Safe Loading and Cargo Securing Zagreb 11 th

Safe Loading and Cargo Securing Zagreb, 11 th November 2010 Patrick Philipp Head – IRU Academy Safe Loading and Cargo Securing Programme 1 © International Road Transport Union (IRU) 2010

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. IRU Academy Safe Loading and Cargo Securing Programme 2 © International Road Transport Union (IRU) 2010

Unsecure cargo is a major cost Overloading is a key concern! Source: Europol IRU Academy Safe Loading and Cargo Securing Programme 3 © International Road Transport Union (IRU) 2010

Cargo Securing Comparison of Cargo Securing according to: Rev pr. EN 12195 -1 IMO/ILO/UN ECE (Jan 2009) (2001) EN 12195 -1 (Dec 2003) IRU Academy Safe Loading and Cargo Securing Programme 4 © International Road Transport Union (IRU) 2010

Different requirements in guidelines and standards IRU Academy Safe Loading and Cargo Securing Programme 5 © International Road Transport Union (IRU) 2010

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 pr. EN 12195 -1 (rev: 2009 -1) Load restraining on road vehicles – Safety – Part 1 Calculation of securing forces IRU Academy Safe Loading and Cargo Securing Programme 6 © International Road Transport Union (IRU) 2010

Cargo Securing Cargo securing guidelines IMO/ILO/UN ECE 2001 EN 12195 -1 IRU Academy Safe Loading and Cargo Securing Programme Dec 2003 7 Rev pr. EN 12195 -1 Jan 2009 © International Road Transport Union (IRU) 2010

Cargo Securing Differences in the basic principles in the guidelines and standards Item Acceleration coefficients (road transport) - Forward - Sliding sideways - Tipping sideways + Direct lashings + Frictional lashings IMO/ILO/UN ECE EN 12195 -1 Rev pr. EN 12195 -1 cx = 1. 0 cy = 0. 5 cx = 0. 8 cy = 0. 5 (FT=LC) cy = 0. 5 (FT=STF) cy = 0. 7 (FT=LC) cy = 0. 7 (FT=STF) cy = 0. 6 (FT=LC) cy = 0. 5 (FT=STF) or cy = 0. 6 (FT=LC/2) fs = 1. 0 fs = 1. 25 fs = 1. 1 Safety factor in calculations of frictional (top over) lashings - Forward fs = 1. 0 - Sideways and backward fs = 1. 0 IRU Academy Safe Loading and Cargo Securing Programme 8 © International Road Transport Union (IRU) 2010

Cargo Securing Differences in the basic principles in the guidelines and standards Item Friction factor established by friction test - Frictional lashings IMO/ILO/UN ECE EN 12195 -1 Rev pr. EN 12195 -1 µ =µs 0. 925 Dynamic friction µd = µ s f µ Dynamic friction µd = µs 0. 70 Dynamic friction µd = µ s f µ Conversion factor fµ for direct lashings fµ = 0, 70 fµ = µd/µs 0. 75 < fµ < 1. 0 Internal friction Included Not included Included Coefficient of transmission (k-factor) k=2 k =1. 5 k=2 - Direct lashings Static friction µs IRU Academy Safe Loading and Cargo Securing Programme 9 µ fµ © International Road Transport Union (IRU) 2010

Cargo Securing Differences in the basic principles in the guidelines and standards Item IMO/ILO/UN ECE Some differences in table of friction factors, e. g: - sawn wood against µ = 0. 50 fabric base laminate/plywood µ = 0. 40 - sawn wood against steel Not included sheet - steel crate against fabric base laminate/plywood EN 12195 -1 Rev pr. EN 12195 -1 µ = 0. 50 µ = 0. 45 µ = 0. 40 Not included µ = 0. 30 µ = 0. 45 Verification of the efficiency of securing arrangement by Calculations Static inclining test Dynamic driving test (road transport) Lashing protocol Included Not included IRU Academy Safe Loading and Cargo Securing Programme 10 © International Road Transport Union (IRU) 2010

