Distribution Solutions

Guidelines
for cargo securing in Steel Distribution
and Steel Service Centers
Content
1. legal basis p 4
1.1. necessity of loading security p5
1.2. responsibility / liability for loading security p5

2. technical basis p 6
2.1. reactions of the vehicle p6
2.2. reactions of the loading p6
2.3. physical power p 6
example of calculation in annex

3. technical equipment of trucks p 10

3.1. loading area p 10
3.2. front walls p 12
3.3. side walls p 13
3.4. calculation of stanchions or head walls p 14
3.5. lashing points p 15
3.6. stocking of the equipment for loading security p 16

4. technical equipment of loading aids p 17

4.1. anti-slip-mats p 17
4.2. loading wood p 18
4.3. pallets p 19
4.4. strip aids p 19
4.5. edge protectors p 22
4.6. tarpaulins p 23
4.7. shrink films p 23
4.8. danger signs p 24

5. preparation, packaging of the material p 25

5.1. preparation of long material p 25
5.2. packaging of sheets and plates p 28
5.3. packaging of small pieces p 28

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Content 1. Legal Basis

5.4. packaging of bended rebars p 29 Cargo security is not an end in itself, This booklet is a guideline providing in charge of the cargo securing
but is mandatory by law to prevent you with ideas how to prevent our operations will be held criminally
damages. It is important to notice loaded goods from falling of trucks liable, but can also involve (and this
6. loading plan p 31 that liability in case of damages and trailers. is highly dependent on the specific
applies as well in case of imprudent It is mandatory to make a HIRA national criminal law systems)
7. fixing of the load p 32 or reckless action as in the case regarding the cargo securing safety middle and top managers of the
7.1. form closure p 32 of omission (lack of the required rules in each plant, to make sure, that ArcelorMittal legal entity having had
diligence - negligence). all special circumstances are taken a relevant role in those operations,
7.2. anti-slip-mats p 41
into account. and who
7.3. grounding with wood p 42 The main principle is that - either i) must ensure the availability of all
7.4. lashing p 43 in the normal and usual course When loads are lost during transport the security means,
7.5. direct lashing p 46 of business, as in the case of there is a real danger that persons ii) train the relevant employees about
8. loading control p 47 the fulfilment of any contractual get severely inured (can even results the risks and good practices,
obligation - individuals must always in one or more fatalities). In that iii) is eventually directly in charge of
perform their obligations according case not only civil liability (monetary the assessment of the compliance of
to the general legal duty of being indemnification) but also criminal all the security processes and of the
ANNEXE - example of calculation in annex as diligent as possible (which also liability (fines, prison, etc.) will be correct performance of the works.
includes checking by AM that involved. This criminal liability is even
our sub-contractor complies existing without any calamity, for
with regulations and has taken all example when inappropriate securing
measures to prevent any injury or is assessed at a police road check. In
damage). addition, not only the people directly

4 5
1.1. Necessity of cargo security 2. Technical basis

The necessity of cargo security to know what the minimum cargo since the national legislation in the These guidelines are written for road transport.
results form the accident prevention securing requirements are for a given different EU member states typically To understand the necessity of the cargo security, one must know the main technical basis.
standards and instructions, the cross-border transport operation. requires the means of securing to Cargo security must work for the normal traffic situations, like full braking, strong, sudden emergency avoidance, fast
above mentioned general principles This is why in any event, securing of comply with European standards, but bends and bad streets!
of liability, and many legal standard cargo on a vehicle should be carried mostly without prescribing the norms Normal traffic situations does not mean an extra slow and careful drive to the customer around the corner, but must
rules, which range from very detailed out according to all legislations in detail. always be calculated on the extreme driving situations!
laws on specific cargo and loading applicable in all countries where
safety procedures existing in some the transport will pass by. These Such guidelines are a relevant
countries, to just general principles legislations ultimately all actually refer reference for all public or private 2.1. Reactions of the vehicle
of due diligence and administrative or are expected to refer in the near parties directly or indirectly concerned
regulations existing in other countries, future to the “European Best Practice by cargo securing, they represent the In case of strong breaking, combined with emergency avoidance, the vehicle may swing. Here, we have very strong
which apply in general terms to such Guidelines on Cargo Securing for accumulated knowledge of European force to front and side. In case of a fast bend, the vehicle may decline, here, the centrifugal force is increased!
works. Road Transport”, although the level experts in this field, and are designed

Rules on cargo securing exist in several

of implementing these guidelines
may vary. Also other European norms
to lead all the parties involved to
the adequate safety level required
2.2. Reactions of the loading
EU Member States, but often differ like EN 12195-1, EN 12195-2, EN to perform international transport The load must not start to move! The power of a moving mass is much higher than the power of a stationary mass. If
in content and scope, making it very 12195-3, EN 12195-4, EN 12640 operations. the loading has the space to swing, it buckles easily the front or the side wall of the truck.
difficult for international transporters and EN 12642 (XL) are important, In cases of breaking or sharp bend, the load may slip or tip over.

Important:
In view of the general principles of liability mentioned above, such standards should be seen as a «MUST» and not 2.3. Physical power
a «CAN». It is the job of the acting responsible persons, the loading employees and the drivers, to guarantee and
define how to assure the danger will be excluded. It is clear, that the vertical mass must be taken completely.
But also the horizontal forces are clearly defined.
To the front, 80% of the mass must be taken (in UK and Scandinavia even 100%),
To the side and backwards 50% of the masses must be taken.
1.2. Responsibility / Liability for cargo security: These forces can be taken by
- friction
In brief: Those persons potentially - form closure
responsible and liable for cargo Conclusion: the only way to manage liability is:
- top lashing
security are: 1. to do whatever is possible to avoid any risks
- front end, rear end and loop lashing
1. The loader (the person, who puts 2. to be able to show proof of the risk analysis/
the load on the truck) measures taken
Friction is created by micro fine surface roughness, which interlocks with each other. Steel on wood has a coefficient
2. His / her supervisor 3. to have available a handbook containing guidelines
friction of 0,2. When using an anti-slip-mat, the coefficient rises up to 0,4 - 0,7, depending on the producers
3. His/her Company which will be implemented by the operational
guarantee.
4. The driver staff of AM and ultimately also to third parties,
On wet, oily or dirty loading areas this data reduces drastically! Dirt, oil, sand etc. must be avoided! An important tool
5. His / her supervisor clearly showing that AM aims at the highest/best
for loading security is a broom!
6. His/her Company standard of cargo securing.

