Kögel Load Securing

IllustrationsIllustration may similar show optional / can extrainclude equipment special / The equipment products are subject to continuous technical modifications Why so much talk about the art of engineering? ...... 3

Kögel Load Securing – basics and regulations ...... 4

Kögel Certified body stability according to EN 12642 XL ...... 6

Kögel Load Securing for partial loads ...... 7

Kögel Friction-locked Load Securing ...... 8

Kögel Automotive ...... 9

Kögel Transport solutions for the beverage industry ...... 10

Kögel Coilfix and Paperfix ...... 12

Kögel White Goods, Tyre Transport ...... 14

Kögel Boards and Palleted Goods, Octabin ...... 15

Kögel Box Trailers ...... 16

Kögel Tests ...... 17

Kögel Quality Characteristics ...... 18

Kögel Product Ranges ...... 20 Why so much talk about the art of engineering?

Because there is genius in it and because prowess is behind it.

Comprehensive competence and experience, creativity and openness, consistent marketing and customer orientation: these are the foundation that the innovative force is based on which Kögel uses to develop and implement transport solutions. State-of-the-art design and simulation software are used - however innovation starts in the mind and a pencil sketch is still generally the ﬁ rst step in the complicated process from the basic idea to the perfect end product. A special feature at Kögel is the close collaboration with the customer throughout all phases of development to be Highly professional equipment is used for able to always keep the practical requirements in mind and for the development and material testing. to gather the important impulses from the marketplace: Approaches to solutions are discussed with customers, prototypes are tested together and customer feedback is incorporated into further development and optimisation. All components are tested in our own experimental department under extreme conditions which go far beyond the normal requirements. The vehicles are subjected to intensive driving and rough road tests, in rain, snow and ice and under a scorching sun. This is because only products that pass these strenuous tests will be capable of withstanding all stresses and strains of day-to-day use for many more years to come. Kögel places great store on high-quality materials, extraordinary workmanship and quality-oriented sequences throughout the production process.

The most important innovation factor at Kögel consists of the competent, creative and committed members of staff.

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 3 Kögel Load Securing

Load Securing – basics and guidelines

1. VDI 2700

VDI 2700 describes which inertial forces affect the load. In order to secure the load, these forces must be set against the Load Securing measures. With stable cargo, through the friction of the load or the loading equipment (e.g. pallets) alone, one part of the inertial force is absorbed in the floor. Nevertheless, as the illustration clearly shows, a large proportion of surplus inertial force is still remaining. These forces must be neutralised with Load Securing equipment (see Figure 1).

2. EN 12642 L – stability requirements for standard bodies

In addition to VDI 2700, there are other European standards for the regulation of Load Securing. EN 12642 specifies the minimum requirements for a body which can absorb at least part of the excess inertial forces (see illustration). As such a body cannot accommodate all those forces described in VDI 2700, additional protection for form-locked loading is required depending on the weight of the cargo and the friction. Kögel bodies with drop sides are certified according to EN 12642 L also fulfil the minimum requirements which are formulated in the standard. In addition to the forces absorbed in the body, other Load Securing equipment, such as lashing points, tension straps or load securing wedges, must still be used on these vehicles. Only then are all the inertial forces described in VDI 2700 neutralised (see Figure 2).

3. Certified body stability according to EN 12642 XL

To ensure that the load is secured without any additional Load Securing measures on the loading platform, body stability levels must be increased. Kögel bodies with sliding tarpaulins fulfil the stability requirements for reinforced bodies according to EN 12642 XL in the same way as fixed body vehicles. For vehicles with this certificate, the Load Securing process operates very simply: via the body. If the vehicle is fully loaded and form-locked, or still partially secured to prevent slippage, the body's structure is used for Load Securing purposes. The body absorbs the forces arising from the driving dynamics according to VDI 2700. This means: No additional Load Securing elements are required for form-locked loading (see Figure 3).

