Information on the proper handling and transportation of scrap

Transcription

1 Information on the proper handling and transportation of scrap

2 Preliminary remarks This brochure will provide you with tips and hints for the proper loading and unloading of scrap into and out of freight cars. They are based on experience and are intended to make your work easier. Our specialists from DB Cargo AG Loading Consultancy Service will be glad to support you with their knowledge and expertise in all matters relating to scrap transport. Please also speak with the responsible customer service representative, who will give you important tips and be happy to help you. Please remember that in addition to the General Terms and Conditions for the Performance of Services of DB Cargo AG, the loading guidelines of the International Union of Railways also apply to ensure safety of rail transport. DB Cargo AG: Scrap transport in figures 2016 Tonnage carried 8,075 Mio. t Domestic share (t) 71.9 % Single car transport share (t) 83.7 % International share (t) 28.1 % Block train transport share (t) 16.3 % No. of freight cars 7,200 Switching, moving, loading and unloading freight cars correctly Switching and moving When switching or moving the freight cars in the loading and unloading areas, only use the drawgear or the capstan shunting hooks of the freight cars. On no account use grabs or lifting magnets on parts of the vehicle superstructure (car bodies) or on steps or handles to move the cars. This would result in the components being damaged or destroyed, as their strength is many times less than that of the draw and capstan shunting hooks on the freight car. On level and straight track, the capstan shunting system can hitch onto the draw hook of the freight car at a maximum angle of 30 in the horizontal plane and 25 in the vertical plane relative to the car center line. Maximum traction of the capstan shunting system when moving the freight cars with capstan shunting hooks: 30 kn! Loading and unloading During loading and unloading, freight car brakes must not be applied; the cars shall be secured against rolling with an allowance of around 1 m, so that the freight cars can move if the lifting gear strikes the end walls. Please arrange processes in your facilities accordingly. Scrap parts on the tracks cause serious damage to the underframes, bogies and wheelsets of rail vehicles. Such damage is often hidden and difficult to detect during technical car inspections, resulting in a high risk of rail accidents. If you have any questions on switching, moving, loading and unloading freight cars, please contact our experts in the DB Cargo AG Loading Consultancy Service. They will be happy to help you. During shunting at an angle of 30 to the car center line on level track, the shunted car group must not exceed 240 t with standardized capstan shunting hooks and 120 t with the other capstan shunting hooks or lugs. Please also limit the speed of the capstan cables of such systems to a maximum of 1 m/sec. 2 3

3 Special features of scrap and scrap transportation Scrap has been transported by rail for decades, and the special transportation requirements for scrap, resulting from its special material properties and the special circumstances of its transport, have been in place for just as long. Scrap is generally sharp and can seriously damage freight cars if not loaded and unloaded properly. Type Ea freight cars just the thing for transporting scrap Scrap handling generally takes place at speed, which implies a certain risk of it being carried out improperly, with freight cars damaged in the process. The different carrying capacities of the freight cars for each line category should be noted as otherwise load limits could be exceeded. These special requirements call for special transportation rules and measures that can only partially be derived from the standard industrial classification of scrap into scrap types. Type Ea four-axle open-top freight cars are generally used for scrap transport. With these cars, letters such as the following are used to describe essential additional characteristics. The following illustrations show two types of opentop freight cars. For further information see our online freight car catalog (in German only) at: Eaos-x (with four wheelsets) Cubic capacity: approx. 72 m 2 Maximum payload: 57 t Eanos-x (with four wheelsets) Cubic capacity: approx m 2 Maximum payload: 66 t 4 5

4 Equipment and instructions for scrap handling The standard lifting gear and material-handling equipment types for loading scrap are: Orange-peel grabs Lifting magnets Chutes, especially for small to medium-size bundled scrap Conveyors To ensure proper handling of scrap there are certain binding threshold values and principles to be complied with. They are derived from the dimensions of the freight cars, their carrying capacity and the relative sensitivity of certain components to strong external forces. This refers to the floors, the cantrails, doors and end walls as well as the underframes including the springs and bearings in particular. The following guidelines and rules apply for the individual devices in the proper handling of scrap: Orange-peel grab (suitable for loading and unloading) A flat closing curve reduces the risk of damage to the floor. The maximum opening width should be 2,000 mm, the maximum empty weight should not exceed 2,000 kg. Lifting magnets (suitable for loading and unloading) Max. diameter of 1,500 mm. The recommended net mass of the magnets for light scrap and fast working should be between 1,500 and 2,000 kg. If the magnets are much heavier, there is a risk that the cars will temporarily become overloaded and the axles and underframe will be damaged. Lifting magnets should be operated extra carefully. On no account should you place the magnet on the scrap in an uncontrolled manner with a lot of force! Otherwise parts of the load especially with cutting scrap may be pressed into the floor and vehicle underframe. When unloading with strong lifting magnets there is a danger that the entire car will be raised. This may not only lead to the car being damaged, but also to derailment. As recommended for the orange-peel grabs, the operator pulpits must allow the operators to see into the freight cars. For optimum unloading combine various types of lifting gear. The initial unloading may be carried out using the orange-peel grab and the remaining scrap unloaded using the lifting magnet. Chutes for bundled-scrap loading 500 mm mm 2000 mm Operators working in the operator pulpits of the cranes or mobile devices must be able to see inside the freight cars in order to be able to use the grabs. When using the cable suspensions of the orange-peel grabs, swinging should be restricted, possibly by using a harness. Orange-peel grabs are less suited for unloading any remaining scrap; lifting magnets should be used for this instead. The chutes should be designed based on the average bundle net mass and where possible agreed with our loading consultancy service experts during the project planning phase. This will ensure optimal scrap loading. Depending on the strength of the individual freight car floors, the drop heights for the scrap pieces shall be reduced in accordance with their mass: to 1.5 m for approx. 200 kg to 1.2 m for approx. 400 kg to 1.0 m for approx. 800 kg The maximum chute inclination in relation to the car floor is 30, because if the inclination is any higher the relationship between mass and drop height as indicated in the above table will be considerably exceeded. Baffles mounted in front of the discharge device will reduce this effect. During loading, drop heights can be increased depending on the loading system if the car floor is already covered with a layer of bundled scrap. Conveyors Only suitable and permitted for small-sized, lightweight scrap, e.g. shredder waste. If the conveyors are solely used for this purpose, the interaction between the load and the freight car is relatively unproblematic. For items with higher net masses, such as ingots, the same conditions apply as for chutes. 6 7

5 Imprint Contact DB Cargo AG Rheinstrasse Mainz Germany Information hotline for new customers Phone: neukundenservice@deutschebahn.com Published by Deutsche Bahn AG Campaign Management (GNM) Potsdamer Platz Berlin Germany Photo credits DB AG / Reinhard Jakubowski DB AG / Michael Neuhaus All details subject to change without notice, no liability for errors or omissions Last modified in April 2017