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Î P
A truck must be clean and tidy! Wood and straps causes people to fall, sand, water and oil make it slippery. Before it is
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started, clean it up!

Form closure results of a direct closure of the loading at the front wall or the side wall. This example shows the results of a bad cargo securing: The result was of the load at a normal breaking, a
The front wall should resist 40% of the maximum cargo load; most are constructed to resist maximum 5 to. Some 1. No form closure to front damaged truck, a damaged load and a lucky driver, he
front walls are constructed to resist a higher force, the old ones sometimes resist a lot less! 2. No anti slip mats was not hurt, lost his/her drivers license plus receive a big
The side walls resist 30% of the maximum cargo load, but on the complete board size, not on one point. 3. No front end lashing financial fine for both the loader and driver.
A certificate is mandatory. 4.Just two straps top lashing for 10 tons sheets

Clamping is done with lashing wires, lashing chains and lashing straps.
The lashing material does not pull the whole resisting power down, but much less! They only increase the friction. A
5 to lashing strap holds 500 kg down, with an optimum angle of nearly 90 degrees! If the angle is only 30 degrees, it Chart «lashing»: dynamic friction coefficients
pulls only half! Initial Tension
But the strap must be in a good condition and torsion-free tensed. per tension 0,1 0,2 0,25 0,3 0,4 0,5 0,6
So, we operate with 400 kg per strap. 100 kg 20 40 50 60 80 100 120
It depends also on the coefficient of friction. The higher, the better! 200 kg 40 80 100 120 160 200 240
300 kg 60 120 150 180 240 300 360
400 kg 80 160 200 240 320 400 480
500 kg 100 200 250 300 400 500 600
600 kg 120 240 300 360 480 600 720
700 kg 140 280 350 420 560 700 840
800 kg 160 320 400 480 640 800 960
900 kg 180 360 450 540 720 900 1080

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Raising of the friction by lashing per lashing strip
©Foto: Klaus Brändle

Attention! The more flat the lashing angle a, the less the friction force between load and
loading area!
This example does not make any sense! Angle a
1. Only top lashing without form closure, without anti friction mats does not give enough friction. 90 degrees 100%
2. The many straps give such a strong force to the trailer, that it is bent and badly damaged. 60 degrees 87%
3. It takes hours to fix those 90 strips. Time is money, so it is very uneconomic. 45 degrees 71%
30 degrees 50%
15 degrees 26% Here is a lashing crosswise to driving direction set.

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 Clean palletized sheet-packages, with anti-slip mats,

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with 3 lashing straps braced.
Attention! The angle is 30 degrees!
Do we have a form closure?
Are the packages in a form stable condition?
3. Technical Equipment of Trucks

To guarantee the security of the heavy steel loads, trucks must have a minimum equipment.
The vehicle must be able to load all normal occurring load safely. The cargo safety must be technically safe and
economical. Depending on the products, a special truck is necessary.

3.1. Loading Area

The loading area has to be in wood, the best is hardwood. It has a good grip when walking on it and withstands
Clean packed beam-bundles, with anti-slip-mats, braced

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occasional impact by the steel- when loading.
with many lashing straps.
Depending on the products, the loading area must have special equipment, described below.
The angle is steep, edge protection is included.
A number of lashing points is always mandatory.
Do we have a form closure?
Are the packages in a form stable condition?
3.1.1. Sheets and Plates

Sheets and plates can be laid on the flat loading area. There is no special performance necessary; they only need a
number of lashing points and, depending on the sizes, a possibility for stanchions to bring a form closure.

3.1.2. Coils

If coils are loaded lying (vertical axis), there is the same performance of the loading area like for sheets and plates
necessary. If the coils are loaded standing (horizontal axis), a coil-dumper and stable stanchions are mandatory.
Do it in a way, that the load can be divided on the axes, and that the coils cannot roll off. The coil-dumper must be
parallel to the drive direction, or have a certification. Small coils in coil container need to be approved by th BA safety

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manager.

3.1.3. Long Products

Long products must often be secured at several points. That’s why lashing
points are necessary on the loading area, not only at the edges. Ideal are
Example of a load without any form closure, without anti slip mats, but with a good top lashing. fixing trails. There must be enough points on the truck; every bar must be
This was only window dressing! fixed minimum twice or more, depending on the position and weight. The
fixing trails must be fixed with the truck on there whole length, not only at
Examples for calculations with / without anti slip mats can be found in the annex. the edges.
Also column lines are necessary, to bring the products with different length
a form closure to front. Often the products are unloaded with chains or
forklifts, so we need fixed woods crosswise the driving direction.

Right side: example of a fixing trail

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3.1.4. Rebars and Wire Mesh

Wire mesh must be fixed to all directions. There must be columns, fixed to the loading, with minimum the same
height as the loading. The material must not start to move.
Rebars need a form closure to front and side, so, positioning of many columns is a good solution.

3.1.5. Combined Loadings

Often different products are transported at the same time. We need trucks with a flexible loading area. 3.2. Front Walls
Loading rectangular wood must be removable, but be fixed during the transport, either by fixing to the floor or with
anti slip mats. Front walls must secure the loading from slipping over the front edge of the loading area.
To be able to load single sheets or several positions of sheets under the long products a flexible height is a good So, they must be as high as the highest loading.
practice. They must also withstand a pressure of minimum 5 to.

