An Introduction to. Damage Prevention. Box Car Edition

Transcription

1 Vision To be the provider of choice for advancing railway safety and technology Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads An Introduction to Author Damage Prevention Box Car Edition Click to edit Date or other subtitle(s) ok to delete if not needed 2017 TTCI/AAR 1

2 Introduction to Damage Prevention The following presentation is a preview of a new training series under development by DPLS. Portions of this program have been abbreviated for presentation purposes. Watch for details regarding the release of the entire Damage Prevention Training Series in our DPLS Newsletter or online at: TTCI/AAR 2

3 Introduction to Damage Prevention While this presentation is static, the actual training programs will incorporate audio and video. Subject matter will be presented in modules of 7 to 20 minutes duration with content subdivided by program outline TTCI/AAR 3

4 Introduction to Damage Prevention Course Outline: Safety Rail Equipment Class Lettering and Markings Orientation Load Planning Mandatory Rules General Guidelines Load Securement Materials Material Handling Equipment Long range goal: Commodity specific loading and securement Training Modules 2017 TTCI/AAR 4

5 Safety, first, last and ALWAYS! Rail Yard and Dock Safety PPE Hard hat; Safety vest; Steel toed shoes with a defined heel and ankle support; Safety glasses. Safety First, Last and Always! 2017 TTCI/AAR 5

6 Safety, first, last and ALWAYS! Rail Yard and Dock Safety Safe Practices DO NOT step or walk on rails; DO NOT stand in track gauge; DO NOT walk between cars closer than 40 feet apart; DO NOT cross tracks while car(s) are in motion; DO NOT cross tracks closer than 20 feet from the end of a railcar; DO NOT jump from a railcar, always climb down using handholds and steps provided TTCI/AAR 6

7 Safety, first, last and ALWAYS! Rail Yard and Dock Safety Safe Practices Use 3-point contact when climbing on or into railcars; Use caution when opening a boxcar, trailer or container door; Never jump from a railcar to the ground, always use a ladder or the safety appliances provided; LOOK, LISTEN and LIVE! 2017 TTCI/AAR 7

8 Rail Equipment Railcar Types Class X Boxcar XM - Boxcar for general service equipped with side or side and end doors; XF - Non-insulated boxcar similar in design to XM, designed and specially prepared with a U,S, Food and Drug Administration approved white epoxy or other comparable white coating to seal interior walls, doors, and ends, and provide a smooth, durable surface to prevent contamination; XL - Loader equipped. Similar in design to XM, with steel perforated side walls or equipped with interior side rails for securement of certain types of lading and/or permanently attached movable bulkheads; XP - Boxcar similar in design to XM, but which is specially equipped, designed, and/or structurally suitable for a specific commodity loading TTCI/AAR 8

9 Rail Equipment Railcar Types Class F Flat Car FM - Ordinary flat car for general service. This car has flooring laid over sills and without sides or ends. FB - Bulkhead flat cars. FBC - Flat car constructed with a center beam above the car deck from bulkhead to bulkhead. FC - Flat cars specifically equipped to carry trucks, trailers, containers, chassis, or removable trailer bodies for the transportation of freight in TOFC/COFC service. FCA - Flat car, articulated multi-unit, specially equipped to carry trailers, containers, chassis, or removable trailer bodies for the transportation of freight in TOFC/COFC service TTCI/AAR 9

10 Rail Equipment Railcar Types Class G Gondola Cars Class H Hopper Cars Class R Refrigerator Cars Class T Tank Cars Class L Special Cars 2017 TTCI/AAR 10

11 Rail Equipment Boxcar Features Doors 8 ft. to 16 ft. wide openings Sliding Weather protection only Plug May resist some nominal load forces; Flush with interior side walls Combination 2017 TTCI/AAR 11

12 Rail Equipment Boxcar Features Cushioning Standard Draft Gear 3 in. travel, limited cushioning; Cushioned 10 in. to 20 in. hydraulic cushioning Sliding Center Sill Becoming obsolete 2017 TTCI/AAR 12

13 Rail Equipment Boxcar Features Side Bearings Standard Roller Limit car body roll Constant Contact 2017 TTCI/AAR 13

14 Rail Equipment Boxcar Features Interior Equipment Bulkhead Doors Being phased out Floor Tracks For use with web strap assemblies Sidewall and Doorpost Anchors Typically 1 ½ in. opening to anchor steel or nonmetallic strap 2017 TTCI/AAR 14

