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Safe Loading and Cargo Securing

Safe Loading and Cargo Securing. Zagreb, 11 th November 2010. Patrick Philipp Head – IRU Academy. Unsecure cargo is a major risk. Euro Contrôle Route (ECR) an association of 14 European countries for the inspection of road transport, notes that:.

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Safe Loading and Cargo Securing

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  1. Safe Loading and Cargo Securing Zagreb, 11th November 2010 Patrick Philipp Head – IRU Academy

  2. Unsecure cargo is a major risk Euro Contrôle Route (ECR) an association of 14 European countries for the inspection of road transport, notes that: • 25% of all commercial vehicle accidents in Europe are caused by poorly secured loads. • Over 2300 accidents per year are due to poor cargo securing.

  3. Unsecure cargo is a major cost Overloading is a key concern! Source: Europol

  4. Cargo Securing Rev prEN 12195-1 (Jan 2009) IMO/ILO/UN ECE (2001) EN 12195-1 (Dec 2003) Comparison of Cargo Securing according to:

  5. Different requirements in guidelines and standards

  6. Cargo Securing Guidelines and Standards for Cargo Securing • European Best Practice Guidelines on Cargo Securing for Road Transport • IMO/ILO/UN ECE • Guidelines for packing of cargo transport units (CTU’s) • with IMO Model Course 3.18 • Standard EN 12195-1 • Load restraint assemblies on road vehicles – Safety – • Part 1: Calculation of lashing forces • Updated version Standard prEN 12195-1 (rev: 2009-1) • Load restraining on road vehicles – Safety – Part 1 • Calculation of securing forces

  7. Cargo Securing Cargo securing guidelines Rev prEN 12195-1 Jan 2009 IMO/ILO/UN ECE 2001 EN 12195-1 Dec 2003

  8. Cargo Securing Differences in the basic principles in the guidelines and standards

  9. Cargo Securing Differences in the basic principles in the guidelines and standards

  10. Cargo Securing Differences in the basic principles in the guidelines and standards

  11. Cargo securing examples

  12. Cargo Securing example 1 H L B Required number of top over lashings to prevent sideways sliding Curtain sided trailer, aluminium floor and strong headboard Wooden boxes Length = 13.6 m Height = 2.55 m Breadth = 2.48 m Quantity = 8 pieces H × B × L = 2 × 2 × 1.7 m Weight = 3 000 kg/box Total cargo weight: 24.0 tonnes Web lashings LC = 1 600 daN = 1.6 tonnes = 16 kN STF = 400 daN = 0.4 tonnes = 4 kN Friction between floor and cargo  = static = 0.4

  13. Cargo Securing example 1 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (6) Equation (10) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 3 tons g = 9.81 m/s2 cy= 0.5(table 2) cz = 1.0 (table 2) µd = µs × 0.7 = 0.28 (section 6.1) k = 1.5(section 6.2) FT= 0.4 ton ≈ 4 kN α = 84.3º where m = 3 tons g = 9.81 m/s2 cy = 0.5 (table 2) cz = 1.0 (table 2) µ = µest= 0.4(table B.1) α = 84.3º FT = 0.4 ton ≈ 4 kN fs = 1.1 Answer n = 3.9 n = 1.02 n = 0.9

  14. Cargo Securing example 1 Rev prEN 12195-1 9 top over lashings (with supporting beam) • Friction factor µ = 0.4 • Lashing force FT = STF • K-factor k = 2 • Safety factor fs = 1.1 Required number of top over lashings to prevent sideways sliding Rev prEN 12195-1 IMO/ILO/UN ECE EN 12195-1 16 top over lashings (Two lashing / section) 8 top over lashings (One lashing / section) 32 top over lashings (Four lashings / section) Reasons for the difference: • Dynamic friction µd = 0.7  s= 0.28 • Lashing force FT = STF • K-factor k = 1.5 • Safety factor fs = 1.0 • Static friction s = 0.4 • Lashing force FT = STF • K-factor k = 2 • Safety factor fs = 1.0

  15. Cargo Securing example 2 Steel crates H Side bottom blocking Blocking B Required number of top over lashings to prevent sideways tipping Curtain sided trailer with strong headboard Length = 13.6 m Height = 2.55 m Breadth = 2.48 m Quantity = 99 pcs in 11 sections Cargo section dimensions: H × B × L = 2.4 × 2.4 × 1.2 m Weight = 2 000 kg/section Total cargo weight: 22.0 tonnes H/B = (2.4/2.4) =1 Number of rows = 3 Web lashings LC = 1 600 daN = 1.6 tonnes = 16 kN STF = 400 daN = 0.4 tonnes = 4 kN

