M-1002 MSRP-C3 - 2014

11/2014
Association of American Railroads

SAFETY AND OPERATIONS
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION C-III
SPECIFICATIONS FOR TANK CARS

SPECIFICATION M-1002
ISSUE OF NOVEMBER 2014
Compiled under the direction of the Committees responsible for the subjects shown herein.
This issue of the Specifications for Tank Cars is presented in dual form with SI units
parenthetical to conventional units. Guidelines for this conversion are given in Appendix H.
Published by
The Association of American Railroads

425 Third Street SW, Washington, DC 20024
Copyright Association of American Railroads
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12/2/2014 12:42 PM
Copyright 2014 by the Association of American Railroads (AAR)
Safety and Operations
425 Third Street SW
Suite 1000
Washington, DC 20024
All rights reserved, including the right to reproduce this book in any form. It is the AARs intention that this
publication be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform
interchange of rail equipment in North America. To this end, only excerpts of a rule or specification may be
reproduced by the purchaser for their own use in promoting this objective. No portion of this publication may be
displayed or otherwise made available to multiple users through any electronic distribution media including but not
limited to a local area network or the Internet. No portion may be sold or used for advertisement or gain by any entity
other than the AAR and its authorized distributor(s) without written permission from the AAR.
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
ORDERING INFORMATION
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SUBSCRIPTIONS are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification
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MSRP-A1 The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and
INDEX recommended practices. It is available online at http://www.aar.com/standards/publications.php. This
easy-to-access document is a convenient way to quickly identify in which manual a specific document
resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been
updated via Circular Letter.
MSRP-AS MSRP-AS serves as a supplement to all MSRP sections and is available as a free download at
ADMINISTRATIVE http://www.aar.com/standards/publications.php. All users are governed by the administrative standards in
STANDARDS MSRP-AS in addition to the standards and specifications in each section of the Manual of Standards and
SUPPLEMENT Recommended Practices.
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Executive Director, Tank Car Safety
425 Third Street SW
Suite 1000
Email: kdorsey@aar.org
Phone: 202-639-2262
Fax: 202-639-2356
11/2014 C-IIIi
THIS PAGE LEFT BLANK INTENTIONALLY
C-IIIii 11/2014
TO THE USER
Section C, Part III, Specifications for Tank Cars, Manual of Standards and Recommended Practices
of the Association of American Railroads is Specification M-1002, and it is issued under the
authority of the Risk Management Committee. It covers tanks for dangerous commodities (or
hazardous materials) subject to U.S. and Canadian government regulation with supplementary
AAR requirements, and tanks for commodities not classified as hazardous materials and
consequently subject only to AAR regulation. The car structure is covered by a portion of Section C,
Part II, Specification M-1001, as well as a portion of this specification. There are six chapters:
Chapter 1: Introductions, Approvals, and Reports
Chapter 2: AAR Special Requirements for DOT Tank Cars
Chapter 3: Specifications for AAR Tank Car Tanks
Chapter 4: Reserved
Chapter 5: General Design and Test Requirements
Chapter 6: Car Structure Design and Test Requirements
There also is a series of appendices covering tank appurtenances, tank design, materials, welding,
repairs, alteration, lining, marking, nondestructive testing, and certification of tank car shops. This
publication supplements the U.S. Department of Transportation (DOT) Hazardous Materials
Regulations for Railroad Transportation, Title 49 CFR, Parts 170-180.
Revisions and additions to text and figures are identified by a bold, black, vertical line on the
unbound margin of the page adjacent to the affected change. The date of such revisions and
additions is indicated by date at the bottom of the page.
USERS GUIDE
Section C, Part III, consists of the following:
Preface: A listing of the subjects covered in the individual volumes making up this
manual. This preface is part of each section.
Table of Contents: Identification of the chapters and appendices in numerical order.
Specification M-1002: The body of this volume is a single specification setting forth
mandatory requirements for virtually all phases of tank car design.
Recommended Practices: Appendix J and Appendix U
RELATED SECTIONS
Section C, Part III, Specifications for Tank Cars, should be used in conjunction with Section C, Car
Construction Fundamentals, and Section C, Part II, Specifications for Design, Fabrication and
Construction of Freight Cars. Other sections containing pertinent information are the following:
Section BCouplers and Freight Car Draft Components
Section DTrucks and Truck Details
Section EBrakes and Brake Equipment
Section GWheels and Axles
Section HJournal Bearings and Lubrication
RESPONSIBILITY
The coverage of Section C, Part III, Specifications for Tank Cars, is the responsibility of the AAR
Tank Car Committee.
EFFECTIVE DATE
This November 2014 issue of M-1002 includes Tank Car Committee actions through the January
2007 meeting.
11/2014 C-IIIiii
PREFACE
The Manual of Standards and Recommended Practices of the Safety and Operations Department,
Association of American Railroads, is issued by authority of the Management Committee of the
Division and includes all regularly adopted specifications, standards, and recommended practices
of the Association of American Railroads.
The manual is composed of the following sections:
Section ASAdministrative Standards Supplement serves as a supplement to all MSRP
sections (this is available as a free download at http://www.aar.com/standards/publications.php)
Section ATable of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/standards/publications.php)
Section BFreight Car Draft Components (100 Series)
Section CCar ConstructionFundamentals and Details (200 and 2000 Series)
Section C, Part IIDesign, Fabrication, and Construction of Freight Cars, M-1001
Section C, Part IIISpecifications for Tank Cars, M-1002
Section DTrucks and Truck Details (300 and 3000 Series)
Section EBrakes and Brake Equipment (300, 400, 3000, and 4000 Series)
Section E, Part IIElectronically Controlled Brake Systems (4200 Series)
Section FSensors
Section GWheels and Axles (600 Series)
Section G, Part IIWheel and Axle Shop Manual (600 and 700 Series)
Section HJournal Bearings and Lubrication (700 Series)
Section H, Part IIRoller Bearing Shop Manual (700 Series)
Section H, Part IIILubrication (Shop) Manual (700 Series)
Section IIntermodal Equipment Manual
Section JSpecification for Quality Assurance, M-1003
Section K, Part IRailway Electronics Systems Architecture and Concepts of Operation
(9000 Series)
Section K, Part IILocomotive Electronics and Train Consist System Architecture
(9100 Series)
Section K, Part IIIWayside Electronics and Mobile Worker Communications
Architecture (9200 Series)
Section K, Part IVOffice Architecture and Railroad Electronics Messaging (9300 Series)
Section K, Part VElectronics Environmental Requirements and System Management
(9400 Series)
Section K, Part VIRailway Data Management and Communications (9500 Series)
Section LLettering and Marking of Cars (900 Series)
Section MLocomotives and Locomotive Interchange Equipment (500 and 5000 Series)
Section NMulti-Level Manual (800 Series)
Section SCasting Details
Section S, Part IITruck Details and Casting Codes (300 and 3000 Series)
Section S, Part IIICoupler and Yoke Details (100 Series)
Specifications are designated with an M prefix (e.g., M-900). Standards are prefixed S (e.g.,
S-900). Recommended Practices carry the prefix RP (e.g., RP-900).
C-IIIiv 11/2014
TABLE OF CONTENTS
Chapter Subject Page
1 Introductions, Approvals, and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III1
2 AAR Special Requirements for DOT Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III69
3 Specifications for AAR Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III83
4 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III99
5 General Design and Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III101
6 Car Structure Design and Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III113
Appendix Subject Page

A Tank Car Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III115
B Certification of Tank Car Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III145
C Marking of Tank Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III175
D Retest and Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III193
E Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III229
H Basic Philosophy and Principles for the Metrication of the AAR Specifications for Tank Cars . . . . C-III329
J Threaded and Bolted Flange Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III337
L Interior Cleaning, Lining, and Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III343
M Specifications for Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III349
R Repair, Alteration, and Conversion to Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III369
S Loading Appurtenances for Tank Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III409
T Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III413
U Maintenance Program Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III457
W Welding of Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III469
X DOT Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III545
Y Selected AAR Circular Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III547
11/2014 C-III [M-1002] v

LIST OF FORMS
See back of book for AAR forms for reproduction by the proponents.
Form 4-2 Application for Approval and Certificate of Construction
Form 4-2.1 Approval AAR Tank Committee
Form 4-3 Application for Approval of Pressure Relief Device
Form 4-4 AAR Tank Service Trial Report
Form 4-5 Application for Approval of Valves, Closures, and Fittings
Form 4-6 Final Service Trial Inspection Report
Form 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures,
and Fittings
Exhibit B-1 Exhibit B-1 Subcontractor Evaluation Sheet

Exhibit B-2 Exhibit B-2 AAR Tank Car Committee Shop Evaluation
Exhibit B-3 Exhibit B-3 Application for Tank Car Facility Technical Certification and Change
Notification Form
Exhibit B-3A Certification Additional Information Form
Certificate of Test Form
Exhibit R-1 Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion

Exhibit R-2 Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack
Repairs
Form SS-1 Form SS-1 Report of Tank Car Stub Sill Inspection
Form SS-3 Form SS-3 Report of Tank Car Stub Sill Inspection
Suggested Format for Welding Procedure Specification (WPS)

Suggested Format for Procedure Qualification Record (PQR)
Record of Welder Performance Qualification Test
C-III [M-1002] vi 11/2014

M-1002 CHAPTER 1
CHAPTER 1
INTRODUCTIONS, APPROVALS, AND REPORTS
CONTENTS
Paragraph Subject Page

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III3
1.1.1 Historical Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III3
1.1.2 Legal Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III3
1.1.3 General Design Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III4
1.1.4 List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III5
1.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III12
1.3 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.1 Car Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.2 DOT Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.3 AAR Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.4 Safety Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.5 Interchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.6 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III30
1.3.7 Editions of Referenced Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III31
1.3.8 Calibration and Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III31
1.3.9 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III31
1.3.10 Age Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.11 Head Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.12 Rebuilt Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.13 Commodity Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.14 Reporting Marks and Car Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.15 Documentation at the Sale of Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III32
1.3.16 Requirements for Tank Cars with Gross Rail Load Over 263,000 lb to 286,000 lb, Inclusive. . . . . . C-III32
1.3.17 Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III33
1.4 Procedures for Securing Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III33
1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III33
1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2) . . . . . . . . . . . . . . . . C-III34
1.4.3 Application Form AAR 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III38
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction. . . . . . . . . . . . . . . . . . . . . . C-III42
Fig. 1.2 Form AAR 4-2.1 Supplementary page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III43
1.4.4 Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III44
1.4.5 Service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III44
1.4.6 Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III47
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device . . . . . . . . . . . . . . . . . . . . . . . . . C-III50
1.4.7 Valves, Closures, and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III51
Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III53
1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings. . . . . . . . . . . . . . C-III54
11/2014 C-III [M-1002] 1

CHAPTER 1 M-1002
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves,
Closures, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III56
1.4.9 AAR Service Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III57
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III61
1.4.10 Final Service Trial and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III62
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III63
1.4.11 Certified Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III64
1.5 Certification of Independent Third Parties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III65
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III65
1.5.2 Requirements and Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III65
1.5.3 Procedures for Obtaining Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III65
1.6 Document Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III66
C-III [M-1002] 2 11/2014

M-1002 CHAPTER 1
CHAPTER 1. INTRODUCTIONS, APPROVALS, AND REPORTS

1.1 Introduction
1.1.1 Historical Record
Specifications for Tank Cars first appeared as a report to the former Master Car Builders
Association in 1903. The report was approved, revised, and issued by the American Railway
Association in 1925 and adopted March 1, 1931, by the Association of American Railroads (AAR).
On July 1, 1927, Interstate Commerce Commission specifications were issued for tank car tanks
for transportation of articles classed as dangerous by ICC Regulations, and AAR specifications for
such tanks became obsolete.
The ICC regulations have been published and revised as a part of Title 49, Code of Federal
Regulations. After passage of the Department of Transportation Act in October 1966, these
regulations became the DOT Hazardous Materials Regulations, effective April 1, 1967. The
Hazardous Materials Regulations currently include Title 49, Code of Federal Regulations, Parts
100199.
The specifications in this volume also prescribe AAR specifications for tank car tanks for the
transportation of nonhazardous and DOT low-hazard commodities.
This issue of the AAR Specifications for Tank Cars dated November 2014 supersedes the issue
dated October 2007.
For current issues of the DOT Hazardous Materials Regulations, refer to Title 49, CFR, Parts 100
199 published annually, revised each year, and available from the Government Printing Office. A
comprehensive compilation of the hazardous materials transportation regulations (all modes) is
published annually and updated quarterly as AAR Bureau of Explosives Tariff No. BOE-6000 and
can be obtained at http://www.boepublications.com.
DOTs hazardous materials regulations are available for viewing or download from their Web site
at http://phmsa.dot.gov/regulations.
In Canada, Transport Canada, Transport Dangerous Goods Directorate, Regulatory Affairs
Branch, prepares and administers the regulations for transport of dangerous commodities. The
Transportation of Dangerous Goods Regulations and Act are available for viewing or download
from Transport Canadas Web site at http://www.tc.gc.ca/eng/menu.htm.
1.1.2 Legal Authority
The Department of Transportations hazardous materials regulations are issued under the
authority of the Hazardous Materials Transportation Act as amended, 49 U.S.C. sections 1801 et
seq.
Transportation of Dangerous Goods Regulations are issued by Transport Canada under the
authority of the Transportation of Dangerous Goods Act, 1992.
11/2014 C-III [M-1002] 3

CHAPTER 1 M-1002
1.1.3 General Design Requirement

Tank cars are subject to the following:
AAR Manual of Standards and Recommended Practices (MSRP):
Section C, Car Construction Fundamentals, (e.g,. S-2034, Car Builder Certification
and S-2044, Safety Appliance Requirements for Freight Cars)
Section C, Part II, Design, Fabrication, and Construction of Freight Cars (M-1001)
Section C, Part III, Specifications for Tank Cars (M-1002)
Section B, Couplers and Freight Car Draft Components
Section D, Trucks and Truck Details
Section E, Brakes and Brake Equipment
Section E, Part II, Electronically Controlled Brake Systems (when so equipped)
Section F, Sensors (when so equipped)
Section G, Wheels and Axles
Section H, Journal Bearings and Lubrication
Section J, Specifications for Quality Assurance (M-1003)
Section L, Lettering and Marking of Cars
Section S, Part I, Castings
Section S, Part II, Truck Dimensions
Section S, Part III, Coupler and Yoke Dimensions
Field Manual of the AAR Interchange Rules
Office Manual of the AAR Interchange Rules
Title 49 Code of Federal Regulations, Parts 171-180, 215, 231, 232
Transportation Dangerous Goods (TDG) Regulations
Transport Canada (TC) TP14877
1.1.4 Certified tank car builders must have a designated and approved facility on the North
American continent where final assembly and/or acceptance inspections and tests of cars are
performed prior to release for interchange service. Assembly facilities that do not qualify as
certified car builders must be inspected by the Committee and may be approved as final
assemblers upon demonstration of the relevant qualifications outlined in M-1002.
C-III [M-1002] 4 11/2014

M-1002 CHAPTER 1
1.1.5 List of Specifications

A complete list of former and present tank car specifications is given in Table 1.1.
Table 1.1 List of tank car specifications (page 1 of 6)

(See end of table for footnotes)
Originally Latest Obsolete for New Operational
Specification Approved Revision Construction Status
a/ by AAR b/ b/ c/
ARA-I Before 1903 1-1-03

ARA-II 1-1-03 5-1-17
ARA-III 5-1-17 7-1-27
ARA-IV 5-1-17 7-1-27
AAR-IV-A 10-1-25 7-1-27
ARA-V 1-1-18 7-1-27
ARA-VI 1-1-25 10-10-29
AAR-201A35 3-1-31 1-31-55 8-1-62
AAR-201A35W 3-1-37 11-13-68
AAR-201A70W 1-31-55 11-13-68
AAR-201A80W 3-22-65 3-22-65
AAR-203 3-1-31 8-31-56
AAR-203DW 11-10-71
AAR-203W 8-1-41 11-10-71 d/
AAR-203 Special 8-31-56

AAR-204W 12-17-58 11-13-75 d/
AAR-204X 4-27-67 4-27-67 d/
AAR-205A300W 6-14-51 6-14-51 e/
AAR-206W 6-28-62 11-10-71

AAR-207A20W 4-21-65 11-10-71
AAR-207A28W 4-21-65 11-10-71
AAR-207A40W 4-21-65 11-10-71
AAR-207A40W6 4-21-65 11-10-71
AAR-207A48ALW 4-22-65 11-10-71
AAR-207A48W 4-22-65 11-10-71
AAR-207A60ALW 4-22-65 11-10-71
AAR-207A60W 4-22-65 11-10-71
AAR-207A80ALW 4-22-65 11-10-71
AAR-207A80W 4-22-65 11-10-71
AAR-208 11-13-68 11-10-71
AAR-211A60W1 11-10-66 11-10-71
AAR-211A60W2 11-10-66 11-10-71 10-12-78
AAR-211A60W7 11-10-71
AAR-211A60ALW1 11-10-66 11-10-71
AAR-211A100W1 11-10-66 11-10-71
AAR-211A100W2 11-10-66 11-10-71 10-12-78
AAR-211A100W3 Pending Implemented CPC
11/2014 C-III [M-1002] 5
CHAPTER 1 M-1002

a/ by AAR b/ b/ c/
AAR-211A100W5 Pending Implemented CPC

AAR-211A100W6 11-10-71
AAR-211A200W1 11-10-66
AAR-211A100ALW1 11-10-66 11-10-71
AAR-211J100W1 Pending Implemented CPC
ICC-103 7-1-27 12-19-64
DOT-103 12-19-64
ICC-103A 7-1-27 12-19-64
DOT-103A-ALW 8-21-51 12-31-71 10-1-03
ICC-103AL 11-5-37 10-6-47 8-31-56
DOT-103ALW 8-21-51 12-31-71 10-1-03
DOT-103ANW 8-31-56 12-31-71 10-1-03
DOT-103AW 1-7-41 12-31-71 10-1-03
ICC-103B 7-1-27 12-19-64
DOT-103BW 1-7-41 12-31-71 10-1-03
ICC-103B100W 12-31-52 12-19-64
ICC-103C 8-15-28 8-31-56
ICC-103CAL 4-20-48 11-14-49 8-31-56
DOT-103CW 1-7-41 12-31-71 10-1-03
DOT-103DW 8-31-56 12-31-71 10-1-03
DOT-103EW 8-31-56 12-31-71 10-1-03
DOT-103W 1-7-41 12-31-71 10-1-03
ICC-104 7-1-27 12-19-64
ICC-104A 7-1-27 8-31-56 f/
ICC-104A-ALW 10-25-52 9-21-54 g/
ICC-104AW 1-7-41 8-31-56 h/
DOT-104W 1-7-41 12-31-71 10-1-03

ICC-105 7-1-27 10-19-29
ICC-105A100 7-1-27 12-19-64 f/
ICC-105A300 8-15-28 8-31-56

ICC-105A400 12-15-28 8-31-56
ICC-105A500 12-15-28 8-31-56
ICC-105A600 12-15-28 8-31-56
DOT-105A100W 1-7-41 12-31-71 h/ i/
DOT-105A200F 12-19-64 12-31-71 11-30-84 d/
DOT-105A200W 9-23-57 12-31-71 i/
DOT-105A300W 1-7-41 12-31-71 i/
DOT-105A400W 1-7-41 12-31-71 i/
DOT-105A500W 1-7-41 12-31-71 i/
C-III [M-1002] 6 11/2014

M-1002 CHAPTER 1

a/ by AAR b/ b/ c/
DOT-105A600W 1-7-41 12-31-71 i/
DOT-105J100W 8-31-81 i/
DOT-105J200W 8-31-81 i/
DOT-105J300W 8-31-81 i/
DOT-105J400W 8-31-81 i/
DOT-105J500I 3-16-09
DOT-105J500W 8-31-81 i/
DOT-105J600I 3-16-09
DOT-105J600W 8-31-81 i/
DOT105S100W 8-31-81
DOT105S200W 8-31-81
DOT-105S300W 8-31-81 i/
DOT-105S400W 8-31-81 i/
DOT-105S500W 8-31-81 i/
DOT-105S600W 8-31-81 i/
DOT-105A100ALW 10-25-52 12-31-71 i/
DOT-105A200ALW 9-23-57 12-31-71 i/
DOT-105A300ALW 8-31-56 12-31-71 i/
DOT-105J200ALW 8-31-81 i/
DOT-105J300ALW 8-31-81 i/
ICC-106A500 10-10-29 12-19-64

DOT-106A500X 4-19-46 12-31-71 j/
ICC-106A800 10-10-29 12-19-64

ICC-106A800NCI 12-31-52 12-19-64
DOT-106A800X 4-19-46 12-31-71 j/
ICC-106A800XNC 12-19-64
DOT-107A 1-13-32 9-15-71
ICC-108 7-1-27 8-31-56
ICC-108A 7-1-27 8-31-56
DOT-109A100ALW 6-18-57 12-31-71
DOT-109A200ALW 6-25-57 12-31-71
DOT-109A300ALW 9-23-57 12-31-71
DOT-109A300W 6-15-51 12-31-71
DOT-110A500W 8-21-51 12-19-64 j/
DOT-110A600W 2-12-75 j/
DOT-110A800W 8-21-61 12-19-64 j/
DOT-110A1000W 12-19-64 j/
DOT-110A3000W 11-8-61 5-19-94 12-31-78 j/
DOT-110A2000W 10-4-93 5-19-94 j/
11/2014 C-III [M-1002] 7

CHAPTER 1 M-1002

a/ by AAR b/ b/ c/
ICC-111A60ALW 7-19-59 12-19-64 5-27-67

DOT-111A60ALW 5-27-67
DOT-111A60ALW1 5-27-67 12-31-71
DOT-111A60ALW2 5-27-67 12-31-71
DOT-111A60F1 2-17-63 12-31-71 11-30-84 d/
DOT-111A60W1 2-17-63 12-31-71

DOT-111A60W2 11-11-65 12-31-71
DOT-111A60W5 11-11-65 12-31-71
DOT-111A60W6 1-10-92
DOT-111A60W7 5-27-67 12-31-71
ICC-111A100ALW 5-22-65 5-27-67
DOT-111A100ALW 5-27-67
DOT-111A100ALW1 5-22-65 12-31-71
DOT-111A100ALW2 5-27-67 12-31-71
DOT-111A100F1 9-25-63 12-31-71 11-30-84 d/
DOT-111A100F2 9-25-63 12-31-71 11-30-84 d/
DOT-111A100W1 9-23-57 12-31-71

