Load security for Sheeted paper Paper reels Stand: Feb. 2012
Content: Table of contents General Part 1 Introduction and scope, STVO (German road traffic regulations) 22 Loading Part 2 Basic rules and principles 2.1 Creating unit loads 2.2 Definition of form fit 2.3 Part loads / package freight Part 3 Minimum requirements for means of transport Part 4 Minimum requirements for vehicle specifications and equipment Part 5 Unit loads and packing Part 6 Classic mistakes in load security and packing Road vehicles examples A. Load security for paper reels "upright loading" A. Load security for paper reels "flat loading" C. Load security for sheeted paper D. Load security for sheeted paper in box vehicles E. Load security for mixed loads Containers examples F. Load security for paper reels in ISO overseas containers Appendix Explanation of abbreviations
Part 1 Introduction and scope Introduction The following section explains examples that show Papierfabrik Scheufelen's most important stowing and loading methods. These instructions cannot cover all possible loading types, due to the large variety of ways that freight can be loaded onto vehicles / into containers. They focus on upright and flat paper reels and sheeted paper in road vehicles. However, container loads are also featured. Scope These instructions are binding on the Lenningen site (loading, material planning, handling).
Part 2 Basic rules and principles All loads must be secured against the stresses normally encountered during transport (including package freight) When loading paper reels, these instructions assume all unit loads are at risk of tipping. An on-site calculation is therefore not necessary. Loads on road vehicles without sides (curtain-sided trailers) must always be secured with friction-enhancing underlays and straps using downward and diagonal lashings. Only sheeted goods may be loaded into box bodies downward lashings can be dispensed with here if the goods can be loaded with a virtual form fit in a single layer, the empty space is filled with padding and the vehicle can absorb the stresses in the bodywork (but not in marine transport). In the context of securing loads, transport personnel are "assistants" and must obey the instructions of shipping personnel. Following instruction, transport personnel may themselves load sheeted paper from the order-picking area / high-bay store using the electric pallet truck, but they remain "assistants" and must obey the instructions of shipping personnel. The instructions of the driver must be obeyed in respect of operational safety (e.g. load distribution on the vehicle). Exceptions to this are obvious errors by the driver or defects in the vehicle. The Material Planning unit or a supervisor must be consulted in this case. Cargo must be loaded such that there is a form fit with the front wall. Additional loads/package freight (sheeted paper) As unit loads frequently do not fill the full loading width, all loads on side-walled vehicles and curtain-sided trailers must always be secured with at least one lashing strap per loading metre and non-slip mats and corner protectors. Drivers must check load security at appropriate intervals and perform follow-up operations to secure the load as necessary STVO (German road traffic regulations) 23). Loads in box bodies and containers must be secured such that there is a form fit with the front and side walls. All empty space in the container longitudinal to the vehicle axis/container axis must also be secured using airbags as padding. The last row in the container is also secured with lashing straps.
Where paper reels are loaded two or three high, non-slip mats must be placed between the reels. Do not load pressure-sensitive goods on top of each other! Upright paper reels must always be underlaid with at least two strips of non-slip mat per row of reels. The vehicle floor must be swept clean for loading and must be cleaned before loading (reporting to warehouse office). Example:
2.1 Creating unit loads For palletised, upright paper reels, at least two non-slip mats must be placed as an intermediate layer between the pallet and reel. Paper reels must be tied to the pallet. Corner protector Lashing strap, plastic strapping Non-slip mat
2.2 Definition of "form fit" for paper reels and sheeted goods Permissible free space is not defined in the VDI (Association of German Engineers) guidelines or in other guidelines/legislation. To date, no clear definition exists for what is a permissible free space in terms of "form fit". Cargo cannot generally be loaded in such a way that it is rigid, and therefore does not move, which would be the ideal situation. In VDI guideline 2700 ff., the permissible free space for a "form-fit" load is limited to a "few cm". However, these free spaces must not lead to any potential risk. "Loading-related gaps" are normal in loading and occur repeatedly. To provide assistance in reaching decisions when working with Scheufelen-specific loads (reel and sheeted goods), the term "form fit" should be used for gaps in the transverse direction with just a few cm to the side. "Loading-related gaps" should be kept as small as possible in the longitudinal direction. If form-fit loading is not possible due to the load dimensions, the load must always be secured by additional measures (combination of downward lashings and frictionenhancing underlays). Form-fit loading is only possible for vehicles with sides or a box body. Form-fit loading is possible in this case if the bodywork demonstrably allows this (certification). Form-fit loading perpendicular to the direction of travel is not possible for curtain-sided trailers due to the flexible walls. Special-purpose vehicles with appropriate certification are an exception to this rule, but their market share remains low. In the case of Scheufelen, this applies only to sheeted goods.