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Example for a flexible usable trailer. Also there are often front walls for partition necessary. They should be divisible and must also resist a pressure of 5 to on the
whole size, not at one point.
Stanchions aside, four possibilities to build a front wall for partition, here are also lashing points.

Attention! Take care of a good condition! The wood must not be rotten, there must not be heavy damage.

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Example of a good truck for combined loading.
The roof and the side curtain can be opened front or back.
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Many fixing points are on the whole truck.
Here is no form closure! There are no anti-slip-mats used. This Even on extendable trailers a front wall partition is necessary
Rectangular wood helps the cargo secure. is very dangerous and forbidden! and possible. So short bars can be combined and safely
Loading straps in a good condition. transported with extra long bars.

12 13
 Î
This front wall is taken by loading chains.
So no form closure is possible. Very bad!

3.3. Side Walls 3.4. Calculation of stanchions or head walls

Side walls are the external border of the loading area. They prevent light products from falling down, but they are not Weight cargo ( in ton) which you can load against the headboard or per stanchion
usable for our heavy steel products.
They should close the loading area completely and be 500 - 800 mm high. Some products can be loaded without if forces are in the front direction if forces are in the side direction
them, but they are still useful in the front area.
strength without anti-slip with anti-slip mat strength without anti-slip with anti-slip mat
The best are produced in aluminium, the hinged stanchions in steel. The side walls must have hinged steps on front,
head-board mat between between every stanchion (in mat between between every
middle and on the backside. The hinged steps must have ergonomic supporting straps in its whole length. Both must
or stanchion every «unit-load» «unit-load» - ton) every "unit-load" "unit-load" -
be very solid.
(in ton) and floor-»unit- µd = 0,6 and floor-"unit- µd = 0,6
An efficient load security can be obtained by stanchions from steel tubes. They must have such a high number, that
load» - µd = 0,2 load" - µd = 0,2
they fix the load safely, and that enough slings can be fixed on the load.
Especially for bended rebars, we need enough stanchions to prevent the loading from falling of the truck. Those 1 1,7 5,0 1 3,3 unlimited
stanchions resist normally 1 ton, a certificate is mandatory! 2 3,3 10,0 2 6,7 unlimited
Many products, esp. bended rebars need form closure to the side. If there are no stanchions to the side, a loop 3 5,0 15,0 3 10,0 unlimited
lashing is necessary! 4 6,7 20,0 4 13,3 unlimited
5 8,3 25,0 5 16,7 unlimited
6 10,0 30,0 6 20,0 unlimited
7 11,7 not applicable 7 23,3 unlimited
8 13,3 not applicable 8 26,7 unlimited
9 15,0 not applicable 9 30,0 unlimited
10 16,7 not applicable 10 33,3 unlimited
11 18,3 not applicable
12 20,0 not applicable
13 21,7 not applicable
14 23,3 not applicable
15 25,0 not applicable

Those packages of bended rebars are not secured enough by one lashing strap. If it breaks, the side walls must take the whole
force. If the loading is once moving, the side walls can keep only very light loadings from falling!

14 15
3.5. Lashing Points
At the lashing points the lashing straps and lashing chains are fixed. They must be fixed over the whole loading area.
On both sides the lashing points must be fixed. They must be proved on a 2 ton force when using lashing straps and 4
ton when using lashing chains and be able to take the normal used hooks of chains and straps.
Number of lashing points: You can never have enough! But the minimum is one per meter on both sides.
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There are never enough attachment points on a truck for mixed loadings. Here, you can also put stanchions all over the loading
area.

3.6. Stocking of the equipment for loading security.

For the stocking of lashing straps, edge protectors and wood we need the right possibilities.
The best is a lockable box fixed on the truck and a box for the necessary wood to be fixed.
The equipment for loading safety must not lie unfixed on the loading area!

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Example of a correctly fixed attachment point.
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Examples of very bad «attachment points»

Depending on the loading products, there must be enough lashing points on the loading area. Best, they are lashing
trails, so there are lashing points on the whole widths of the truck. The lashing trails are fixed crosswise to the driving
direction. They must resist the complete force by lashing and fit to the normal lashing straps. The distance should be
each 1m, or at a minimum, lashing points each meter and lashing trails each 2 m.
Depending on the products, there are stanchions or front walls for partition necessary. They should be departed
regular, at a loading area of 13,6 m they are fixed at 3,4, 6,8 and 10,2 m, in the width at both sides and on 1/3 of
the width. They must resist 5 ton in total to front direction. This box for lashing strips is very good, but some of the lashing strips are to be discarded!
The stanchions are put in embed trails.

In these trails the stanchions and lashing strips can be fixed. The front walls for partition can be fixed on the stanchions, like
here, or must be build in a hinged way.

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 Contact area of plate

Anti-slip
-material
4. Technical equipment of loading aids wooden-
beam
Aids for load safety must be suitable for their purpose. Certificates for these products must be present.

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They must not be used higher than the normal load limit. Each manipulation or miss usage is strictly forbidden!

4.1. Anti-slip-mats

Anti-slip-mats greatly increase the friction between wood and steel, they must be laid between every layer. Each For separate loaded sheets and plates.
loaded - layer must be completely divided by anti-slip-mats, but it should not be laid on the whole loading area (no Even if the sheets touch each other, the friction is enough, if minimum 3 pieces of anti slip mats (100 x 100 x
carpeting). In the steel distribution strips are useful. 8 mm, friction min. 0,6) are laid crosswise to the driving direction, minimum each meter (Dr. Werner Schmidt,
So, the number of the necessary lashing strips can be reduced enormous. Verladeempfehlung für Bleche, Dresden 2011). So, our strips are good, but minimum laid in less than one meter
The gliding friction point can be increased a lot by anti-slip-mats, depending on the producers description, it can be apart.
seen as μ= 0,6. Using a gliding friction point higher than μ= 0,6 is not advisable.
Here exist different kinds and models, most fulfil the physical numbers.