4 INERT FORCE OF THE CARGO

FRICTION FORCE LOAD SECURING ENERGY

INERT FORCE OF THE CARGO

Figure 1: Corresponds to the maximum inertial forces arising from the driving dynamics; if the cargo is in a stable position,FRICTION the inertial FORCE force then counteractsLOAD SECURING the frictional ENERGY force between the load and vehicle floor. INERT FORCE OF THE CARGO

INERT FORCE OF THE CARGO FRICTION PLATFORM L LOAD SECURING

FRICTION FORCE LOADINERT SECURING FORCE OF THEENERGY CARGO

FRICTION PLATFORM L LOAD SECURING INERT FORCE OF THE CARGO

INERT FORCE OF THE CARGO Figure 2: WithFRICTION form-locked loading, additionalPLATFORM Load XLSecuring measures are required.

FRICTION PLAINERTTFORM FORCE L OF THE CARGOLOAD SECURING

FRICTION PLATFORM XL

INERT FORCE OF THE CARGO

FRICTION PLATFORM XL

Figure 3: With form-locked loading, no additional Load Securing measures are required.

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 5 Kögel Load Securing

Certified body stability according to EN 12642 XL

With sliding tarpaulin bodies The body fulfils the requirements in accordance with EN 12642 XL with the following elements:

Front wall Roof Flexible roof Side walls

– Standard aluminium front wall With the integrated roof cover – For loading from above – Strengthened side tarpaulin with additional stabilising reinforcing belts hanging in the (standard from back to front, made of high-strength, closely profiles inside are no longer a problem. optionally also from front to woven material with reinforce- back) this is particularly ment; reinforced stakes suitable for transporting long – Reinforced sliding sideposts loads – Lattices are not required for – Loading area is freely appropriate cargo accessible if loading from above – Roof type meets the requirements of EN 12642 XL

Lifting roof Floor Rear wall doors

– Complete with mechanical/ – Heavy-duty floor construction The body is additionally hydraulic lifting equipment with antislip screen-printed strengthened with the optimum – Continuously height surface for a fork-lift axle load arrangement of the integrated adjustable of 7,200 kg power brace locks and hinges. – Fulfils the BGV D 29 – A fork-lift axle load of guideline 9,000 kg for paper transport is optionally available – Operating lever on the corner posts – Also certified according to EN 12642 XL

6 Load Securing for partial loads The Kögel Load Securing package for partial loads builds on the Load Securing measures via the body in accordance with EN 12642 XL. The load can be fixed in position by form-locked securing using modular components at any point in the vehicle – either in the direction of travel or crosswise.

Steel-combi anchor rail

as side Load Securing rail as lateral pallet limiting rail as variable pallet limiting

The steel-combi anchor rail with – Pins on the steel-combi rail integrated adjustment steps anchor rail ensure form-lock- – Secure the load on a load form the basis for the partial ing with the external frame carrier load concept. – Used to mount locking beams – Apart from securing the load for securing partial loads carrier in the lower part, the – Loading aid and tarpaulin attached second pallet protection limiting rail also secures the cargo placed on it – Can be combined with friction-locked Load Securing

Load locking beams Insertable stakes

Locking beams Vario locking beam Insertable stakes with lock This can be mounted to the The locking beam with variable lateral load securing rails, lateral fixing position grid is used to fix The vehicle's frame provides the Insertable stakes with spring bolt pallet limiting rail or the Vario additional locking elements possibility of inserting square locking that lock automatically are locking beam (additional locking beams or pipe stakes into the vehicle floor optionally available. They are belts). – Extendable from 1,650 at different positions in longitudi- extremely useful particularly for millimeters to 2,500 millim- nal and lateral directions and can transport without body. eters also be used for securing partial loads or at the front wall. – Suitable for securing loads in a vertical and horizontal direction

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 7 Kögel Load Securing

Friction-locked Load Securing For the transportation of some goods, it is not possible to use the form-locking method to secure the load. Kögel also offers the ideal solutions for different industries.

Lashing options

Lashing rings (standard) Lashing rings (heavy duty) Lashing eyelet on front wall

–– Fastening force up to –– Fastening force up to In accordance with EN 12640 2 tonnes 4 tonnes for load securing of cargo –– Visible from the inside in –– Required for coil transport positioned directly against the front wall. accordance with EN 12640 –– For maximum strength in direct fastening –– Optionally available in addition to standard lashing Cargo control winch rings For tie-down lashing of the load, tension straps or wire rope can be used which are tensioned by means of a cargo control winch.

