Kasgro-BNSF Flat Car Project

Client Name: Kasgro-BNSF
Project Type:
Project Location: Southlake, TX and New Castle, PA
Completion Date: 12/31/2008

TTS was contracted to design a 60’-0” flat car to be used for a rail train that hauls 1600’ 140 lbs rail. All AAR rules and structural load cases had to be met, and the design of the flat car also had to meet the customer’s specifications. The specs included the application of three different fixtures for shipping 1600’ rails on the cars. TTS also needed to incorporate and update the rail detection system that was used on the tunnel cars at both ends of the train. The car body and trucks were designed for a gross rail load of 286,000 lbs and a minimum AAR M-1001, and to meet all required load cases. A plate element finite element analysis was created using Algor software to evaluate the car body under the combined lateral, longitudinal and vertical cases. The project was completed successfully, and the train is still in operation today.

The Solution

The car body and trucks were designed for a gross rail load of 286,000 lbs and a minimum AAR M-1001, and to meet all required load cases. A plate element finite element analysis was created using Algor software to evaluate the car body under the combined lateral, longitudinal and vertical cases. The model included all structural components of the car and was evaluated using a non-linear, large deflection static analysis formulation. The rail train consisted of three specific car types that utilized the same flat car structure. The tie down car was at the center of the train that secured the 1600 foot rail. TTS worked in conjunction with the customer on the air system and hydraulic system that was applied to the tie down car.  The roller cars supported the rail throughout the rest of the train. The third car was the tunnel car and these were at both ends of the train. The tunnel car incorporated a rail detection system and unloading rollers, and TTS also worked closely with the customer to apply all the components to the flat car.

The Challenge

The challenge on this project was to design a 60’ flat car to be used as a rail train, meeting all AAR rules and structural load cases put forth by the AAR. The design of the flat car also had to meet the customer’s specifications. The specs included the application of three different fixtures for shipping 1600’ rails on the cars. The car needed to be designed to haul 1600’ long 140 pound rail.  TTS also needed to incorporate and update the rail detection system that was used on the tunnel cars at both ends of the train.

The Results

TTS successfully designed a 60’ flat car that could handle the AAR load cases and meet the customer’s requirements and application of the rail stands for all three cars used on the rail train.