4.2. Loading wood

Between the steel layers squared timbers are used, to give a better possibility for unloading.
On sharp edged products (beams, bars) hardwood is necessary, everywhere else soft wood is allowed.
Also woods are used to fix the loadings or to secure it from tipping.

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Only rectangle wood, which lies on both ends on the ground, is allowed. Square woods can tip or roll. Round wood is
forbidden.
Anti friction mats The wood must not be brittle, strongly round edged, cracked, split otherwise.
are used as strips ©foto: Dolezych

Good practice: Anti friction mats are nailed on wooden beams Loading wood must be stocked clean, to give a good grip.
P Short U-beams are practical to transport big round bars.
Attention! Use anti-slip-mats!

18 19
 4.4.2. Lashing chains

Lashing chains can secure heavy loads on trucks. It is a connection pieces:

steel lashing tool, bended on a lashing point on trucks. It -buckles, splits
is built by chain, a spindle lasher and a connection piece -strong signs of consumption or rust
4.3. Pallets (hook, shackle). -no labels on the chains
-expanding of the hook
To load short lengths or to produce a form closure, wooden pallets or steel pallets are used. Lashing chains must be discarded when:
Wooden pallets can be made of soft wood, but must have enough solidity. round steel chains: If it is necessary to discard the chain, the lashing tool
The wood must not be split or damaged. -surface splits must be suspended immediately, cut into pieces and
Steel pallets must not be too much rusted or deformed. If they are to much deformed, they can loose there solidity. -steching of more than 3% or consumption of 10% disposed of. Lashing tools, which are not cut, are often
-viewable buckles reused by «cost-savers»!

4.4. Strip aids

4.4.1. Strap steel-cables

Strap steel cables can be used, together with cable winches and lashing points.
The cable winches are often fixed on the trucks.

Strap steel cables must be discarded when:

- excessive signs of wear with abrasion of more than 10%

of rope diameter
- damaging of a wire rope clamp or a aplice
- squeezing, where the rope is flat for more than 15%
- large amounts rust
- buckles and torsions
-a lot wire breaks.

Examples of broken or damaged chains

4.4.3. Lashing Straps

A lashing strap is a tool for cargo security, which can be If it is necessary to discard the strap, the lashing straps
fixed with a lashing point, to secure the load on street must be trashed immediately. Cut them before disposing
vehicles. A lashing strap is made of a belt, a tensioning of them! Lashing straps, which are not destroyed, will be
element (ratchet) and fasteners (hooks). collected from the waste and reused by extreme-savers!

They must be discarded if:

-cuts of more than 10% of diameter
-damages of the main seam
-missing or damaged label
Examples of broken or damaged steel cables -deformation by heat
-damages by aggressive chemicals
-deformation of the hook more than 5%
-breakings, cuttings or bad rust of ratchets or fasteners

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 Î Î

©foto: Dolezych
©foto: Dolezych
These lashing straps must be discarded immediately. Don´t leave those strips on the vehicles! Cut and dispose of them! The hooks at the end of lashing straps can be built in different ways. Here is an open and a closed one shown, depending of the
fixing job, both are very useful.

4.5. Edge Protectors

When lashing sharp edged loads, the lashing straps are often cut. To prevent this, edge protectors are often used. They
are either:
-strong plastic covers round the lashing strips
-plastic angles, which are put under the lashing strips at the sharp edges.

Those edge protectors must not be made by anti-slipping materials (anti-slip-mats, old gloves etc.), because the power

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of the strip must be turned around as equal as possible. Anti slip materials reduce the lashing power immensely!
Short edged sheets are forbidden. They get lost on the street and expose people to danger! Edge protectors must have
a buckle on both sides of the lashing strap.

This lashing strap is in danger of being destroyed by the sharp edge of the wood. This lashing strip is completely worn out.
It can be destroyed by using.

©foto: Dolezych
Example of a flexible hose as edge protector

©foto: Dolezych

This is a new lashing strap.

P These labels are mandatory like a registration plate on a car. This edge protector is very good.
Attention: Where is the label? The lashing strip is turned, so it looses a
lot of its power!

22 23
 ©foto: Dr. Werner Schmidt
Example of a very good edge protector
PÎ This is just a bend sheet, not a good edge Protector. The
vibration could easily make the sheet slip out and injure people.
Very dangerous!

4.6. Tarpaulins 4.8. Danger Signs

Tarpaulins are often put on the load to protect them. In the steel business they are only allowed to protect from rain and These are danger signs or flashing alarm lamps.
dust, they are not cargo securing tool! Every load, which is over the edges of the loading area, must be protected by danger signs, or when it is dark, with
lamps.
4.7. Shrink Films
Small parts (cut beams, Tip burned plates) are often sent on pallets and are secured by shrink films.

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They must be used as instructed by the manufacturer.
If it is done correctly, the pallet is one product, which is fixed on the vehicle.

Shrink films can secure pockets,

or cut beams on pallets.

24 25
5. Preparation, Packaging of the Material
Material, which is unstable in itself, must be packed to be one package / bundle.

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This action is carried out in the preparation area, before the loading. Material, which is delivered packed by the
supplier, must be checked by the sending company for the quality of the packaging, if necessary, it must be repacked
before sending.
Eventually, sensitive material must be protected by the packaging from weather damage or mechanical damage.
In those countries, where European Guidelines are transferred into law and where the packages are not stripped
according to a mill standard, we recommend to calculate the cargo securing lashing with a friction coefficient of 0.2. For small bundles strong adhesive tapes are well usable. Beam bundles must be bended well also.

Regarding to the European Guidelines for cargo securing, to be considered a «homogeneous loading unit» or «unity
load», the package must resist a lift up to 26 degrees, without any parts moving in the bundle. From spring 2011
mandatory only in Belgium. The packages must resist movements in all directions.

Examples of a lifted package to 26 degrees, long and flat products

5.1. Packaging of long material

Long material (beams, bars, tubes) can be loaded separately or in bundles.
Single beams normally have no packaging, except against rust.