DOT-111A100W2 9-23-57 12-31-71
DOT-111A100W3 9-23-57 12-31-71
DOT-111A100W4 9-23-57 12-31-71
DOT-111A100W5 7-19-59 12-31-71
DOT-111A100W6 7-19-59 12-31-71
DOT-111A100W7 Pending Implemented CPC
DOT-111J100W1 Pending Implemented CPC
DOT-111S100ALW2 Pending Implemented CPC
DOT-111S100W1 Pending Implemented CPC
DOT-112A200W 2-17-63 7-13-78 k/
DOT-112A340W 2-17-63 7-13-78 k/
DOT-112A400F 12-20-61 7-13-78 11-30-84 d/
DOT-112A400W 9-23-57 7-13-78 k/
DOT-112A500W 6-20-60 7-13-78 k/
DOT-112J200W 10-16-91 k/
C-III [M-1002] 8 11/2014

M-1002 CHAPTER 1

a/ by AAR b/ b/ c/
DOT-112J340W 10-19-77 7-13-78 k/
DOT-112J400F 10-19-77 7-13-78 11-30-84 d/
DOT-112J400W 10-19-77 7-13-78 k/
DOT-112J500I 3-16-09
DOT-112J500W 10-19-77 7-13-78 k/
DOT-112S200W 10-16-91 k/
DOT-112S340W 10-19-77 7-13-78 k/
DOT-112S400F 10-19-77 7-13-78 11-30-84 d/
DOT-112S400W 10-19-77 7-13-78 k/
DOT-112S500W 10-19-77 7-13-78 k/
DOT-112S600I 3-16-09
DOT-112T200W 10-16-91 k/
DOT-112T340W 10-19-77 7-13-78 k/
DOT-112T400F 10-19-77 7-13-78 11-30-84 d/
DOT-112T400W 10-19-77 7-13-78 k/
DOT-112T500W 10-19-77 7-13-78 k/
DOT-113A60W 7-24-63 11-13-75 l/
DOT-113A90W Pending DOT Approval

ICC-113A120W 12-19-64 12-6-67
DOT-113A175W 12-19-64 11-13-75 10-1-84 l/
DOT-113B60W 7-11-69 3-3-72

DOT-113C60W 12-6-67 3-2-72 l/
DOT-113C120W 12-6-67 11-13-75 l/
DOT-113D60W 12-6-67 3-2-72 l/
DOT-113D120W 12-6-67 11-13-75 10-1-84 l/
DOT-114A340W 12-19-64 7-13-78 k/
DOT-114A400W 11-11-65 7-13-78 k/
DOT-114J340W 10-19-77 7-13-78 k/
DOT-114J400W 10-19-77 7-13-78 k/
DOT-114S340W 10-19-77 7-13-78 k/
DOT-114S400W 10-19-77 7-13-78 k/
DOT-114T340W 10-19-77 7-13-78 k/
DOT-114T400W 10-19-77 7-13-78 k/
DOT-115A60ALW 11-11-65 12-31-71

DOT-115A60W1 11-11-65 12-31-71
DOT-115A60W6 11-11-65 12-31-71
DOT-116A****W 11-11-65 5-11-72
DOT-117A340W 11-10-66 5-11-72 DOT-E
DOT-120A200ALW 5-11-72
11/2014 C-III [M-1002] 9

CHAPTER 1 M-1002

a/ by AAR b/ b/ c/
DOT-120A100W 10-18-94
DOT-120A200W 10-18-94
DOT-120A300W 11-10-66
DOT-120A400W 9-20-72
DOT-120A500W 3-2-72
DOT-120A600W 3-19-74
DOT120J100W 3-19-74
DOT120J200W 3-19-74
DOT120J600W 3-19-74
DOT-121A500W 11-13-68 3-2-72 m/
Emergency USG-A 6-15-42 8-31-56

Emergency USG-B 6-15-42 8-31-56
Emergency USG-C 6-15-42 8-31-56
a/ Tank car tanks with the specification marking ICC placed thereon before January 1, 1970,
may be continued in service as marked.
b/ AAR-approved dates for AAR specifications; ICC-effective dates for ICC specifications; ICC- or
DOT-effective dates for DOT specifications.
c/ DOT-E indicates that a DOT exemption is required for any tank of the referenced
specification.
d/ Conversions only.
e/ Specification AAR-205A300W superseded by DOT-109A300W.
f/ Specification ICC-104A superseded by ICC-105A100.
g/ Specification ICC-104A-ALW superseded by DOT-105A100ALW.
h/ Specification ICC-104AW superseded by DOT-105A100W.
i/ Specifications DOT-105A, J, and S define certain tank protective devices required by DOT
173.31. See paragraph 1.2.1.1.
j/ Effective after 7/1/94, approvals are by DOT.
k/ Specifications DOT-112A, J, S, and T and Specifications DOT-114A, J, S, and T define certain
tank protective devices required by DOT 173.31. See paragraph 1.2.1.1.
l/ See 174.83 for special handling requirements.
m/ Existing cars restenciled DOT-120A500W, new construction not authorized.
C-III [M-1002] 10 11/2014

M-1002 CHAPTER 1
Table 1.2 Data for tank cars in interchange service not otherwise listed in these specificationsa/
Specification AAR-201A70W 113A175Wb/ 113D120Wb/
Lading temp, F 423 155
Material Al Alloy ASTM A240304, 304L, or TC133
Insulation Optional 179.4004
Burst pressure, psi (kPa) 350 (2413) 440 (3034) 300 (2068)
Tank construction Fusion-welded Fusion-welded. Impact tests
reqd. (welds and plate)
Minimum plate thickness 1/2 in. (5/8 in. bottom) 5/16 in. 3/16 in.
Shell
Heads 5/8 in. or 1/2 in. (2:1) 5/16 in. 3/16 in.
Dome 1/2 in.
Dome expansion capacity 2%
Test pressure, psi (kPa) 70 (483) 175 (1207) 120 (827)
Pressure relief devices Valve Valve and vent Valve and vent
Valve S-T-D pressure, psi 35 (241) 115 (793) 75 (517)
(kPa)
Valve vapor-tight pressure, psi 28 (193) 95 (655) 60 (413)
(kPa)
Valve flow rating pressure, psi 45 (310) 125 (862) 85 (586)
(kPa)
Vent burst pressure, psi (kPa) 175 (1207) 120 (827)
Bottom outlet Optional
a/ Obsolete ICC tank car specifications conform to corresponding DOT specifications except for
method of tank construction or fittings arrangement. Metric equivalents shown for pressures
only.
b/ See also M-1002, 1982
11/2014 C-III [M-1002] 11

CHAPTER 1 M-1002
1.2 Definitions (page 1 of 14)

Chapter/
Term Definition Appendix
AAR Association of American Railroads
AAR Specification The specifications of design, fabrication, and construction of fright cars, published by 1
M-1001 the AAR.
Accidental damage (AD) A physical defect of an item caused by contact with an object during the manufacture, U
maintenance, or operation of the tank.
Acoustic emission A nondestructive test method, utilizing sounds emitted by materials when under stress, W
inspection (AE) to detect internal or surface discontinuities.
Activity code A tank car activity that requires M-1002 certification. As information, this code directly B
relates to commodity outlined in the AAR Manual of Standards and Recommended
Practices, Section J (M-1003), Appendix A.
AISI American Iron and Steel Institute
Air inlet A valve or closure that is used to introduce air or other vapor into the tank. 1
Alteration A change in tank or service equipment that does not change the specification but that B, R
does change the Certificate of Construction.
ANSI American National Standards Institute
Approach channel The passage through which the fluid must pass to reach the operating parts of a A
pressure relief device.
Approved Approval by the AAR Tank Car Committee. 1
ASME American Society of Mechanical Engineers
ASNT American Society for Nondestructive Testing
Assemble Construction of a tank car without welding on the tank car tank. B
ASTM American Society for Testing and Materials
Atmospheric pressure Atmosphere pressure equals 14.696 psia (101.325 kPa [abs.]). A
AWS American Welding Society
Bench test A leak test of a valve or fitting mounted on a test fixture to determine pressure-retention D
integrity of the valve or fitting and, if required, to determine the pressure-retention
integrity of the operable valve seat by a visual inspection through the valve port opening
at the time of test.
Except for pressure relief devices, valves and fittings are to be tested in both the open/
plugged and non-plugged closed positions. Afterward, the valve is tested on the tank
to determine the integrity of the fluid seal joint between the valve and the tank.
Reclosing pressure relief device: The purpose of this test is to ensure that start-to-
discharge pressure and vapor-tight pressure settings are within tolerance.
Blister A lesion in an AHF tank car tank of at least 1/4 in. (6.35 mm) depth or height and of a R
diameter greater than 3 in. (76.2 mm).
Bottom outlet valve A device on the bottom of the tank that is operated either by a handle attached to the 1
valve or by a mechanism extending through the top of the tank. The latter is referred to
as a top-operated bottom outlet valve.
Bottom shell That portion of a tank car tank surface, excluding the head ends of the tank, that lies D
within 2 ft, measured circumferentially, of the bottom longitudinal centerline of the tank
car tank.
Bottom washout A plugged and flanged opening in the bottom of a tank to facilitate cleaning of a car that A
does not have a bottom outlet valve.
Breaking pin An operating part that holds a disc of metal closing the inlet of a pressure relief valve A
and that is designed to break in tension at a load caused by a predetermined pressure.
C-III [M-1002] 12 11/2014

M-1002 CHAPTER 1

Chapter/
Breather vent A device having an operating part that is a permeable disc or a disc having a breather A
hole or slit.
Built date (tank car) The date (month and year) that the completed car is shipped from the car builders 1
facility. Tank cars shipped to lining applicator, whether or not returned to the car builder
after lining, are considered built as of the first departure from the car builders facility
Burst pressure The value of the inlet static pressure at which a rupture disc device or breaking pin A
device functions.
Butt joint A joint type in which the butting ends of one or more work pieces are aligned in W/R
approximately the same plane.
Butt weld A nonstandard term for a weld in a butt joint. It may be either single or double welded. W/R
C Degrees Celsius
Capacity (tank car) A tank cars shell full volume. 1
Car owner See Tank car owner 2, L
Certificate Written testimony of qualification. T
Certification, Personnel Written testimony of qualification. The act of determining, verifying, and attesting in T
writing to the qualification of personnel in conformance to specified requirements.
Certification, Tank Car A formal procedure by which the AAR Tank Car Committee verifies (and attests in B
Facility writing by issuing a certificate) that a tank car facility has undergone an inspection and
has demonstrated compliance with federal regulations and with the AAR Manual of
Standards and Recommended Practices, Section C, Part III, M-1002.
Certified car A stub-sill, non-pressure, non-exterior coiled car built prior to July 1, 1974, and meeting 1
the requirements of paragraph 1.4.10.
Certified Tank Car A facility that possesses a valid tank car facility certificate. B
Facility
Certifying agency The employer of the person being certified. T
Certifying authority The person or persons designated in the written practice to sign certifications on behalf T
of the employer.
CFR Code of Federal Regulations
CGSB Canadian General Standards Board
Check valve A valve that automatically closes to stop the flow of liquid or vapor in one direction. A
Class (tank car) A general designation usually including several specifications (e.g., Class DOT-111A 1
or Class DOT-111A***W*). The word class is used if the designation embraces
several specifications. Therefore, AAR-208 is a specification, not a class; but DOT-
103W is a class when used to cover W, AW, BW, etc., and a specification when the
basic DOT-103W is itself referenced.
Cleaning Encompasses chemical, thermal, and mechanical techniques for the preparation of the L
interior surfaces of tank car tanks and/or valves and fittings.
Closing pressure The pressure, measured at the valve inlet, at which the valve closes, flow is A
substantially shut off, and there is no measurable lift.
Closure A device that closes an opening into the tank, valve, or fitting. Examples include but are A
not limited to pipe plugs, quick-disconnect caps, blind flanges, manway covers, outlet
caps, eduction pipe caps, and fill hole covers.
Closure assembly An assembly of parts, semi-permanently connected, that operates together to secure 1
the closure in the closed positions, excluding a hinged and bolted manway cover.
Coating applicator The firm that is executing the specified work. L
11/2014 C-III [M-1002] 13

CHAPTER 1 M-1002

Chapter/
Combination device (a) A breaking pin in combination with a pressure relief valve in which the breaking pin A
is located between the tank and pressure relief valve.
(b) A rupture disc in combination with a pressure relief valve in which the rupture disc
is located between the tank and pressure relief valve, and may be located within the
pressure plate.
Committee AAR Tank Car Committee 1
Company A facility or group of facilities under common ownership that utilize the same program W
of welding standards and documentation.
Connections Consists of flanges and appurtenances around the end of a nozzle to secure a bolted 1
or hinged and bolted cover. Fittings, manway covers and closures are secured to the
connections with bolts and nuts.
Contracting authority The coating/lining owner who is responsible for the approval of a completed tank car L
coating/lining system, including periodic inspection interval, test technique, and
acceptance criteria.
Conventional unit The U.S. customary (English) units, such as the inch, pound, gallon, etc. H
Conversion A change in tank or service equipment that changes the specification. B, R
Corrosive product Any product that has a corrosion rate as defined in Appendix L, paragraph 7.3. L
Corrosive to the tank or A material identified in the regulations or a material that, when in contact with the inner L
service equipment shell of the tank or service equipment, has a corrosion rate on steel greater than
2.5 milli-inch per year (mpy) (0.0025 inch per year).
Crack A fracture type of discontinuity characterized by a sharp tip and separation of material R
extending partially but not necessarily completely through the cross-section of a
member.
CSA Canadian Standards Association
Defects Abrasions; corrosion; cracks; dents; flaws in welds; distortions; erosion; missing, D, L, R, T,
damaged, leaking, or loose components and fasteners; and other conditions or W
imperfections that may make a tank car unsafe for transportation and/or require it to be
removed from service.
Dent A deformation that changes the tank contour from the original manufactured state. R
Design level of reliability The level of reliability that is built into the tank car. Therefore, it is inherent in its D
and safety specification, design, and manufacture.
Director Executive DirectorTank Car Safety (AAR)
Discharge channel The passage through which the fluid must pass beyond the operating parts of a A
pressure relief device. This includes all piping or exhaust flue, screen, and weather
covering that may be applied on the housing.
Discharge flow The ratio of the actual flow to the flow of an ideal conduit with the same orifice area. A
coefficient
Discontinuity An interruption of the typical structure of a material, such as a lack of homogeneity in T, W
its mechanical, metallurgical, or physical characteristics. A discontinuity is not
necessarily a defect.
Discontinuities, service Any service equipment that projects beyond the shell envelope. 2, E
equipment
Documented The condition of being in written or electronic form. T
Double-welded butt joint A butt joint welded from both sides. W
C-III [M-1002] 14 11/2014

