Quality Lead Team Update Quality Lead Team Update Large Diameter Rolls and 60’ ’ Railcars Railcars Large Diameter Rolls and 60 Mini- -Paper Workshop on Damage Paper Workshop on Damage Mini Resolution Resolution
AAR – – Quality Lead Team for Quality Lead Team for AAR the Prevention of Damage to Paper Products the Prevention of Damage to Paper Products 2009 Team Members Abitibi Consolidated - Randy Caine BNSF Railway – Jerry Jones Canadian National Railways - John Green CSX Transportation - Gary Johnson (Chairman) Forest Prod. Assoc. of Canada - David Church Brianna Hodges Georgia-Pacific Corporation - Jerome Williams Union Pacific Railroad - -Brent Lichty Norfolk Southern - Tommy Ford Packaging Corp. of America - Neal Reidenbach Glenn McDonald Weyerhaeuser - Brian Rio Whitney Nelson Transportation Tech. Center, Inc. - Mike Sandoval Canadian Pacific Railway - Louis LeBlanc • Review and Finalization Best Practices for Loading Roll Paper in Rail Cars – Possible Translating the Manual Into French and Spanish – On-Line Download •AAR Researching Data Collected Thus Far to Acquire A Weight Threshold for Level 4 Airbags In A Horizontal Application. Weight Limits to Specify the Level of Airbag to Be Utilized In Shipments •Loading Patterns for 60’ Cars Having 16’ Door Openings – QLT Team Recommends Only Methods Provided in Pamphlet 39. All Other Patterns Must Go Through AAR Testing. •Large Diameter Rolls 60” Plus In 60’ Cars Having 16’ Door Openings – Shippers Should Work With Individual Railroad Damage Prevention Teams – Must Be AAR Tested
60” ”, 67 , 67” ”, 70 , 70” ”, 72 , 72” ”, 77 , 77” ” - - Diameter Rolls in Diameter Rolls in 60 60’ Cars Having 16’ Door Openings – – No AAR Approved Patterns No AAR Approved Patterns BNSF working with Clearwater and Georgia Pacific on Interline moves • Provide Loading and Securement Methods •Origin and Destination Inspections •Local Impact Test by Shipper & BNSF to determine effectiveness • Petition AAR for Impact Test Upon Success of Local Testing
Airbag 60” DIAMETER ROLLS
77” DIAMETER ROLLS 175,000+ LBS
NO MATTER THE CHALLENGE WE’LL FIGURE A WAY TO HAUL IT TEAM WORK…WORKING TOGETHER TO SOLVE PROBLEMS
Mini- -Paper Workshop Paper Workshop Mini “Moving to Damage Free Moving to Damage Free “ Shipments by Rail” ” Shipments by Rail
30 Years Back In Time 30 Years Back In Time Printing Paper Pulpboard - Kraft 38- -40 40” ” Diameter Diameter 58” ” Diameter rolls Diameter rolls 38 58 Metal cores – – 3 3” ” 3” ” cores cores Metal cores 3 2- -1 1- -2 Load Pattern 2 Load Pattern 1- -1 off 1 off- -set load set load 2 1 pattern pattern Braced by steel Braced by steel strapping “ “Key Lock Key Lock” ” strapping 10' 9' 6" 50' 6"
30 Years Later 30 Years Later Printing Paper Pulpboard - Kraft 38” ”/40 /40” ” now 42 now 42” ”, 45 , 45” ”, 50 , 50” ”, , 58” ” still mainstay still mainstay – – some some 38 58 52” ”, 60 , 60” ” diameter rolls diameter rolls 50” ” and up to 70 and up to 70” ” 52 50 diameters diameters Metal cores to fiber cores Metal cores to fiber cores and now some plastic Wood blocking and now and now some plastic Wood blocking and now air bag braced & non- air bag braced & non - Core ID’ ’s of 3 s of 3” ”, 5 , 5” ”, 6 , 6” ” and and Core ID metallic strapping metallic strapping greater greater 58” ” still in 1 still in 1- -1 off 1 off- -set load set load 58 Variety of basis weights Variety of basis weights pattern pattern and widths and widths Air bags as bracing Air bags as bracing Different load patterns Different load patterns
Equipment Changes Over the Years Equipment Changes Over the Years Old Standard 50’ ’ Old Standard 50 – – non non- -cushioned (some 10 cushioned (some 10” ” cushioned equipped) cushioned equipped) – sliding doors sliding doors – The “ “New Fleet New Fleet” ” The – – 50 50’ ’, 60 , 60” ” and 62 and 62’ ’ inside length inside length – high cube high cube – – high capacity cars high capacity cars – – 15 15” ”, 18 , 18” ” and 20 and 20” ” cushion units cushion units – – Plug doors Plug doors – – Multi Multi- -use car use car – – Strap cars Strap cars –