  16. Cargo Securing example 2 Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (11) Equation (16) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 2 tons/section g = 9.81 m/s2 cy = 0.5 or 0.6 (table 2) cz = 1.0 (table 2) d = 1.2 b = 0.4 w = 0.8 FT = STF or LC/2 ≈ 4 kN or 8kN N = 3 fs = 1.1 α = 90º where m = 2 tons/section g = 9.81 m/s2 cy= 0.7 (table 2) cz = 1.0 (table 2) h = 2.4 w = 2.4 k = 1.5 (section 6.2) FT= 0.4 ton ≈ 4 kn α = 90º Answer n = 0.9/section n = 5.4/section n = 0.9/section

  17. Cargo Securing example 2 Rev prEN 12195-1 11 top over lashings (One lashing / section) • Acceleration factorcy = 0.5 or cy = 0.6 • Lashing force FT = STF or FT = 0.5  LC • K-factor k = 2 • Safety factor fs = 1.1 • Internal friction considered Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE EN 12195-1 11 top over lashings (One lashing / section) 66 top over lashings (Six lashings / section) Reasons for the difference: • Acceleration factorcy = 0.7 • Lashing force FT = STF • K-factor k = 1.5 • Safety factor fs = 1.0 • No instructions for internal friction • Acceleration factor cy = 0.5 • Lashing force FT = STF • K-factor k = 2 • Safety factor fs = 1.0 • Internal friction considered

  18. Cargo Securing example 3 Required number of top over lashings to prevent sideways sliding and tipping Curtain sided trailer with strong headboard Paper reels H2 H1 B1 B2 One layer Two layers • Quantity = 36 reels in 12 sections • H × B = 1.3 × 1.1 m / reel • Weight = 650 kg / reel • Total cargo weight: 23.4 tonnes • H1/B1= (1.3/2.2)  0.6 • H2/B2= (2.6/2.2)  1.2 • Number of rows = 2 • Static friction between floor and reel and between reels, static = 0.5 • Friction factor = 0.46 (0.5  0.925) Length = 13.6 m Height = 2.55 m Breadth = 2.48 m Web lashings LC = 1 600 daN = 1.6 tonnes = 16 kN STF = 400 daN = 0.4 tonnes = 4 kN

  19. Cargo Securing example 3 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (10) Equation (6) EU Best Practice Guidelines - Cargo Securing (p.108) where m1 = 1.3 tons (one layer) m 2 = 2.6 tons (two layers) g = 9.81 m/s2 cy = 0.5 g (table 2) cz = 1.0 g (table 2) µ = µest= 0.46 (Annex B) α1 = 85.6º α2 = 87.8º FT = 0.4 ton ≈ 4 kN fs = 1.1 where m1 = 1.3 tons (one layer) m2= 2.6 tons (two layers) g = 9.81 m/s2 cy= 0.5 g (table 2) cz = 1.0 g (table 2) µd = µs × 0.7 = 0.35 (section 6.1) k = 1.5 (section 6.2) FT= 0.4 ton ≈ 4 kN α1 = 85.6º α2 = 87.8º Answer n1 = 0.91/section n2 = 1.82/section n1 = 0.20/section n2 = 0.39/section No sliding

  20. Cargo Securing example 3 Required number of top over lashings to prevent sideways tipping - one layer IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (11) Equation (16) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 1.3 tons/section g = 9.81 m/s2 cy = 0.5 g or 0.6g (table 2) cy = 1.0 g (table 2) d = 0.65 b = 0.55 w = 1.1 FT = STF or LC/2 ≈ 4 kN or 8 kN N = 2 fs = 1.1 α=85.6º where m = 1.3 tons/section g = 9.81 m/s2 cy= 0.7 g (table 2) cz = 1.0 g (table 2) h = 1.3 w = 1.1 k = 1.5 (section 6.2) FT= 0.4 ton ≈ 4 kN α= 85.6º Answer No tipping No tipping No tipping

  21. Cargo Securing example 3 Required number of top over lashings to prevent sideways tipping - two layers IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (11) Equation (16) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 2.6 tons/section g = 9.81 m/s2 cy = 0.5 g or 0.6g (table 2) cz = 1.0 g (table 2) d = 1.3 b = 0.55 w = 1.1 FT = STF or LC/2 ≈ 4 kN or 8 kN N = 2 fs = 1.1 α= 87.8º where m = 2.6 tons/section g = 9.81 m/s2 cy= 0.7 g (table 2) cz = 1.0 g (table 2) h = 2.6 w = 1.1 k = 1.5 (section 6.2) FT= 0.4 ton ≈ 4 kN α= 87.8º Answer n2 = 0.5/section n2 = 4.6/section n2 = 0.7/section