M-1002 CHAPTER 1

Chapter/
Effective seal Any flanged, threaded, or other gasket fitting design that, as tested using approved E
NDT LT procedures, meets the acceptance criteria.
Employer The corporate, private, or public entity that employs personnel for wages, salary, fees, T
or other considerations.
Environmental damage Corrosion, erosion, or other physical deterioration of an items strength or resistance to U
(ED) failure because of chemical interaction with its climate or environment.
Equipment, explosion Apparatus enclosed in a case that is capable of withstanding an explosion of a A
proof specified gas or vapor that may occur within it; and of preventing the ignition of a
specified gas or vapor surrounding the enclosure by sparks, flashes, or explosion of the
gas or vapor within; and that operates at such an external temperature that a
surrounding flammable atmosphere will not be ignited thereby.
Equipment, intrinsically Equipment and wiring that is incapable of releasing sufficient electrical or thermal A
safe energy under normal or abnormal conditions to cause ignition of a specific hazardous
atmospheric mixture in its most easily ignited concentration.
Equivalent kind Replacement with a model that has the same form, fit, and functions. A pressure relief 1
valve with flow capacity exceeding the requirements on the approved certificate is also
equivalent kind. Any equivalent kind replacement must use a valve or fitting with an
AAR approval that is current.
Essential variables, NDT Those NDT parameters considered critical, that if changed require new qualification T
and demonstration of the NDT procedure.
Essential variables, Required when notch toughness testing is part of the specification, and are in addition W
supplementary to the essential variables for each welding process.
Essential variables, Those variables in which a change, as described in the specific variables, is considered W
welding to affect the mechanical properties of the weldment, and shall require requalification of
the WPS.
Evaluation A determination of the significance of a relevant indication. T
Examination Conducting the NDT methods that will be performed for the employer. For practical T
examinations, questions and answers need not be written, but observations and results
must be documented.
Excess flow valve A device designed to automatically close if the rate exceeds a specified value. 1
Experience Work activities accomplished in a specific NDT method under the direction of qualified T
supervision, including the performance of the NDT method and reports, but not
including time spent in organized training.
Exterior heater system A half pipe system welded to the exterior of the tank that uses a fluid medium to heat 1
the lading from outside the tank for the purpose of unloading.
F Degrees Fahrenheit
Fabricate (fabrication) The construction of a tank car tank consisting of a shell and heads with connections W
welded directly thereto, with or without stub sill and body bolster components.
Facility, tank car An entity that manufactures, repairs, inspects, tests, qualifies, maintains, alters, or B
converts a tank car, ensuring that the tank car conforms to published rules, regulations,
and specifications.
Fatigue damage (FD) The initiation and subsequent propagation of a crack or cracks due to cyclic loading. U
Fill hole cover The covering for a hole in a manway cover for loading the car without removing/opening 1
the manway cover.
Fillet weld A weld of approximately triangular cross-section joining two surfaces approximately at W
right angles to each other, in a lap, tee, or corner joint.
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Fitting A pressure-retaining part that is in contact with the lading and has no operating 1
components, made of one or more pieces, that joins service equipment to the tank car
tank or joins two pieces of service equipment. This does not include gaskets or
fasteners.
Fitness-for-service The tank car conforms to federal regulations, industry standards, and the owners U
acceptance criteria, and is otherwise suitable for continued service.
Flow capacity Flow capacity of a pressure relief device in cubic feet per minute (cubic meters per A
second) of air at standard conditions when tested at the required flow rating pressure.
Flow rating pressure The inlet static pressure at which the relieving capacity of a pressure relief device is A
measured for rating purposes.
Fluoroscope A phosphor screen, X-ray image intensifier, or other fluorescent medium that emits W
visible light in direct proportion to the amount and distribution of radiation impinging on
its input surface.
Fluorotape A tape recording of an image from the output of a fluoroscope. The image is recorded W
on video magnetic tape for playback on a suitable monitor.
Forge welding A welding process wherein coalescence is produced by heating in a forge or other W
furnace and by applying pressure or blows.
FRA Federal Railroad Administration
Fracture Complete separation of material extending through the entire cross-section of the plate. R
Full fillet weld A fillet weld whose size is equal to the thickness of the thinner member being joined. W
Fusible plug device A non-reclosing pressure relief device designed to function by yielding or melting of a A
plug of suitable material.
Fusion welding Any welding process that uses fusion of the base metal to make the weld. W
Gauging device A system that furnishes an indication of the liquid level inside a tank, not the visual A
gauge in the manway.
General examination A written examination addressing the basic principles of the applicable NDT method. T
Gouge A deformation caused by mechanical means that results in the loss of parent or weld R
metal.
Groove weld A weld made in the groove between two members to be joined. W
Hard conversion When products are hard converted, the design of the item in SI metric units results in H
a physical change and the product is not interchangeable with earlier products built to
the conventional unit design.
Heat treatment Heating and cooling a metal or alloy in such a way as to obtain desired conditions or W
properties. Heating for the sole purpose of hot working is excluded from the meaning
of this definition.
Huddle chamber The configuration of the valve body seat and the immediately adjacent downstream A
parts that redirect the flow of the effluent, causing a popping action by lifting the valve
stem.
ICC Interstate Commerce Commission
Image quality indicator A device whose image in a radiograph is used to determine radiographic quality level. W
(IQI)
Initiator A company or organization that is responsible for identifying and reporting inspection U
results and failures of a material or service.
Injurious defect Any discontinuity (e.g., crack, lamination, pit, or hard spot) that results in a change in R
the materials physical properties so as not to meet specification limits.
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Inspection and test A careful and critical examination of a tank car or portions thereof, performed by D,U
qualified personnel following the owners qualified procedures.
Inspector A person authorized by the tank owner or, when not authorized by the owner, W
designated by the tank fabricator or car builder, to perform inspection.
Interior coating Any paint-type protective covering applied in one or more layers to the interior of a tank L
car tank to act as a barrier between the base metal and the commodity.
Interior heater system A piping system located within the tank that uses a medium to heat the lading within D
the tank for the purposes of unloading.
Interior lining Any sheet or laminated type material, glass, or fused metal applied to the interior of a L
tank car tank to act as a barrier between the base metal and the commodity.
Interpass temperature In a multipass weld, the temperature of the weld area between weld passes. R, W
Interpretation (of NDT The determination of the relevance of indications. T
test data)
ITP Independent Third Party
kPa kilopascals gauge
kPa (abs.) kilopascals absolute
Lap joint A joint between two overlapping members in parallel planes. W
Leak test A leak test of the installed valve or fitting performed below the tank test pressure. D
Except for pressure relief devices, valves and fittings are to be tested in both the
open/plugged and non-plugged closed positions. The purpose of this test is to
determine the integrity of the fluid seal joint between a valve or fitting and the tank,
to determine pressure retention integrity of a valve, and to determine the pressure-
retention integrity of the operable valve seat by a visual inspection through the
valve port opening at the time of test.
Pressure relief device: The purpose of this test is to determine the integrity of the
fluid seal joint between a pressure relief device and the tank, plus the integrity of
the device seals.
Non-reclosing pressure relief device: The purpose of this test is to check for
through-wall corrosion pitting and leakage from threaded connections during
pressurization.
Leak tight An item of service equipment that shows no leakage on the downstream side when A
pressure is applied to the upstream side. All service equipment including closures must
be leak tight under loading conditions and during transit.
Lining For stenciling purposes, interior lining or interior coating is identified as lining on the C
qualification stencil.
Lining or coating owner The party financially responsible for the maintenance for the lining or coating. D, L, U
Lining/coating, corrosion A lining/coating applied to the interior of the tank to prevent corrosion of the tank. L
protection
Lining/coating, product A lining/coating applied to the interior of the tank to prevent contamination of the lading L
purity (product).
Liquefied compressed A gas that, under the charged pressure, is partially liquid at a temperature of 70 F 5
gas (21.1 C).
Liquid level control An automatic system that generates a signal to open or close valves at a A
device predetermined level.
Liquid penetrant A nondestructive test method utilizing contrasting liquids/dyes that penetrate to W
inspection (LP) highlight discontinuities open to the surface (cracks, porosity, seams, etc.).
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Liquid tight All closures, except pressure relief valves, are designed to meet the test pressure of A
the tank without leakage. All final closures must show no leakage at loading conditions
and during transportation.
Liquid valve Any valve that is opened and closed manually or automatically to permit the passage A
of liquid into or out of the tank.
Magnetic particle A nondestructive test method utilizing variations in magnetic fields to detect W
inspection (MT) discontinuities at or slightly below the surface. Limited to ferromagnetic materials.
Maintenance Upkeep or preservation, including repairs necessary and proper to ensure an in- B, D
operation tank cars specification until its next qualification. This also includes
qualification of each repair, but does not necessarily result in a change to the
qualification date stenciled on the tank.
Maintenance program The owners or manufacturers procedures to maintain fitness-for-service. U
Manufacturer of A certified facility that produces a pressure-retaining tank component ready to be used B
pressure-retaining tank by a certified facility.
components
Manufacturer of tank car A certified facility that produces a tank car capable of rolling on its own wheels. B
Manufacturer of tank car A certified facility that produces a tank car tank without the capability of rolling on its B
tank own wheels.
Manufacturer of tank car A certified facility that produces service equipment ready to be applied to a tank car. B
service equipment
Manway The opening on the top of the tank to allow access to the interior for inspection and 1
maintenance or loading and unloading.
Manway cover The closure for the manway that is either a hinged and bolted manway cover or a semi- 1
permanently bolted manway cover or pressure plate.
Marked Applied with either stencil or decal. C
Marked pressure The pressure indicated on the nameplate of a piece of service equipment. A
Method One of the disciplines of NDT (e.g., ultrasonic testing) within which many techniques T
may be included.
Mobile unit A vehicle assigned to a certified tank car facility that is supplied with the equipment, B
material(s), and personnel capable of performing the tank car activities identified in the
facilitys certification.
Modification Any change to a tank car that affects the certificate of construction including an 1
alteration or conversion.
NACE NACE International, formerly National Association of Corrosion Engineers. L
NDT Level III An individual certified by the company as qualified to administer the NDT program. T
Self-certified or appointment by the company is deemed as not meeting the
requirements of Appendix T. Only an individual meeting the testing requirements of
Appendix T, paragraph 1.8.4, can be certified as an NDT Level III.
NGT National Gas Taper Thread
Nondestructive See Nondestructive testing (NDT) T
examination (NDE)
Nondestructive testing A process that involves the inspection, testing, or evaluation of materials, components, T
(NDT) or assemblies for discontinuities, properties, and/or other flaws without impairing or
destroying the parts serviceability.
Non-liquefied A gas that, under the charged pressure, is entirely gaseous at a temperature of 70 F 5
compressed gas (21.1 C).
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Nozzle Consists of a circular or noncircular tube having either a flange or lugs welded to one 1
end. The other end is welded to the tank car tank through an opening sized to the tube
of the nozzle.
Attachments to nozzle of jacket flashing, outage markers, eye bolt hinge tabs, and H&B
manway hinge tabs may be added after unit PWHT.
NPT American Standard Taper Pipe Thread
On-site inspection An evaluation performed at a tank car facility to determine if the tank car activities it B
performs comply with the applicable AAR specifications and federal regulations.
Operator/user A facility that loads or unloads a tank and then offers the car for transportation. U
Outside agency A company or individual who provides NDT services and whose qualifications to T
provide these services have been reviewed and approved by the employer contracting
the company or individual.
Pad An attachment welded directly to the tank under a bracket or light structure for the R
purpose of preventing damage to the tank through fatigue, over-stressing, denting,
puncturing, or tearing.
Padding The introduction of an inert gas under pressure into the vapor space of a tank car tank 2
to create a nonflammable or moisture-free atmosphere.
Patch plate A steel plate applied as an overlay in a corroded area. R
Pit A surface defect resulting from localized corrosion where the cavity diameter at the R
metal surface is equal to or less than the cavity depth.
Pits (grouped) Adjacent pits that are separated by a distance less than two times their average R
diameter.
Pits (random) Adjacent pits that are separated by a distance greater than six times the material R
thickness.
Plug weld A weld made in a circular hole in one member of a joint, fusing that member to another W
member. A fillet-welded hole is not to be construed as conforming to this definition.
Postweld heat treatment Any heat treatment subsequent to welding. W
Practical examination An examination used to demonstrate an individuals ability in conducting the NDT T
methods that will be performed for the employer. For practical examinations, questions
and answers need not be written, but observations and results must be documented.
Preheat The heat applied to the base metal or substrate to attain and maintain the preheat R, W
temperature.
Preheat temperature, The temperature of the base material in the volume surrounding the point of welding R, W
welding immediately before welding is started. In a multi-pass weld, it is also the temperature
immediately before the second and subsequent passes are started.
Pressure plate A bolted manway cover that is designed for the mounting of pressure relief devices, 1
valves, and other closures.
Pressure regulator at The pressure 10 psig higher than the start-to-open pressure; the regulator is adjusted A
10 scfm air and set to flow 10.0 scfm 1.0 scfm of air at this pressure.
Pressure regulator start- The pressure at which the flow is 0.2 scfm to 0.6 scfm of air as measured with a flow A
to-open pressure meter or by collecting a timed volume of air by the displacement of water.
Pressure regulator The pressure with a flow of less than 0.1 scfm and nearly bubble tight. The lower limit A
reclosing pressure for an acceptable reclosing pressure is 80% of the start-to-open pressure.
Pressure regulator valve A device used to maintain a constant pressure in a tank car. As the pressure in the tank A
car increases, the valve opens to relieve pressure.
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Pressure relief device A device that is designed to prevent the rise of internal pressure in excess of a specified A
value resulting from exposure to abnormal conditions. Pressure relief device is
synonymous with the expression safety relief device.
Pressure relief valve A spring-loaded device, actuated by inlet static pressure, that relieves excess pressure A
and recloses after normal conditions are restored.
Pressure-retaining Items integral to the tank car tank (shell, heads, nozzles, flanges, sumps, outlet B
component saddles, and all components welded thereto that contain the lading) excluding service
equipment and valves/fittings.
Primary valve or closure The first device after the tank that closes the flow of liquid or vapor. Examples include 1
valves, pipe plugs, caps, and blind flanges.
Procedure A detailed, written instruction for conducting nondestructive testing. Procedures shall T
be approved by an NDT Level III certified in the applicable method.
Procedure qualification A document providing the actual welding variables used to produce an acceptable W
record (PQR) procedure qualification test weld and the results of tests conducted on the weld.
psi pounds per square inch gauge
psia pounds per square inch absolute
Purging The replacement of air or other vapors in a tank car by introducing gaseous nitrogen or 2
other cryogenic liquids under low pressure and venting the resulting gas mixture.
Purging is generally used as part of the cleaning operation for tank cars or for cars
being prepared for a change in commodity service.
Qualification, NDT The education, skills, training, knowledge, and experience required for personnel to T
personnel properly perform to a specified NDT level.
Qualification, tank car A careful and critical examination of a tank car, based on a written program, to verify B, D
that the tank car conforms to specification, followed by a representation that the tank
car conforms to the specification.
Qualification, welder The demonstration of a welders or welding operators ability to produce welds meeting W
performance prescribed standards.
Qualification, welding A record of welding variables used to produce an acceptable test weldment and the W
procedure results of tests conducted on the weldment to qualify a welding procedure specification.
Qualified The welder, welding operator, or welding procedure qualification requirements of W, 6/3
Appendix W have been met.
Radiograph The film transparency or paper image obtained by development of a sensitized W
emulsion film after passage of radiation (X-rays or gamma rays) through an object to
expose the emulsion.
Radioscopy (RT) A nondestructive test method of observing the internal characteristics of objects that W
are opaque to light with X-rays or gamma rays, specifically with radiographic or
fluoroscopic techniques.
Radiotape A film or paper radiograph or fluorotape. W
Reactive to the tank or A material that, in contact with the inner shell of the tank or with the service equipment, B, L
service equipment may react to produce heat, gases, and/or pressure that could substantially reduce the
effectiveness of the packaging or the safety of its use.
Rebuild A complete disassembly of a valve or fitting to inspect the pressure-containing and D
operating components for noticeable defects, cleaning as necessary, restoration of
components that have noticeable indications of defects, and replacement of all resilient
components. See Appendix A, paragraph 3.11.1, for maintenance limitations.
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Refresher training Training to refresh and/or update the theoretical knowledge and skills of the technician T
as deemed necessary by the Level III.
Registration An acknowledgment from the AAR that a tank car facility has stated and submitted B
checklists indicating that the facility meets all the applicable requirements of the AAR
Manual of Standards and Recommended Practices, Section C, Part III, Appendix B.
Reinforced tank shell A nonstandard term for a weld in a butt joint; the portion of a butt weld (butt joint, groove R, W
butt weld (butt joint, weld) covered by a reinforcing pad.
groove weld)
Reinforcing pad An attachment welded directly to the tank to support structural components. R
Reliability The quantified ability of an item or structure to operate without failure for the specified D
period of its design life or until its next qualification.
Remanufacture Performed only by, or with approval of, the original equipment manufacturer (OEM), D
that includes the complete disassembly and cleaning of the valve or fitting to verify that
all components are within tolerances and restoration or replacement of components,
including replacement of resilient components, to the specification.
Replacement in-kind Replacement with the same manufacturer, model, size, and capacity. 1
Repair To restore defective tank car service equipment to the original AAR-approved design R
and function, or reconstruction of a tank car tank/tank car to its original AAR-approved
design and function.
Representation Attesting through documenting, in writing or by marking on the tank (or jacket), that a D
tank car is qualified.
Reseal A disassembly of a valve or fitting as necessary to access resilient components, D
followed by an inspection of the sealing surfaces, replacement of resilient components,
and reassembly of the valve or fitting.
Rules AAR interchange rules. C
Rupture disc The operating part of a rupture disc device. A
Rupture disc device Consisting of a rupture disc and a rupture disc holder, a non-reclosing pressure relief A
device actuated by inlet static pressure and designed to function by bursting of a
pressure-containing disc.
Safety system Thermal protection systems, insulation systems, tank head puncture-resistance D
systems, coupler vertical-restraint systems, and systems used to protect
discontinuities, service equipment (e.g., skid protection and protective housings) as
required in the regulations.
Sample valve A valve that is opened and closed manually to allow collection of a small amount of 1
lading for analysis.
Score A narrow deformation caused by mechanical means wherein parent or weld metal is R
upset and relocated.
Seat That part of the pressure relief valve in its orifice area that forms a seal with the stem A
and adjacent parts.
Secondary valve or The first device downstream from the primary closure that closes the flow of liquid or 1
closure vapor if the primary closure would be normally operated. Examples include valves, pipe
plugs, caps, and blind flanges.
Service equipment Pressure relief devices, valves, closures and fittings; devices used for loading and 1, B, C, D
unloading, venting, sampling, vacuum relief, measuring the amount of lading and/or
lading temperature, or flow restriction.
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Service equipment The party financially responsible for the maintenance of the service equipment. U
owner
Service reliability A systematic evaluation of an item based on an analysis of collected information from U
assessment in-service experience to verify an items resistance to failure and deterioration.
Set pressure The pressure, measured at the valve inlet, at which a pressure relief valve is set for A
start-to-discharge.
Shell-full The liquid volume at the transition point at which air or vapor becomes entrapped in a 1
location that is not in direct communication with all top fittings. See Fig. E.14 for
examples.
SI unit The official abbreviation, in all languages, for the International System of Units. The H
International System is not the old centimeter gram-second system, but a modernized
version of it. It is a coherent system in which there is a one-to-one correspondence
among all the base units and derived units. The SI style for writing large numbers calls
for eliminating commas and writing numerals in groups of three on either side of the
decimal point.
Significant digit Any digit that is necessary to define the specific value or quantity. When measured to H
the nearest 1 meter (m), a distance may be recorded as 157 m; this number has three
significant digits. If the measurement had been made to the nearest 0.1 meter (m), the
distance may have been 157.4 m; this number has four significant digits.
Single-welded butt joint A butt weld with filler metal added from one side only. W
Size (fillet) For equal leg fillet welds, the leg lengths of the largest isosceles right triangle that can W
be inscribed within the fillet weld cross-section. For unequal leg fillet welds, the leg
lengths of the largest right triangle that can be inscribed within the fillet weld cross-
section.
Slot weld A weld made in an elongated hole in one member of a joint, fusing that member to W
another member. The hole may be open at one end. A fillet-welded slot is not to be
construed as conforming to this definition.
Soft conversion When conventional units are soft converted, the physical dimensions of an item remain H
unchanged and the units of measurement are in SI terms.
Specific examination A written examination to determine an individuals understanding of procedures, codes, T
standards, specifications, and equipment or instrumentation for an NDT method used
by the employer.
Specification (tank car) The specific designation within a class (e.g., Specification DOT-111A100W2). 1
Spring-loaded check A check valve that has its valve maintained in the closed position by a spring and that T
valve is opened by the valve mounted above it.
Stamped Steel-stamped. C
Standard conditions 60 F (15.56 C) and 14.696 psia (101.325 kPa [abs.]). A
Start-to-discharge The pressure, measured at the valve inlet, at which there is a measurable lift of the A
pressure closure device on a pressure relief valve or at which discharge becomes continuous as
determined by seeing, feeling, or hearing.
Start-to-leak pressure The pressure, measured at the valve inlet of a pressure relief valve, at which the A
relieved fluid is first detected at the down-stream side of the seat.
Start-to-open pressure The pressure, measured at the valve inlet of a vacuum relief valve, at which the relieved A
fluid is first detected at the downstream side (internal to the tank) of the valve seat.
Station stencil Unique identifier assigned to each certified tank car facility by AAR. B
Stenciled Applied with paint or decal. C
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Stress-relief heat Uniform heating of a structure or a portion thereof to a sufficient temperature to relieve W
treatment the major portion of the residual stresses, followed by uniform cooling.
Stripping Encompasses chemical, thermal, and mechanical techniques of removal of existing L
linings or coatings from tank car tanks and/or valves and fittings.
Stub sill tank car A stub sill tank car (or a tank car without continuous center sill) has draft sills at each 1
end of the tank instead of a continuous center sill and utilizes its tank as a part of the
car structure.
Supply container A container that complies with DOT specifications for cargo tanks, portable tanks, or 5
compressed gas cylinders.
Surface area The tank surface area of a single-unit, single-compartment tank car tank is the A
outside area of the tank shell, the end-closure heads, and, in the case of an
expansion dome-type tank, the dome cylinder and dome head, but in either case
does not include any appurtenances.
The tank surface area of a single-unit, multiple-compartment tank car tank
constructed with single or dual internal heads, or of separate tanks banded
together, is the total outside surface area of each of the individual tanks so formed.
Surface crack Separation of material extending 1/16 in. or less through the tank plate thickness. R
Surge pressure A device incorporated into the design of a tank car or attached thereto that, by design, A
reduction device reduces the internal surge pressures at the pressure relief device interface.
Tack weld A weld made to hold the parts of a weldment in proper alignment until the final welds W
are made.
Tack welder One who performs manual or semiautomatic welding to produce tack welds. W
Tank car A tank car tank mounted on or forming part of a car structure, including all components B
necessary and proper for railroad service.
Tank car activity A function performed at a facility that requires certification in accordance with the AAR B
Manual of Standards and Recommended Practices, Section C, Part III (M-1002),
Appendix B. As information, tank car activity relates directly to the commodity
outlined in the AAR Manual of Standards and Recommended Practices, Section J
(M-1003), Appendix A.
Tank car facility A fixed location built, established to perform, or arranged to perform tank car activities B
identified by the activity code(s) to which it is certified.
Tank car owner The owner of the reporting mark stenciled on the car. Where multiple owners exist D, U
under one reporting mark, the Owners Mark field in UMLER is to be used.
Tank car tank Consists of a shell, heads, nozzles, sumps, interior heater coils, and all welds joining B
them. This includes all components welded thereto that contain the lading.
Tank test date (initial The date of test of the tank on the completed car must be the same year as the built 1
stenciled) date of the car. The car builder must record the test data and provide it to the original
owner. The initial tank test date may be the same as the built date, provided the tank
test was conducted within 6 months prior to the built date.
Tanks As used in this specification means tank car tank. B
Technical performance The demonstration of competence in an NDT method or technique by a qualified T
individual. The NDT-qualified individual has demonstrated the ability to apply NDT
technical knowledge and complete NDT assignments.
Technique A specified process within an NDT method, for example magnetic particle yoke T
technique.
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Temporary weld A weld made to attach a piece or pieces to a weldment for temporary use in handling, R, W
fitting, or working on the weldment.
Temperature sensing A part or parts that permit the determination of the temperature of a tanks contents. A
equipment
Thermometer well A closed pipe filled with a fluid medium that extends through a cover plate into the tank 1
that allows the insertion of a thermometer and is closed with a threaded cap.
Throat (fillet) Theoretical throat. The distance from the beginning of the joint root perpendicular to the W
hypotenuse of the largest right triangle that can be inscribed within the cross-section of
a fillet weld.
Top shell The tank car tank surface, excluding the head ends and bottom shell of the tank car D
tank.
Training An organized program developed to impart the knowledge and skills necessary for T
qualification.
Type (tank car) Designates the approving authority (e.g., AAR, ARA, ICC, DOT, or USG). Preferred 1
usage is, for example, DOT tank cars.
Ultrasonic inspection A nondestructive test method that transmits ultrasonic energy through the test material W
(UT) to detect internal and surface discontinuities. Used also for thickness measurements.
UMLER Universal Machine Language Equipment Register
Vacuum relief valve A pressure relief device designed to admit air to prevent an excessive internal vacuum A
and to reclose after normal conditions have been restored.
Valve or fitting owner The party responsible for bearing the cost of the maintenance of the valve or fitting. D
Valve stem A central movable shaft attached to an integral head or multiple-piece assembly that A
contains pressure at the orifice of a pressure relief valve.
Valves A device attached to a tank car tank designed to control flow of lading into and out of A
the tank.
Purposes include, but are not limited to the following: measure fluid pressure and
temperature; sample fluids in the tank; detect or determine liquid levels; or relieve over-
pressures for purposes of emergency relief or temperature control.
Vapor valve Any valve that is opened or closed manually or automatically to permit the passage of A
vapor into or out of the tank.
Vaporizer A device used to evaporate liquefied compressed gases, usually where the required 5
flow rate exceeds the normal flow rate achieved by natural heat transfer from the
atmosphere.
Vapor-tight pressure The pressure, measured at the valve inlet after closing, at which no further fluid flow is A
detected at the downstream side of the seat of a pressure relief valve.
Visual An inspection of valves, fittings, and closures, without disassembly, for obvious signs D
of defects.
Visual inspection A nondestructive test method utilizing vision to detect surface imperfections in W
materials (including welds).
Weld surfacing or weld The application by welding of a layer, or layers, of material to a surface to obtain desired R, W
buildup dimensions or properties, as opposed to making a joint.
Welder One who performs manual or semiautomatic welding. W
Welding operator One who operates adaptive control, automatic, mechanized, or robotic welding W
equipment.
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Welding procedure A document providing in detail the required variables for specific application to ensure W
specification (WPS) repeatability by properly trained welders and welding operators.
Wheel burn Damage to tank shell due to frictional contact with a rotating wheel, resulting in metal R
flow and/or discoloration due to frictional heat.
Written practice A document prepared by the employer to specify methods, requirements, examination, T
records, certifying official, etc., for a companys NDT personnel certification program.
1.2.1 Tank Car Definitions
Tank cars currently in service are of three types: DOT, AAR, and ICC. See paragraph 1.1.4 for
specifications in effect for new construction.
1.2.1.1 DOT Tank Cars
DOT tank car specification numbers consist of a class designation followed by identifying letters
and numbers. In all classes except 103, 104, and 113, the class designation is followed by an A,
which has no special significance. Suffix W denotes a fusion-welded tank; suffix F denotes a
forge-welded tank; and suffix X has special significance as discussed below. The absence of a
suffix indicates seamless tank construction.
Class DOT-103*W tank cars are insulated or uninsulated nonpressure cars with an expansion
dome. The expansion capacity in the dome is listed below. Class 103*W cars built for specific
services or requiring special fittings or materials of construction are designated by letters
interposed for the asterisk.
Table 1.3 Class DOT-103*W expansion capacity and suffix letters
Bottom Bottom Minimum Percentage
Tank Outlet Washout Expansion
(No Ltr.) 2
A Carbon steel No 1
AL Aluminum alloy 2
A-AL Aluminum alloy No 1
AN Nickel No 1
B Carbon steel, elastomer lined No No 1
C Alloy steel No No 1
D Alloy steel 2
E Alloy steel No 1
Class DOT-104W tank cars are insulated carbon steel nonpressure cars with an expansion dome
and having a minimum expansion capacity of 2% in the dome.
Class DOT-105A, J, or S***W tank cars are insulated carbon or alloy steel pressure cars, with a
manway nozzle, designed for top loading and unloading; bottom outlet or washout prohibited.
Class 105A or J***ALW tank cars are similar except that they have aluminum alloy tanks. Class
105A***F has forge-welded tanks.
Table 1.4 Class DOT-105A, J, or S***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture
resistance, and top-and-bottom shelf couplers
S = equipped with tank head puncture resistance and top-and-bottom shelf
couplers
11/2014 C-III [M-1002] 25