Cargo securing examples IRU Academy Safe Loading and Cargo Securing Programme 11 © International Road Transport Union (IRU) 2010

Cargo Securing example 1 Required number of top over lashings to prevent sideways sliding Curtain sided trailer, aluminium floor and strong headboard Wooden boxes H L Length = 13. 6 m Height = 2. 55 m Breadth = 2. 48 m B Quantity = 8 pieces H × B × L = 2 × 1. 7 m Weight = 3 000 kg/box Total cargo weight: 24. 0 tonnes Web lashings LC = 1 600 da. N = 1. 6 tonnes = 16 k. N STF = 400 da. N = 0. 4 tonnes = 4 k. N Friction between floor and cargo = static = 0. 4 IRU Academy Safe Loading and Cargo Securing Programme 12 © International Road Transport Union (IRU) 2010

Cargo Securing example 1 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) EN 12195 -1 Rev pr. EN 12195 -1 Equation (6) Equation (10) where m g cy cz = 3 tons = 9. 81 m/s 2 = 0. 5 (table 2) = 1. 0 (table 2) µd = µs × 0. 7 = 0. 28 (section 6. 1) k = 1. 5 (section 6. 2) FT = 0. 4 ton ≈ 4 k. N α = 84. 3º = 3 tons = 9. 81 m/s 2 = 0. 5 (table 2) = 1. 0 (table 2) µ = µest= 0. 4 (table B. 1) α = 84. 3º FT = 0. 4 ton ≈ 4 k. N fs = 1. 1 Answer n = 0. 9 n = 3. 9 IRU Academy Safe Loading and Cargo Securing Programme 13 n = 1. 02 © International Road Transport Union (IRU) 2010

Cargo Securing example 1 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE EN 12195 -1 Rev pr. EN 12195 -1 8 top over lashings 32 top over lashings 9 top 16 topoverlashings (One lashing / section) (Four lashings / section) (with beam) (Two supporting lashing / section) Reasons for the difference: • • Static friction s = 0. 4 Lashing force FT = STF K-factor k = 2 Safety factor fs = 1. 0 • Dynamic friction µd = 0. 7 s= 0. 28 • Lashing force FT = STF • K-factor k = 1. 5 • Safety factor fs = 1. 0 IRU Academy Safe Loading and Cargo Securing Programme 14 • • Friction factor µ = 0. 4 Lashing force FT = STF K-factor k = 2 Safety factor fs = 1. 1 © International Road Transport Union (IRU) 2010

Cargo Securing example 2 Required number of top over lashings to prevent sideways tipping Curtain sided trailer with strong headboard Steel crates Blocking H Side bottom blocking B 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 × 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 da. N = 1. 6 tonnes = 16 k. N STF = 400 da. N = 0. 4 tonnes = 4 k. N IRU Academy Safe Loading and Cargo Securing Programme 15 © International Road Transport Union (IRU) 2010

Cargo Securing example 2 Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) EN 12195 -1 Rev pr. EN 12195 -1 Equation (11) Equation (16) where m = 2 tons/section g = 9. 81 m/s 2 cy = 0. 7 (table 2) cz = 1. 0 (table 2) g = 9. 81 m/s 2 cy = 0. 5 or 0. 6 (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 d = 1. 2 b = 0. 4 w = 0. 8 FT = STF or LC/2 ≈ 4 k. N or 8 k. N N =3 fs = 1. 1 α = 90º Answer n = 0. 9/section n = 5. 4/section IRU Academy Safe Loading and Cargo Securing Programme 16 n = 0. 9/section © International Road Transport Union (IRU) 2010

