM D412, Die C 4.8 (696) with grain 2.1 (304.5) across grain Hardness ASTM D2240 Shore A Tear Resistance ASTM D (119.7) with grain (Die B) 44 (250.8) across grain Coefficient of Friction ASTM D Use only cushion-equipped boxcars for this loading method Use this method to load metal coils on platforms/skids with the eye vertical Two aluminum coil sizes were used during testing: 68-in.-diameter coils on 71 in. skids. Two coils stacked with a total height from 70 in. to 78 in., with each stack of skids weighing between 16,500 lb and 18,200 lb (paragraph 8.3.6) 89-in.-diameter coils on 90 in. skids. Three coils stacked with a total height of approximately 68 in., with each stack of skids weighing between 24,500 lb and 26,400 lb (paragraph 8.3.7) Secure platforms/skids to the coils with 1¼ in in. steel straps or approved polyester plastic strapping (PET strapping) to restrict movement both lengthwise and crosswise on the platform/skids during transit. Place rubber mats, minimum in. thick, between the stacked coil skid and the coil beneath it. When coils are stacked three high, unitize the bottom coil to the second coil and the second coil to the top coil with 1¼ in in. steel straps, one perpendicular to the other. Additionally, unitize the entire three-coil stack (including skid) with two 1¼ in in. steel straps; again, one perpendicular to the other. NOTE: Protect PET strapping from contacting coil edges and other sharp areas Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb, as shown in Figure 5.2. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 8 3

38 FLOOR-ANCHORED SYSTEMS in.-Diameter Coils Load coils down the center of the car. Place rubber mats, minimum in. thick by 1 ft wide, on the car floor to contact skid runners when positioned. Mats should extend a minimum of 4 in. beyond the face of the skids, as shown in Figure 8.3. Figure in.-diameter coils on rubber mats with floor-anchored straps split coils Secure one foam cushion pad, typically 54 in. 24 in. 3¼ in. thick, at the center of the pad with a preferred density of 4 lb/ft 3 between each endwall and adjacent coil Secure 36 in. 6 in. 2 in. foam blocks with a preferred density of 4 lb/ft 3 between the coils Anchor each endwall coil using two 4-in.-wide web strap assemblies. Place one strap assembly around the front of each endwall coil at the base of the coil, securing the coil lengthwise against the endwall. Place the second web strap assembly centered over the top of the coil parallel to the car endwall. Anchor web straps into the floor by inserting T-hooks into the anchor plates. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb, as shown in Figure 8.3. Tensioning ratchets are located near the sidewall Anchor the second coil that is against the endwall coil by using three 4-in.-wide web strap assemblies. Place one strap assembly around the front of this coil at the base of the coil, securing the coil lengthwise against the endwall. Anchor two additional strap assemblies diagonally over the top of the stack of coils. Anchor web straps into the floor by inserting T-hooks into the anchor plates Anchor all other coils using four 4-in.-wide web strap assemblies. Place two strap assemblies around the front and rear of each coil at the base of the coil. Anchor two additional strap assemblies diagonally over the top of each stack of coils. Anchor web straps into the floor by inserting T-hooks into the anchor plates Note that the doorway unit may be positioned at an approximate 45 angle to the car sides. Some variation may be necessary depending on the weight and number of coils being loaded. 8 4 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

39 FLOOR-ANCHORED SYSTEMS in.-Diameter Coils Load coils down the center of the car. Place rubber mats, minimum in. thick by 1 ft wide, on the car floor to contact skid runners when positioned. Mats should extend a minimum of 4 in. beyond the face of the skids. See Figure 8.4. Figure in.-diameter coils on rubber mats with floor-anchored straps split coils Secure one foam cushion pad, typically 54 in. 24 in. 3¼ in. thick, at the center of the pad with a preferred density of 4 lb/ft 3 between each endwall and adjacent coil Anchor each endwall coil using three 4-in.-wide web strap assemblies. Place one strap assembly around the front of each endwall coil at the base of the coil, securing the coil lengthwise against the endwall. Anchor two additional strap assemblies diagonally over the top of each stack of coils. Anchor web straps into the floor by inserting T-hooks into the anchor plates. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb, as shown in Figure 5.2. Tensioning ratchets are located near the sidewall Anchor all other coils using four 4-in.-wide web strap assemblies. Place two strap assemblies around the front and rear of each coil at the base of the coil. Anchor two additional strap assemblies diagonally over the top of each stack of coils. Anchor web straps into the floor by inserting T-hooks into the anchor plates Note that the doorway unit may be positioned at an approximate 90 angle to the car sides. Some variation may be necessary depending on the weight and number of coils being loaded. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 8 5