CHAPTER 1 M-1002
Class DOT-106A***X tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a maximum stress level in the shell.
Table 1.5 Class DOT-106A***X suffix letters
X = Fusion-welded longitudinal tank seam and forge-welded head seams
XNC = Nickel clad
NCI = Nickelchromiumiron
Class DOT-107A**** tank cars are uninsulated high-pressure service cars having several
permanently mounted seamless, forged, and drawn steel tanks designed to a maximum stress
level in the shell.
Class DOT-109A***W tank cars are insulated or uninsulated carbon steel pressure cars with a
manway nozzle, designed for top loading and unloading, bottom washout optional.
Class DOT-109A***ALW tank cars are similar except they have aluminum alloy tanks.
Class DOT-110A***W tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a burst pressure.
Class DOT-111A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The expansion capacity in the tank is 2%. Class DOT-111A***W* tank cars built
for specific services or requiring special fittings or materials of construction are designated by
suffix letters or numerals. Class DOT-111A***F* have forge-welded tanks converted from
Specification ICC-105A300, 400, or 500. Suffix letters are shown in Table 1.6.
Table 1.6 Class DOT-111A***W* suffix letters
Bottom Bottom
Tank Outlet Washout
ALW1 Aluminum alloy
ALW2 Aluminum alloy No
W1 Carbon steel
W2 Carbon steel No
W3a/ Carbon steel
W4a/ Carbon steel No No
W5 Carbon steel, elastomer lined No No
W6 Alloy steel
W7 Alloy steel No No
F1 Carbon steel
F2 Carbon steel No
a/ Insulation required.
Table 1.7 Class DOT-111A, J, or S***W* delimiter letters

A = equipped with top-and-bottom shelf coupler
J = equipped with top-and-bottom shelf coupler, tank head puncture-resistance
system, and thermal protection
S = equipped with top-and-bottom shelf coupler and tank head puncture-
resistance system
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M-1002 CHAPTER 1
Class DOT-112A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars, with a manway nozzle and without bottom connections, designed for top loading and
unloading.
Table 1.8 Class DOT-112A, J, S, or T***W suffix letters
J = equipped with jacketed thermal protection, tank head puncture resistance,
and top-and-bottom shelf couplers
S = equipped with head shields and top-and-bottom shelf couplers
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-113****W tank cars are vacuum-insulated cars having an inner container and carbon
steel outer shell. The insulation system is designed for a holding time. Class DOT-113 cars are
designed for specific loading and shipping temperatures and have certain materials and fittings
requirements as designated by the intermediate letter.
Table 1.9 Class DOT-113****W suffix letters
A = Minus 423 F (253 C) loading; high alloy steel inner container; special
fittings and insulation for refrigerated (cryogenic) liquid hydrogen
C = Minus 260 F (162 C) loading; high alloy steel inner container; special
fittings for refrigerated (cryogenic) liquid natural gas, refrigerated
(cryogenic) liquid methane (DOT exemption required), or refrigerated
(cryogenic) liquid ethylene
D = Minus 155 F (104 C) loading; nickel alloy steel inner container; special
fittings for refrigerated liquid ethane (DOT exemption required) or
refrigerated (cryogenic) liquid ethylene
Class DOT-114A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars with a manway nozzle and optional noncircular cross-section. An additional group of
valves and fittings may be provided in another location.
Table 1.10 Class DOT-114A, J, S, or T***W suffix letters
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-115A***W* tank cars are insulated nonpressure cars having an inner container and
carbon steel outer shell with optional bottom connections. Suffix letters are shown in Table 1.11.
Table 1.11 Class DOT-115A***W* suffix letters
W1 = Steel inner container
W6 = Alloy steel inner container
ALW = Aluminum inner container
Class DOT-120A, J, or S***W tank cars are insulated pressure cars with a manway nozzle. An
additional group of valves and fittings may be provided in another location
Class DOT-120***ALW tank cars are similar except that they have aluminum alloy tanks.
11/2014 C-III [M-1002] 27

CHAPTER 1 M-1002
1.2.1.2 AAR Tank Cars

Most AAR tank cars have DOT/TC counterparts, the main specification differences being that only
partial postweld heat treatment is required and radioscopy is not required for carbon steel tanks.
Suffix W denotes a fusion-welded tank.
Class AAR-201A**W tank cars, now obsolete for new construction, are insulated or uninsulated
aluminum nonpressure cars with an expansion dome.
Class AAR-203*W tank cars are insulated or uninsulated nonpressure cars with an expansion
dome. These cars conform, with certain exceptions, to Class DOT-103W.
Table 1.12 Class AAR-203*W suffix letters
(No letter) = carbon steel
D = alloy steel
Class AAR-204 tank cars are vacuum-insulated cars having an inner container and carbon steel
outer shell. They are designed for loading of liquid argon, nitrogen, or oxygen. Specification AAR-
204W tank cars are similar in concept to Class DOT-113****W cars. Suffix letters are shown in
Table 1.13.
Table 1.13 Class AAR-204 suffix letters
X = Conversion from XT boxed tank cars
W = Fusion-welded alloy steel inner container and carbon steel outer shell
Specification AAR-205A300W tank cars are now designated DOT-109A300W

Specification AAR-206W tank cars are insulated nonpressure cars having an inner container
and carbon steel outer shell. These cars conform, with certain exceptions, to Class DOT-
115A***W*.
Table 1.14 Specification AAR-206W suffix letters
Class AAR-207A**W* pressure-differential covered hopper cars are designed for 15 psig
(103 kPa) minimum internal pressure and are used for the transportation of granular commodities
that are unloaded pneumatically. Suffix letters are shown in Table 1.15.
Table 1.15 Class AAR-207A**W* suffix letters
W = Carbon steel fusion-welded tank
ALW = Aluminum alloy fusion-welded tank
W6 = Alloy steel fusion-welded tank
Specification AAR-208 tank cars are nonpressure cars having wood-staved metal hooped tanks
for the transportation of certain food-grade materials.
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M-1002 CHAPTER 1
Class AAR-211A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The numeral after W designates specific outlet and bottom connection options.
These cars conform, with certain exceptions, to Class DOT-111A***W*. Suffix letter or numerals
are shown in Table 1.16.
Table 1.16 Class AAR-211A***W* suffix letters
W1 = Carbon steel tank
2% minimum expansion capacity in tank
Optional bottom outlet or washout
No bottom outlet
Optional bottom washout
2% minimum expansion capacity in tank
Insulation required
Optional bottom outlet or washout
No bottom outlet washout
Elastomer lining
W5 = Carbon steel, elastomer lined
No bottom outlet
No washout
W6 = Alloy steel
Optional bottom outlet or bottom washout
W7 = Alloy steel
No bottom outlet or bottom washout
ALW = Aluminum alloy tank
1.2.1.3 ICC Tank Cars

ICC tank car specifications, in general, were redesignated DOT specifications. Those tank cars not
so redesignated have riveted or forge-welded tanks, but conform in other respects to corresponding
DOT classes.
Class ICC-103 and Class ICC-104 have riveted tanks.
Specification ICC-103 CAL has a triple-riveted aluminum tank with 1% minimum expansion
capacity dome.
Class ICC-105A*** have forge-welded carbon steel tanks.
Class ICC-106A*** tanks are identical to DOT-106A***X except they have forge-welded
longitudinal seams.
1.2.1.4 Emergency USG Tank Cars
Emergency USG* tank cars are insulated or uninsulated carbon steel nonpressure cars with 2%
capacity expansion domes. They were built during World War II for transportation of petroleum
products limited to 8 lb/gal (0.959 kg/L), and vapor pressure not exceeding 16 psia at 100 F
(110 kPa [abs.] at 37.8 C). They became obsolete for new construction in 1956.
11/2014 C-III [M-1002] 29

CHAPTER 1 M-1002
1.3 General Requirements

1.3.1 Car Structure
All car structure details must comply with these specifications and with related specifications and
publications listed in AAR Specification M-1001, paragraph 1.1.2.
1.3.2 DOT Tanks
All tanks and appurtenances constructed for use in transporting materials classed as dangerous
by the DOT must comply with the applicable DOT specifications and supplementary AAR
requirements. The DOT specifications are general and minimum for tanks and equipment
therefor.
1.3.3 AAR Tanks
AAR-specification tanks are for use in the transportation of materials not classed as dangerous by
the DOT, except that certain low- and medium-hazard materials are permitted in AAR-
specification tanks, reference 49 CFR 173.240, 173.241, and 173.242. Such tanks and
appurtenances must comply with all applicable AAR specifications and requirements in effect at
the time of construction.
1.3.4 Safety Appliances
Safety appliances must comply with the current issue of DOT Railroad Safety Appliance
Standards, 49 CFR 231. Appurtenances such as platforms and ladders for loading and unloading
must comply with Appendix S.
1.3.5 Interchange
Any tank car tank that does not meet prescribed test and qualification requirements is not
authorized in railroad interchange.
A valid Certificate of Construction and, when applicable, Exhibit R1 reports (see Appendix R)
must exist for any completed tank car in railroad service.
The Field Manual of the AAR Interchange Rules, Rule 90.A.1, prohibits the use of freight cars
(including tank cars) in interchange over 40 years from date built except as otherwise provided for
in the Office Manual of the AAR Interchange Rules, Rule 88.
1.3.6 Approvals
1.3.6.1 Design and materials for fabrication, alteration, conversion, or welded repairs must be
approved, per paragraph 1.4 of this chapter. Design and materials of all valves and closures on
tank cars must be in accord with Appendix A and must be approved. Design, materials, and flow
capacity ratings of pressure relief devices used on tank cars must be approved.
1.3.6.2 Revision or substitution for any valve or fitting, except substitution of equivalent kind
approved on the Certificate of Construction, or the addition of supplemental valves or fittings to
the tank or to those fittings covered by the certificate constitutes an alteration as defined in
Appendix R and must be approved.
1.3.6.3 Closures manufactured according to a nationally recognized standard may replace a valve
or closure without AAR approval of the arrangement, except for bottom outlet valves and bottom
outlet closure. Such an application requires an R1 listing the fitting removed and the type of
closure applied.
1.3.6.4 Replacement of an AAR-approved valve or closure with another AAR-approved valve or
closure requires car owner approval.
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M-1002 CHAPTER 1
1.3.6.5 In addition to valves and/or closures approval requirements, the fittings arrangement on
the tank car also requires approval. The fittings arrangement is identified on the Form AAR 4-2
and is approved as part of the tank car design. If the fittings arrangement is altered, the alteration
must be approved. The alteration of the fittings arrangement must be submitted using the Form
AAR 4-2.
1.3.7 Editions of Referenced Specifications
Unless a specific year is recorded after the specification number, wherever AAR, ASTM, AWS, or
other specifications are noted, the latest editions are approved.
1.3.8 Calibration and Capacity Tables
1.3.8.1 Calibration
The procedures for tank car calibration are set forth in API Standard 2554, Measurement and
Calibration of Tank Cars. For all cars constructed after May 1, 2001, gauged or strapped
capacities shall be rounded to the nearest 10-gal and 50-L increments. Rounding is to be
performed after any conversion of units. For cars constructed prior to May 1, 2001, conformance to
this standard is optional.
1.3.8.2 Capacity Tables
For all cars constructed after May 1, 2001, capacity tables shall be provided by the car builder.
Capacity tables shall conform to the following:
1.3.8.2.1 Tables shall list outage volumes (volume of air or vapor above the surface of a liquid)
corresponding to distances measured downward from the shell-full (zero-outage) level.
1.3.8.2.2 Tables shall begin at the shell-full (zero-outage) level and continue for the full depth of
the tank.
1.3.8.2.3 If English units are used, volumes shall be whole U.S. gallons and distances shall be
inches in one-quarter-inch increments. If metric units are used, volumes shall be whole liters and
distances shall be whole centimeters.
1.3.8.2.4 All tables must show an effective date.
1.3.8.2.5 For reference, the following conversion factors are to be used:
Multiply U.S. gallons by 3.785 to convert to liters.
Multiply imperial gallons by 1.201 to convert to U.S. gallons.
Multiply imperial gallons by 4.545 to convert to liters.
Multiply inches by 2.540 to convert to centimeters.
1.3.8.2.6 Tank cars may be grouped when assigning capacity tables if the measured (water
gauged or strapped) shell-full capacity of the tank is within 0.1% of the shell-full capacity used in
the gauge table.
1.3.9 Gauging
Tank car tanks can be gauged by built-in gauge marker, tell-tale valve, or electronic or magnetic
gauging device as may be in accordance with the specification. Gauging can alternatively be
accomplished by scale weighing, liquid metering, or by use of poles and outage/innage tables,
depending upon the commodity and class of car involved. Procedures for gauging tank car tanks
are detailed in API Measurement Standard 3.2, Tank GaugingGauging Petroleum and
Petroleum Product in Tank Cars.
Effective August 1, 2005, tank cars equipped with slip tube gauging devices must have them
removed no later than the next tank qualification event. Cars altered under this rule need not
meet the capping kit requirements of Appendix E, paragraph 3.1.6.
11/2014 C-III [M-1002] 31

CHAPTER 1 M-1002
1.3.10 Age Limits

There is no life limit on a tank car tank if the tank conforms to both the federal regulations and
the AAR requirements. Underframes built prior to July 1, 1974, have an AAR life limit of 40 years,
unless the underframe is rebuilt or has received extended service status. Underframes built since
July 1, 1974, have an AAR life limit of 50 years. When applying a tank to a new or existing
underframe, the Tank Car Committee must approve the application. After applying a tank to a
new or existing underframe, the tank must be qualified to verify tank integrity.
1.3.11 Head Shields
Head shields must be applied by certified facilities and appropriate reports submitted.
1.3.12 Rebuilt Status
Requests for rebuilt status for tank cars must be made in accord with the Office Manual of the
AAR Interchange Rules, Rule 88, and not on Form AAR 4-2.
1.3.13 Commodity Change
If a tank car is designated for a specific commodity on its Certificate of Construction and is used to
transport another commodity or class of commodities, the commodity change alters the Certificate
of Construction and therefore must be approved by the car owner and meet all federal regulations.
1.3.14 Reporting Marks and Car Numbers
Changes in reporting marks and car numbers affect the validity of the Certificate of Construction
and must be reported on Exhibit R1. Both old and new numbers must be reported. This is in
addition to UMLER procedures and the requirements of the Office Manual of the AAR Interchange
Rules, Rule 88, for such changes.
1.3.15 Documentation at the Sale of Tank Cars
At the sale of a tank car, the car owner must transfer the documents outlined in paragraph 1.6.4 to
the new car owner.
1.3.16 Requirements for Tank Cars with Gross Rail Load Over 263,000 lb to 286,000 lb,
Inclusive
This subsection applies to tank cars with gross rail load over 263,000 lb to 286,000 lb, inclusive. It
specifies requirements for new construction and alterations to existing cars that increase gross rail
load. It does not apply to upgrades of cars from 70 ton to 100 ton or to existing six- or eight-axle
equipment. New construction and gross rail weights of tank cars in excess of 286,000 lb are
prohibited. Compliance with this subsection is required for cars ordered after July 25, 1997.
1.3.16.1 All Cars
1.3.16.1.1 Cars must be in conformance with the Office Manual of the AAR Interchange Rules,
Rule 88.
1.3.16.1.1.1 Cars must be in conformance with the truck requirements located in S-286 as
required in the Office Manual of the AAR Interchange Rules, Rule 88.
1.3.16.1.2 AAR cars must be stenciled AAR Class-211W or Class-204W.
1.3.16.1.3 Cars must be registered in UMLER with Star Code L or M as appropriate.
1.3.16.2 New Cars
Form AAR 4-2, Application for Approval and Certificate of Construction, must specify the gross
rail load for which the cars are designed and must certify that all of the requirements of
paragraph 1.3.16.1 are met.
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M-1002 CHAPTER 1
1.3.16.3 Existing Cars

1.3.16.3.1 Form AAR 4-2, Application for Approval and Certificate of Construction, must be
submitted to the Tank Car Committee for approval to increase the gross rail load above 263,000 lb
if cars were not so originally approved. This application must specify the gross rail load to which
the cars are being altered and must be accompanied by a letter from a certified car builder stating
that all of the requirements of paragraph 1.3.16.1 are met or by complete documentation,
specifications, and stress analysis as described in Office Manual of the AAR Interchange Rules,
Rule 88, Section C.3.
1.3.16.3.2 Cars that are altered to increase gross rail load must have trucks, center sills or stub
sills, body bolsters, and draft systems inspected in accord with the Field Manual of the AAR
Interchange Rules, Rule 88, Section B.2 and structural elements inspected in accord with 49 CFR
180.509(e).
1.3.16.3.3 Existing cars may have gross rail load increased above 263,000 lb if originally
designed for the higher load and so noted on the Certificate of Construction.
1.3.16.3.4 Tank cars that exceed 263,000 lb due to the addition of approved safety features must
be in compliance with paragraph 1.3.16.3.1 but need not comply with paragraph 1.3.16.3.3.
1.3.17 Maintenance Program
The provisions of Appendix U apply to the following entities:
Tank car owner
Service equipment owner
Lining or coating owner
Tank car manufacturing facility
Tank car repair facility
Operator/User
Subcontractor
1.4 Procedures for Securing Approval
1.4.1 General
Paragraph 1.3.6 of this specification and U.S. Department of Transportation (DOT) and Transport
Canada (TC) regulations require AAR Tank Car Committee (Committee) approval of designs and
materials used for the construction, conversion, alteration, or welded repair of tank car tanks. The
Committee has delegated to the AAR Safety and Operations Department the authority on its
behalf to approve applications provided that
they have been reviewed and deemed to be in accord with AAR, DOT, and TC requirements
by an independent third party (ITP) that has been certified by the Committee in accord
with paragraph 1.5, or,
they meet the requirements for precedent approval outlined in paragraph 1.4.2.3.
The AAR may elect to request a Committee ballot on any application for approval. Such a request
should be made within 10 days of receipt of the application.
Applications for approval of service equipment will continue to be approved by the Tank Car
Committee in accord with paragraphs 1.4.6 and 1.4.7.
11/2014 C-III [M-1002] 33

CHAPTER 1 M-1002
1.4.1.1 AAR Tank Car Application for Approval and Certificate of Construction
Web-Based System
Effective January 1, 2015, applicants are required to use the AAR Tank Car Application for
Approval and Certificate of Construction Web-Based System for submittal of applications for tank
car designs. This system encompasses the entire process of seeking approval of tank car designs.
Tank car design applicants, AAR, and certified ITPs are required to obtain access to this system
and will use it in processing applications through the approval process, including the certificate of
construction submittal. A system user guide is available to those who obtain access.
To obtain access to the Tank Car Application for Approval and Certificate of Construction
Web-Based System, contact Railincs Customer Support Center (CSC) where the application is
hosted and maintained on behalf of the AAR. Customer support can be reached at 877-724-5462 or
via email to csc@railinc.com.
1.4.1.1.1 Drawings and Supporting Documents
In addition to the Form AAR 4-2, which must be completed in its entirety by the applicant, all
applicable drawings and supporting documents must also be uploaded following the outlined
instructions within the system. These drawings/documents must all be in PDF format.
1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2)
All applications for approval, both nonprecedent and precedent (as defined herein), must be
submitted to the Executive DirectorTank Car Safety using Form AAR 4-2, Application for
Approval and Certificate of Construction. Form AAR 4-2 is reproduced in this manual in Fig. 1.1,
and paragraph 1.4.3.1 contains instructions for its completion.
Precedent applications (i.e., applications based on prior Committee-approved applications) will
be evaluated by AAR staff as described in paragraph 1.4.2.3.
Nonprecedent applications (and listed major deviations from precedent applications) will be
reviewed and evaluated by a certified ITP, selected by AAR staff from a list of contractors approved
by the Tank Car Committee. Handling of nonprecedent applications is further described in
paragraph 1.4.2.2.
1.4.2.1 Fees
Application fees are listed in the Office Manual of the AAR Interchange Rules, Appendix E. In
addition, applicants are responsible for the cost associated with the review of applications by an
ITP. Applicants will receive invoices for fees related to the application process.
1.4.2.2 Nonprecedent Applications
Nonprecedent applications are those not based on previously approved designs. When required by
AAR Specification M-1001 or paragraph 1.4.2.5 of this specification, one copy of the application
with multiple sets of drawings must also be furnished to the AAR Technical Services Section for
approval of brake systems and car structure.
The certified ITP assigned by AAR staff will review the application for compliance with AAR and
DOT/TC requirements and will deal directly with the applicant to resolve any discrepancies. The
Director must receive copies of all correspondence related to resolution of questions on the
application. The AAR will be notified by the certified ITP through the web-based system that the
application is satisfactory. The ITP is required to respond to either the applicant or AAR, as
appropriate, within 21 days of receipt of the application. If a discrepancy leads to an application
revision, the ITP is required to respond to the applicant or AAR within 14 days of receipt of the
revised application.
In the event that an ITP and the applicant cannot resolve discrepancies in an application and the
ITP recommends against approval, the applicant may request Tank Car Committee review of the
application in accord with the process outlined in paragraph 1.4.2.12.
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M-1002 CHAPTER 1
1.4.2.3 Precedent Applications

Precedent approval may be requested on car designs where the tank and attachments thereto do
not incorporate major changes from designs previously approved. Precedent applications may
reference a design identical to that for which approval is requested or they may contain limited
revisions to the original design as listed in paragraph 1.4.2.4. Deviations from the previously
approved design must be summarized and submitted with the application. Drawings that clarify
changes that fall within the scope of precedent approval also may be attached.
AAR staff may approve a request for precedent approval without ITP review provided that the
referenced precedent certificate of construction was approved within the preceding 10 years. The
application may include changes listed in paragraph 1.4.2.4. The AAR is required to respond to the
applicant, as appropriate, within 21 days of receipt of the application.
1.4.2.4 Design Differences Acceptable for Precedent Approval
Subject to the limitations outlined in paragraph 1.4.2.3, permitted design differences from
previously approved designs may include the following:
Changes in tank length only, provided that the rail load limit is not increased
A reduction in rail load limit
A change in arrangement or number of heater coils, including deletion of the entire system
or application of a previously approved system
Changes to appurtenances used for loading and unloading, provided that they are in
compliance with Appendix S and the AAR Interchange Rules
Changes to trucks, braking systems, or draft systems, provided that they are in compliance
with the AAR Interchange Rules
Use of previously approved tank opening reinforcements, nozzles, and protective housings,
provided that the approved design and application were for tanks of equal or greater test
pressure
Application or rearrangement of previously approved fittings, provided that they had been
approved for tank cars of equal or greater test pressure
Changes to materials of previously approved fittings that are necessary for compatibility
with lading, provided the changes do not reduce the strength of the fitting or its
components (see paragraph 1.4.5.3.3)
Application of previously approved head shields, thermal protection systems, or insulation
systems or the deletion of such systems
Changes to approved head shields, thermal protection systems, or insulation systems
necessary to conform to changes in tank geometry
Changes to car structure that are not in violation of paragraph 1.4.2.5
Changes necessary to accommodate tank geometry that do not reduce the strength of a
previously approved underframe
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CHAPTER 1 M-1002
1.4.2.5 Design Differences That May Not be Approved by Precedent