Cargo Securing example 2 Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE EN 12195 -1 Rev pr. EN 12195 -1 11 top over lashings 66 top over lashings 11 top over lashings (One lashing / section) (Six lashings / section) (One lashing / section) Reasons for the difference: • • • Acceleration factor cy = 0. 5 Lashing force FT = STF K-factor k = 2 Safety factor fs = 1. 0 Internal friction considered • • • Acceleration factor cy = 0. 7 Lashing force FT = STF K-factor k = 1. 5 Safety factor fs = 1. 0 No instructions for internal friction IRU Academy Safe Loading and Cargo Securing Programme 17 • 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 © International Road Transport Union (IRU) 2010

Cargo Securing example 3 Required number of top over lashings to prevent sideways sliding and tipping Curtain sided trailer with strong headboard Paper reels H 2 H 1 B 1 One layer • • Quantity = 36 reels in 12 sections H × B = 1. 3 × 1. 1 m / reel Weight = 650 kg / reel Total cargo weight: 23. 4 tonnes H 1/B 1= (1. 3/2. 2) 0. 6 H 2/B 2= (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 da. N = 1. 6 tonnes = 16 k. N STF = 400 da. N = 0. 4 tonnes = 4 k. N IRU Academy Safe Loading and Cargo Securing Programme B 2 Two layers 18 © International Road Transport Union (IRU) 2010

Cargo Securing example 3 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) Rev pr. EN 12195 -1 Equation (6) Equation (10) where m 1 = 1. 3 tons (one layer) m 2 = 2. 6 tons (two layers) g = 9. 81 m/s 2 cy = 0. 5 g (table 2) cz = 1. 0 g (table 2) µd = µs × 0. 7 = 0. 35 (section 6. 1) µ = µest= 0. 46 (Annex B) k α 1 = 85. 6º = 1. 5 (section 6. 2) FT = 0. 4 ton ≈ 4 k. N α 1 = 85. 6º α 2 = 87. 8º FT = 0. 4 ton ≈ 4 k. N fs = 1. 1 Answer No sliding n 1 = 0. 91/section n 2 = 1. 82/section IRU Academy Safe Loading and Cargo Securing Programme 19 n 1 = 0. 20/section n 2 = 0. 39/section © International Road Transport Union (IRU) 2010

Cargo Securing example 3 Required number of top over lashings to prevent sideways tipping - one layer IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) EN 12195 -1 Rev pr. EN 12195 -1 Equation (11) Equation (16) where m = 1. 3 tons/section g = 9. 81 m/s 2 cy = 0. 7 g (table 2) cz = 1. 0 g (table 2) g = 9. 81 m/s 2 cy = 0. 5 g or 0. 6 g (table 2) cy = 1. 0 g (table 2) h = 1. 3 w = 1. 1 k = 1. 5 (section 6. 2) FT = 0. 4 ton ≈ 4 k. N α = 85. 6º d = 0. 65 b = 0. 55 w = 1. 1 FT = STF or LC/2 ≈ 4 k. N or 8 k. N N=2 fs = 1. 1 α =85. 6º Answer No tipping IRU Academy Safe Loading and Cargo Securing Programme 20 No tipping © International Road Transport Union (IRU) 2010

Cargo Securing example 3 Required number of top over lashings to prevent sideways tipping - two layers IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) EN 12195 -1 Rev pr. EN 12195 -1 Equation (11) Equation (16) where m = 2. 6 tons/section g = 9. 81 m/s 2 cy = 0. 7 g (table 2) cz = 1. 0 g (table 2) g = 9. 81 m/s 2 cy = 0. 5 g or 0. 6 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 k. N α = 87. 8º d = 1. 3 b = 0. 55 w = 1. 1 FT = STF or LC/2 ≈ 4 k. N or 8 k. N N=2 fs = 1. 1 α = 87. 8º Answer n 2 = 0. 5/section n 2 = 4. 6/section IRU Academy Safe Loading and Cargo Securing Programme 21 n 2 = 0. 7/section © International Road Transport Union (IRU) 2010

