Closed Car Loading Guide Part 2 Best Practices for Loading Roll Paper in Railcars Approved August 2016 by the Damage Prevention and Freight Claim Committee Copyright © 2016 by the Association of American Railroads (AAR) 425 Third Street SW Washington, DC 20024 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. Best Practices for Loading ROLL PAPER IN RAILCARS (Supersedes Best Practices for Loading of Roll Paper in Railcars issued May 2011 Cancels Pamphlet No. 39 issued April 2011) Issued: August 2016 Published by Transportation Technology Center, Inc. 55500 DOT Road Pueblo, CO 81001 (Printed in U.S.A.) © 2016 TABLE OF CONTENTS Title Page 1.0 Introduction 1–1 1.1 Overview 1–1 1.2 Reference Documents 1–1 1.3 Rail Transportation Environment 1–2 2.0 Selection and Preparation of Car 2–1 3.0 General Loading Information 3–1 3.1 Overview 3–1 3.2 Maximum Load Weight 3–1 3.3 Distribution of Weight Crosswise in Cars 3–1 3.4 Center of Gravity 3–2 4.0 Loading Considerations 4–1 5.0 Blocking and Bracing Materials 5–1 5.1 Steel Strapping 5–1 5.2 Nonmetallic Strapping 5–1 5.3 Lumber 5–1 5.4 Air Bags 5–1 5.5 Rubber Mats 5–2 5.6 Void Fillers 5–2 5.7 Risers 5–6 6.0 Load Securement 6–1 6.1 Vertical Air Bags 6–1 6.2 Horizontal Air Bags 6–2 6.3 Securing Incomplete Layers of Paper Rolls 6–2 6.4 Roll Omission 6–6 6.5 Mixed Load Patterns of the Same Diameter Rolls 6–7 6.6 On-Side Loading (Also Referred to as Bilge or “T” Loading) 6–7 6.7 Anchored Loads 6–13 7.0 Doorway Protection 7–1 7.1 Rule 7, AAR Circular No. 42-K 7–1 7.2 Wood 7–1 7.3 Roll Cores 7–1 7.4 Steel Strapping 7–2 7.5 Nonmetallic Strap 7–3 7.6 Key Lock Strapping 7–4 7.7 Inset Doorway Loading 7–5 7.8 Anchored U-Straps (or Key-Anchored Straps) 7–9 7.9 Anchored S-Straps 7–10 7.10 Rubber Mats 7–11 7.11 Exceptions 7–14 Closed Car Loading Guide—Loading Roll Paper in Rail Cars –i Title Page 8.0 Best Practices Load Plans 8–1 8.1 How to Use This Section 8–1 8.2 Load Plans—50 ft Cars 8–5 8.2.1 50 ft Car—40 in. Diameter Rolls 8–5 8.2.2 50 ft Car—42 in. Diameter Rolls 8–13 8.2.3 50 ft Car—45 in. Diameter Rolls 8–17 8.2.4 50 ft Car—50 in. Diameter Rolls 8–21 8.2.5 50 ft Car—58 in. Diameter Rolls 8–27 8.2.6 50 ft Car—60 in. Diameter Rolls 8–33 8.2.7 50 ft Car—72 in. Diameter Rolls 8–35 8.3 Load Plans—60 ft Cars 8–37 8.3.1 60 ft Car—40 in. Diameter Rolls 8–37 8.3.2 60 ft Car—42 in. Diameter Rolls 8–39 8.3.3 60 ft Car—45 in. Diameter Rolls 8–43 8.3.4 60 ft Car—448 in. Diameter Rolls 8–47 8.3.5 60 ft Car—50 in. Diameter Rolls 8–51 8.3.6 60 ft Car—58 in. Diameter Rolls 8–57 8.3.7 60 ft Car—60 in. Diameter Rolls 8–63 8.3.8 60 ft Car—72 in. Diameter Rolls 8–65 8.3.9 60 ft Car—84 in. Diameter Rolls 8–67 9.0 Glossary 9–1 10.0 Circular OT-34-G 10–1 11.0 Equipment Diagrams for Unrestricted Interchange Service 11–1 12.0 Damage Prevention Product Vendor List 12–1 –ii Closed Car Loading Guide—Loading Roll Paper in Rail Cars LIST OF FIGURES Figure 3.1 Side view of example load . 3–3 Figure 5.2 Void fillers used with contour buffer pads . 5–3 Figure 5.3 Contour buffer pads used with vertical air bag. 5–3 Figure 5.4 Endwall filler in pulpboard load. 5–4 Figure 5.5 Honeycomb filler along sidewall in pulpboard load. 5–4 Figure 5.6 Wooden 2 × 4s and 2 × 6s used as lengthwise fillers in cushion equipped cars. 5–5 Figure 5.7 Sidewall fillers. 