40 FLOOR-ANCHORED SYSTEMS 8.4 Coil Harness Kits Method Use only cushion-equipped boxcars for this loading method. Coils used during testing ranged from 54 in. to 71 in. wide and weighed from 12,000 lb to 24,000 lb. See Figure 8.5. PLAN VIEW SIDE VIEW TOP HARNESS UNIT Figure 8.5 Coil harness kits Method Use this method to load aluminum coils on platforms/skids with the eye vertical. Secure platforms/skids to the coils with 1¼ in in. steel straps or approved PET strapping to restrict movement on the platform/skids during transit. NOTE: Protect PET strapping from contacting coil edges and other sharp areas Load coils down the center of the car with the platforms/skids abutting one another, as shown in Figure 8.5. Note that the doorway unit may be positioned at an approximate 45 angle to the car sides. Some variation may be necessary depending on the weight and number of coils being loaded. Place 30 in. 60 in. rubber mats, minimum 0.12 in. thick, on the car floor to contact skid runners when positioned Secure one 8 in. 20 in. 3½ in. thick foam cushion pad with a preferred density of 4 lb/ft 3 between each endwall and adjacent coil Secure 9 in. 4 in. 2 in. thick corrugated blocks, with a minimum dynamic compression strength of 39 lbf/in. 2, between coils Anchor each coil using four 4-in.-wide web strap assemblies. Place two strap assemblies around the front and rear of each coil at the base of the coil. Anchor web straps into the floor by inserting T-hooks into the anchor plates. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb. Tensioning ratchets are located near the sidewall Secure the doorway unit and each adjacent unit at both ends of the car with an over-the-top harness consisting of one 4 in. web-over strap, one 2 in. encircling web strap, and two 2-in.-wide web strap assemblies anchored to the floor or to the assembly chains. The 2 in. straps must have a 1,200 lb minimum working load limit Ensure that straps are straight and not twisted before tensioning. 8 6 Closed Car Loading Guide Minimum Loading Standards for Coiled Metal

41 FLOOR-ANCHORED SYSTEMS 8.5 Coil Harness Kits Method Use only cushion-equipped boxcars for this loading method. Coils used during testing weighed from 9,000 lb to 12,000 lb. See Figure 8.6. COIL HARNESS KIT FOAM PADS COIL HARNESS KITS (6) COIL HARNESS KITS (2) COIL HARNESS KITS (6) RUBBER MATS UNDER SKID RUNNERS Figure 8.6 Coil harness kits Method Use this method for loading steel coils on platforms/skids with the eye vertical. Secure platforms/skids to the coils with 1¼ in in. steel straps, approved PET strapping, or stretch-film roping to restrict movement on the platform/skids during transit. NOTE: Protect PET strapping from contacting coil edges and other sharp areas Load coils down the center of the car with the platforms/skids abutting one another, as shown in Figure 8.6. Place sections of rubber mat (minimum coefficient of friction of 0.90 preferred) on the car floor to contact the skid runners when positioned for shipment Secure one 9 in. 24 in. 4 in. thick foam cushion pad with a preferred density of 4 lb/ft3 between each endwall and adjacent coil, and between each coil in all sections Anchor each section of four units using two coil harness kits (web straps and assemblies) placed over two adjacent lateral units. Some variation may be necessary depending on the weight and number of coils being loaded. Anchor web straps into the floor by inserting T-hooks into the anchor plates located fore and aft of each section. Use web strap assemblies (strap, ratchets, and related hardware) with a minimum load rating of 18,000 lb. Tensioning ratchets are located near the sidewall Ensure that straps are straight and not twisted before tensioning. Closed Car Loading Guide Minimum Loading Standards for Coiled Metal 8 7