Cargo Securing example 3 Required number of top over lashings to prevent sideways sliding and tipping IMO/ILO/UN ECE EN 12195 -1 9 top over lashings 36 top over lashings (One lashing / 4 tonnes of cargo to prevent tipping and wandering) Rev pr. EN 12195 -1 10 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) (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) Reasons for the difference: • 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 • 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 IRU Academy Safe Loading and Cargo Securing Programme 22 • • • 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 © International Road Transport Union (IRU) 2010

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 da. N = 1, 6 tonnes = 16 k. N STF = 400 da. N = 0. 4 tonnes = 4 k. N IRU Academy Safe Loading and Cargo Securing Programme 23 © International Road Transport Union (IRU) 2010

Cargo Securing example 4 Required number of top over lashings to prevent sideways sliding IMO/ILO/UN ECE EU Best Practice Guidelines Cargo Securing (p. 108) EN 12195 -1 Rev pr. EN 12195 -1 Equation (6) Equation (10) where m g cy cz = 2 tons = 9. 81 m/s 2 = 0. 5 g (table 2) = 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 k. N α = 70º = 2 tons = 9. 81 m/s 2 = 0. 5 g (table 2) = 1. 0 g (table 2) µ = µest= 0. 46 (Annex B) α = 70º FT = 0. 4 ton ≈ 4 k. N fs = 1. 1 Answer n = 0. 6 n = 2. 7 IRU Academy Safe Loading and Cargo Securing Programme 24 n = 0. 7 © International Road Transport Union (IRU) 2010

Cargo Securing example 4 Required number of top over lashings to prevent sideways tipping IMO/ILO/UN ECE EN 12195 -1 EU Best Practice Guidelines Cargo Securing (p. 108) Equation (11) modified for centre of gravity off centre Equation (16) where m = 2 tons/section g = 9. 81 m/s 2 cy = 0. 7 g (table 2) cz = 1. 0 g (table 2) g = 9. 81 m/s 2 cy = 0. 5 g or 0. 6 g cz = 1. 0 g (table 2) d = 1. 35 Rev pr. EN 12195 -1 (table 2) b = 0. 45 d = 1. 35 b = 0. 45 h = 2. 0 w = 0. 9 FT = STF or LC/2 = 4 k. N or 6. 5 k. N k N=2 = 1. 5 (section 6. 2) FT = 0. 4 ton = 4 k. N fs = 1. 1 α = 70º Answer n = 1. 25 n = 30. 0 IRU Academy Safe Loading and Cargo Securing Programme 25 n = 1. 9 © International Road Transport Union (IRU) 2010

Cargo Securing example 4 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 Rev pr. EN 12195 -1 2 top over lashings Reasons for the difference: • • • Static friction s = 0. 4 Acceleration factor cy = 0. 5 Lashing force FT = STF K-factor k = 2 Safety factor fs = 1. 0 • 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 IRU Academy Safe Loading and Cargo Securing Programme 26 • 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 © International Road Transport Union (IRU) 2010

Cargo Securing Comparison between the different guidelines for road transport IRU Academy Safe Loading and Cargo Securing Programme 27 © International Road Transport Union (IRU) 2010

Cargo Securing Comparison between the different guidelines for road transport IRU Academy Safe Loading and Cargo Securing Programme 28 © International Road Transport Union (IRU) 2010

Cargo Securing SAFE ENOUGH! IMO/ILO/UN ECE (2001) EN 12195 -1 (Dec 2003) Rev pr. EN 12195 -1 (Jan 2009) IRU Academy Safe Loading and Cargo Securing Programme 29 © International Road Transport Union (IRU) 2010

IRU Academy Checklist on Safe Loading and Cargo Securing e N IRU Academy Safe Loading and Cargo Securing Programme 30 ! w © International Road Transport Union (IRU) 2010

IRU Academy Interactive Programme on Safe Loading and Cargo Securing C m o i IRU Academy Safe Loading and Cargo Securing Programme g n 31 s o o ! n © International Road Transport Union (IRU) 2010

Worldwide Excellence in Road Transport Training IRU Academy Safe Loading and Cargo Securing Programme 32 © International Road Transport Union (IRU) 2010