Maximum free space interpreting the term "form fit" (practical help) View perpendicular to the direction of travel: Free space between side and load Minimal/few cm = "form fit" in terms of load security (max. 10 cm projection) The prerequisite for this is that the side structure can be proven to withstand the stresses occurring in road traffic perpendicular to the direction of travel. In marine transport, the load must always be secured by downward lashings including in the case of form-fit loading (trailers with and without sides). No "form fit" possible in the upper area, as there is no upper spatial limitation to the loading space. Conventional wood or aluminium supports do not represent physically resilient restraints for the loading area..
2.3 Part loads / package freight requirements for load security If vehicles already loaded by the carrier (contractor) are made available for loading, and the customer (Scheufelen) has agreed to this, the carrier must ensure the preloaded goods are adequately secured to comply with applicable laws and guidelines insofar as this can be assessed through a visual inspection. Examples of goods already loaded that are not secured (package freight) Scheufelen categorically refuses to perform securing measures for third-party goods and/or reloading of third-party loads due to insurance reasons. If necessary, adequate load security/load distribution of preloaded goods must be ensured by the driver at the site. If this is not possible, the vehicle may be rejected by Scheufelen.
Part 3 Minimum requirements for means of transport Curtain-sided trailers Tarpaulin/support frame design Box bodies Containers
General requirements for means of transport For road transport, only vehicles that can withstand the physical demands arising from the load may be used. If the bodywork or segments of the bodywork are used for form-fit load security, the suitability for such must be demonstrated by the carrier/driver at the request of the loader/sender (e.g. front wall strength). The following points are a basic requirement regarding the provision of a vehicle in order to ensure legally-compliant loading in accordance with the relevant provisions (e.g. STVO 22, HGB (German Commercial Code) 411 and CMR for cross-border transport).
3.1 Requirements for means of transport for land transport (incl. combined road/rail and land/sea or ferry) Stresses in road transport e.g. in line with VDI 2700 0,5 g 0,8 g 0,5 g A roll factor of 0.2 must also be employed for lateral acceleration in the case of loads that are at risk of tipping. The bodywork must meet the following minimum requirements: Tested front wall strength of at least > 0.5 times the max. permitted payload. Tested rear portal strength of at least > 0.3 times the max. permitted payload. Tested side wall strength of at least > 0.4 times the max. permitted payload. Values are stated with an assumed coefficient of sliding friction for the vehicle wear floor (load area) of µ=>0.3. The minimum requirements for rear-portal and side-wall strength can be disregarded if the goods are not loaded in the form of a form fit (against and perpendicular to the direction of travel) but instead uses friction-securing (generally downward lashings).
3.2 Combined road/rail transport Requirements for load security for road transport also apply as a minimum to combined transport (road/sea, road/rail). Stresses in combined rail transport: 1,0 g 1,0 g 0,5 g Special attention must be paid to stresses in and against the direction of travel in combined rail transport. An effective restraint system in and against the direction of travel of the truck is essential. Friction-enhancing materials and straps must be used in all cases. Note: When loading upright paper reels, please note example No. 10.
3.3 Combined land/sea transport (roll-on, roll-off traffic) Stresses in marine transport: 0,7 g 0,7 g 2 g Much higher lateral forces (rolling / heaving of the ferry) etc. act on loads in ferry transport than in road and combined road/rail transport. All loads must therefore always be secured by downward lashings with at least one strap per pallet row even if the load is already secured using the form-fit principle. Friction-enhancing materials and straps must be used in all cases. Note: The illustration only shows the physical stresses that are important for loads on road vehicles. The potential directions of stresses on a ferry can be seen in the drawing top left.
Part 4 Minimum requirements for vehicle specifications and equipment
4. Minimum requirements for vehicle specifications and equipment 4.1 Straps At least 14 reusable straps with ratchets in line with EN 12195 T.2 in the pictured quality and perfect condition must be present on the vehicle see Figure 2. More straps may be necessary depending on the dimensions of the individual unit loads. The straps must be used to fix the loads properly using friction locking or downward lashings or diagonal/direct lashings. Data on the strap label Figure 1 Lashing force Lengths L G1 L GF and L GL in m; Standard hand force S HF ; Standard tensioning force S TF (dan) Warning: "Must not be used for lifting!" Strap material Name or logo of manufacturer or supplier; Traceability code of manufacturer Number and section of this European standard: EN 12195-2; year of manufacture; Figure 2 Elongation of the strap in % for LC.