5–5 Figure 5.8 Strip, square, and circular risers . 5–6 Figure 5.9 Risers used to break strata line . 5–8 Figure 6.1 Vertical air bags application . 6–1 Figure 6.2 Horizontal air bags application . 6–2 Figure 6.7 Roll omission method for 40 in. rolls . 6–6 Figure 6.8 Roll omission method for 58 in. rolls . 6–6 Figure 6.9 Pattern variations . 6–7 Figure 6.10 On-side loading of 45 in. diameter rolls . 6–8 Figure 6.11 On-side loading of 50 in. to 56 in. diameter rolls. 6–9 Figure 6.12 On-side loading of 58 in. diameter rolls using blocking rolls . 6–10 Figure 6.13 On-side loading of 58 in. diameter rolls using corrugated chocks . 6–11 Figure 6.14 On-side loading of 58 in. diameter rolls using blocking rolls and unitizing straps . 6–12 Figure 6.15 Completed on-side loading of 58 in. diameter rolls using blocking rolls and unitizing straps . 6–13 Figure 6.16 Anchored load weighing up to 205,000 lb . 6–13 Figure 7.1 Wood doorway protection for a single-layer load . 7–1 Figure 7.2 Fiberboard core wedged between doorposts. 7–2 Figure 7.3 Steel strap doorway protection . 7–2 Figure 7.4 Conventional and belt-type strap applications . 7–3 Figure 7.5 Conventional key band doorway protection. 7–4 Figure 7.6 Key roll patterns for 40-in. to 42-in.-diameter rolls . 7–4 Figure 7.7 Four-roll inset with air bags . 7–5 Figure 7.8 Unitized four-roll inset with air bags. 7–5 Figure 7.9 Four- and six-roll inset units . 7–5 Figure 7.10 Figure-8 unitizing straps . 7–6 Figure 7.11 Four-roll “X” unitizing straps . 7–7 Figure 7.12 One set of four-roll “X” or “Figure-8” unitizing straps . 7–7 Figure 7.13 Two sets of four-roll “X” or “Figure-8” unitizing straps. 7–8 Figure 7.14 Two sets of four-roll unitizing straps . 7–8 Figure 7.15 Anchored U-strap doorway protection . 7–9 Figure 7.16 Anchored S-strap doorway protection . 7–10 Figure 7.17 Rubber mat doorway protection . 7–11 Figure 7.20 Example 58-in. diameter load in a 60-ft. 9-in. boxcar . 7–14 Closed Car Loading Guide—Loading Roll Paper in Rail Cars –iii LIST OF TABLES Table 3.1 Boxcar endwall strength . 3–1 Table 5.1 Performance level application guide . 5–1 Table 5.2 Minimum riser sizes for rolls . 5–6 Table 7.1 Substitution rate for nonmetallic strap as doorway protection. 7–3 –iv Closed Car Loading Guide—Loading Roll Paper in Rail Cars INTRODUCTION 1.0 INTRODUCTION 1.1 Overview 1.1.1 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. Many commodities or packaging types, such as paper, prepared food, plywood, and intermediate bulk containers, are governed in greater detail in individual closed car loading guides. Commodity-specific guides will normally take precedence over these general guidelines. See the back cover for a complete listing of the Association of American Railroads’ (AAR) boxcar loading guides. 1.1.2 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. 1.1.3 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. 1.1.4 The loading rules and/or practices apply to shipments transported in the USA, Canada, and Mexico. 1.1.5 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. In addition, each carrier may have its own requirements. Contact your origin carrier for more information. 1.1.6 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.