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© International Road Transport Union (IRU) 2010 1 IRU Academy Safe Loading and Cargo Securing Programme The IRU Academy is currently developing a training programme on Safe Loading and Cargo Securing. This programme will be made available in multiple languages to IRU Academy ATIs. Please find below a summary of the latest development on the Cargo Securing Standards, including a comparison of the norms and best practices currently in place or in being implemented.

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Page 1: The IRU Academy is currently developing a training ......with IMO Model Course 3.18 Guidelines and Standards for Cargo Securing •Standard EN 12195-1 Load restraint assemblies on

© International Road Transport Union (IRU) 20101IRU Academy Safe Loading and Cargo Securing Programme

The IRU Academy is currently developing a training

programme on Safe Loading and Cargo Securing. This

programme will be made available in multiple languages to

IRU Academy ATIs.

Please find below a summary of the latest development on

the Cargo Securing Standards, including a comparison of the

norms and best practices currently in place or in being

implemented.

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© International Road Transport Union (IRU) 20102IRU Academy Safe Loading and Cargo Securing Programme

Safe Loading and Cargo

Securing

Status - November 2010

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 3

Unsecure cargo is a major risk

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.

Euro Contrôle Route (ECR) an association of 14 European countries for the inspection of road transport, notes that:

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 4

Source: Europol

Overloading is a key concern!

Unsecure cargo is a major cost

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 5

Comparison of Cargo Securing according to:

Cargo Securing

IMO/ILO/UN ECE(2001)

EN 12195-1(Dec 2003)

Rev prEN 12195-1 (Jan 2009)

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 6

Different

requirements in

guidelines and

standards

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 7

• IMO/ILO/UN ECE

Guidelines for packing of cargo transport units (CTU’s)with IMO Model Course 3.18

Guidelines and Standards for Cargo Securing

• 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

Cargo Securing

• European Best Practice Guidelines on Cargo Securing for

Road Transport

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 8

IMO/ILO/UN ECE2001

Rev prEN 12195-1Jan 2009

EN 12195-1Dec 2003

Cargo securing guidelines

Cargo Securing

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 9

Differences in the basic principles in the

guidelines and standards

Item IMO/ILO/UN ECE EN 12195-1 Rev prEN 12195-1

Acceleration coefficients

(road transport)

- Forward

- Sliding sideways

- Tipping sideways

+ Direct lashings

+ Frictional lashings

cx = 1.0

cy = 0.5

cy = 0.5 (FT=LC)

cy = 0.5 (FT=STF)

cx = 0.8

cy = 0.5

cy = 0.7 (FT=LC)

cy = 0.7 (FT=STF)

cx = 0.8

cy = 0.5

cy = 0.6 (FT=LC)

cy = 0.5 (FT=STF) or

cy = 0.6 (FT=LC/2)

Safety factor in

calculations of frictional

(top over) lashings

- Forward

- Sideways and backward

fs = 1.0

fs = 1.0

fs = 1.0

fs = 1.0

fs = 1.25

fs = 1.1

Cargo Securing

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 10

Differences in the basic principles in the

guidelines and standards

Item IMO/ILO/UN ECE EN 12195-1Rev prEN 12195-

1

Friction factor

established by friction

test

- Frictional lashings

- Direct lashings

Static friction µs

Dynamic friction

µd = µs fµ

Dynamic friction

µd = µs 0.70

Dynamic friction

µd = µs fµ

µ =µs 0.925

µ fµ

Conversion factor fµ for

direct lashings

fµ = 0,70 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

Cargo Securing

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

Differences in the basic principles in the

guidelines and standards

Item IMO/ILO/UN ECE EN 12195-1 Rev prEN 12195-1

Some differences in table

of friction factors, e.g:

- sawn wood against

fabric base

laminate/plywood

- sawn wood against steel

sheet

- steel crate against fabric

base laminate/plywood

µ = 0.50

µ = 0.40

Not included

µ = 0.50

µ = 0.40

Not included

µ = 0.45

µ = 0.30

µ = 0.45

Verification of the

efficiency of securing

arrangement by

Calculations

Static inclining test

Calculations Calculations

Static inclining test

Dynamic driving

test (road transport)

Lashing protocol Included Not included Included

Cargo Securing

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 12

Cargo securing

examples

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 13

Wooden boxes

L

B

H

Quantity = 8 pieces

H × B × L = 2 × 2 × 1.7 m

Weight = 3 000 kg/box

Total cargo weight: 24.0 tonnes

Length = 13.6 m

Height = 2.55 m

Breadth = 2.48 m

Web lashingsLC = 1 600 daN = 1.6 tonnes = 16 kN

STF = 400 daN = 0.4 tonnes = 4 kN

Friction between floor and cargo = static = 0.4

Required number of top over lashings to prevent sideways

sliding

Curtain sided trailer, aluminium floor

and strong headboard

Cargo Securing example 1

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 14

Required number of top over lashings to prevent sideways

sliding

Rev prEN 12195-1IMO/ILO/UN ECE

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

Answer

EN 12195-1

Td

zy

Fµk

gmµccn

sin

)(s

T

zyf

gmµccn

sin2

)(

n = 3.9

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

n = 1.02n = 0.9

Equation (10)Equation (6)EU Best Practice Guidelines -

Cargo Securing (p.108)