Bundles, which are not well packed, are single beams. There must be anti-slip-mats put between each single beam! Or,
each beam must be calculated as a single unit.
Well packed beams are one unit load devise. But the bundles must be well packed, to prevent of losing single beams.
A single bend (steel or plastic) never fits. Two bends are the minimum, bigger packages need several bends more.
The packaging materials must have enough lashing power, to fix the bundles. The weak points are often the fasteners
and the binding points of the wires.

This are typical bundles of long products. Do the beams in the middle of the
bundle resist? Probably, they slip off, then other means are to be done, like
form closure.

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 5.2. Packaging of sheets and plates
Quarto plates and wide plates are often unpacked, even as single plates. Both galvanized and normal sheets often have
a paper or metal packaging and at minimum edge protection.
Even here: packages, which are not banded, are single loading units where anti-slip-mats must be put in between!

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Banded packages are a unit load devise. The packages must be banded longitudinal and crosswise in a strong way.
Single sheets can work like an axe or a big knife! They must be banded in every direction, to prevent even the smallest
movement, minimum two bands in each direction on all packages bigger than 400 mm.

To unload packages in a safe way, wooden square beams are directly banded in the packages. In case of stacking, the
Paper under the steel strip can prevent any surface damage. Each wire on the bundle must be twisted several times.
Attention! It may decrease the stability of the bundle, esp. when
wood must have the same distance, to prevent transport or stocking damages.
wet. If they are only moved by magnets, the wood can be left.

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Another problem are stitching wires, which can injure people, and make an easy loading / unloading more complicate.
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5.3. Packaging of small pieces
These are first class sheet packages!

Wires and straps, which are to long, must be removed.

Sawed beams or Tipp burned plates are often so small, that they cannot be secured well in it single parts. In spite of
Products with a sensitive surface must be placed in a wooden box, to prevent damages. This must have a form closure;
their small size, they can be very dangerous.
even here a slipping inside the box can cause bad damage!
Large quantities of these parts must be put in a metal box. It must be higher than the material.
Small quantities must be secured on a pallet with bandings or a shrink film, so they cannot slip of the pallet.
The pallet must be stable, so it can fix the weight of the loading even in extreme driving situations. Broken pallets must
be changed! Big sawed beams or tip burned plates can be secured as normal beams or plates.

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Cutted steel parts can be fixed on pallets with steel strips.
Attention! Each part must be fixed in each direction unmovable
Cutted steel parts or small parts can be packed in a wooden or
steel box. The parts must not move inside the box so the box
with the pallet! could be destroyed.

28 29
5.4. Packaging of bended rebars
Rebars are often delivered in small bended pieces, even in big numbers. They must be fixed in a bundle, so they cannot
fall of the crane or the truck.
This can be done by wires, cables, boxes or big packs.
Beside the safety, economics must be taken into account.

With this rest of wire mesh, the bended rebars are safe in 2
directions, but not in 4!
If a plastic sheet is binded into the wire mesh,
This paperboard is a small help, but this
one wire is not enough.
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Those bent rebars are fixed in themselves. So, it is treated as a
unit, if it is banded to one package.
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Here, the packaging wires got loose.Very dangerous!
If the paper gets wet
It can be fixed in all directions. It has no function.

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©foto: Dr. Werner Schmidt

©foto: Dr. Werner Schmidt

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Bundles must be bended in a proper and tight way. The fixing wire must not be used for lifting!
Here, the fixing wires must be increased the tension.
The minimum are two wires for each bundle. Shorter beams must be bended with two wires into a bigger package.
Longer or bigger packages need more wires, they must be divided all over the complete length.
The lifting of the packages must be done with cables or chains, which normally stay on the bundles for unloading. Only
Small bended rebars can be packed very well Here, the packaging wires got loose. in extraordinary situations, wires of minimum 5 mm can be used for lifting, but they must be separate. Never hook at
in big packs. Very dangerous! the binding wires!

30 31
6. Loading plan 7. Fixing of the Load
Before starting the load, the responsible for loading should consider the points below. If all conditions for load security are in place, load security must be done!
First think, second act. Depending on the loading plan and the tour, the load can be loaded on the truck.

Every truck needs a load distribution plan. Here it is to be decided, where which tonnage can be put on the truck.
This is made either by the truck manufacturer or the truck owner.
7.1. Form closure
Here are mandatory requirements:
The load must not start to move on the loading area. So, it must have a real form closure on fixed points in all directions.
-maximum and minimum load on the front axe.
Loading gaps, even only a few centimetres, are unacceptable!
-maximum and minimum load on the rear axe.
In some countries, regarding European Guidelines, 8 cm are tolerable.
-maximum total load
-safe manoeuvrability of the truck.
7.1.1. Form closure to front
A loading plan gives a plan for the individual loading.
The load must lie directly at the front wall. There must not be gaps between the front wall and the load.
Here are mandatory requirements:
Load, which is towards the rear, must lie against at the front load or a separate wall.
-weight of each package
The front wall and the separate walls must resist a pressure of 5 tons! But not each stanchion, Stanchions on new trucks
-form of each package
normally resist between 1 and 1,2 tons.
-height of the centre of mass
The load must not be higher than the front wall, minimum the load must be secure with enough space to the front wall.
-sensitivity of the material
If pallets are loaded high, be aware of tip force!
-possibility of loading security
-order of unloading
-method of unloading by the customer

The loading must be planned to:

- make an economic tour
- beware of damaging the material
- make a loading security possible
- prevent the vehicle being overloaded.

The loading plan is made best by an experienced driver and the loading team together.
The final responsibility for the loading plan remains with the carrier: He is to «veto» an inappropriate loading or stowing.

Î
A loading plan is seldom written down or recorded.

The plates lie at the stanchions. The lower packets have form closure with
The Inox - tubes lie at the front wall. each other. Good!
The tubes and the merchant bars have no The upper package has only a form closure
form closure. Change it! in a part to the wooden bar. Is the package
a single unit?