Design differences from previously approved designs that constitute major changes and categorize
an application as one requiring Committee or ITP review include the following:
Changes in tank shell diameter, shell thickness, or alloy
Changes to structural stiffeners used in or on tanks
An increase in the rail load limit
Design changes to full-length and stub sill underframes, other than those required to
accommodate changes in tank geometry
Substitution of a lower strength alloy for a previously approved higher strength material
for tank shell and heads or car underframe
Use of fittings not previously approved
Use of tank openings, reinforcements, nozzles, or protective housings not previously
approved
Changes to closures and covers, other than those required to apply previously approved
fittings
Use of head shields, thermal protection systems, or insulation systems not previously
approved
1.4.2.6 Structural Requirements
All tank cars for which AAR approval is requested must comply with the car structure, design, and
testing requirements outlined in 6 of this specification and AAR Specification M-1001. Tank cars
designed for gross rail loads in excess of 263,000 lb on four axles must have the car structure
approved by the Equipment Engineering Committee.
1.4.2.7 New and Untried Types
Applications for approval of new and untried types of tank cars must be made to the Tank Car
Committee and must include a completed Form AAR 4-2 with all drawings and data pertaining to
the tank shell, heads, and appurtenances. Approval by the Tank Car Committee is required for
completion of the Certificate of Construction.
Applications for approval of designs where the components of the car structure, whose primary
function is to support loadings exclusive of internal tank pressure, are of a new and untried type
as defined in paragraph 1.2.1 of the Manual of Standards and Recommended Practices, Section
C-II, Specification M-1001, require approval of the Equipment Engineering Committee. Applicant
must submit a cover letter with 15 sets of applicable arrangement and detail drawings and other
supporting data to the Director for distribution to that committee.
Applications for approval of designs where the brake equipment or its operation are of a new and
untried type, as defined in paragraph 1.2.1 of MSRP Specification M-1001, require approval of the
Equipment Engineering Committee and the Braking Systems Committee. Applicant must submit
a cover letter with 25 sets of brake arrangement drawings and other supporting data to the
Director for distribution to the committees.
When tests are conducted in support of new and untried cars designs or of cars incorporating
changes of a new and untried type, tests must comply with applicable chapters of MSRP
Specification M-1001.
1.4.2.8 Alteration, Conversion, or Repair
For alterations, conversions, or welded repairs using previously approved procedures and
materials, an Exhibit R1 report in compliance with Appendix R must be submitted. For
alterations, conversions, or welded repairs using procedures or materials that have not been
previously approved, an application must be submitted on Form AAR 4-2. Such applications will
be handled as outlined in paragraph 1.4.2 and related subsections.
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M-1002 CHAPTER 1
1.4.2.9 Safety Appliances

Safety appliances must be in accord with U.S. Department of Transportation Federal Railroad
Administration (FRA) regulations. Questions pertaining to safety appliances or their application
to the car must be handled directly with the FRA Office of Safety.
1.4.2.10 Approval of Applications
Upon confirmation from the ITP and any involved Technical Services Committee that an
application is in good order, AAR will process the application for approval and so notify the
applicant. The approved application will become the Certificate of Construction for the car or cars
identified thereon when certified per paragraph 1.4.3.3 and serves as notice of approval to all
parties.
1.4.2.11 Committee Process
Applications that are referred to the Tank Car Committee pursuant to paragraph 1.4.1 or
paragraph 1.4.2.3 will be handled by mail ballot and will be approved by majority vote unless
advised by any member of the Committee or by AAR staff that approval appears to be in violation
of the specifications or will represent a hazardous condition. In the event such advice is received,
all committee members will be notified, and those members previously voting to approve the
application will be asked to reconsider their vote.
A Committee member having comments on any application being considered must, within 15 days
of receipt of the application, direct his or her comments to the applicant with copies to the balance
of the Committee and to the Director. The applicant must respond to Committee comments within
30 days, directing his or her response to each member of the Committee and to AAR staff. Failure
to respond will be cause for disapproval of the application.
Once an applicant has furnished all additional information requested in Committee comments, all
Committee member(s) initially commenting on the application must resubmit a ballot within
15 days of the applicants response. A Committee member having taken exception to an
application and then approving it based on satisfactory applicant response to comments must
direct approval to the Director with copies to the applicant and the balance of the Committee.
If sufficient ballots to constitute action have not been received within 45 days from receipt of the
application by AAR, staff will poll each member of the Committee to expedite response. AAR staff
must notify the applicant of the status of his or her application within 60 days of receipt of the
application. A written explanation must be provided for any application that is disapproved or
held pending additional information.
1.4.2.12 Disapproved Applications
If an application is disapproved pursuant to action of the Tank Car Committee, the applicant may,
by written notice to the Director, petition the Committee for review of the application at a regular
or special meeting of the Committee to be held not later than 90 days from receipt of the notice.
The applicant must attend any such meeting and will be granted the right to present additional
information is support of the application. AAR must notify the applicant of the action of the
Committee within seven business days following the meeting.
If tank cars covered by formally disapproved applications are subsequently offered for interchange
service, the Director will notify all AAR member railroads and appropriate movement restrictions
will be placed in the Universal Machine Language Equipment Register (UMLER) file.
11/2014 C-III [M-1002] 37

CHAPTER 1 M-1002
1.4.3 Application Form AAR 4-2

1.4.3.1 Instructions
1.4.3.1.1 The following line-by-line instructions are provided for completing the application
portion of Form AAR 4-2:
Line Instruction
1. Indicate by an X in the appropriate block whether nonprecedent or precedent approval,
based on a precedent already approved by the Committee, is requested. AAR staff will
assign nonprecedent requests to the Committee or to an ITP, as appropriate.
2. Indicate if the application concerns construction, conversion, alteration, repair, or other
(provide description for other).
3. Enter the application number, which will be provided by the Director on request. The
number will be prefixed to indicate the nature of the application according to the following
code. This application number will become the certificate number upon receipt of
certification.
Code Description Code Description Code Description

A ConstructionNonprecedent F ConstructionPrecedent L ConstructionNonprecedent
Committee Ballot AAR Approve AAR Approve
B ConversionNonprecedent G ConversionPrecedent M ConversionNonprecedent
C AlterationNonprecedent H AlterationPrecedent N AlterationNonprecedent
D Welded RepairNonprecedent J Welded RepairPrecedent P Welded RepairNonprecedent
E Other Nonprecedent K OtherPrecedent Q OtherNonprecedent
In the event that the method of approval changes after submission, the AAR staff will
revise the prefix to correspond to the proper code.
4. Enter the date of the original application. Dates of revisions to the application must be
shown under Revisions.
4.1 Enter the date the order was made with the Tank Car Builder. MM/DD/YYYY
5. Enter a file number or builder lot number.
6. Enter the name of the applicant. For new construction, the applicant must be the tank car
builder. For conversion, alteration, or repair, the applicant must be the car owner or the
facility authorized to perform such work.
7. Enter the tank specification to which the tank is to be built (e.g., DOT-111A100W1).
8. If the car is to be operated under a specification other than the one shown on Line 7, the
stenciled specification must be entered here (e.g., AAR-211A100W1).
9. The reporting marks and car numbers entered here must be those that are or will be
recorded in the Official Railway Equipment Register covering the car or cars in question.
10. Enter the total number of cars represented by the car numbers or series shown on Line 9.
11. If the car is designed for a specific commodity, enter its proper shipping name. If the car
is not designed for a specific commodity or is limited to certain commodities, enter the
words (Initial lading) and products authorized by DOT Part 173 for which there are no
special commodity requirements and nonregulated commodities compatible with this
class of car. If special commodity stenciling is required, it must be shown under Notes.
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M-1002 CHAPTER 1
Line Instruction
12. If the car is designed for a specific commodity, enter the weight of the commodity in
pounds per gallon or pounds per gallon and kilograms per liter. When Line 11 shows DOT
Part 173 and an initial commodity, show the weight of the initial commodity.
13. Enter the tank capacity in U.S. gallons or U.S. gallons and liters. For nonpressure cars,
record shell-full volume. For pressure cars, record shell-full volume plus volume of
manway nozzle.
14. Enter the as-designed outage in U.S. gallons or U.S. gallons and liters.
15. Enter the material specifications for tank shell and heads and their respective
through specifications and thicknesses.
16.
17.
18.
15.1 Indicate whether or not the tank head material is normalized. (Yes= normalize; No=not
normalized)
15.2 Indicate whether or not the tank head is spliced. (Yes or No)
15.3 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
16.1 Indicate whether or not the tank shell material is normalized. (Yes= normalize; No=not
normalized)
16.2 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
19. Where linings are required by the specification, the lining material and thicknesses must
be shown.
20. Enter tank inside diameter, in inches, at center and at tank ends. May also be submitted
21. in both inches and millimeters.
22. This item refers to dished heads and, when such heads are used, the main radius in inches
or inches and millimeters must be entered.
23. Enter the actual test pressure for which the tank is designed, including maximum
pressure relief device setting permitted by 49 CFR 179.15. Use psi or psi and kPa.
24. Enter the type of insulation used (e.g., fiberglass, cork, polyurethane, etc.)
25. Enter the thickness of insulation in inches, or inches and millimeters, for all insulated
tanks.
26. The thermal conductivity of the insulation must be shown in the units indicated at 60 F
(15.6 C). (Mineral wool, ceramic fiber, or other thermal protection materials are not
considered insulation.) SI equivalent units are kJmm/hm2C.
27. These items must indicate whether the pressure relief device is a valve, vent, or breather
28. vent. The number of such devices and the start-to-discharge pressure or bursting pressure
must be shown in psi or psi and kPa.
27.1 Enter the number of safety relief devices.
29. For pressure relief devices, the required flow capacity in cubic feet per minute, or cubic
feet per minute and cubic meters per second, must be entered.
30. When pressure relief devices are used, enter the actual flow capacity provided.
31. Enter the exterior tank surface area in square feet or square feet and square meters.
32. For tank cars with an underframe, enter full. For stub sill cars, enter the code for the
stub sill style (see Appendix R, Exhibit R-2, fourth page, for builder and sill codes).
11/2014 C-III [M-1002] 39

CHAPTER 1 M-1002
Line Instruction
33. Enter the height from top of rail to the center of gravity of the tank car in inches or inches
and millimeters. If the center of gravity height exceeds 84 in. (2130 mm) on cars with four-
wheel trucks having 6 1/2 in. 12 in. journals or larger, an asterisk must be used to refer
to a comment under Notes, indicating car truck centers or truck spring travel.
34. Enter the estimated light weight of the completed car in pounds or pounds and kilograms.
35. Indicate if car is constructed to AAR Clearance Diagram Plate B, C, E, or F.
36. The rail load limit must be shown and must be compatible with the truck capacity for the
number and size of axles used. If gross weight on rail exceeds 263,000 lb with
6 1/2 in. 12 in. journals, approval of the AAR Equipment Engineering Committee is
required (see paragraph 1.4.2.6).
37. Enter the truck capacity in tons.
38. If the car is fitted with head shields, indicate whether half or full.
38.1 Enter the thickness in inches of the head shield material.
39. Drawings. Enter the drawing number of all drawings relevant to the application in the
through first column headed Drawing Number. Enter information in the next two columns
53. concerning prior approvals in accord with the following instructions.
a. If a cited drawing is being submitted for ITP or Committee consideration without
reference to a previously approved drawing, leave the second and third columns blank.
Prints must be furnished and an explanation provided by letter or separate sheet.
b. If a cited drawing has been previously approved by an ITP or the Committee and
nothing has changed on that drawing, enter the application number of the prior
approval in the third column and leave the second column blank. Submission of these
precedent drawings is not required unless the application includes both precedent and
nonprecedent drawings that will require ITP review, in which case all drawings are to
be submitted, including the precedent drawings.
c. If a cited drawing is based on a previously approved drawing, but with changes
permitted under paragraph 1.4.2.4, enter the precedent drawing number in the second
column and its approved application or certificate number in the third column. Prints
of the new drawings must be furnished with the application, and deviations from the
precedent drawing must be explained by letter or on an attached sheet.
d. Applications prefixed F, G, H, J, or K may not be referenced. Only applications under
which a drawing has been reviewed and approved may be referenced.
e. If a precedent drawing is from a current application that is pending approval, indicate
Pend after the application number in the third column.
f. If drawings cited as prior approvals have not been approved within the past 10 years,
such drawings must be resubmitted with the application.
g. All prints of drawings and calculations submitted with Form AAR 4-2, must carry a
current approval signature or initial by the proponent, and must be marked with the
application number with which they are submitted.
54. Applications for new construction must include a drawing that indicates structural welds
to be inspected during requalification. For jacketed cars, the drawing must include
dimensions referenced to a visible area of the car.
C-III [M-1002] 40 11/2014

M-1002 CHAPTER 1
1.4.3.1.2 Application for approval of new tanks to be mounted on existing car structures must be
accompanied by a statement under Notes that Car structure complies with all requirements of
the AAR Interchange Rules and is suitable for continued service.
1.4.3.1.3 Applications for conversion, alteration, or repair must indicate current specification,
former lading, date built new, and previous certificate number(s) under Notes and must show
specification and new commodity on Line 7 and Line 11, respectively. Supply a supplemental
sheet, if necessary, to associate the car numbers with their previous certificate numbers.
1.4.3.1.4 For applications covering welded repairs on tanks using procedures or materials that
have not been previously approved, fill in Lines 1 through 38, inclusive. Description of damage to
tank, date, place, and circumstances of damage, together with proposed method of making repairs,
must also be submitted under Notes on a continuation sheet.
1.4.3.1.5 For applications covering reconditioning of manway covers for tank cars covered by
DOT 179.100, submit data on original construction, certificate numbers, and car specification,
with drawing numbers used in original construction. Application must include drawings and a
detailed explanation of how repairs are to be made.
1.4.3.1.6 Applications submitted by facilities other than the fabricator of tank shell and heads for
assembly of new tank cars must be accompanied by a statement under Notes that Tank shell
and head fabrication by... (certified facility). Completed car will comply with all applicable AAR
and DOT requirements.
1.4.3.1.7 Certain car designs, appurtenances, valves, fittings, or attachments may be declared by
the Tank Car Committee to be subject to service trials before general acceptance for new
construction. Such service trials and their restrictions must be identified by the applicant or AAR
under Notes. Service trial numbers are assigned by the Director. See paragraph 1.4.9.
1.4.3.1.8 DOT exemptions, special approvals (SAs), or Canadian special permits applicable to the
car or commodity must be identified under Notes. A copy of the latest revision must be submitted
with the application.
1.4.3.1.9 Applications for increased truck capacity must be supported by justification (with
calculations if necessary) to verify the structural adequacy of the car for increased capacity and
braking requirements.
1.4.3.1.10 Valves are to be identified by manufacturer, size, and identification number on the
drawings or application, whether or not supplied by the proponent.
1.4.3.1.11 The method of anchoring the jacket of an insulated car must be submitted with Form
AAR 4-2.
1.4.3.2 Approval
AAR staff complete the Approval section of Form AAR 4-2 based on action taken on the
application.
1.4.3.3 Certification
The Certification section of Form AAR 4-2 is to be completed only after the approved application
has been received from AAR and the referenced construction, alteration, conversion, or repair has
been completed. Certification is accepted only from a responsible Quality Control representative
acting for the facility performing the work, from an officer of the company performing the work, or
from the car owner. When signed by all parties, the completed Form AAR 4-2 is recognized as the
Certificate of Construction for the car or cars identified thereon.
11/2014 C-III [M-1002] 41

CHAPTER 1 M-1002
APPLICATION FOR APPROVAL AND CERTIFICATE OF CONSTRUCTION

1. APPROVAL REQUESTED OF: PRECEDENT 2. TYPE: CONSTRUCTION WELDED REPAIRS 3. AAR NO.
NONPRECEDENT ALTERATION OTHER 4. DATE
CONVERSION 4.1 ORDER DATE
5. APPLICANT NO.
6. APPLICANT 7. TANK SPECIFICATION
8. STENCILLED SPEC
9. REPORTING MARKS AND NUMBERS 10. NUMBER OF CARS
11 Initial Commodity 12 Density (Lb Per Gallon)

13 Full Water capacity, (Gallons) 14 Dome Capacity or Outage (Gallons)
15 Material Type / Grade Heads 15.1 Head Material Normalized
15.2 Tank Head Spliced 15.3 Charpy Requirements
16 Material Type and Grade Shell 16.1 Tank Shell Material Normalized
16.2 Charpy Requirements 17 Material Thickness Heads (Inches)
18 Material Thickness Shell (Inches) 19 Lining Type
20 Inside Diameter Center (Inches) 21 Inside Diameter End Rings (Inches)
22 Head Radius, Main (Inches if not 2:1) 23 Test Pressure (PSI)
24 Insulation Type 25 Insulation Thickness (Inches)
26 Thermal Conductivity (BTU in/hr. ft sq. degree F) 27 Type of Safety Relief Devices
27.1 Number of Safety Relief Devices 28 Pressure Relief Device Start-to-Discharge (PSI)
29 Pressure Relief Device Flow Capacity (CFM Required) 30 Pressure Relief Device Flow Capacity (CFM Actual)
31 Tank Surface Area (Sq Ft) 32 Underframe or Stub Sill Type
33 Center of Gravity Loaded (Inches)loaded 34 Estimated Light Weight (lb)
35 AAR Clearance Diagram 35 Rail Load Limit. (lb)
37 Truck Capacity (Tons) 38 Head Shield Type
38.1 Head Shield Thickness (inches)
Notes:
Original certificate
Builder
Date
Former lading
The Following Prior Approval Apply

The Following Drawings Apply Drawing Number Drawing Number Application / Certificate no.
39 General Arrangement
40 Tank Arrangement
41 Reinforce Openings Including Calculations
42 Anchorage, Including Calculations
43 Fittings Arrangement
44 Manway Assembly
45 Protective Housing
46 Venting, Loading, and Discharge Valves
47 Pressure Relief Devices
48 Heater Systems (Int. Ext. )
49 Gauging Devices
50 Bottom Outlet Valve
51 Repairs
52 Manway Cover
53 Calculations
54 Tank Qualification Drawing
REVISIONS: APPLICATION BY:
I certify the foregoing conforms to all applicable DOT and

AAR requirements. Including specifications, regulation, rules
of interchange and the DOT Railroad Safety Appliance
Standards.
SIGNATURE
TITLE
APPROVAL - AAR Tank Car Committee

Date Approved:
(Signature) on behalf of Tank Car Committee
CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications,
regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as
required by 49 CFR Part 179.5 before these cars are placed in service.
Initials and Car Numbers
Name Date
Title
Form AAR 4-2 Revised10.2014
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction
C-III [M-1002] 42 11/2014

M-1002 CHAPTER 1
AAR No. __________________________
Applicants No. _____________________
Date _____________________________
APPLICATION BY: __________________________________________

I certify that the foregoing conforms to all applicable DOT and AAR
requirements, including specifications, regulations, rules of interchange,
and the DOT Railroad Safety Appliance Standards.
SIGNATURE _______________________________________________
TITLE_____________________________________________________
APPROVALAAR Tank Car Committee
Date Approved _____________________________________________

(signature) on behalf of the Tank Car Committee
Form AAR 4-2.1 Revised 7/30/2014 Page of
Fig. 1.2 Form AAR 4-2.1 Supplementary page

11/2014 C-III [M-1002] 43
CHAPTER 1 M-1002
1.4.4 Certificate of Construction

1.4.4.1 Certificate of Construction for Tank Car Tank, Equipment, and Complete Car
1.4.4.1.1 See DOT 179.5. The Certificate of Construction is the lower portion of Form AAR 4-2.
After receipt of the approved application from the Director, the applicant must complete the
Certificate of Construction on the original, furnish copies as required below, and store the original
information in such a way that a printable electronic copy or paper copy can be obtained and that
changes to the original information can be detected.
1.4.4.1.1.1 Effective January 1, 2015, applicants are required to use the AAR Tank Car
Application for Approval and Certificate of Construction Web-Based System for completing the
Certificate of Construction.
1.4.4.1.2 For all tank cars built, the facility assembling the completed cars must furnish a
Certificate of Construction, Form AAR 4-2, to the owner and the Director certifying that tank,
equipment, and car comply with all the requirements of the specifications. (For Class DOT-107A,
see also paragraph 1.4.4.2.)
For alterations, conversions, or welded repairs requiring approval, the Certificate of Construction
portion of Form AAR 4-2 must be completed and submitted as required above.
1.4.4.1.3 When cars or tanks identical in all details are covered on one application and are built
in series, one certificate will suffice for each series when submitted to the owner and to the
Director. One copy of the Certificate of Construction must be furnished to the Director for each car
number or consecutively numbered group or groups covered by the original application.
1.4.4.1.4 Cars or tanks must not be placed in service until the Certificate of Construction has
been submitted.
1.4.4.2 Certificate of Construction for Class DOT-107A Tank Cars
For Class DOT-107A tank cars, in addition to the Certificate of Construction Form AAR 4-2,
certified inspectors reports as required by DOT 179.500-18 must be submitted.
1.4.5 Service Equipment
Service equipment as used in this section is inclusive of the terms pressure relief devices, valves,
closures, and fittings.
1.4.5.1 Closures and Fittings
1.4.5.1.1 Any special closure assembly design having operating parts requires Tank Car
Committee approval.
1.4.5.1.2 Any modification to a bottom outlet closure as defined in Appendix E, Figs. E.24.1
through E.24.9, requires Tank Car Committee approval.
1.4.5.1.3 Tank car closures do not require Tank Car Committee approval if they are
manufactured in accordance with a nationally recognized standard (e.g., AAR, SAE, ASME, ANSI,
MIL).
1.4.5.1.4 Manway covers, if manufactured in accordance with Appendix E, do not require
approval by the Tank Car Committee; otherwise, they must be approved.
1.4.5.1.5 Nonmetallic fittings require Tank Car Committee approval.
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M-1002 CHAPTER 1
1.4.5.1.6 Metallic fittings require Tank Car Committee approval unless all of the following
conditions are met:
Parts are manufactured in accordance with a nationally recognized standard (e.g., SAE,
ASME, ANSI, MIL) or Appendix M.
Parts are designed to meet or exceed the operating pressure rating of a tank car.
Parts are designed to be leak tight.
Parts must be joined in accordance with Appendix E, as specified by the tank car
manufacturer or owner, or ASME Section 8, Division 1.
Fitting must be marked with the name of the manufacture and pressure rating and with
additional markings as agreed to by purchaser and manufacturer.
Approval is granted for the application of the fitting to the tank car when the Form AAR
4-2 for the tank car is approved for a specific application for new construction, alteration,
conversion, or repair.
1.4.5.2 Approval of Service Equipment
Tank car service equipment must be approved by the Tank Car Committee. Approvals of service
equipment must be renewed every 10 years. Approvals will be marked with the expiration date,
which shall be the end of the month in which the approval was executed plus 10 years. Table 1.17
outlines the devices by group, committee approval, and what form is to be used. The application
process, instructions, and forms are provided within this chapter.
Table 1.17 Service equipment approvals (page 1 of 2)