VarioFix perforated Tension strap steel external frame The ergonomically designed long –– Cargo can be safely secured lever ratchets with tension force at any place on the vehicle offer optimum lashing. with short distances between slots –– Lashing angle and lashing capacity in accordance with EN 12640 –– The perfect lashing angle with optimised outer frame design prevents wear of the tension straps

8 Automotive – Load Securing with optimal loading volume utilisation In the automotive industry, pallet cages, Euro pallets and small-sized carriers are mainly used to transport automotive parts. These carriers place special demands on the vehicle with regard to the loading process and Load Securing. In this case, the optimal transport solution is the Kögel Mega, the vehicle with more internal height. The loading area can be used up to a height of 3 metres; when loading, the lifting roof can be raised. The Kögel Mega with additional options fully complies with Daimler Load Securing 9.5, one of the most important guidelines for the transportation of automotive parts. The guideline specifies a strengthened body (in accordance with EN 12642 XL), a pallet limiting strip, additional lashing points and ample tarpaulin reinforcement. Furthermore, securing of partial loads must also be possible on the vehicle. The Kögel Mega with its modular body components offers the following solutions:

Reinforced body Pallet limiting strip VarioFix perforated Load Securing for partial loads – Standard reinforced body as The pallet limiting strip prevents steel external frame per EN 12642 XL movement of the sharp-edged – The standard perforated steel In combination with the VarioFix external frame, other Kögel – Body includes: patented roof plate-type bases on the cage external frame meets the solutions such as the Vario construction, optimised front boxes to the tarpaulins and requirements of Daimler Load locking beam, basic locking wall, reinforced side tarpau- resulting damage. Securing 9.5 beam or telescopic locking beam lins, approved lifting roof, – Many lashing options as per can be also be used for the Load high floor load-bearing EN 12640 Securing for partial loads. capacity and rear doors with – Can be used even in combina- integrated power brace locks tion with the screwed pallet limiting strip for form-locked load securing

Corner posts Insertable steel-combi with mounting slots anchor rail as They are used for installing pallet limiting strip locking beams or lashing eyelets – The pallet limiting strip can – If the pallet limiting strip is for Load Securing for partial also be installed after loading not mounted, other goods loads at the rear of the vehicle if – Protects tarpaulin from such as white goods can also the distance between the load damage by the plate-type be transported and rear portal is more than bases of the pallet cages 15 cm.

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 9 Kögel Load Securing

Beverages – Transport solutions for the beverage industry In the beverage industry, cargo is transported first and foremost using standardised boxes placed on Euro pallets. If the Kögel vehicle is fully loaded, the reinforced body without any additional lattices is sufficient for securing loads having a minimum width of 2,400 millimeters. For additional load securing, on the one hand, in the floor area or partial loading and narrow cargo on the other, the following Kögel Load Securing elements are used:

Reinforced body Load Securing for partial Removable lateral pallet Aluminum slats

–– Standard reinforced body as loads limiting rails Suitable for a width of the load per EN 12642 XL The pallet limiting rails can also The steel-combi anchor rails with of at least 2,400 millimeters. –– Body includes: patented roof be used for accommodating other integrated adjustment raster are construction, optimised front Load Securing elements required locked to the VarioFix external wall, reinforced side tarpau- for partial Load Securing such as frame with pins; Two rails one lins, approved lifting roof, the Vario locking beam or above the other are used: high floor load-bearing telescoping locking beam. –– Bottom rail locked to the capacity and rear doors with external frame for form-locked integrated power brace locks Load Securing of pallets –– Top rail fixed to the bottom rail with a bolt and provides form-locked load securing for the crates –– Using additional lattices is possible as an alternative

Lateral load securing rails

The lateral Load Securing track holds additional locking beams for securing partial loads.

10 Twin-level transportation of empties and barrel goods

Twin-level transportation Barrel goods

Time and money can be saved The standard Kögel trailer by transport of empties in two transports barrel goods safely. layers. No additional reinforced components are required.

Special solutions:

Other Load Securing solutions have been developed for securing crates on beverage pallets (load in the range between 2,200 millimeters and 2,400 millimeters).