32 33
Î Î P P

©foto: Stute
The separate wall gives a form closure for the shorter bars, the Lying coils need a form closure too, or a front –end lashing.
longer bars have form closure to the front wall. Good solution. One belt is never enough. Those three are good. Don´t forget
The plates and tubes have no form for a Those single stanchions are not enough for a form closure.
The round bars lie in the U-beams, to prevent them from the edge protectors!
form closure. Change it! Here a complete wall is necessary!
rolling. Anti slip mats are used. Don´t forget the lashing strips!

P
Preparation of a coil well: Stanchions for form closure to front.
Anti slip mats under the coil
P
Slit Coils are fixed at the stanchions with strips to avoid them
tipping. Attention! Those strips must be fixed before the
P
If lying coils are in a package and cannot move to front or back,
One strap per coil is tolerable.
P
This is a professional front wall.
It can be removed easily,
C-hook of the crane is removed! The last coil needs 2 straps as a minimum. It can be put into each fixing trail,
It fixes thin and oily material too.

P P
Standing coils in a coil well. Form closure to front by stanchions. Form closure to the side is partially done by the coil well,
additional with the lower chains. Te V-rigging to front and back keeps them on place, even at emergency situations. Keep the
P
This rectangle wood produces a form closure to the front,
that’s, why it is positioned upright.
V-rigging near the coil eye, to prevent the whole chain-system from moving.

34 35
P P
Form closure to front can be built with a wall by stanchions (left) or directly to the front wall (right).
On the right picture you can see a rectangular wood, lying on the ground. This cannot tilt over.
Î
These bent rebars must be laid at the front wall or at the
front packet.
Î
Here is no form closure. The straight rebars can be catapulted
to the front like spears!

Î P

©foto: Dr. Werner Schmidt

©foto: Dr. Werner Schmidt

Left photo: This is not real form closure with the lower tubes. The upper tubes are already higher than the front wall! After re-
P
Good example for a form closure to front.
P
Mixed loading of rebars and wire mesh
A form closure to front is absolutely mandatory!
loading, the whole load could be fixed on the truck, with 3 pallets the height of the front wall was increased. Take care of the
maximum force to the pallets! Are the pallets strong enough? Under the pallet (2. layer) anti slip mats are
placed.

Î P
On the left picture is no form closure to front, on the right it was done with a wooden pallet. The load must be put even on the
whole platform; the rear load must press in its completeness to the pallet.
P
Here is no form closure. The bended packages must lay
directly at each other!
P
Especially those mixed loadings need a deep attention to the
form closure of each position!

36 37
7.1.2. Form closure to rear

When accelerating the vehicle or breaking down by a non elastic push, the load can get forces to the rear. This power must
be absorbed too. This does not work with a wall mostly, but with anti-slip-mats and lashing. Because the anti-slip-mats
Î
The sheets just lie on each other. No form closure to front or
side.At an evasive manoeuvre, the sharp edged sheets can cut
Î
Form closure to the front is done. Form closure to the side is
only at the side stanchions. The plates can slip.
increase the friction, a normal lashing is normally enough.
the lashing straps! The load must not start to move! The loading gap must be filled.

7.1.3. Form Closure to side

The load must not slip to the side. The best absorbing is with a form closure to the side.
Often, the side wall is not stable enough, here are rackets a good solution. The load must touch them directly, or, because
it mostly doesn’t fit to both sides, the gaps must be fitted with wood.
Only lashing, with the stanchions as «emergency breaks» after some distance is not enough!

Î
Form closure doesn’t exist. Neither to front nor to the side or
rear. No anti-slip-mats. No possibility for lashing on the loading
Î
If the filling of gaps is not possible, intermediate wood must be
put in place and a lashing on fixing trails is mandatory.
area. Very bad!

Form closure to the side stanchions is good. Form closure with stanchions is a good solution.
Loading gaps must be filled with wood. Loading gaps must be filled with wood.
The lashing straps cannot work, when they don’t touch the The right bundle is banded with lashing strips.
load! The left bundle is not banded. Here, each
beam is one single loading package!

P P
Form closure to one side allows to press the load with straps towards the stanchion, the straps hold them in the other direction.
So, straps can be crossed over another, lower bundle. The bundles in the middle must be banded separately!

38 39
 P
Big round bars need special load safety. They can roll to the side.
Change the round surface with a special wood or a U - beam to a higher friction to the ground, allowing a safe fixing to the side
P
The load must never be higher than the stanchions! Fixing points for stanchions to bring a form closure are all over the truck.
Lashing points are all over the truck. So the small packages of bended rebars can be fixed, and high stacks of wire mesh also.
with loop lashings, no top lashing!

Only a single wood is not enough, the load must be secured versa rotation either, it must be fixed on several points on
the whole length.

P
P
Form closure to one side allows to press the load with straps towards the stanchion, the straps hold them in the other direction.
So, straps can be crossed over another, lower bundle. The bundles in the middle must be banded separately!
Damageable goods must be put in a wooden box.

Form closure to the stanchions at the side is good.

If a form closure to both sides is difficult, the load can
be bended at the stanchion to the side. Take care of the
maximum capacity of the strips!
©foto: Dr. Werner Schmidt

©foto: Dr. Werner Schmidt

P
Wire mesh cannot be calculated at best. To the side, either stanchions or a loop lashing is necessary.
The wire mesh is separately fixed, the banded wire mesh again separately.
P
Form closure to the side can be produced by a loop lashing to a stanchion.
The stanchion fixes the load to one side, the strap to the other!

40 41
7.2. Anti-slip-mats
Between each horizontal layer, which are not banded together (bundles & packages), anti-slip-mats must be 7.3. Filling with wood
implemented.
This can be between load floor and steel, between loading floor and wood, between wood and steel, between two Often form closure cannot be made directly, because the load and the form of the truck do not fit perfectly. Form
wooden beams or between two layers of steel. closure can be made packing out with wood. But this must be done professional. Pay attention to the direction of the
One layer without anti-slip-mats makes the other anti-slip-mats useless! wood structure!