Device Group Committee Approval Form
Air inlet Valve Yes 4-5
Air inlet Closure No N/A
Bottom outlet valve Valve Yes 4-5
Bottom washout Closure Yes 4-5
Breather vent Valve Yes 4-5
Check valve Valve Yes 4-5
Closure, metallic Closure No N/A
Closure, nonmetallic Closure Yes 4-5
Closure assembly Closure Yes 4-5
Combination device PRD Yes 4-3
Excess flow valve Valve Yes 4-5
Fill hole cover, metallic Closure No N/A
Fill hole cover, nonmetallic Closure Yes 4-5
Fitting, metallic Fitting No N/A
Fitting, nonmetallic Fitting Yes 4-5
Fusible plug device PRD Yes 4-3
Gauging device Closure Yes 4-5
Liquid valve Valve Yes 4-5
Manway cover Closure Yes 4-5
Manway cover assembly Closure Yes 4-5
Pressure plate Closure No N/A
Pressure-regulator valve PRD Yes 4-3
Pressure-relief device PRD Yes 4-3
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CHAPTER 1 M-1002
Table 1.17 Service equipment approvals (page 2 of 2)

Device Group Committee Approval Form
Pressure-relief valve PRD Yes 4-3
Primary valve Valve Yes 4-5
Primary closure, metallic Closure No N/A
Primary closure, nonmetallic Closure Yes 4-5
Rupture disc Closure No N/A
Sample valve Valve Yes 4-5
Secondary valve Valve No N/A
Secondary closure Closure No N/A
Surge-suppression device No N/A
Spring-loaded check valve Valve Yes 4-5
Temperature-sensing equipment Closure Yes 4-5
Thermometer well Closure Yes 4-5
Vacuum-relief valve Valve Yes 4-5
Valve Valve Yes 4-5
Vapor valve Valve Yes 4-5
1.4.5.3 Renewal of Service Equipment Approvals

Applicant shall submit application packages for renewal at least 60 days prior to the expiration
date of the most recent approval. The most recent approval shall remain in effect until such time
the applicant is notified of disapproval or the renewal is approved.
1.4.5.3.1 Previously approved service equipment for which the current approval has lapsed may
continue in service for the life of the tank car on which it was originally applied and may be
replaced in-kind on existing tank cars without reapproval. Manufacture of such service equipment
is not authorized. To manufacture once the current approval has lapsed, the applicant must
reapply.
1.4.5.3.2 Any changes to an approved device require submission to the Executive DirectorTank
Car Safety for approval unless paragraph 1.4.5.3.3 of this chapter applies.
1.4.5.3.3 The following changes to an approved device, if they do not affect the operation of the
device, do not require submission to the Tank Car Committee and may be listed under the current
approval:
External changes to previously approved devices
Changes in materials of construction
Changes in materials that are compatible with the intended commodity service
Changing a spring with another spring having the same spring constant
Changing a coating on a valve designed to be coated
Designs previously approved but of smaller sizes or lower pressure ratings
Secondary closures of generic design
For devices that are flow rated, see additional requirements in Appendix A, paragraph 5.1.
Any other change requires submission to the Executive DirectorTank Car Safety for approval.
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M-1002 CHAPTER 1
1.4.5.4 Sale of Previously Approved Design

1.4.5.4.1 Sale of the company manufacturing the approved design where the design will continue
to be manufactured by the same facility under the same processes and quality assurance only
requires notification of the committee of the change of ownership.
1.4.5.4.2 Sale of an approved design to a company with a current C4 certification, Appendix B,
paragraph 2.1.1: the purchasing company may manufacture the approved device after notification
of the committee of the purchase of the design.
1.4.5.4.3 Sale of an approved design to a company without a current C4 certification, Appendix B,
paragraph 2.1.1: the purchasing company must gain a C4 certification and committee approval
before manufacturing the design.
1.4.6 Pressure Relief Devices
1.4.6.1 Procedures for Approval of Pressure Relief Devices (Form AAR 4-3)
1.4.6.1.1 To secure approval of pressure relief devices as required by paragraph 1.3.6, the
application package as defined in paragraph 1.4.6.1.2 must be submitted to the following:
Executive DirectorTank Car Safety
425 Third Street S.W., Suite 1000
Washington, D.C. 20024
Note: All submitted materials must be marked with an assigned AAR number.
1.4.6.1.2 The application package for pressure relief devices shall consist of the following:
Form AAR 4-35
Test results required in Appendix A, paragraph 5.3
Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
Flow test facilitys report, if applicable
Supplemental information as applicable
Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
11/2014 C-III [M-1002] 47

CHAPTER 1 M-1002
1.4.6.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form:
The applicant must request an AAR number from the Executive Director.
The applicant must be the valve manufacturer or its agent.
The date must be that on which the application is completed.
The applicants number blank is for the convenience of the applicant.
The device identification number is for the convenience of the applicant (e.g., catalog
number).
1.4.6.2.1.1 The numbered items must be entered as follows:
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility used to determine the flow capacity of pressure relief valves, as
required in Appendix A.
3. Record the location of the test facility.
4. Record the date the flow rating tests were conducted.
5. Write the authorized observers name here.
6. Record the identity of each device tested, as required in Appendix A, paragraph 5.2.
7. Record the start-to-discharge pressure in psi (or psi and kPa) of each device tested.
8. Record the flow rating pressure in psi (or psi and kPa) of each device tested.
9. Record the vapor-tight pressure in psi (or psi and kPa) of each device tested.
10. Record the flow capacity in cfm (air) or cfm and m3/s (air).
11. Record the official flow capacity in scfm (air) or scfm and standard m3/s (air), obtained at
the required flow rating pressure in psi (or psi and kPa) by an approved method (see
Appendix A, paragraph 5.2).
12. Enter Regulated Commodity, Non-Regulated Commodity, or Specific Commodity.
13. Drawings. Under these items, all drawings relevant to the application must be listed in
through the first column headed Drawing Number. Information for columns two and three under
Precedent shall be determined by the appropriate following instructions:
14.
15.
16.
a. If a drawing has been previously approved by the Tank Car Committee, enter the
certificate number of the approval in the third column and leave the second column
blank. Prints need not be submitted.
b. If a new drawing is submitted for Committee consideration, leave the second and third
columns blank. Prints must be furnished and an explanation provided by letter or
separate sheet.
c. If a new drawing is submitted for Committee consideration and a precedent drawing
is appropriate, enter the precedent drawing and its application or certificate number
in columns two and three. If the precedent is pending before the Committee, indicate
Pend after the application number. Prints of the new drawing must be furnished and
deviations must be explained by letter or separate sheet.
d. If a precedent is pending before the Committee, indicate Pend after the application
number. Prints of the new drawings are not required to be submitted, but deviations
must be explained by letter or separate sheet.
e. Under b, c, or d above, if the same new drawing and precedent are shown on another
pending application, this information must also be indicated by letter or separate
sheet. The first approval received must be the approval of record for the drawing.
C-III [M-1002] 48 11/2014
M-1002 CHAPTER 1
Line Instruction
f. All drawings submitted with Form AAR 4-3 must carry a current approval signature
or initial by the proponent.
14 Note: When the design of a pressure relief device is such that the spring follower is guided
by the mounting nozzle, the mounting nozzle shall be considered as a required part of the
application and a drawing of the nozzle in sufficient detail to show critical dimensions
shall be included. When the pressure relief device design does not require the mounting
nozzle to act as a guide for the spring follower, the word None can be used in the space
for this item.
1.4.6.2.2 Certification
The applicant signs the form under Certification attesting to the above entries.
1.4.6.2.3 Approval by AAR Tank Car Committee
1.4.6.2.3.1 The Executive DirectorTank Car Safety completes the approval section of the form
based on action taken on the application.
1.4.6.2.3.2 The Approval of Service Trial section is designated for approving the device for a
service trial.
1.4.6.2.3.3 The Approval of Design section is designated for approving the device either after
successful completion of a service trial or in the case where a service trial is not required and the
device is approved without a service trial.
11/2014 C-III [M-1002] 49

CHAPTER 1 M-1002
APPLICATION FOR APPROVAL OF PRESSURE RELIEF DEVICE
AAR NO. PRD-

Applicants No.
APPROVAL REQUESTED OF AAR TANK CAR COMMITTEE Date
Device identification No.
Applicant
1. Manufacturer
Address
2. Test facility name 3. Test facility location
4. Test date 5. Observer
6. Device 7. Start-to-discharge 8. Flow rating 9. Vapor-tight 10. Flow capacity
Number psi kPa psi kPa psi kPa SCFM std.m3/s
11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa)
Test medium
12. Commodity: Regulated Commodity Nonregulated Commodity Specific Commodity
Precedent
The following drawings apply Drawing number Application/
Latest revision Drawing number Certificate
13. Valve Assembly..
14. Valve Mounting Nozzle..
15. .
16. .
REVISIONS:
CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and
the devices tested conform with the drawings listed above.
By: Title
APPROVAL of Service Trial by AAR Tank Car Committee
AAR Service Trial Required Service Trial Number: ST-__________
Date Approved for Service Trial

APPROVAL of Design by AAR Tank Car Committee
Date Service Trial Completed Date AAR Received )RUPAAR 4-6
Date Approved
Expiration Date
Form AAR 4-3 Revised 8/1/2014
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device
C-III [M-1002] 50 11/2014

M-1002 CHAPTER 1
1.4.7 Valves, Closures, and Fittings

1.4.7.1 Procedures for Approval of Valves, Closures, and FittingsApplication Form
AAR 4-5
1.4.7.1.1 To secure approval of valves, closures, and fittings as required by paragraph 1.3.6, the
application package as defined in paragraph 1.4.7.2.2 must be submitted to the following:
1.4.7.1.2 The application package for valves, closures, and fittings shall consist of the following:
Form AAR 4-5
application and certification portions of the form.
The applicant must request an AAR number from the Executive Director.
Applicant must be the manufacturer of the device or its agent.
Describe the device and its function in accord with the definitions and requirements of
Appendix A.
Spaces for the applicants number and the device identification number are for the
convenience of the applicant (e.g., index, catalog, or type numbers).
1.4.7.2.2 The numbered items must be entered as follows:
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility that tested the device, if other than the manufacturers.
3. Record the date testing was completed for subject device.
4. Indicate the applicants observers name and title.
5. Indicate the procedure used to test the prototype device and the number of devices tested.
6. Indicate the number of cycles to which a device was subjected at high and low
temperatures and at the given pressure, as well as the specific test medium used (e.g., air,
water, etc.).
7. Indicate the commodity or commodity type.
8. Indicate the flow rate of the device in gallons per minute, or gallons per minute and liters
per minute, if applicable.
9. Indicate the drawing number showing the application of the device to the car and the basic
material. When applicable, reference a precedent drawing with AAR application number.
11/2014 C-III [M-1002] 51

CHAPTER 1 M-1002
Line Instruction
10. Indicate the drawing number of the device assembly and basic material and, when
applicable, reference a precedent drawing with AAR application number.
11. Indicate the drawing number and material specification of individual parts.
12. Provide a basic statement that the facility has a quality control program to provide
compliance with drawings and specifications.
1.4.7.2.3 Revisions/Certification
The Revisions space is provided to indicate any revisions to the original application.
The applicant signs the form under Certification, attesting to the above entries.
1.4.7.2.4 Approval by AAR Tank Car Committee
The Executive DirectorTank Car Safety completes the approval section of the form based on
action taken on the application.
The Approval of Service Trial section is designated for approving the device for a service trial.
The Approval of Design section is designated for approving the device either after successful
completion of a service trial or in the cases where service trial is not required and the device is
approved without a service trial.
C-III [M-1002] 52 11/2014

M-1002 CHAPTER 1
APPLICATION FOR APPROVAL OF VALVES, CLOSURES, AND FITTINGS

Applicant AAR No.
Description of Device
Applicant No. Device Ident. No. Date
1. Manufacturer
2. Address City State Zip
3. Test facility if other than the manufacturer Address
Title: .
TEST PROCEDURE
5. Description of prototype testing:

6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
F psi F _psi
C _kPa C kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
F psi F _psi
C _kPa C kPa
F psi F _psi
C _kPa C kPa

7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity
8. Flow rate (if applicable) gpm ( L/min)

Drawing Number Precedent
Applicable drawings Material latest revision Drawing Number Application/Certificate
9. Device application . . . . . .
10. Device assembly . . . . . . . .
11. Device details . . . . . . . . . .
12. Quality Control Statement
REVISIONS:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices
tested conform with drawings listed above.

By Title
APPROVAL AAR Tank Car Committee Service Trial Required
Service Trial Number

APPROVAL AAR Tank Car Committee Service Completed / Not Required
Date Service Trial Completed Date AAR Received Form AAR 4-6 .
Date Approved _____________________________________
Expiration Date ____________________________________ ________________________________________________
Form AAR 4-5 Revised 10/2014
Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings
11/2014 C-III [M-1002] 53

CHAPTER 1 M-1002
1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings
1.4.8.1 Procedures for RenewalApplication Form AAR 4-7
1.4.8.1.1 To secure approval for renewal of approval for pressure relief devices, valves, closures,
and fittings as required by paragraph 1.3.6, the completed application package as defined in
paragraph 1.4.8.1.2 must be submitted to the following:
1.4.8.1.2 The application package for renewals shall consist of the following:
Form AAR 4-7
application and certification portions of the form.
The applicant must request an AAR number from the Executive Director
Applicant must be the manufacturer of the device, or its agent.
Spaces for the applicants number and the device identification number are for the
convenience of the applicant (e.g., index, catalog, or type numbers).
Line Instruction
1. Enter the AAR Number assigned by the Executive Director.
2. Enter the date which the application is completed.
3. Enter the previous AAR approval number under which the device was approved by the
Tank Car Committee.
4. Enter the applicants name.
5. Enter the applicants Address, City, State, and ZIP.
6. Provide an applicable drawing number.
7. Enter the latest revision.
8. Enter the date of the latest revision.
9. Enter detail description of the device.
10. For convenience of the applicant, enter the device ID No. (e.g., index, catalog, type
numbers).
11. If the subject device is unchanged, the applicant signs the certification attesting to the
entries on the form and enters the applicants title.
12. Identify the previous and current drawings, and if on service trial the service trial number.
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M-1002 CHAPTER 1
Line Instruction
13. Indicate whether or not the change supersedes the drawings.
14. Describe the changes and the reasons for making the changes.
15. Provide a statement about the operational effect of the changes.
16. Identify the drawing submitted with this application.
17. If the device has changed, then the applicant signs the certification that the data is correct
and conforms with AAR Specifications for Tank Cars and the device conforms with
drawing listed on the form
1.4.8.3 Certification
The applicant signs the Certification, attesting to the entries. Enter the applicants title. Applies
to Line 11 or 17, whichever is applicable.
1.4.8.4 Approval
The Executive Director completes the approval section of the form based on action taken on the
application.
11/2014 C-III [M-1002] 55

CHAPTER 1 M-1002
APPLICATION FOR RENEWAL OF APPROVAL FOR PRESSURE RELIEF

DEVICES, VALVES, CLOSURES, AND FITTINGS
1. AAR APPROVAL No.

2. Date of Application
3. Previous AAR Approval
4. Applicant:
5. Address:
6. Drawing No. 7. Latest rev. 8. Date of latest rev.
9. Description of device: 10. Device ID No.
CERTIFICATION: The subject device is unchanged from the previous approval, and conforms with the
latest revision of AAR Specifications for Tank Cars, Appendix A. The device conforms
with drawing listed above.
11. By: Title:
If device is changed since latest approval, fill in the following blanks
12. Reference Previous Drawing New Drawing If on Service Trial

No. Rev. Date No. Rev. Date S.T. No.
13. New drawing supersedes previous one or does not obsolete it
CHANGES REASONS FOR CHANGES
14. a. a.
b. b.
c. c.
d. d.
(if needed use supplemental sheet)
15. Normal operational effect of changes of device:
16. Drawing submitted with this application:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars,
Appendix A. The device conforms with drawing listed above.
17. By: Title:
APPROVAL AAR Tank Car Committee:
Date Approved:
(Signature) on behalf of Committee
Form AAR 4-7 8/1/2014
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and
Fittings
C-III [M-1002] 56 11/2014
M-1002 CHAPTER 1
1.4.9 AAR Service Trials

A service trial is an in-service examination that evaluates the performance of a specified number
of tank cars or its service equipment for a defined period of time.
1.4.9.1 Authorization for Service Trials for Tank Cars
1.4.9.1.1 The first cars built by a new manufacturer of tank cars or a new production facility of an
established manufacturer or tank cars are subject to a service trial.
1.4.9.1.2 The number of tank cars subject to a service trial shall be
50new tank car manufacturer
25new tank car facility of an existing builder
These may be increased by the Tank Car Committee depending on the circumstances at time of
build.
1.4.9.1.3 The following requirements apply to tank cars under service trial:
Notification to the AAR of the date the cars are placed in service
Minimum 100,000 miles or 10 years, first qualification
Annual visual inspection of draft sill and bolster
Annual report by tank car giving, miles and trips for the year, and results of annual
inspection
Stub sill inspection at the conclusion of the service trial
Final report by tank car having total mileage, trips, and results of stub sill inspection
1.4.9.2 Authorization for Service Trials for Service Equipment
1.4.9.2.1 All new devices may be subjected to service trials. Service trials, when required by the
Tank Car Committee, must be reported on Form AAR 4-4. The service trial may be waived by the
Tank Car Committee after considering the supporting material in the application.
The applicant has 30 days to appeal the request for service trial. In its challenge appeal, the
applicant must provide reasons why a service trial in unnecessary. The appeal must be filed with
the Executive Director for disposition by the Tank Car Committee.
1.4.9.2.2 The requirements for a service trial are as follows:
1.4.9.2.2.1 The sample size and post-trial teardown requirements are provided in Table 1.18.
Table 1.18 Service trial parameters