15 Rail Equipment Boxcar Lettering & Markings 2017 TTCI/AAR 15

16 Rail Equipment Boxcar Lettering & Markings 2017 TTCI/AAR 16

17 Rail Equipment Boxcar Lettering & Markings 2017 TTCI/AAR 17

18 Rail Equipment Boxcar Orientation B End A End Right Side Left Side Observer B End A End Brake Wheel Left Side, Right Side Stack, Row Layer 2017 TTCI/AAR 18

19 Load Planning - Boxcars Circular 42-K: Mandatory Rules 1. Inspection and Selection of Cars 2. Clearance at Side Bearing - Loaded Cars 3. Maximum Load Weight 4. Distribution of Weight - Lengthwise in Cars 5. Distribution of Weight - Crosswise of Car 6. Loading, Blocking and Bracing - Box Cars 7. Doorway Protection 8. Center of Gravity 9. Special Equipment 10. Opening and Closing of Doors 2017 TTCI/AAR 19

20 Load Planning - Boxcars Circular 42-K: Mandatory Rules 1. Inspection and Selection of Cars (A) Cars must be inspected by carrier before placing for loading. Cars must also be inspected by shipper at loading point to see that they are in suitable condition to carry load safely to destination. Cars must have sound roofs, sides, floors and end walls, and operable, snug fitting doors. (B) (1) Box cars for the loading of metals of heavy concentrated weight - for example; tin plate, copper anodes, lead ingots, cathodes, zinc slabs and spelters and all other high density commodities - must be inspected by the originating carrier (either before they are placed for loading or at loading point), to see that they are in suitable condition to safely carry loads to destination. (B)(2) When ordering box cars for loading concentrated weights of heavy commodities, shippers have the responsibility of notifying serving carriers of this purpose and of not loading any cars not inspected per Rule 1(B)(1) TTCI/AAR 20

21 Load Planning - Boxcars Circular 42-K: Mandatory Rules 1. Inspection and Selection of Cars (3) Railroads must inspect box cars furnished for loading of metals of heavy concentrated weight - for example; tin plate, copper anodes, lead ingots, cathodes, zinc slabs and spelters and all other high density commodities, to insure they meet one of the following requirements: a. Car stenciled adjacent to door opening 25K or 50K which indicates floor loading capacity. b. Have wood floor of 2-1/4 inch thickness in sound condition supported by at least three metal floor stringers on each side of center sill full length of car. c. If equipped with sliding sill under frame, have wood floor of 2-1/4 inch thickness in sound condition supported by at least two metal floor stringers on each side of center sill full length of car. d. If equipped with steel floors or special type wooden flooring full length of car provided, the overall strength of the floor is not less than that of a floor with three stringers as specified as in the foregoing. If in doubt, obtain verification of the floor strength from the Mechanical Department of Car Owner TTCI/AAR 21

22 Load Planning - Boxcars Circular 42-K: Mandatory Rules 1. Inspection and Selection of Cars Also, such floors and supporting structure must be in good condition when cars are loaded. The shipper should check the box car 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, Figure 1, to the routing or placard board on each side of box cars in which metals with densities exceeding 400 lbs. per cubic foot and/or exceeding 800 lbs. per square foot floor bearing area are loaded. Load, occupying less than total floor space, must be secured so as not to permit movement that would have an accumulative effect of overloading one end or one side of car when loaded in accordance with Rule 4(G) TTCI/AAR 22

23 Load Planning - Boxcars Circular 42-K: Mandatory Rules 1. Inspection and Selection of Cars 2. Clearance at Side Bearing - Loaded Cars 3. Maximum Load Weight 4. Distribution of Weight - Lengthwise in Cars 5. Distribution of Weight - Crosswise of Car 6. Loading, Blocking and Bracing - Box Cars 7. Doorway Protection 8. Center of Gravity 9. Special Equipment 10. Opening and Closing of Doors Each Rule in Circular 42 will be explained in the same level of detail in the complete training program 2017 TTCI/AAR 23

24 Load Planning - Boxcars General Guidelines Inspect lading before loading car. Do not load damaged lading TTCI/AAR 24

25 Load Planning - Boxcars General Guidelines 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. Right!! Wrong!! 2017 TTCI/AAR 25

26 Load Planning - Boxcars General Guidelines Use separating material as needed between layers. Stow like-sized shipping containers in stacks, and use divider material between stacks of different-sized shipping containers and shipping containers of different densities TTCI/AAR 26