4.2 Lashing points A sufficient number of suitable lashing points must be ensured (in line with EN 12640), and in any event at least 14 pairs of lashing points for a 13.6 m semi-trailer, for example. When purchasing new vehicles, it must be ensured that the positions of lashing points can be altered so that the position of the lashing material can be adjusted to the distribution of the load. The effectiveness of the straps (pretensioning) must be checked by the driver at appropriate intervals. Discard criteria for lashing straps examples Damage such as Tears, cuts, notching, cracks, deformation due to heat (strap) High corrosion, wear Deformation in metal parts Knotting Strap labels are missing or are not legible
4.3 Corner protection for paper reels At least 28 suitable corner protectors in perfect condition must be carried. (For design, see picture) Damaged or dented corner protectors must not be used. Corner protection for sheeted paper A sufficient number of corner protectors must be carried depending on length (at least 1 metre).
4.4 Friction-enhancing materials (non-slip mats) As a basic principle, non-slip mats must be used that can be demonstrated to achieve a coefficient of friction of > 0.7 and are suitable for transporting paper reels and sheeted paper. 4.5 Airbags The manufacturer s instructions must be complied with (e.g. internal pressure and user information).
4.6 Wooden wedges Protection to prevent wedges from detaching in road traffic (against the direction of travel, flat reels perpendicular to the direction of travel) To secure flat reels, the last two reels must always be secured with nailed wedges. Wooden wedges with the following angle geometry must be used to secure flat paper reels with a diameter of max. 1.3 m. K Hmin = 0,05 x d Y= mind.35 4.7 Wooden wedges Protection to prevent wedges from detaching in combined transport (road/rail flat reel perpendicular to the direction of travel) To secure flat reels, the last two reels must always be secured with "nailed wedges". Wooden wedges with the following angle geometry must be used to secure flat paper reels with a diameter of max. 1.3 m. Y= mind.35 K Hmin = 0,15 x d Note: The wedges must be fixed (nailed) and must not splinter.
Part 5 Unit loads and packing
Examples for the most common unit loads and packing Packaging must be able to protect the goods during transport and handling. All examples relate to paper reels and sheeted paper as shown in the following. Paper reels on pallets Paper reels without pallets
Sheeted paper reamed, shrink-wrapped with film, strapped Sheeted paper shrink-wrapped (large format) Sheeted paper shrink-wrapped (standard)
Part 6 Classic mistakes in load security and packing
Downward lashings are only effective if all loads are subjected to pressure! Pressure point No pressure point Pressure point Load is not secured Solution: Use restraint system / diagonal lashings Only use undamaged pallets!
Pallet with open shrink-wrap do not load!
Section "A" Load security for paper reels "upright loading" - Curtain-sided trailer or - Tarpaulin/support frame design
Example 1 Trailer 13.60 m with lashing points - Paper reels upright, in centre - Without pallet - Single row Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Example 2 Trailer 13.60 m with lashing points - Paper reels, upright - Double row Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Example 3 Trailer 13.60 m with lashing points - Paper reels, upright - Single or double row Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Example 4 Trailer 13.60 m with lashing points - Paper reels, upright, strapped into bunches - Double row Note: - Underlay with non-slip mats - Ensure weight distribution - Strapped into bunches (attach centre strap) - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Section "B" Load security for paper reels "flat loading" - Curtain-sided trailer or - Tarpaulin/support frame design
Example 5 Trailer 13.60 m with lashing points - Paper reels, flat - Single or double row Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Section "C" Load security for sheeted paper on pallets - Curtain-sided trailer or - Tarpaulin/support frame design
Example 6 Trailer 13.60 m with lashing points - Sheeted paper on pallets - Various formats - Single or double row Note: - Underlay with non-slip mats - Strap down tightly by hand using reusable straps with corner protectors
Example 7 Trailer 13.60 m with lashing points - Sheeted paper on pallets - Various formats - Single or double row - Doubled-up in part Note: - Underlay with non-slip mats - Strap down using reusable straps with corner protectors - Only double-up large format, 2 reusable straps per pallet
Section "D" Load security for sheeted paper on pallets in box bodies
Box vehicles - Minimum requirements for vehicle specifications and equipment If box vehicles are used, the carrier must ensure the bodywork is sufficiently robust to absorb forces generated in form-fit loading in accordance with VDI guideline 2700 ff The carrier must also ensure that loads in box bodies have restraints that enable the forces that are generated to be absorbed reliably at least against the direction of travel. Suitable items for this include rodding and other equipment that can be locked in place by means of form fitting. Telescopic bars that are held in place by a friction-type connection are not permitted for containing the acceleration forces that result in the case of sheeted paper. If the measures above are not available, straps must be used for strapping down. However, the basic requirement for this is the availability of lashing points on / in the load area. Further load security / packing materials (e.g. padding, non-slip mats, corner protection) must, where necessary, be used in line with the attached specification.