Minimum Subject
Minimum Sample to Post-Trial Maximum That
Device Sizea/ Teardown May Be Applied
Pressure relief valve or bottom outlet valve 25 5 50
Top valve or excess flow valve 15 3 200
Other primary closure 15 3 50
Sample line valve, gauging device, or vacuum relief 10 2 50
device
Thermometer well or auxiliary fittingb/ 5 2 50
a/ Devices destroyed accidentally during a service trial do not need to be replaced provided the
minimum required for a teardown remain in service.
b/ Teardown does not require a Tank Car Committee-designated observer.
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CHAPTER 1 M-1002
1.4.9.2.2.2 The maximum number of units that can be applied to tank cars may be exceeded if
authorized by the Executive Director or his designee. After receipt of approval for non-regulated
service, the maximum number of units that may be applied in regulated service is no longer
restricted.
1.4.9.2.2.3 The devices in the service trial must average 5,000 loaded miles and 10 loaded trips
per year. If at the 1-year anniversary one or both of these averages are not being met, the applicant
may apply to the Tank Car Committee for modification of these averages.
1.4.9.2.2.4 For non-regulated commodities, each car set of the device must be subjected to a trial
of 1 year minimum duration.
1.4.9.2.2.5 For regulated commodities, each car set of the device must be subjected to a trial of
2 years minimum duration.
1.4.9.2.2.6 Successful completion of 1 year, 5,000 loaded miles, and 10 load cycles in regulated
commodity service may be used to qualify the device for non-regulated service.
1.4.9.2.2.7 In cases where a proponent believes that the standard field service trial format is not
applicable when considering the intended application of the service equipment in the field, the
applicant can propose an alternate field service trail format as an attachment to the applicable
Form AAR 4-3 or 4-5. Proper justification, including applicable test data, must be submitted as
part of the attachment to Form AAR 4-3 or 4-5.
1.4.9.2.2.8 If the service trial is not completed within 3 years from the start date, the service trial
will be terminated and any approvals will be revoked unless continuation is requested from the
applicant and approved by the AAR Tank Car Committee.
1.4.9.2.2.9 Difficulties experienced during the service trial (e.g., leakage, breakage, or
performance problems) must be reported as soon as known to the Executive Director for review by
the Tank Car Committee and reported on the next submitted Form AAR 4-4. The report should
include a description of the issue along with the corrective action. If the analysis indicates an
operational issue (failure to close or otherwise secure the device) and does not affect the
functionality of the device, report as such on the next Form AAR 4-4 and no further analysis is
required as part of the service trial.
1.4.9.2.3 Teardown Inspection
The purpose of the teardown is to examine a number of devices at the conclusion of their service
trial and determine from signs of wear what should be the qualification interval for the device.
1.4.9.2.3.1 Observer of Teardown
Unless the Tank Car Committee has specified their observer of the teardown, the observer shall be
the QA manager of the applicant.
1.4.9.2.3.2 Teardown of Device
Before tearing down a device, it must be subjected to the applicants acceptance test of
manufacture and must be cycled one time with the device meeting the test requirements of
Appendix D.
All components of a torn-down device must be kept together for 180 days pending Tank Car
Committee request to examine the device.
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M-1002 CHAPTER 1
1.4.9.2.3.3 Documentation
Copies of any tests and notes of conditions found shall be kept. Photographs of each step of the
teardown process and each individual component must be kept.
A copy of the test and inspection procedure and copies of each bench test and appropriate
photographs shall be included with the submission of the Form AAR 4-6.
1.4.9.2.3.4 At the conclusion of a service trial, Form AAR 4-6 Final Service Trial Inspection
Report, with any design changes the service trial indicates are necessary must be submitted to
the Tank Car Committee for approval with a copy of the original application. The Tank Car
Committee may request additional tests to supplement the manufacturers tests or service trials
prior to acceptance of the device.
1.4.9.3 Service Trial Report Form AAR 4-4
Service trial data must be submitted to the Executive Director on Form AAR 4-4, AAR Tank Car
Service Trial Report, at 6 month intervals before the April and October meetings of the Tank Car
Committee, no later than April 1 and October 1. Failure to submit the report may result in
cancellation of service trial authorization and revocation of all approvals. The Executive Director
shall be notified when the service trial starts; 90 days before the 2-year service trial ends; and
90 days before teardown is planned.
1.4.9.3.1 Instructions
1.4.9.3.1.1 The following instructions must be followed by the proponent when completing the
Service Trial Report.
AAR number is the same number used on Forms AAR 4-2, AAR 4-3, or AAR 4-5.
AAR docket number is the number assigned by the Director to review a specific item when
requested by the Tank Car Committee.
AAR service trial number is the number issued by the Director at the time the application
is processed.
Reporting company is the applicant or applicants representative having knowledge of the
performance and service of the device.
The date must be the date on which the report is completed.
Period covered is the period from the date of application or date of last report to the
required reporting date as specified above.
1.4.9.3.1.2 Enter the numbered items as follows:
Line Instruction
1. The applicants number blank is for the convenience of the applicant.
2. The device identification number is for the convenience of the applicant (e.g., catalog
number).
3. Record the date the device was initially installed on the car.
4. Describe the device as it was described on Form AAR 4-2, 4-3, or 4-5, giving function in
accord with the definitions and requirements of Appendix A.
5. Record the total number of cars authorized by the Tank Car Committee to have device
applied and the number of cars covered by the individual report.
6. Record the specific car numbers.
7. Indicate the commodity or commodity type.
8. Indicate the date of initial installation of the device.
9. Indicate the number of loaded trips and total miles the car moved in the period covered by
the report.
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CHAPTER 1 M-1002
Line Instruction
10. Show the total number of loaded trips and the total distance for each car to date for this
service trial. Indicate the average trips and distance for all cars.
11. Indicate the loading temperature of commodity, if known and applicable.
12. Indicate the unloading temperature of commodity, if known and applicable.
13. Indicate the loading pressure, if applicable.
14. Indicate the unloading pressure, if applicable.
15. Indicate the operational or performance difficulties encountered. Specify by car number.
16. These items provide recommendations to the Tank Car Committee.
through
17.
18.
C-III [M-1002] 60 11/2014

M-1002 CHAPTER 1
AAR TANK CAR SERVICE TRIAL REPORT*

AAR No.
AAR Docket No.
Reporting company AAR Service Trial No.
Address Date
Covering Period

1. Applicants No. 2. Device Identification. No.
3. Description of device
4. Number cars authorized to applicant 5.Number of cars this report
9. This Report 10. To Date
8. Date Initial
6. Reporting Marks 7. Commodity
Installation Loaded Distance Loaded Distance
Trips (Miles) Trips (Miles)
AVERAGES
11. Loading temperature F ( C) 12. Unloading temperature F ( C)

13. Loading Pressure psi ( kPa) 14. Unloading pressure psi ( kPa)
15. Maintenance required (specify by reporting mark and car no.)
16. General performance remarks
17. Continue test

18. Discontinue test

Final acceptance subject to Tank Car Committee Approval on Form AAR 4-6.

*This report is to be completed and submitted to the Executive Director every six months as required in Chapter 1 of M-1002. Failure to
submit report may result in cancellation of service trial authorization, and revocation of all approvals.

Submitted by Title

Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report
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CHAPTER 1 M-1002
1.4.10 Final Service Trial and Inspection

1.4.10.1 Procedures for Acceptance of Final Service Trial and InspectionReport
Form AAR 4-6
The acceptance of a service trial is based on the report of post-trial teardown, which must be filed
on Form AAR-4.6.
Final Service Trial Inspection Report. This form must be submitted to the Executive Director for
distribution to the Tank Car Committee. (Note: RPI representatives serving on the Tank Car
Committee will not receive sensitive information.)
AAR number is the same number used on Forms AAR 4-3 or AAR 4-5.
AAR docket number is the number assigned by the Executive Director to review a specific
item when requested by the Tank Car Committee.
AAR service trial number is the number assigned to the device for which this report is
presented.
The date must be the date on which this report is completed, signed, and forwarded to the
Tank Car Committee for approval.
Line Instruction
1. Enter the name and address of the applicant to whom service trial is assigned.
2. Enter the name and address of the device manufacturer, if different than that of the
applicant.
3. The description designation and/or model number of the device should be the same as
4. shown on Form AAR 4-3 (see Fig. 1.3) or Form AAR 4-5 (see Fig. 1.4).
5. Enter the total number of devices of this description or model number in the service trial
sample.
6. Enter the number of devices from the service trial sample that are included in the tests
and inspections reported.
7. Enter the total load/unload cycles, total loaded mileage, and total service time for the
service trial sample and average for the devices to be torn down. (Details for each device
or car should be available on Form AAR 4-4 submitted during the service trial.)
8. Enter actual test conditions to which each teardown sample is subjected (see Chapter 1,
paragraph 1.4.9 for teardown sample size). Comment on test results, physical condition,
corrosion, wear, etc. Compare critical dimensions to original.
9. Show drawing numbers and indicate revisions made during service trial.
10. Conclusions are those of the proponent after the tear down.
11. Recommendations are those of the designated Tank Car Committee observer.
12. The form is signed by the applicant or manufacturer (or agent) performing the tests and
inspections. The signature of the independent observer (if designated by the Committee)
also appears.
13. Upon successful completion based on the comments in Lines 10 and/or 11, the Executive
Director will approve the Final Service Trial Inspection Report and complete the approval
of the Form AAR 4-3 or 4-5, as appropriate.
1.4.10.2.3 The samples examined must have had the full range of service trial experience.
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M-1002 CHAPTER 1
FINAL SERVICE TRIAL INSPECTION REPORT

1. Applicant AAR No.
Address AAR Docket No.
2. Manufacturer AAR Service Trial No.
Address Date
4. Device designation or model no.
5. Total number of devices in service 6. Number of devices for teardown
7. Service data for service equipment under this inspection
Total load/unload cycles and average Total loaded mileage and average
Total service time and average
8. Teardown data Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

From car number
Last lading
Model no.
Serial no.
Test pressure psi (kPa)
Test temp F (C)
Test medium
STD psi (kPa)
Vapor tight, psi (kPa)
Test remarks...
Physical condition..
Compare critical final
dimensions to original...
9. Drawing numbers.....
(Ref. Form AAR 4-3 or AAR 4-5)
Revisions made......
Revision date..........
10. Conclusions
11. Recommendations to Tank Car Committee
12. CERTIFICATION
The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested
conform to the drawings listed above.
MANUFACTURER or APPLICANT INDEPENDENT OBSERVER/QA MANAGER
(Signature) (Signature)
Title Title
Company Company
13. APPROVAL AAR Tank Car Committee
Date approved
Form AAR 4-6 Revised 2-8-2014
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report
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CHAPTER 1 M-1002
1.4.11 Certified Status

1.4.11.1 Requirements for Obtaining Certified Status
A car owner/builder may elect to obtain certified status for stub sill, nonpressure, nonexterior-
coiled tank cars built prior to July 1, 1974, per Field Manual of the AAR Interchange Rules, Rule
88B.12.c. A petition for such status can be made to the Director and must be submitted as follows:
1.4.11.1.1 A special drawing approximately 8 1/2 11 in. for each type of stub sill (underframe)
to be certified must be submitted, covering general details including the following ranges:
Length over strikers
Truck centers
Inside tank diameters
Truck capacity
Typical variations in reinforcements
Type of materials
Typical welding details
Variations in details, such as slabbing materials, tank head and shell materials, length of slabs,
etc., are to be tabulated on the drawing.
1.4.11.1.2 Two tabulations are to be prepared as follows:
1.4.11.1.2.1 Car tabulation(s) by type of stub sill (underframe) showing car numbers (or car
number series where applicable).
1.4.11.1.2.2 Tabulation by car number, showing the following:
Type of stub sill construction
Length over strikers
Truck centers
Truck capacity
Capacity, gallons (liters)
Tank materialsat end of stub sill and/or at the end of the stub sill slabbing plate.
Shell thickness
Length of stub sill slabbing, within 10 in. (254 mm) increments
Test data reference (by test number and date)
Tank shell diameter (inside)
Year built new
1.4.11.1.3 Submit test data as specified in paragraph 6.3 of AAR Specification M-1001.
1.4.11.1.4 Submit stress calculations as specified in paragraph 6.2 of AAR Specification M-1001.
Include a comparison summary of calculated and measured stresses.
1.4.11.2 Approval
1.4.11.2.1 When approved by the Equipment Engineering Committee and the Tank Car
Committee, the Technical Services Section of the AAR will assign a certified status number in
accord with Office Manual of the AAR Interchange Rules, Rule 88, and advise the applicant.
1.4.11.2.2 The car owner must periodically submit to the AAR a listing of car modifications and
stenciling dates, if so requested.
1.4.11.2.3 In the event forthcoming tests or in-service operation proves the design inadequate, a
reevaluation of a certified status approval will be made.
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M-1002 CHAPTER 1
1.5 Certification of Independent Third Parties

1.5.1 General
1.5.1.1 Paragraph 1.4.1 of this specification provides for review of applications for construction,
conversion, or alteration of tank cars by a certified, independent third party (ITP) who verifies
that the applications meet all AAR, DOT, and Transport Canada requirements. This section sets
forth the minimum qualifications for ITPs and outlines the procedures to be followed by a
prospective ITP to obtain Tank Car Committee certification.
1.5.1.2 An ITP may be either an individual, a partnership, or a larger organization employing
individuals who possess the necessary qualifications and meet other requirements as further
described below.
1.5.2 Requirements and Qualifications
1.5.2.1 A certified ITP must possess, or utilize individuals who possess, at least a Bachelor of
Science degree in an engineering discipline conferred by an ABET-accredited college or university.
Registration as a professional engineer (PE) in the state in which the ITP practices is also
required. In addition, a prospective ITP must document a minimum of 5 years of experience in
tank car design, construction, operation, and/or repair or a related discipline, as deemed
acceptable by the Tank Car Committee. At the discretion of the Committee, the requirement for
PE registration may be waived in consideration of higher levels of technical knowledge and
experience related to tank cars.
1.5.2.2 A certified ITP must demonstrate a comprehensive working knowledge of U.S. and
Canadian federal regulations governing tank car design, construction, and repair, AAR
Interchange Rules, and AAR Standards and Recommended Practicesparticularly M-1002. An
ITP must possess or have access to the above documents as well as to relevant American Welding
Society (AWS) and American Society of Testing and Materials (ASTM) standards.
1.5.2.3 A certified ITP may not review an application that he/she, or an entity with which he/she
is affiliated, has submitted.
1.5.2.4 A certified ITP must agree to be bound by terms of a standard AAR contract.
1.5.3 Procedures for Obtaining Certification
The following procedures are to be followed by an applicant who desires to be certified as an ITP by
the AAR Tank Car Committee:
1.5.3.1 A letter of application must be filed with the Director, stating a desire to become certified
as an ITP for review of tank car applications and providing the technical background and general
business history of the applicant. The application must specifically address each item outlined in
paragraph 1.5.2.
1.5.3.2 The Director will arrange an opportunity for the applicant to meet with the AAR Tank
Car Committee at a scheduled meeting to discuss the application and address any questions from
members of the Committee.
1.5.3.3 Approval of the applicant must be by unanimous vote of the Committee. In the event
unanimous approval is not achieved, the applicant shall be advised of the reason(s) and may
request a second meeting with the Committee to further clarify the application.
1.5.3.4 Upon approval by the Tank Car Committee, the applicant will enter into a written
contract with AAR to review and verify applications, as an independent third party, on behalf of
the Committee.
1.5.3.5 Independent third party contracts will be subject to periodic review and renewal at the
discretion of the Tank Car Committee.
11/2014 C-III [M-1002] 65

CHAPTER 1 M-1002
1.6 Document Retention

1.6.1 This section describes the minimum documentation requirements for certified and
registered facilities and for tank cars in interchange service, and the minimum retention periods of
those documents. In general, documents that pertain to individual tank cars must be retained by
the owners of those cars; documents that pertain to linings and coatings must be kept by the
owners of those components; documents that pertain to the qualification of facilities to perform
work on tank cars must be retained by those facilities; and documents that pertain to approvals of
valves and fittings must be retained by the manufacturers of those components. While valid
means
the document has not expired; and
the document is not preceded by another document containing the same subject matter.
1.6.2 This standard is mandatory after January 1, 2008.
1.6.3 Documents may be retained as paper originals, as copies of originals, or in electronic
format, and must be available upon request by AAR or government representatives.
1.6.4 Table 1.19 lists the documents that must be retained by the car owner. Upon the sale of a
car, the documentation pertaining to that car must be transferred to the new owner. The table lists
the document by type and references the requirements for such document, the parties responsible
for retaining the document, and the minimum retention period for each type of document.
Table 1.19 Documents retained by car owner (page 1 of 2)

Document Retention Period
Original and subsequent certificates of construction Life of car
Forms AAR 4-2, R-1, and R-2 for modifications and repairs Life of car
General arrangement, tank, and fittings drawings Life of car
Drawings used for precedent for repairs 10 years
Tank head and shell plate mill test certificates None
Tank head and shell plate material identification None
Radiographs and radiographic reports or UT reports 10 years
Postweld heat treatment record (consistent with radiograph retention time) 5 years
Impact, corrosion, and harness tests when required by specification 5 years
Thermal analysis of thermal protection systems Life of car
Capacity table (gauge table) Life of car
Tank maintenance and qualification records Next qualification inspection
Visual
Structural
Thickness
Service equipment
D-3 form: Certificate of tank test
Certificate of pressure relief device test
Certificate of interior heater coil test
Leak testing
Safety systems
NDT inspection records Next Inspection
Service reliability assessment data Life of car + 10 years
SS-1 and SS-3 stub sill inspection forms (inboard and outboard of the bolster) Next Inspection
C-III [M-1002] 66 11/2014

M-1002 CHAPTER 1
Table 1.19 Documents retained by car owner (page 2 of 2)

Permits While valid
FRA/TC alternative inspection and test protocol. This does not transfer the approved While valid
alternative inspection and test protocol, but merely acknowledges that alterative means of
compliance exist. New owners must apply under the terms of 49 CFR 180.509(k),
180.509(j), and Transport Canada (TC) TP14877.
Ductile iron castings 5 years
Certified inspectors reports for Class DOT-107A tanks Life of tank
1.6.4.1 Table 1.20 lists the documents that must be retained by each certified and registered tank
car facility:
Table 1.20 Documents retained by certified and registered tank car facility
Certification/registration of facilities 6 years
Welding procedure and procedure qualification While valid
Performance qualification of welders and operators While valid, plus 90 days
Procedure qualification While valid
NDT written practice While valid
NDT certification records While valid, plus 90 days
NDT procedure requirements While valid
Results of radiographic examinations (radiographs may be retained or discarded) 5 years
Exhibit B-1 Subcontractors evaluation sheet (requires an annual review) While valid
1.6.4.2 Table 1.21 lists the documents that must be retained by each registered manufacturer of a
tank car pressure relief device, and service equipment:
Table 1.21 Documents retained by registered manufacturer of tank car pressure relief device and service equipment
Final service trial inspection report 2 years
Service trial report Duration of trial
Approval of pressure relief devices 10 years
Approval of valves and fittings 10 years
1.6.4.3 Table 1.22 lists the documents that must be retained by each lining or coating owner:
Table 1.22 Documents retained by lining or coating owner

Rubber lining qualification report While valid
Application/removal or lining inspection While valid
11/2014 C-III [M-1002] 67

CHAPTER 1 M-1002
C-III [M-1002] 68 11/2014

M-1002 CHAPTER 2
CHAPTER 2
AAR SPECIAL REQUIREMENTS FOR DOT TANK CARS
CONTENTS

2.1 Special Commodity Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III71
2.1.1 Argon, Carbon Dioxide, Nitrogen, and Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III71
2.1.2 Hydrogen Sulfide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III71
2.1.3 Molten Sulphur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III72
2.1.4 Hydrogen Fluoride, Anhydrous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III72
2.1.5 Vinyl Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III74
2.1.6 Aluminum Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III74
2.1.7 Totally Contained Commodities (Shipped in Tank Cars not Equipped with Pressure Relief Devices)C-III74
2.2 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III75
2.2.1 Pressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III75
2.2.2 Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III75
2.2.3 Fittings for Acid Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III75
2.2.4 Eduction Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.5 Two-Bolt Swing Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.6 Lead Rupture Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.7 Vacuum Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.8 Electrical Bonding and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.9 Internal Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.10 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III77
2.2.11 Bottom Outlet Caps and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III78
2.2.12 Internal Heater Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III78
2.2.13 Gas Purging Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III78
2.2.14 Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III78
2.2.15 Thermal Protection Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III78
2.2.16 Re-Stenciling AAR Class Cars to DOT/TC Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III79
2.3 Special Requirements (Proposed Revisions to DOT Specifications). . . . . . . . . . . . . . . . . . . . . . . . . . C-III79
2.3.1 AAR Special Requirements for DOT Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III79
2.4 Shipper Requirements in Addition to DOT Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III80
2.4.1 Outage Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III80
11/2014 C-III [M-1002] 69

CHAPTER 2 M-1002

2.5 Requirements for DOT/TC Tank Cars Weighing Over 263,000 lb GRL. . . . . . . . . . . . . . . . . . . . . . . . C-III80
2.5.1 All Class DOT/TC Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III80
2.5.2 Class DOT/TC-111 Nonpressure Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III80
2.5.3 Class DOT/TC Pressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.5.4 Class DOT/TC-113 Cryogenic Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.5.5 Class DOT/TC-115 Nonpressure Tank Cars (tank within a tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.6 Top Fittings Protection Requirements for Nonpressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.7 Requirements for Cars Built for the Transportation of Packing Group I and II Materials with the
Proper Shipping Names Petroleum Crude Oil, Alcohols, n.o.s., and Ethanol and Gasoline
Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.7.2 Top Fittings Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.7.3 Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III81
2.7.4 Tank Material and Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III82
C-III [M-1002] 70 11/2014

M-1002 CHAPTER 2
CHAPTER 2. AAR SPECIAL REQUIREMENTS FOR DOT TANK CARS

2.1 Special Commodity Requirements
2.1.1 Argon, Carbon Dioxide, Nitrogen, and Oxygen
2.1.1.1 Tank cars in argon, carbon dioxide, nitrogen, and oxygen service must be marked with the
following stencils:
Stencil REGULATING VALVE(S) (VENTING NORMAL), RELIEF VALVE, or
RUPTURE DISC in 1 in. letters, minimum, over or under the discharge pipes from the
respective devices.
Stencil REGULATING VALVE(S) VENTING NORMAL, in 3 in. letters, minimum, on
each side of the insulation jacket in the REMARKS position as shown in Appendix C,
Fig. C.2.
2.1.1.2 Tank cars in carbon dioxide service shall have the pressure regulator valves tested in
accordance with Appendix A.
2.1.2 Hydrogen Sulfide
2.1.2.1 DOT exemption required.
2.1.2.2 Tank cars used to transport hydrogen sulfide must comply with Specification
DOT-105J600W or DOT-120J600W and with the following additional special requirements:
2.1.2.2.1 No welding or welding repairs are permitted on the tank shell, heads, or manway nozzle
after the tank is postweld heat treated. When such welding is necessary, the tank must be
postweld heat treated as a unit after welding is completed. Welding after postweld heat treatment
is permitted only to external pads that have been welded in place prior to postweld heat
treatment.
2.1.2.2.2 Tank must be postweld heat treated at 1100 F (593 C) minimum; postweld heat
treatment at the alternate lower temperatures in Appendix W is prohibited.
2.1.2.2.3 Plates for the tank shell, heads, and manway must comply with Specification ASTM
A516 Grade 70 normalized or ASTM A537 Class 1.
2.1.2.2.4 Manway stud and nut material, including that material inside the protective housing,
must comply with Appendix M, modified by heat treatment to the following properties:
Hardness Rc 22 maximum
Tensile strength 90,000 psi (621 MPa) minimum
Yield strength 75,000 psi (517 MPa) minimum
2.1.2.2.5 Valves, valve parts, fittings, and other appurtenances must comply with National
Association of Corrosion Engineers Publication MR-01-75. Ferritic stainless steels and
free-machining stainless steels must not be used. Series 300 stainless steels, except for Type 303,
must be used.
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CHAPTER 2 M-1002
2.1.2.2.6 Special tank material requirements:

