DATA SHEET GENERAL WORK PERFORMED. D3g CAR SHOP AND REPAIR YARD DESIGN: HEAVY FREIGHT CAR REPAIRS October 1999 July 1968 (D3j.03)

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1 GENERAL DATA SHEET Heavy freight car repairs are defined by the AAR as any work on acar requiring more than 100 man-hours to complete. This generally includes repair or rebuilding of cars damaged in wrecks, derailments or accidents, as well as necessary work on bad order cars to upgrade or restore them to service for an additional period. As indicated above, repairs to damaged cars constitute aprimary and important function of any car shop. However, there are two other major types of work performed: (1) programmed repairs, and (2) new car construction. Programmed repairs are those normally performed on afixed cycle basis, wherein all cars of agiven class or series are given heavy repairs at fixed intervals, say five to eight years. Under such aprogram all cars of aspecified series are cycled through, torn apart and completely rebuilt, overhauling all components, replacing defective and worn parts, relining interiors, updating equipment, and repainting and restenciling. Sheet #: Title: Reformated: First Issued: Originally Compiled by: References: D3g CAR SHOP AND October 1999 July 1968 (D3j.03) Robert J. Jefferys Car Builders' Cyclopedia 20th Edition st Edition Simmons-Boardman Publishing Corp. Page: 1of 7 Heavy freight car repair facilities will be adaptable primarily to model railroads of larger size which are able to devote the necessary "land" area for such an activity.they may also be considered for incorporation in layouts devoted primarily to depicting aterminal or yard area of amajor railroad. In the latter instance, such afacility could provide considerable activity by requiring the switching of cars in and out. This would include not only the cars requiring repairs, but also the many carloads of incidental materials and supplies, particularly if amajor car building program is to be represented. Flow diagram below shows processes planned for cars WORK PERFORMED and trucks undergoing repairs. Indicated are the areas on both sides of the production lines which were to be tooled and permanently devoted to specialized building and rebuilding operations. New car construction is frequently undertaken by many railroads either to fill a deficiency of cars of aparticular type, or to keep the shop force and facilities busy during slack periods. Whole series of cars are frequently built in company shops utilizing parts and subassemblies purchased from the outside or fabricated in the railroad's own shops. Figure 1: FLOW DIAGRAM

2 LOCATION DATA SHEET Sheet #: Title: Page: D3g CAR SHOP AND 2of 7 Aheavy repair shop preferably is located near the geographical center of the railroad or area it is to serve, and preferably near aclassification yard to minimize any back haul or extra movement of cars. Arather considerable amount of track space should be made available on which to accumulate and classify the bad order cars to assure steady shop operation and permit proper inspection of the cars prior to their delivery to the shop. Most railroads consolidate these operations at one or two points on their systems. Where possible (even on smaller railroads) the facilities should be arranged for repair operations on but one class of car. This permits concentration of materials as well as the installation of subassembly lines for asmoother, faster work flow. If an entire car shop cannot be assigned to one particular car type, it is frequently possible to arrange for repairs to but one class at atime and to perform any miscellaneous heavy repair work at other shops in other locations. OPERATION The flow diagram (Figure 1) illustrates the basic operations performed in aheavy freight car repair facility. The exact sequence of operations, even the operations themselves, may and do vary from shop to shop and railroad to railroad. ATYPICAL REPAIR FACILITY Atypical, modern, freight car repair shop plan is shown in Figure 2. The shop has over 187,000 square feet under roof, and there are some 20,000 feet of trackage involved. The facility has all the space and equipment necessary for the fabrication of new cars. This shop has apair of through tracks which serve as production lines. The building is asteel framed, aluminum sheathed structure with corrugated plastic panels incorporated in the side walls to admit natural illumination. Mercury arc high bay lighting and flourescent side wall mounted fixtures co mbine to provide artificial illumination. The main repair bay has aheight of 44 feet from the bottom of the roof chord to the reinforced concrete floor. The main repair and assembly shop is 600 feet long by 100 feet wide, through which two production tracks extend while athird, material track, runs down the center. There is an outside stripping area equipped with permanent scaffolds. At right angles to the main shop is afabricating shop equipped with all the necessary metal and woodworking tools. The two production tracks, upon leaving repair shop, pass through asandblast shed, and then int o a325 foot by 50 foot paint building. Acrossover between the tracks makes it possible to select painting in either the automatic booth (D) or the hand booth (E). Construction of buildings of this general type will vary according to the individual railroad practices as well as geographical location. The main building, however, should be of steel frame construction to support the craneways. Sidewalls may be of brick, concrete, concrete block, with panels of glass block, wired glass, or other facilities for ventilation. Doors should be of motor operated overhead design. Lighting should be adequate for dark days and nighttime work.