Bracing, Dunnage & Packaging Bracing, Dunnage & Packaging Air bags – – both paper and both paper and Air bags poly poly Non- -metallic strapping metallic strapping Non Riser material Riser material Contour Filler Material Contour Filler Material Honeycomb Filler Material Honeycomb Filler Material Improved Wrappers and Improved Wrappers and Headers Headers
The “ “Original Original” ” Damage Types Damage Types The Edge Damage Wet Damage Flat Spot Crushed Core Gouged Chaffed Rolls
n o i t a n i m Out-of Round a t n o Starred C Chafe Gouged d e l a e c n o C Split Edge r n T o t s r u B t i s n a r T d p e c o e s T e l Crushed Core e p e Flat Spot r C t i s n a r T e t W
2 Things Have Remained Constant 2 Things Have Remained Constant Rolls are “ROUND” Boxcars Aren’t
Resolving Damage Issues Resolving Damage Issues Water damage Edge damage - - chaffing chaffing Water damage Edge damage – – Inspect car before loading Inspect car before loading – – Consistent diameters in Consistent diameters in same stacks same stacks – Utilize approved load Utilize approved load – pattern, bracing method and – Load tightly each end and Load tightly each end and pattern, bracing method and – doorway protection use approved bracing doorway protection use approved bracing method method Gouged rolls Gouged rolls – – On multi On multi- -layer loads; break layer loads; break – – Inspect car Inspect car the strata line each end of the strata line each end of – Remove protruding objects – Remove protruding objects load load – Inspect handling equipment Inspect handling equipment – Crushed cores Crushed cores Flat spots Flat spots – Utilize approved load Utilize approved load – – Inspect rail equipment – Inspect rail equipment pattern and bracing method pattern and bracing method – Utilize approved pattern and Utilize approved pattern and – – Change pattern Change pattern ……… ……… – bracing method bracing method – Provide side wall protection Provide side wall protection –
Flat Spots – – Transit Burst (Crepe) Transit Burst (Crepe) Flat Spots TBOX 665002 TBOX 665003 Doorpost Condition of sidewalls and endwalls can magnify problem
Flat Spots – – Transit Burst (Crepe) Transit Burst (Crepe) Flat Spots Contact Points How To Reduce or Eliminate
Additional Protection at Sidewalls Additional Protection at Sidewalls ½” folded folded ½” honeycomb honeycomb material at material at contact contact points of points of rolls and rolls and sidewalls. sidewalls.
Transfer of forces thru honeycomb into doorpost roll
Positioned off floor Maybe an improvement ……………
Other means to resolve flat spots, Other means to resolve flat spots, transit burst (crepe) transit burst (crepe) Reject cars that have excessive bowed Reject cars that have excessive bowed sidewalls. Damage can actually happen during sidewalls. Damage can actually happen during loading operations! Excessive? loading operations! Excessive? Change load pattern that will result in fewer rolls Change load pattern that will result in fewer rolls contacting sidewalls contacting sidewalls Reduce lengthwise void that air bags is being Reduce lengthwise void that air bags is being used to fill lengthwise void. used to fill lengthwise void. Load off sidewall – – but still maintain tight but still maintain tight Load off sidewall lengthwise load lengthwise load
Change your pattern Change your pattern How many rolls in CAR “A” each car? How many rolls are contacting sidewalls CAR “B” in each of these cars?
Crushed Cores, Edge Damage or Crushed Cores, Edge Damage or Water damage Water damage 10' 9' 6" 60' 9"
Other Tips to Consider… ….. .. Other Tips to Consider Fine Paper, Newsprint or Printing Paper should be loaded in cushioned equipped cars only. Does load pattern match car size – may not be able to load a 9’ 2” car with same pattern as a 9’ 6” width car. If load/doorway type requires doorway protection – is car equipped for securing straps? What about your customer? – Can they accept high cube cars – Some older facilities can not accept plug door cars. If your customer is critical – choose the best car to meet they needs.
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