Reversible slats Load Securing for partial

–– At least three rows of loads with reversible slats aluminium reversible slats are The reversible slats can be used for lateral Load Securing combined with the lateral Load Securing tracks. –– The reversible slats can be inserted in the standard stake pockets

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 11 Kögel Load Securing

Coilfix, Cable and Paperfix – Transport solutions for heavy roll-shaped cargo

Coilfix

Coilfix Coil trough 4-tonne

The Coilfix Load Securing system For guaranteed safe loading, the heavy-duty lashing rings is used for form-locked loading of vehicle is equipped with a coil They allow secure bracing of coils and unstable split strips with trough according to VDI 2700 heavy coils and steel bands in roll diameters of 900 millimeters which can accommodate steel the area around the coil trough to 2,200 millimeters. Due to the coils and split strips with and are compatible with flat arrangement of the tension diameters ranging from 900 to standard split strip securing beam as well as the insertable 2,200 millimeters. systems. stakes (according to the SIDMAR guideline), any damage to the coils and split strips is avoided.

12 Paperfix

Floor Adapter plate Patented variable

– Non-slip floor with high The plate can be flexibly load securing wedges load-bearing capacity for mounted anywhere on the With the practical and easy-to-fit – Horizontal rolls crosswise to secure loading of large, heavy complete floor area and also wedge, loads such as paper rolls the direction of driving: wedge paper rolls allows form-locked Load can be securely transported in a with inclined surface area – Recessed loading tracks made Securing at positions in the form-locked fashion in all loading towards the roll, secured to of aluminium or steel for vehicle which are not covered by positions according to VDI 2700. the front and rear the loading track arrangement. form-locked anchoring – Load Securing force of – Horizontal rolls longitudinal to of the variable Load Securing 2,500 daN per wedge the direction of driving: wedge wedges – Vertical roll: wedge as with inclined surface area – Fork-lift axle load: end stop to the front towards the roll, secured to 9 tonnes for paper model the side – Horizontal rolls longitudinal to the direction of driving: wedge with inclined surface area to the front side of the roll, secured to the front

VarioFix perforated- Load Securing body Toolbox steel external frame (storage box) The toolbox provides additional For securing unstable rolls at The load securing box can be storage space. any position on the external used as storage for wedges and frame. Load Securing gear.

Certified front wall with Joloda container

– With integrated transport container for 24 load securing wedges and 2 paper rollers – Theft-proof Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 13 Kögel Load Securing

White goods Household goods can be transported safely in Kögel Mega vehicles: due to the lifting roof and the internal height of 3 metres, the goods are extremely easy to load and transport.

Centre stake bearing Certified body without Laterally-adjustable rear

To take full advantage of the full lattices portal load width, sliding sideposts are For the transportation of In order to allow loading from parked at another part of the household appliances, a loading the rear, the corner posts can be external frame and additional width of up to 2,540 millimeters mechanically adjusted in a stake bearings are required. is required; in order that the lateral direction. body has this width, it must comply with the requirements of EN 12642 XL without lattices and the welded pallet limiter; the body of the Kögel sliding tarpaulin vehicles fulfils these conditions.

Tyre transport

Secure solution for tyres

Kögel vehicles conform to the DIN EN 12642 Code XL certifi- cation for Load Securing. The vehicle body with additional equipment can be used to transport tyres stacked, arranged and packed with a technical payload up to 18,000 kg.

14 Boards and palleted goods Boards and palleted goods such as cardboard stacks, bricks, bags or particle board can be secured with Kögel Load Securing elements.

VarioFix perforated Friction-locked Screwed stake bearings Front wall steel external frame Load Securing In order that the full loading A certified front wall in – Cargo can be safely secured Versatile Kögel Load Securing width can be also be flexibly accordance with EN 12642 XL at any place on the vehicle elements such as tension straps used with boards and palleted is required to absorb the with short distances between with long-lever ratchets, standard goods, additional stake accelerating forces to the front. slots or 4 tonne heavy-duty lashing bearings on the external frame must also be available for this – Lashing angle and lashing rings can secure the load at the transport solution. capacity in accordance with VarioFix perforated steel EN 12640 external frame; other auxiliary accessories recommended by – The perfect lashing angle with manufacturers such as edge the optimised outer frame protectors are compatible Kögel design prevents wear of the Load Securing elements. tension straps

Octabin

With form-locked loading in or transverse to the direction of travel the load is secured by the stability of the vehicle body.

Locking beams Octabin reversible slats

Partial loads are secured to Loads are secured from the side the rear with locking beams using a minimum of three combined with steel C anchor rails. specially developed Octabin reversible slats.