  22. Cargo Securing example 3 Rev prEN 12195-1 10 top over lashings (five lashings / six sections loaded in two layers to prevent tipping, and one lashing / 1-2 sections of cargo loaded in one layer to prevent sliding) • Friction factor µ = 0.45 • Acceleration factor cy = 0.5 or cy = 0.6 • Lashing force FT = STF or FT = 0.5  LC • K-factor k = 2 • Safety factor fs= 1.1 • Internal friction considered Required number of top over lashings to prevent sideways sliding and tipping IMO/ILO/UN ECE EN 12195-1 36 top over lashings (five lashings/section when loaded in two layers to prevent sliding and tipping, and one lashing/section when loaded in one layer to prevent sliding) 9 top over lashings (One lashing / 4 tonnes of cargo to prevent tipping and wandering) Reasons for the difference: • Dynamic friction µd = 0.7s= 0.35 • Acceleration factor cy = 0.5 (sliding) and cy = 0.7 (tipping) • Lashing force FT = STF • K-factor k = 1.5 • Safety factor fs = 1.0 • No instructions for internal friction • Static friction s = 0.5 • Acceleration factor cy = 0.5 • Lashing force FT = STF • K-factor k = 2 • Safety factor fs = 1.0 • Internal friction considered

  23. Cargo Securing example 4 Required number of top over lashings to prevent sideways sliding and tipping Truck with plyfa floor Heat exchanger with steel feet • The heat exchanger is blocked in forward direction. • H × B × L = 2.0 × 0.9 × 2.1 m • Centre of gravity: h × b × l = • 1.35 × 0.45 × 1.05 m • Weight = 2000 kg = 2 tonnes • h/b= (1.35/0.45) = 3.0 • Number of rows = 1 • Static friction µstatic = 0.4 and friction factor µ = 0.45 Length = 8. m Height = 2.55 m Breadth = 2.48 m Breadth between lashing points = 2.36 m Web lashings LC = 1 600 daN = 1,6 tonnes = 16 kN STF = 400 daN = 0.4 tonnes = 4 kN

  24. Cargo Securing example 4 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (10) Equation (6) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 2 tons g = 9.81 m/s2 cy= 0.5 g(table 2) cz = 1.0 g (table 2) µd = µs × 0.7 = 0.28 (section 6.1) k = 1.5(section 6.2) FT= 0.4 ton ≈ 4 kN α = 70º where m = 2 tons g = 9.81 m/s2 cy = 0.5 g(table 2) cz = 1.0 g(table 2) µ = µest= 0.46(Annex B) α = 70º FT = 0.4 ton ≈ 4 kN fs = 1.1 Answer n = 0.6 n= 2.7 n = 0.7

  25. Cargo Securing example 4 Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE Rev prEN 12195-1 EN 12195-1 Equation (11) modified for centre of gravity off centre Equation (16) EU Best Practice Guidelines - Cargo Securing (p.108) where m = 2 tons g = 9.81 m/s2 cy= 0.7 g (table 2) cz = 1.0 g (table 2) d = 1.35 b = 0.45 h = 2.0 w = 0.9 k = 1.5 (section 6.2) FT= 0.4 ton = 4 kN α = 70º where m = 2 tons/section g = 9.81 m/s2 cy = 0.5 g or 0.6g (table 2) cz = 1.0 g (table 2) d = 1.35 b = 0.45 w = 0.9 FT = STF or LC/2 = 4 kN or 6.5kN N = 2 fs = 1.1 α = 70º Answer n = 1.25 n= 30.0 n = 1.9

  26. Cargo Securing example 4 Rev prEN 12195-1 2 top over lashings • Friction factor µ = 0.45 • Acceleration factor cy = 0.5 or cy = 0.6 • Lashing force FT = STF • or FT = 0.5  LC • K-factor k = 2 • Safety factor fs = 1.1 Required number of top over lashings to prevent sideways sliding and tipping IMO/ILO/UN ECE EN 12195-1 2 top over lashings 30 top over lashings Reasons for the difference: • Dynamic friction µd = 0.7  s= 0.28 • Acceleration factor cy = 0.5 (sliding) and cy = 0.7 (tipping) • Lashing force FT = STF • K-factor 1.5 • Safety factor fs = 1.0 • Static friction s = 0.4 • Acceleration factor cy = 0.5 • Lashing force FT = STF • K-factor k = 2 • Safety factor fs = 1.0

  27. Cargo Securing Comparison between the different guidelines for road transport

  28. Cargo Securing Comparison between the different guidelines for road transport

  29. Cargo Securing IMO/ILO/UN ECE (2001) EN 12195-1 (Dec 2003) Rev prEN 12195-1 (Jan 2009) SAFE ENOUGH!

  30. IRU Academy Checklist on Safe Loading and Cargo Securing New!

  31. IRU Academy Interactive Programme on Safe Loading and Cargo Securing Coming soon!

  32. Worldwide Excellence in Road Transport Training

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