7.3.1. Filling up to the front

Often, the load must have distance to the front wall, to prevent one axe from overloading. This gap must be filled
with wood. Here are no «Alibi-walls» allowed, but professional building components must be built. The new front wall
must resist 5 tons, like the original!
The height of the front wall must be as high as the load bundle.

P
The front wall must be stable versa tipping.

©foto: Dr. Werner Schmidt

7.3.2. Filling up to the side

To the side we often need a form closure too. If this cannot be done to the stanchions directly, the gaps must be filled
with wood. Here, too, are no «Alibi-buildings» allowed, only good conditioned, fixed building components are allowed.

7.3.3. Filling up of different heights

Anti-slip-mats must be put between each layer. If single plates or beams are not bundled, each plate is one load
Each bundle must be secured against slipping. unit.
Mixed loads for different customers must often be loaded in different layers. The different products and different
Does the bundle in the middle have form closure? An anti slip mat in between is mandatory!
Prove it! The loose wooden beams in the rear must be fixed.
lots have different heights. They must be supported with wooden building components, to bring each bundle a form
The loose wooden beams in the rear must be fixed. closure. wThis can be done by single woods or wooden pallets.
But here too, no «Fantasy-towers» are allowed, only professional building components.
©foto: Dr. Werner Schmidt

©foto: Dr. Werner Schmidt

P
Under rebars and wire mesh, anti slip mats are mandatory too.
Put stanchions under the steel load, and anti slip mats on both sides.
P
This is professionally build! Behind the fixed hollow sections is a small sheet-package, behind it a stack of pallets. A form closure
to the side is here impossible. Take care of anti-slip-mats and enough lashing strips. Better one strip too much! A loop lashing
The anti slip mats must have the width of the wooden beams as a minimum. would be the best alternative.

42 43
7.4. Lashing
Lashing is fixing of the load with lashing straps, lashing cables or lashing chains.
Top lashing is not the main load security, but an addition to the form closure before.
To fix the load only with lashing straps, the steel packet must be covered nearly completely with lashing straps. This is
never a good solution.
Top lashing additional to a front-end and a rear-end lashing can be a good solution.
Î
With this angle, the lashing strap has no force!
The fixing trail exists, so use it!
Î
The bundles in the middle have no contact with the lashing
strap. Place the bundles in a different way, make sure, there is
Use anti-slip-mats! contact from the lashing strap to all bundles, or secure
Each lashing must be controlled after 10 – 15 km, because the vibration force might loose it. each bundle separately.

Î
The small bundle bright steel has no form closure to
the left side and no force of the lashing strip.
P
Standing coils must stand in a coil well.
Lashing through the coil-eye to all sides!
Î
These lashing straps make no sense.
Fix them on fixing trails or load completely different. slip-mats!
Î
The upper plates are banded in an extreme flat angle. Use anti-

Insufficient! Additional lashing over the top is mandatory too. Can you give the plates a form closure to side? Can you bundle
Attention! Unloading of these slitted coils is problematic. They the plates?
hang at the tip of the C-hook. Better: Load each package
against separate stanchions

When over the top lashing, the lashing straps are put over the load, which are fixed on the loading floor. These
lashing straps must be angled as steep as possible, to give a high pressure. The more flat the lashing angle, the less
the lashing force!
So, the load must be put as close to the lashing points as possible, or there must be many lashing points all over the
Î
Those bent rebars can slip between the stanchions. One lashing
strap is no lashing strap. Here are much more lashing straps
Î
The merchant bars in the middle have no contact to the lashing
strips.Bind in between on the fixing trails.
loading floor. necessary.
A rough rule of the thumb: With a perfect angle, form closure to front and anti slip mats, minimum 1 strap per two Bend the rebars to a packet, which is easier to secure.
tonnes load is necessary, for clear and simple loads!

44 45
Î
The rebar spreaders are well lashed.
The bent rebars are not lashed enough with two strips. The
Î
The wire mesh must be lashed separate first. The flap
stanchions keeps only very few. The red stanchion is good.
7.5. Front end lashing - Horizontal securing
The embracing is a special kind of direct lashing. Often, single rebars or small bundles are transported, which must lie
directly at the side stanchions. Form closure to side can be done with lashing the load directly at these stanchions or a
loop lashing. Here, the lashing strips are turned around the load and bended at both ends around the stanchion and the
form closure is not enough! The rear rebars need a separate Here are more of them necessary!
lashing point.
wall. The bended wire mesh need a second strip too.
In one direction, the load is fixed by form closure, in the other by the strips. Attention! Take care of the maximum force.

The end of lashings must be fixed, as it is done here in a good

practice. They are never allowed to be a reason to stumble.
P
With two loops a slip to the front is prevented. The loops are at
the front side crosswise.
Those loops replace the form closure to front. Take care of the
extension force!
Take care of the certification of the attaching points; some are
only tested to an angle higher than 30 degrees.

©foto: Dr. Werner Schmidt

all front + anti slip mats are mandatory!
P
Those panels are very sensitive. If you give a very high force to the lashing, the panels are damaged. So, a perfect form closure to Example of a complete lashing.
Top lashing is RED.
Front end lashing of wire mesh is another solution.
It needs special equipment, but it is very effective.
Attention! Those high loads may tip over to the side. The form closure to both sides is necessary. Front end lashing is BLUE & GREEN.
Rear lashing is BLACK & GREY

46 47
8. Loading Control
Even with reliable employees, a control system is necessary.
First, all employees must know the regulations. They must be trained intensively, only when they have all the
knowledge; they can perform a professional cargo security.
Train all employees, who are working in this field, regularly.
Give them beside the big external training, small internal training, eventually when you find mistakes or especially good
loads.