3 TYPICAL REPAIR FACILITY -continued Sheet #: Title: Page: D3g CAR SHOP AND 3of 7 1.Stripping area 2.Steel yard, 200'x75' 3.Fabricating shop, 250'x75' 4.Blacksmith shop, 100'x75' 5.Main repair shop, 600'x100' 6.Machine shop, 100'x75' 7.Truck shop, 100'x75' 8.Lumber storage and mill, 125'x125' 9.Storeroom, 125'x75' 10.Shop office, 46'x25' 11.Lunch room, 77'x25' 12.Locker room, 130'x25' 13.and 14. Undercoating and sandblast area, 300'x70' and 200'x51' 15.Paint shop, 325'x51' 16.Paint storage and locker room, 137'x25' 17.General office, 59'x40' 18.Compressor buidlijng, 40'x24' 19.Fuel oil storage Figure 2: TYPICAL REPAIR FACILITY

Page: 4of 7 MATERIAL STORAGE, SHOP EQUIPMENT PAINTING AND MACHINERY Awell designed facility must include storehouse facilities adequate for storing, handling and distributing the large volume of

4 Page: 4of 7 MATERIAL STORAGE, SHOP EQUIPMENT PAINTING AND MACHINERY Awell designed facility must include storehouse facilities adequate for storing, handling and distributing the large volume of material required. Where sufficient space is available in the car shop or other fabrication shop, plates, structural shapes, bar iron, wood, etc., may be stored indoors under overhead cranes, thereby reducing costs and delays due to bad weather. Otherwise, paved areas should be provided near material tracks for storage of these items, preferably under ashed roof. This applies to other items not particularly affected by the weather as well, such as bolsters, side frames and fabricated parts. The shop in Figure 5has been used for building large numbers of box cars for this railroad. The floor has 5½" of reinforced concrete. Two separate car puller systems are shown in dotted lines along the four assembly tracks. Grooves put the cables for these below the level of the floor. The entire repair area should be adequately equipped with compressed air, oxygen outlets, electric power receptacles, and heavy portable equipment, and should provide for drinking water as well as fire protection. Painting is important, particularly for more modern day railroads where better looking and brightly colored cars are prevalent. The paint facility should be designed of fire-resistant construction with concrete floors sloped to drain, rounded corners to facilitate cleaning, and separated away from other facilities sufficiently to minimize chance of fire. Heated drying rooms may be used, but these are being rendered obsolete with the more modern quick-drying paints. Important, of course, is surface preparation, done by sand or shot blasting, scraping, burning, and chemical paint removers. Machinery requirements may vary from those needed for alight repair facility,to those required for a complete and modern shop such as provided in alarge production car manufacturing plant. Much depends upon whether components and sub-assemblies are purchased outside, or whether Figure 3a: CANOPIES AND EXHAUST SYSTEM FOR HAND PAINTED CARS

5 MATERIAL STORAGE, SHOP EQUIPMENT PAINTING AND MACHINERY -continued Page: 5of 7 the basic raw materials are purchased and the fabrication of sub-assemblies is done in the facility. Heavy equipment requirements would include crane trucks, fork lift trucks, tractors, trailers, platform trucks, hand trucks, wagons, buggies, overhead cranes, jib cranes, hoists and monorails. Cranes will vary from 20 to 50 tons capacity over heavy repair tracks to 5to 10 tons capacity for materials handling. SHOP DESIGN REQUIREMENTS The AREA has set certain minimum requirements for good shop design. These are: 1. Distance from center-line of outside repair track to nearest projection on wall, 11feet minimum. 2. Centerline to centerline of adjacent repair tracks, 18 to 22 feet. Where columns are located between tracks, hold the 22 feet. 3. Minimum distance from top of rail to bottom of traveling overhead crane, 23 feet. Where there is no overhead crane, the minimum overhead clearance should be 20 feet. 4. Minimum tracks door size 13 feet wide by 17 feet high. 5. Entire area concreted, with jacking pads and facilities located as required. OTHER FACILITIES AND EQUIPMENT The accompanying diagrams (Figures 2through 5) illustrate plans of various typical heavy freight car repair facilities and equipment. Each follows the basic features already outlined. Figure 3b: TYPICAL CAR REPAIR SHOP

Page: 6of 7 Important Shop Machines A Angle shear B Gate shear C 400-ton gap punch D 1.

6 Page: 6of 7 Important Shop Machines A Angle shear B Gate shear C 400-ton gap punch D ton multiple punch E Acetylene cutting machine F Acetylene cutting machine G 600-ton press brake Figure 4: ASSEMBLYSHOP H 400-ton beam punch I 350-ton gap punch J Punch and shear K Gate shear L Horizontal punch M Single-end punch N 25-in. beam punch O Punch &Shear P Single-end punch &shear R 800-ton press brake T Rail straightener press U Punch V 250-ton hydraulic press W Shot blast booth X Car positioner Z Track scale Hopper Car Assembly Operations 1 Place underframe assembly on temporary shop trucks. Ream, 2 Ream. 3 Drive diagonal braces, bolsters, body sidebearing supports, and end sills. 4 Apply end-post tees, AB valve, brake cylinder and reservoir. Drive gussets. 5 Apply draft gears, end-post sees and end floor assemblies complete with door frames and hopper sheets. 6 Apply center assembly complete with cross rides and longitudinal hoods, levers, brake chain and rods. 7Drive draft gear retainers, and the center floor assembly. Fit longitudinal hoods to end floors. Apply hand brake. 8 Weld center area of car. 9 Weld center area of car. 10 Hang sides. 11 Ream sides. 12 Drive. 13 Drive. 14 Drive. Apply brake rod and train line. Apply hopper doors and fit up with hinges, locks and spreaders. 15 Drive hopper doors. Apply body brake levers, brake chain and rods 16 Complete branch pipe and retainer application. 17 Shot blast exterior of sides. 18 Weld floors, sides, hoppers and top side angle (right side). 19 Weld floors sides, hoppers and top side angle (left side). 20 Apply coupler, angle cocks, uncoupling levers and remove completed body from shop trucks. 21 Apply car cement to underbody and interior of body. 22 Place car on trucks and paint trucks. 23 Spray paint exterior of car. 24 Weigh and stencil. 25 Final inspection.

7 Page: 7of 7 Figure 5: CAR PRODUCTION SHOP

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