Cargo Securing example 1

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 15

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

Rev prEN 12195-1IMO/ILO/UN ECE

8 top over lashings(One lashing / section)

Required number of top over lashings to prevent sideways

sliding

• 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

Reasons for the difference:

EN 12195-1

32 top over lashings(Four lashings / section)

16 top over lashings(Two lashing / section)

Rev prEN 12195-1

Cargo Securing example 1

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 16

Web lashings

LC = 1 600 daN = 1.6 tonnes = 16 kN

STF = 400 daN = 0.4 tonnes = 4 kN

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

Length = 13.6 m

Height = 2.55 m

Breadth = 2.48 m

Steel crates

B

H

Side bottom

blocking

Blocking

Required number of top over lashings to prevent sideways

tipping

Curtain sided trailer with

strong headboard

Cargo Securing example 2

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 17

Rev prEN 12195-1IMO/ILO/UN ECE

Required number of top over lashings to prevent sideways tipping

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

EN 12195-1

n = 5.4/section

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

n = 0.9/sectionn = 0.9/section

Equation (16)Equation (11)EU Best Practice Guidelines -

Cargo Securing (p.108)

cos)2(sin)1(

)(

2

1

hkwk

wchcgmnF

zy

T))1(25.0(sin

)(

NFw

bcdcgmfn

T

zy

s

Cargo Securing example 2

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 18

Required number of top over lashings to prevent sideways tipping

IMO/ILO/UN ECE

11 top over lashings(One lashing / section)

• Acceleration factor cy = 0.5

• Lashing force FT = STF

• K-factor k = 2

• Safety factor fs = 1.0

• Internal friction considered

Reasons for the difference:

EN 12195-1

• Acceleration factor cy = 0.7

• Lashing force FT = STF

• K-factor k = 1.5

• Safety factor fs = 1.0

• No instructions for internal

friction

66 top over lashings(Six lashings / section)

11 top over lashings(One lashing / section)

Rev prEN 12195-1

• 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

Cargo Securing example 2

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 19

Paper reels

• 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 lashingsLC = 1 600 daN = 1.6 tonnes = 16 kN

STF = 400 daN = 0.4 tonnes = 4 kN

One layer

B1

H

1

Two layers

B2

H2

Required number of top over lashings to prevent sideways sliding and tipping

Curtain sided trailer with

strong headboard

Cargo Securing example 3

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 20

Required number of top over lashings to prevent sideways sliding

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

Rev prEN 12195-1IMO/ILO/UN ECE

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

EN 12195-1

Td

zy

Fµk

gmµccn

sin

)(

s

T

zyf

gmµccn

sin2

)(

n1 = 0.91/section

n2 = 1.82/sectionNo sliding

Equation (10)Equation (6)EU Best Practice Guidelines -

Cargo Securing (p.108)

n1 = 0.20/section

n2 = 0.39/section

Answer

Cargo Securing example 3

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 21

Required number of top over lashings to prevent sideways tipping - one layer

Rev prEN 12195-1IMO/ILO/UN ECE

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

EN 12195-1

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

Equation (16)Equation (11)EU Best Practice Guidelines -

Cargo Securing (p.108)

cos)2(sin)1(

)(

2

1

hkwk

wchcgmnF

zy

Ts

T

zyf

NFw

bcdcgmn

))1(25.0(sin

)(

No tipping No tipping No tipping

Answer

Cargo Securing example 3

© MariTerm i Höganäs AB

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Required number of top over lashings to prevent sideways tipping - two layers

Rev prEN 12195-1IMO/ILO/UN ECE

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

EN 12195-1

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

Equation (16)Equation (11)EU Best Practice Guidelines -

Cargo Securing (p.108)

cos)2(sin)1(

)(

2

1

hkwk

wchcgmnF

zy

T s

T

zyf

NFw

bcdcgmn

))1(25.0(sin

)(

n2 = 0.5/section n2 = 4.6/section n2 = 0.7/section

Answer

Cargo Securing example 3

© MariTerm i Höganäs AB

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 23

Required number of top over lashings to prevent sideways sliding and tipping

IMO/ILO/UN ECE

9 top over lashings(One lashing / 4 tonnes of cargo to

prevent tipping and wandering)

• 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

Reasons for the difference:

EN 12195-1

• Dynamic friction µd = 0.7s= 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

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)

Rev prEN 12195-1

• 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

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)

Cargo Securing example 3

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 24

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 mBreadth 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