27 Load Planning - Boxcars General Guidelines Plan load so that crosswise space is minimized without exceeding an aggregate of 18 in., unless additional appropriate bracing is used. Maintain vertical alignment to prevent crosswise movement TTCI/AAR 27

28 Load Planning - Boxcars General Guidelines Plan loads so that a combination of end wall fillers, separators, and center bracing will facilitate unloading lengthwise lifts from both sides of cars equipped with staggered doors TTCI/AAR 28

29 Load Planning - Boxcars General Guidelines 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, unless a floating load method is used TTCI/AAR 29

30 Load Planning - Boxcars General Guidelines General guidelines from the Closed Car Loading Guide Part 1 will be reviewed in detail 2017 TTCI/AAR 30

31 Load Securement Materials Strapping Steel Uses: Doorway protection; anchored loads; unitizing heavy items. Pro s: Strong, low elongation Con s: Edges can be sharp Approved straps list in Tables 17.8 & 17.9 of the Open Top Loading Rules (harmonized with Closed Car Loading Rules) 2017 TTCI/AAR 31

32 Load Securement Materials Strapping Nonmetallic Uses: Doorway protection, anchored loads, unitizing heavy items. Pro s: Strong Many performance grades Con s: High elongation; Some sizes may not fit into wall anchors Approved straps list in Tables 19.2 & 19.3 of the Open Top Loading Rules 2017 TTCI/AAR 32

33 Load Securement Materials Strapping PET (Polyethylene) Uses: Unitizing packages and bundles. Pro s: Strong, low elongation Con s: Edges can be sharp; Approved straps list in Table 19.1 of the Open Top Loading Rules 2017 TTCI/AAR 33

34 Load Securement Materials Web Strap Assemblies Wall or floor anchored Approved methods for roll paper and metal coils 2017 TTCI/AAR 34

35 Load Securement Materials Cargo Nets Approved for bagged commodities Requires special wall anchors 2017 TTCI/AAR 35

36 Load Securement Materials Lumber / Nails Used primarily for fillers, gates and risers; Limited load securement applications other than doorway protection TTCI/AAR 36

37 Load Securement Materials Air Bags (Pneumatic Dunnage) Polywoven & Paper 2017 TTCI/AAR 37

38 Load Securement Materials Air Bags Vertical Inflation pressures from 4 to 8 psi Keep space filled by airbag less than 12 inches wide after inflation May require protection from sharp edges or pinch points Contour buffer pads improve stability between paper rolls Not intended for re-use 2017 TTCI/AAR 38

39 Load Securement Materials Air Bags Horizontal Used primarily in roll paper loads Generally one bag per layer, but should not be less than 42 in. wide* Proven successful in palletized loads of varying unit weights and densities Buffer sheets may be required 2017 TTCI/AAR 39

40 Load Securement Materials Friction Mats Used primarily between or beneath layers to increase their likelihood of moving as a unit. Folded edge for doorway protection Should cover at least 50% of the surface area 2017 TTCI/AAR 40

41 Load Securement Materials Risers Used to raise freight to break strata lines in loads May be used to block incomplete layers of freight Strip, pad or circular styles Usually made of fiberboard, but may be lumber Minimum strength requirements 2017 TTCI/AAR 41

42 Load Securement Materials Fillers May fill lengthwise or crosswise space May be made of lumber of fiber/corrugated board No more than 3 fillers in any one location 2017 TTCI/AAR 42

43 Load Securement Materials Contour buffer pads Used to stabilize airbags or void fillers between paper rolls This module will go into greater depth on the Do s and Don t of each type of freight securement product TTCI/AAR 43

44 Material Handling Equipment Lift Trucks General purpose fork lift for palletized goods. Special tines for lumber, brick, etc. Clamp lift for unitized goods not on a pallet. Push/Pull lift for slip-sheeted goods TTCI/AAR 44

45 Material Handling Equipment Specialized Lift Trucks Roll paper clamp Drum lift (parrot beak) Carpet ram 2017 TTCI/AAR 45

46 Material Handling Equipment Specialized Lift Trucks Basiloid lifts for large crated products such as furniture and appliances. In addition to lift type identification, this module will address typical damage thatmay be associated with its misuse TTCI/AAR 46

47 An Introduction to Damage Prevention Pop Quiz! What does an X signify is a railcars reporting marks? Where is the boxcar floor capacity rating found? How can you determine if a car has end-of-car cushioning? What class of boxcar is one equipped with floor straps for securing cargo? Besides each outer sidewall, where else would you expect to find the car number stencil? How do you determine which end of the car is the B end? A end? 2017 TTCI/AAR 47