Document all training with the themes, trainer and trained people.
The results of the cargo security must be controlled by the responsible employee, these controls must be documented.
8.3. Control of Suppliers
Many people think, we have no responsibility for supplying trucks. This is wrong in some countries! For the journey to
Vehicles with bad cargo security must not leave the site. In very dangerous cases the police must be contacted.
the next stop to be unloaded, we must take care of the correct security of the remainder of the load.
We can only be protected from this responsibility by refusing the vehicle entrance to our site or by making the right
Make a protocol of the kind of vehicle, registration number, drivers name and the load, the best are photos.
cargo security.
File the protocol and photos minimum 6 months, best 2 years.
Control these trucks before entering the site to prevent trouble, and make a control document with photos.

Would you give the driver your driver´s license? If not, take care of a good cargo security and good documentation!
8.1. Control of own vehicles It is a good practice to control 10% of the trucks / vehicles, loading on the plant.
Own drivers can and must be trained regularly.
In spite of the training, mistakes in cargo security are frequent, even «steel-professionals» are often careless.
External drivers and their superiors must be informed about bad or missing cargo security. 8.4 Summary and conclusion
So, control is important, install a system in your site.
The applicable legislation for cargo securing is the legislation that is applicable to the region or country where the
transport geographically takes place. This means, a cross-border transport is subject to several legislations in succession.
8.2. Control of pick up vehicles While securing, it should be kept in mind, that therefore the most rigorous legislation, which shall be applicable, should
be respected.
Especially small companies, do not take care of load security. Explain the customer the situation, their driver´s license
and yours are to be lost. For this reason, the manual containing guidelines for the operational staff was drafted respecting the highest standards
Before loading, control all external vehicles the qualification for transporting the load, the traffic safety (is the truck able on a technical level, meaning in this case according to German legislation, and the "measures at hand" as understood in
to fulfil its task?) and the existence of the necessary cargo security aids in good condition and in the right number. the application of the German road code by German law enforcement.
If the aids are missing, you must refuse to load, or sell the driver the necessary equipment from your own stock.
Considering all this, it is important to take notice that the manual, for these reasons, mainly presents targets to be aimed
at in a timeframe still to be determined for each separate country. Thus the manual cannot create additional liability to
AM, above the applicable legislation, which of course is to be respected on all levels all of the time and everywhere.

48 49
 Annex
Loading security Calculation
 Example N#1
Forces d’accélération centrifuges et décélaration
1 package sheets, 2500 kg
Following tables are taken into account for calculation examples 1000 x 2000 mm size

Values for example 1 and 2 Necessary safety force to front:

Horizontal inertial force = 80% of the weight: 2000 kg
Chart «lashing»: dynamic friction coefficients
Form closure to front exists = 40% of the weight: 1000 kg
Initial Tension
per tension 0,1 0,2 0,25 0,3 0,4 0,5 0,6 Friction wood - metal = 20% of the weight: 500 kg
100 kg 20 40 50 60 80 100 120 4 lashing strips with nearly 90 degrees angle a 400 kg 640 kg
200 kg 40 80 100 120 160 200 240 Sum 2140 kg
300 kg 60 120 150 180 240 300 360 This pack without form closure:
400 kg 80 160 200 240 320 400 480 Friction with anti-slip-mat 60% of the weight: 1500 kg
500 kg 100 200 250 300 400 500 600 2 lashing strips with nearly 90 degrees angle a 400 kg 960 kg
600 kg 120 240 300 360 480 600 720 Sum 2460 kg
700 kg 140 280 350 420 560 700 840
800 kg 160 320 400 480 640 800 960
900 kg 180 360 450 540 720 900 1080 Necessary safety power to sides:
Horizontal inertial power = 50% of the weight: 1250 kg
Form closure to side exists = 30% of the weight 750 kg
Angle a results in driving direction ß results crosswise to driving direction
Friction wood - metal = 20% of the weight 500 kg
90 degrees 100% 100%
Sum 1250 kg
60 degrees 87% 100%
45 degrees 71% 100% Do you have a safe form closure to both sides? Alternative:
30 degrees 50% 80% Friction with anti-slip-mat 60% of the weight 1500 kg
15 degrees 26% 40% 2 lashing straps with nearly 90 degrees angle a 400 kg 960 kg
Sum 2460 kg

Necessary safety power to back:

Horizontal inertial power = 50 % of the weight: 1250 kg
Here is a form closure in practice impossible, so:
Friction with anti-slip-mat 60% of the weight 1500 kg
2 lashing straps with nearly 90 degree angle a 400 kg 960 kg
Sum 2460 kg

52 53
Example N#2

2 sheet packages on top of each other a 2800 kg = 5600 kg

1000 x 2000 mm

Necessary safety force to front: 80% 4480 kg

Form closure 40% 2240 kg
Friction wood to steel 20% 1120 kg
7 lashing straps with an angle of nearly 90 degrees a 400 kg 1120 kg
Sum 4480 kg

With an angle of 45 degrees = 71%: 10 lashing straps necessary 1136 kg

Sum 4496 kg

How do you bring 7 lashing straps on 2 m length?

With anti-slip-mats, without form closure:
Friction 60% 3360 kg
3 lashing straps a 400 kg 1440 kg
Sum 4800 kg

With an angle of 45 degrees = 71% 4 slashing straps 1363 kg

Sum 4723 kg

Necessary power to sides: 50% 2800kg

Necessary power to back: 50% 2800kg
Friction 20% 1120 kg
11 slashing straps a 400 kg 1760 kg
Sum 2880 kg

How will you get 11 straps on 2 m length?

With anti-slip-mats:
Fristion 60% 3360 kg
We need 2 Straps to fix and beware of vibration power.

Attention! This example is for flat packages, which cannot tipple.

Higher packages must be secured against tilting over.

54
ArcelorMittal
Distribution Solutions
Health, Safety and Environment
24-26, boulevard d’Avranches
L-1160 Luxembourg

with special thanks to

Ludwig Felser & Etienne Winters