H

L

h

l

b

B

H

L

h

l

b

B

Required number of top over lashings to prevent sideways sliding and tipping

Cargo Securing example 4

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 25

Rev prEN 12195-1IMO/ILO/UN ECE

Required number of top over lashings to prevent sideways sliding

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

EN 12195-1

Td

zy

Fµk

gmµccn

sin

)(s

T

zyf

gmµccn

sin2

)(

n = 2.7

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

Equation (10)Equation (6)EU Best Practice Guidelines -

Cargo Securing (p.108)

n = 0.6 n = 0.7

Answer

Cargo Securing example 4

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© International Road Transport Union (IRU) 2010IRU Academy Safe Loading and Cargo Securing Programme 26

Rev prEN 12195-1IMO/ILO/UN ECE

Required number of top over lashings to prevent sideways tipping

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

Answer

EN 12195-1

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

Equation (16)Equation (11) modified for

centre of gravity off centreEU Best Practice Guidelines -

Cargo Securing (p.108)

cos)2(sin)1(

)(

hkwk

bcdcgmnF

zy

T s

T

zyf

NFw

bcdcgmn

))1(25.0(sin

)(

n = 1.25 n = 30.0 n = 1.9

Cargo Securing example 4

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Required number of top over lashings to prevent sideways sliding and tipping

IMO/ILO/UN ECE

2 top over lashings

• Static friction s = 0.4

• Acceleration factor cy = 0.5

• Lashing force FT = STF

• K-factor k = 2

• Safety factor fs = 1.0

Reasons for the difference:

EN 12195-1

• 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

30 top over lashings2 top over lashings

Rev prEN 12195-1

• 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

Cargo Securing example 4

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Cargo weight in ton prevented from

sliding by one Top-Over lashingSideways Forward Backwards

IMO/ILO/ EN Rev prEN IMO/ILO/ EN Rev prEN IMO/ILO/ EN Rev prEN

µ UN ECE 12195-1 12195-1 UN ECE 12195-1 12195-1 UN ECE 12195-1 12195-1

0,05 0,09 0,04 0,08 0,04 0,02 0,04 0,09 0,04 0,08

0,10 0,20 0,09 0,18 0,09 0,04 0,09 0,20 0,09 0,18

0,15 0,34 0,15 0,31 0,14 0,07 0,15 0,34 0,15 0,31

0,20 0,53 0,23 0,48 0,20 0,09 0,21 0,53 0,23 0,48

0,25 0,80 0,31 0,73 0,27 0,12 0,29 0,80 0,31 0,73

0,30 1,20 0,42 1,09 0,34 0,15 0,38 1,20 0,42 1,09

0,35 1,87 0,56 1,70 0,43 0,19 0,50 1,87 0,56 1,70

0,40 3,20 0,74 2,91 0,53 0,23 0,64 3,20 0,74 2,91

0,45 7,20 0,99 6,55 0,65 0,27 0,82 7,20 0,99 6,55

0,50 0,80 0,31 1,07

0,55 0,98 0,36 1,41

0,60 No sliding 1,20 0,42 1,92 No sliding

0,65 1,49 0,48 2,77

0,70 1,87 0,56 4,48

0,75 2,40 0,64 9,60

Comparison between the different guidelines for road transport

Cargo Securing

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Number of Top-Over lashings to prevent slidingSideways Forward Backwards

IMO/ILO/ EN Rev prEN IMO/ILO/ EN Rev prEN IMO/ILO/ EN Rev prEN

µ UN ECE 12195-1 12195-1 UN ECE 12195-1 12195-1 UN ECE 12195-1 12195-1

0,05 100% 204% 110% 100% 200% 99% 100% 204% 110%

0,10 100% 212% 110% 100% 204% 97% 100% 212% 110%

0,15 100% 223% 110% 100% 208% 96% 100% 223% 110%

0,20 100% 237% 110% 100% 212% 94% 100% 237% 110%

0,25 100% 256% 110% 100% 217% 92% 100% 256% 110%

0,30 100% 286% 110% 100% 223% 89% 100% 286% 110%

0,35 100% 335% 110% 100% 229% 87% 100% 335% 110%

0,40 100% 434% 110% 100% 237% 83% 100% 434% 110%

0,45 100% 730% 110% 100% 246% 80% 100% 730% 110%

0,50 100% 256% 75%

0,55 100% 270% 69%

0,60 No sliding 100% 286% 63% No sliding

0,65 100% 307% 54%

0,70 100% 335% 42%

0,75 100% 375% 25%

Comparison between the different guidelines for road transport

Cargo Securing

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SAFE ENOUGH!

IMO/ILO/UN

ECE

(2001)

EN 12195-1

(Dec 2003)

Rev prEN 12195-1

(Jan 2009)

Cargo Securing

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IRU Academy Checklist on Safe

Loading and Cargo Securing

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IRU Academy Interactive Programme

on Safe Loading and Cargo Securing

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© International Road Transport Union (IRU) 201033IRU Academy Safe Loading and Cargo Securing Programme

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