Example 8 Trailer (box) 13.60 m without lashing points - Sheeted paper on pallets - Various formats - Double row, not doubled up Note: - Underlay with non-slip mats - Use padding, observe manufacturer's instructions - Use restraint system (form-fit)
Section "E" Load security for sheeted paper and paper reels (mixed loads) - Curtain-sided trailer or - Tarpaulin/support frame design
Example 9 Trailer 13.60 m with lashing points - Sheeted paper on pallets - Various formats, double row - Paper reels, upright Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Example 10 Trailer 13.60 m with lashing points - Sheeted paper on pallets - Various formats, double row - Paper reels, flat Note: - Underlay with non-slip mats - Strapped down using reusable straps (min. STF 500 dan ) with corner protectors
Section "F" Load security for sheeted paper and paper reels in overseas containers Diagram: Components in container for load security 1 - Lashing loops (corner posts) 4 - Lashing rings 2 - Lashing loops (longitudinal bars) 5 - Wooden base 3 - Corner posts
Container check before loading General: The overall condition of the container must comply with current technical rules. Inwards inspection: Containers must meet the following requirements before loading. Containers that do not meet these requirements, in particular those with leaks, must not be loaded. The manager must be notified immediately in this case. External inspection: The container's supporting parts (corner posts, end cross bars and longitudinal bars) and the twistlocks must not be deformed or damaged. There must be no holes or cracks in the sides or in the top. Doors must be passable and locking devices must work perfectly There must be no hazardous goods stickers / labels on the container from the last load. The CSC plate / ACEP label must be available/valid
. Customs seal approval Issued to container manufacturer by customs. The container can therefore be used in crossborder transport. For: Container Safety Convention Approval The safety approval plate (under agreement of 2 Dec. 1972) must carry a valid inspection date. The next container inspection is shown. Significance: Approved Continuous Examination Programme. Under this, the container is subject to ongoing inspection / repair. The details on the plate / label replace the inspection date mentioned above. Combined customs, CSC and ACEP label Internal inspection: The container must be weatherproof (no light enters when door is closed). The container must be swept clean and free of remnants of previous loads. The container must be free of conspicuous odours The container must be free of nails and other pointed ends or protruding objects. The container base must not have any areas of repair that could cause damage.
Container checklist Checklist for CTU packing guidelines (containers) Container No. Check before loading External inspection Container frame Corner posts Main longitudinal bars End cross bars Sides, base, top: Deformation, breaks, damage etc. Performance testing doors / accessories Opening and closing Locking Securing and locking Fittings and sealing Seals, weather protection CSC safety approval plate: Available? If "not available", do not load container for marine transport! Internal inspection Tightness Damage Protruding nails in base area? Base broken? Lashing points with at least 2000 dan load capacity Lashing points in perfect condition? Container clean / dry / odourless? Other Container OK? Yes No
Example 11 Container 20'+ 40' - Sheeted paper on pallets - Various formats, doubled-up Strap Doors Note: - Fill gaps in load with padding - Ensure padding is impermeable - Create restraint system at the back (single-use straps) - Follow container checklist - Ensure load distribution
Example 12 Container 20'+ 40' - Paper reels, upright, partly doubled-up - Staggered loading Strap - ARM unterlegen Doors Note: - Underlay with non-slip mats, place non-slip mats between reels if doubled-up - Create restraint system at the back (single-use straps) - Follow container checklist - Fill gaps in load with padding
Appendix Abbreviations StVO = German road traffic regulations HGB = German Commercial Code CMR = Convention on the Contract for the International Carriage of Goods by Road CSC = Container Safety Convention Approval Safety plate for approval in international container transport ACEP = Approved Continuous Examination Programme Ongoing inspection / repair Programme CTU = Container Transport Unit Packaging Guidelines S HF = Standard hand force S TF = Standard ten s ioning force Created: 20 Feb. 2012 R. Besemer