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 15 Kögel Load Securing

Box trailers The loads on box trailers are secured by the body – at Kögel this also applies for the range of dry and refrigerated boxes. All vehicle types are statically and dynamically tested according to EN 12642 XL. Double-deck loading has also been certified in accordance with the forces defined in the standard. With the double-deck loading, the side walls are subjected to more load which is accordingly reflected in the test load which has been increased by 3 tonnes. With sliding tarpaulin bodies the body fulfils the requirements in accordance with EN 12642 XL with the following elements:

Reinforced body Anchoring rail

– The whole body absorbs all – Fully recessed anchoring rail forces defined according to for optimum Load Securing EN 12642 XL over the entire load length, – The front wall and the side whether the load is secured wall meet the most rigid test from the front and/or rear with requirements load bars – Optimum for Load Securing Level rails for partial loads with general cargo – Rail system completely integrated in the side wall – It is used for securing heavy-duty locking beams – Small adjustment raster for (up to 2.7 tonnes) adapting to different pallet heights – Two-level loading possible

Friction-locked Floor

Load Securing An antislip surface with high – Optional lashing rings can be friction value guarantees higher used according to EN 12640 adhesion, with both full-surface for friction-locked Load aluminium or screen-printed Securing floor. – Allows other industrial goods etc. to be secured

16 Kögel Tests

Put to the acid test by Kögel The vehicles are subjected to internal tests covering intensive handling and bad weather testing, in rain, snow and ice and under a blazing sun. This is because only products that pass these strenuous tests will be capable of withstanding all stresses and strains of day-to-day use for many more years to come. Kögel insists on high-quality materials, outstanding ﬁ nish and quality-oriented processes throughout the production chain.

Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 17 Kögel Quality Characteristics

Safety Service

Well-thought-out components provide high levels of Our comprehensive service facilities are available at active and passive safety: specially developed any time from anywhere at www.koegel.com. Repair panelling elements on the frame for improved and guarantee services can be simply dealt with aerodynamics, underride guard compliant with the online. Our Kögel Assistance hotline is available new EC Directive, standard Load Securing as per around the clock in many European languages. EN 12642 XL, RSS for greater driving stability and safety-optimised height adjustment valve (lifting roof with BG support). Kögel vehicles also have outstanding trailing characteristics.

Electronic system and lighting Comprehensive testing

EBS is part of standard equipment. The lighting can All vehicle components are checked in dynamic be supplied entirely in LED design, providing driving tests according to the highest standards. long-term durability and reduced power consumption.

Underride guard Environmental protection and sustainability The reinforced underride guard increases safety Kögel vehicles make an active contribution to the levels for all road users. It can be installed reduction in fuel consumption and environmental and replaced separately. pollution: The aerodynamics are optimised, noise emission is constructively reduced, in Light brackets production,strict requirements are observed to The light mounting is made of impact-resistant protect the environment and ensure that the plastic and guarantees 100% corrosion protection. materials used can be recycled . It can be installed and replaced individually.

Corrosion protection Load Securing and body stability

Nano Ceramic plus KTL coating, the most modern Kögel fulfils all stability requirements for reinforced and highest quality industrial surface treatment on bodies according to EN 12642 XL. For vehicles the market provides the same outstanding with this certificate, Load Securing is quite simple: properties as the coating previously applied using with form-locked loading secured at the rear, the zinc phosphate, but it is more environmentally body absorbs all forces arising from the driving friendly and provides a better energy balance. The dynamics according to VDI 2700. durable clean surface coating can be repainted at any time.

CLIMATEX – COILFIX – PurFerro – the Kögel cool air the Kögel Load Securing system the Kögel sandwich-panel distribution system for coils and split strips technology for box and refrigerated vehicles

18 Illustrations may show optional extra equipment / The products are subject to continuous technical modifications 19 Kögel Product Ranges

Platform Trailers Chassis Euro Trailer Demountable Systems

Box Trailers Tipper Trailer Flatbed Trailers

Safety instruction! The trailer may only be used subject to express compliance with all road traffic, employers’ liability insurance association and Load Securing technology regulations. No liability can be accepted for errors or omissions. We reserve the right to make technical changes. Printed in Germany. Reprinting not permitted 09/ 14. Order no.:100-1106-EN