2.1.2.2.6.1 Tank cars intended to be loaded at ambient temperatures must be constructed of steel
listed above that has not less than 20 ftlb (27.1 J) Charpy V-notch impact value at 20 F
(28.9 C). The jacket must be stenciled adjacent to water capacity stencil MINUS 20 F (or
MINUS 20 F OR MINUS 28.9 C) MINIMUM LOADING TEMPERATURE.
2.1.2.2.6.2 Tank cars intended to be loaded at lading temperatures below 20 F (minus 28.9 C)
must be constructed of steel listed above that has not less than 15 ftlb (20.3 J) Charpy V-notch
transverse impact value at 50 F (45.6 C). The jacket must be stenciled adjacent to water
capacity stencil MINUS 50 F (or MINUS 50 F OR MINUS 45.6 C) MINIMUM LOADING
TEMPERATURE.
2.1.2.2.6.3 Impact testing must conform to ASTM A370 and Appendix W, except that all test and
retest specimens (not the average) must meet the requirements.
2.1.2.2.7 Tank anchor-to-tank shell fillet welds must be examined by a suitable nondestructive
testing method to ensure that welds are free from cracks or other detrimental defects.
2.1.2.2.8 Lead-base paints and lead gaskets are prohibited.
2.1.2.2.9 Tank jacket must be stenciled on both sides in letters not less than 4 in. (102 mm) high
HYDROGEN SULFIDE.
2.1.2.2.10 All loose mill scale must be removed from the interior of the tank using Steel
Structures Painting Council Specifications SP7. Surface hardening of parent metal must be
avoided.
2.1.3 Molten Sulphur
2.1.3.1 To ensure structural integrity, tank cars ordered after January 1, 1994, constructed for
the transportation of molten sulphur must have a protective coating, lining, or corrosion-resistant
material in areas of high heat flux to prevent wet elemental sulphur contact corrosion. The
National Association of Corrosion Engineers (NACE) has published NACE Standard
RP0302-2002, Selection and Application of a Coating System to Interior Surfaces of New and
Used Rail Tank Cars in Molten Sulfur Service, available from NACE International, 1440 South
Creek Drive, Houston, TX 77084-4906.
2.1.3.2 To ensure structural integrity, existing tank cars used for the transportation of molten
sulphur must have an inspection and test conducted every 10 years. After an inspection and test,
the owner must ensure that the tank car has a protective coating, lining, liner, or
corrosion-resistant material applied in areas of high heat flux to prevent wet elemental sulphur
contact corrosion. First inspection must be completed before December 15, 2003.
2.1.4 Hydrogen Fluoride, Anhydrous
In addition to the DOT requirements, the following AAR requirements for tank cars used to
transport anhydrous hydrogen fluoride must be met. See Appendix R, paragraph 4.1, for
alteration of existing tank cars to hydrogen fluoride service. New construction must be Class 112
specification (DOT exemption required).
2.1.4.1 Bottom opening in tank shell is prohibited.
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M-1002 CHAPTER 2
2.1.4.2 The steelmaking practice for new fabrication and plates for repairs to tank shell, heads,
and manway nozzles shall provide resistance to hydrogen-induced cracking and blistering. The
steel must meet the following requirements:
Tensile strength is not to exceed 85 ksi.
The steel shall have a specification of 0.006% maximum sulfur content and be calcium
treated to obtain the minimum number of inclusions, inclusion shape control, and
maximum resistance to hydrogen blistering.
Steels with sulfur content above 0.003% shall be tested for hydrogen-induced cracking per
National Association of Corrosion Engineers (NACE) Standard TM-02-84, or be
ultrasonically scanned per ASTM A578, Level C (using a 1 in. circle).
2.1.4.3 Tanks must be postweld heat treated between 1125 F and 1225 F (607.2 C and
662.8 C). Postweld heat treatment at alternative lower temperatures referenced in Appendix W is
prohibited.
2.1.4.4 If welding or welded repairs are required on the tank shell, heads, or manway nozzle after
the tank is postweld heat treated, repairs must be made per Appendix R, paragraph 4.1.
2.1.4.5 The maximum hardness of the tank and welds after postweld heat treatment must not
exceed 20 HRC. If weld repairs are required, hardness measurements shall be made per
Appendix R, paragraph 4.1.
2.1.4.6 Valves, valve parts, and other appurtenances normally in contact with the lading must
comply with NACE Publication MR-01-75 or be of the following materials:
Gold
Platinum
Nickel (except electrolytic and electroless)
Monel (except free-machining)
PTFE
Fluoroelastomer copolymer/tripolymer
Aluminum-silicon-bronze
2.1.4.7 Pressure relief valves must be in combination with either a breaking pin device or a
rupture disc. See DOT 179.15 (e). If the pressure relief valve is in combination with a rupture disc,
the tank must be 112A400W, stenciled -200W and equipped with a combination device set for
-200W requirements, having the disc rated at 150 psig (1034 kPa) and the valve start-to-discharge
at 142 psig (979.1 kPa). The space between the rupture disc and valve must be vented and the vent
must be closed in transportation.
The vent must be checked at each loading to ensure that the rupture disc is not leaking. If the
rupture disc is defective, it must be replaced and the pressure relief valve tested for proper
operation.
2.1.4.8 Studs and bolts used to fasten any valves or fittings to the cover plate or the cover plate to
the manway ring must meet one of the following specifications:
ASTM A193-B7M including Supplement S3 requiring 100% hardness testing
ASTM A193-B7Maximum hardness Brinell 237 (Rc 22)
ASTM A320-L7Maximum hardness Brinell 237 (Rc 22)
ASTM A193-B8, Class 2, Type 304 stainless steel, carbide solution treated and strain
hardened to Brinell 320 (Rc 35) maximum hardness
Rolled threads are required for all studs and bolts.
11/2014 C-III [M-1002] 73

CHAPTER 2 M-1002
2.1.4.9 Nuts used to fasten any valves or fittings to the cover plate or the cover plate to the
manway ring must meet one of the following specifications:
ASTM A194-2HM including Supplement S7 requiring 100% hardness testing
ASTM A194-2Maximum hardness Brinell 237 (Rc 22)
ASTM A194-8F, Type 303 stainless steel, carbide solution treated, machined from cold
drawn bar, Brinell 300 (Rc 32) maximum hardness
2.1.4.10 Fasteners used in valve assemblies must conform to the National Association of
Corrosion Engineers Publication MR-01-75 and must be approved for anhydrous hydrogen fluoride
service. Ferritic stainless steels are prohibited.
2.1.4.11 Each tank car must be marked HYDROGEN FLUORIDE in accord with DOT 172.330.
2.1.4.12 Inspection and Repairs
See Appendix R, paragraph 4.1.
2.1.5 Vinyl Chloride
All tank cars ordered after May 1, 2001, for vinyl chloride service must be equipped with cover
plates as shown in Appendix E, Fig. E.9 (20 in. diameter) or Fig. E.11 (22 in. diameter). Refer to
Fig. E.10 (20 in. diameter cover plate) or Fig. E.12 (22 in. diameter cover plate) for details on
nozzle joints. For details on openings, see Figs. E.19 through E.19.25.
2.1.6 Aluminum Tank Car Tanks
The following commodities are not authorized in aluminum tank car tanks:
Carbon tetrachloride
Chloroform
Ethylene dichloride
Methylene chloride
Propylene dichloride
2.1.7 Totally Contained Commodities (Shipped in Tank Cars not Equipped with
Pressure Relief Devices)
2.1.7.1 The transportation of totally contained commodities in tank cars not equipped with
pressure relief devices must be approved by the Tank Car Committee and be carried out in tank
cars stenciled as AAR Specification tank cars. A DOT exemption is required for totally contained
transportation in a DOT Specification tank car.
2.1.7.2 Proponents desiring to transport a product in a tank car without a pressure relief device
must petition the Tank Car Committee by submitting an Form AAR 4-2 (see Fig. 1.1 on page
C-III42), requesting approval. Technical justification must be submitted with the application and
must include calculations made with the AFFTAC simulation model or approved equivalent
analysis, indicating that the car will survive at least 100 minutes in a pool fire before rupturing.
Such calculations must consider the thermal properties of the commodity, including the coefficient
of expansion, expected exothermic reactions, and other considerations specified by the Tank Car
Committee.
2.1.7.3 Tank Cars must be marked with a commodity stencil as specified in Appendix C,
paragraph 5.1.
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M-1002 CHAPTER 2
2.2 General Requirements

2.2.1 Pressure Tank Car Tanks
2.2.1.1 All steel, single-unit pressure tank car tanks fabricated from plate must be fabricated
from fine-grain steels as described by ASTM A516, ASTM A537, or AAR TC128. Heads and shells
of pressure tank car tanks constructed of ASTM A516 or AAR TC128 must be normalized, effective
January 1, 1989. Tank car heads must be normalized after forming, unless specific approval is
granted for a facilitys equipment and controls.
2.2.1.2 Effective for cars ordered after August 1, 2005, each plate-as-rolled of ASTM A516,
ASTM A302, ASTM A537, and AAR TC128 steel used for pressure tank car heads and shells must
be Charpy impact tested transverse to the rolling direction in accordance with ASTM A20. The
test coupons must simulate the in-service condition of the material and must meet the minimum
requirement of 15 ftlb average for three specimens at 30 F, with no single value below 10 ftlb
and no two values below 15 ftlb. Plates for low-temperature service described in 49 CFR 179.102
that require longitudinal impact testing at 50 F do not require transverse testing at 30 F.
2.2.2 Manway Covers
For dimensions and tolerances of manway covers for tanks covered by DOT 179.100, see
Appendix E. For stud and bolt materials, see Appendix M. Carbon steel manway cover plates used
for pressure cars must be fabricated from fine-grain practice, normalized material.
2.2.3 Fittings for Acid Cars
2.2.3.1 Lead gaskets are prohibited.
2.2.3.2 Fill openings, when used, must be designed as follows:
2.2.3.2.1 For 111A*W2/103AW tanks
Minimum 6 in. (152.4 mm) nominal pipe size opening
Minimum three-bolt or rim-clamping mechanism closure
Cover to be hinged or otherwise attached to tank
Safety feature to prevent removal of cover while tank is under pressure
2.2.3.2.2 For 111A*W5/103BW tanks, as an alternative to the one-bolt clamping arm type, the fill
opening criteria above may be used.
2.2.3.3 The service equipment fitted on top of new nonpressure cars in sulfuric acid service,
ordered built new after June 30, 2010, must meet the requirements of paragraph 9.2.1 of
Appendix E. Subject to paragraph 2.2.3.4, the service equipment fitted on top of nonpressure cars
in sulfuric acid service ordered new before July 1, 2010, and built after August 1, 2002, must meet
the requirements of paragraph 9.2.1 of Appendix E or must be protected by one or more of the
following methods:
2.2.3.3.1 By fitting a protective device mounted to the tank shell and/or manway cover plate.
These protective structural items must meet all of the following criteria:
Must be designed to effectively protect the service equipment and to meet the conditions
listed in paragraph 2.2.3.5.
Must be mounted to the shell through a pad or to the manway cover plate with a welded or
bolted joint having no more than 70% of the strength of the pad-to-shell or manway cover
plate-to-manway nozzle joint.
Must not reduce the pressure relief device flow capacity below the minimum required.
Must provide sufficient drainage and adequate access for personnel to load and unload and
maintain and inspect the service equipment while wearing the appropriate protective gear.
11/2014 C-III [M-1002] 75

CHAPTER 2 M-1002
2.2.3.3.2 By using the filling nozzle as a local protective device for the service equipment fitted on
the manway cover plate, in which case, the following apply:
The filling nozzle and its closure are designed to meet the conditions of paragraph 2.2.3.5.
No service equipment or part thereof extend higher than the top surface of the filling
nozzle cover structure, nor extend beyond the perimeter of the manway cover.
Except for the following item, the service equipment is mounted to the manway cover plate
or to a nozzle welded to the manway cover plate or fill opening through a welded or flanged
connection.
If an air connection is provided, the connection may be threaded, and pipe elements must
be at least extra-strong (XS) in wall thickness and located where ample roll-over protection
is afforded by the filling nozzle. This fitting may be mounted to the manway cover plate or
to a nozzle through a threaded connection.
2.2.3.4 The service equipment fitted on top of nonpressure tank cars built before August 1, 2002,
in sulfuric acid service must meet the requirements of paragraph 9.2.1 of Appendix E or must be
protected by one or more of the following methods by August 1, 2011:
2.2.3.4.1 By fitting a protective device as per paragraph 2.2.3.3.1.
2.2.3.4.2 In the case of service equipment fitted on the manway cover plate, by using the filling
nozzle as a local protective device, where
the service equipment is a non-reclosing pressure relief device mounted on the manway
cover plate through a welded or flanged connection and the device or part thereof does not
extend higher than 1 in. above the top surface of the filling nozzle cover structure, nor
extend beyond the perimeter of the manway cover;
the service equipment is an eduction pipe and its closure assembly made with minimum
NPS 2 extra strong (XS) and the assembly or part thereof does not extend higher than 4 in.
above the top surface of the filling nozzle cover structure, nor extend beyond the perimeter
of the manway cover; and
the service equipment is mounted as per paragraph 2.2.3.3.2 bullets 3 and 4.
2.2.3.4.3 In the case of a non-reclosing pressure relief device mounted on an existing nozzle but
located outside of the manway cover plate, the device may not meet the conditions of
paragraph 2.2.3.5 nor be fitted with a protective device meeting the conditions of
paragraph 2.2.3.5 if
the device is mounted to the nozzle through a welded or flanged connection; and
the device or any part thereof extends no more than 8 in. above the top face of the nozzles
flange and no more than 20 in. above the outer longitudinal centerline of the tank shell as
shown in Fig. E.25.4.
2.2.3.5 The protective device or unprotected service equipment under consideration and tank
must withstand, at a minimum, the following loads applied to the top fittings assembly and nozzle:
1/2W vertical in the downward direction, 1W horizontal in the longitudinal direction, and 1/2W
horizontal in the lateral direction, with each load applied separately as a uniform load over the
projected plane of the element(s) under consideration. For horizontal loads, the height of the
projected plane is from the top of the tank shell at the centerline to the height of the item. 1W is
the cars maximum gross weight on rail minus the weight of the trucks. The stress must not exceed
the following:
The minimum specified tensile strength of the material for the tank, nozzle(s), unprotected
service equipment, and protective device (where applicable); and
The critical buckling stresses of the assembly under consideration.
C-III [M-1002] 76 11/2014

M-1002 CHAPTER 2
2.2.4 Eduction Pipes

The following applies to all pressure and nonpressure tank cars, with and without interior
coatings or linings:
2.2.4.1 Eduction pipes and guides must be designed and installed to prevent contact of the
eduction pipe with the tank shell, sump, or interior coating/lining material. Consideration must be
given to manufacturing tolerances, wear of components, coating/lining thickness, and any
deflection that may occur due to design loads as specified in the Manual of Standards and
Recommended Practices, Section C, Part II, Specification M-1001, paragraph 6.2.
2.2.4.2 Whenever an eduction pipe is removed from a car, a procedure must be in place to identify
the eduction pipe to the car and to ensure proper orientation and fit when reinstalled or when
replaced per the original design.
2.2.4.3 Bleed holes in eduction pipes closed with pipe caps are prohibited. Approved means must
be provided to relieve pressure.
2.2.5 Two-Bolt Swing Closures
When two-bolt swing closures are used as secondary closures on bottom outlets, their use must be
limited to commodities that have a freezing point above 150 F (65.5 C) and that exhibit little or
no vapor pressure at ambient temperatures.
2.2.6 Lead Rupture Discs
Lead rupture discs are prohibited.
2.2.7 Vacuum Relief Valves
Gravity-actuated vacuum relief valves must not be applied or replaced in kind.
2.2.8 Electrical Bonding and Grounding
2.2.8.1 The car design must meet the electrical bonding requirements of AAR Specification
M-1001, paragraph 4.3.6.
2.2.8.2 All tank cars must have two electrical grounding lugs accessible on opposite sides of the
car and located on the inside horizontal plane of the body bolster assemblies (BL and AR). The
grounding lugs must be made of a conductive material that provides solid grounding and must be
attached by a means that provides continuity as specified in Specification M-1001, paragraph
4.3.6. The grounding lugs shall be free of paint to ensure electrical continuity between the
grounding lugs, bolster, and tank shell. Additional bolted grounding studs or welded grounding
lugs may be added on the car, except no grounding point shall be in a location that hinders the safe
operation of tank car loading/unloading. This requirement is in effect for stub sill tank cars
ordered after July 1, 2014.
2.2.9 Internal Reinforcing Pads
Reinforcing pads are required for internal attachments, except gauging bars, pressure relief device
baffle plates, shell stiffeners, and non-anchor-type pipe supports for internal coils. They must be
not less than 1/4 in. thick, have each corner rounded to a 1 in. minimum radius, and be attached to
the tank by continuous fillet weld. Pad venting provision must be considered and tank shell
drainage must be provided.
2.2.10 Insulation
Tank car insulation systems, including foams, must not promote corrosion to steel when wet. Tank
and jacket protective coatings are required. The tested pH of reacted foam-in-place insulation
must be within the range of 5 to 9. The pH of the foam is tested when cured, and granulated foam
is boiled for one hour in deionized water, in a ratio of one part foam to 40 parts water by weight.
11/2014 C-III [M-1002] 77

CHAPTER 2 M-1002
2.2.11 Bottom Outlet Caps and Nozzles

The limiting wear dimensions for bottom outlet caps and nozzles are found in Appendix E,
Figs. E.18 through E.18.5. Caps or nozzles worn to these limits must be removed from service.
Suggested NOGO gauges are shown in Figs. E.18.6 through E.18.9. These gauges also may be used
to verify the integrity of threads on hose connections used at loading and unloading sites.
2.2.12 Internal Heater Connections
Unused internal heater coil couplings in tank shells or heads must be closed only with a threaded
and seal-welded plug.
2.2.13 Gas Purging Standards
2.2.13.1 Each facility that purges a tank car with nitrogen or other cryogenic liquid shall ensure
against the introduction of liquid into the tank through a written procedure, training, supervision,
and appropriate equipment.
2.2.13.2 For recommended nitrogen purging procedures, see the latest edition of Recommended
Procedures for Nitrogen Purging of Tank Cars, Compressed Gas Association, Pamphlet No. CGA
P-16.
2.2.13.3 Tank cars offered in a purged state under pressure must have all service fittings or
fitting groups tagged with a yellow CAUTION tag indicating pressure in the tank and the
pressure at time of offering. A tag must be made of any material capable of withstanding without
deterioration of substantial reduction in effectiveness a 30-day exposure to open weather
conditions.
2.2.14 Pressure Relief Valves
Tank cars in regulated commodity service that are equipped with pressure relief valves
incorporating a 35 psi start-to-discharge pressure must be upgraded to a 75 psi start-to-discharge
pressure at the next shopping, not to exceed next valve qualification time.
2.2.15 Thermal Protection Systems
2.2.15.1 In addition to the requirements of the Federal Regulations, thermal protection systems,
when required, must meet the provisions of this paragraph.
2.2.15.2 Each combination of tank car, pressure relief device, thermal protection system, and
lading material must be capable of withstanding a full-immersion pool fire for 100 minutes and a
torch fire for 30 minutes under the conditions described in paragraph 2.2.15.3 with no release of
lading except through the pressure relief device. An analysis using the computer program
AFFTAC is the recommended means of verifying this.
2.2.15.3 Analyses must be performed with the tank car in both the upright position and
overturned 120 about the longitudinal axis. In addition, the following conditions must be met:
2.2.15.3.1 Initial temperature of the lading material must be 115 F (46 C) for a noninsulated
tank car, 110 F (43 C) for a tank car having a thermal protection system, or 105 F (41 C) for an
insulated tank car.
2.2.15.3.2 The maximum allowable filling limit of the lading material as required by the Federal
Regulations. The filling limits for the winter months must not be used.
2.2.15.3.3 Thermal properties of the lading material must be used. Default properties provided
for the lading material in the analysis software may be used.
2.2.15.3.4 Surface emissivity of tank shell and head or metal jacket must be 0.8.
2.2.15.3.5 Discharge coefficients for the safety relief device shall be 0.8 for vapors and 0.6
for liquids. Other discharge coefficients may be used, provided they are justified by actual flow test
data.
C-III [M-1002] 78 11/2014
M-1002 CHAPTER 2
2.2.15.3.6 The pool fire analysis shall use a fire with a minimum temperature of 1,500 F
(816 C). The torch fire analysis shall use a fire with a minimum temperature of 2,200 F
(1,205 C).
2.2.15.3.7 The analysis must consider the heat flux through tank discontinuities, protective
housings, underframes, metal jackets, insulation, and thermal protection.
2.2.15.4 The thermal conductivity of the thermal protection and insulation material, as a
function of temperature, shall be based upon actual test data.
2.2.16 Re-Stenciling AAR Class Cars to DOT/TC Class
AAR-class tank cars may be re-stenciled to DOT/TC class provided the following conditions are
met:
2.2.16.1 The original construction of the cars must be in accordance with the DOT/TC
specification.
2.2.16.2 At the time of conversion, cars must be qualified to the DOT/TC specification in
accordance with the applicable federal regulation.
2.2.16.3 Identification plates have been added or replaced in accordance with the applicable
federal regulation and with Appendix C, paragraph 3.0.
2.2.16.4 The proponent must submit Exhibit R-1 to AAR.
2.3 Special Requirements (Proposed Revisions to DOT Specifications)
2.3.1 AAR Special Requirements for DOT Tank Cars
2.3.1.1 Bottom Outlets and Bottom Washouts
Reference DOT 179.100-14(a)(3), 179.103-5(b)(4), 179.200-17(a)(7), 179.200-17(b)(3),
179.220-18(a)(6), and 179.220-18(b)(3):
2.3.1.1.1 If the outlet (or washout) nozzle and its closure extends, a) more than 1 in. beyond the
shell envelope and is not provided with bottom discontinuity protection, or b) beyond the bottom
discontinuity protection, or c) below the bottom surface of a continuous center sill, a machined
breakage groove or bolted connection must be incorporated that is designed to fail without
rupturing the tank shell when a horizontal load is applied. The breakage groove or bolted
connection must be located, a) within 1 in. of the tank envelope, or b) within the envelope of a
protective device, or c) above the bottom surface of a continuous center sill. In addition, except for
special application, the breakage groove or the bolted connection must be designed to withstand a
1,000 ftlb (1356 Nm) torque without exceeding the shearing yield strength. The bolted connection
must have threads or a necked-down cross-section located in the shear plane. A breakage groove, if
used, must be a V-groove, cut (not cast) to a depth that will leave the thickness of the nozzle at the
base of the groove not over 1/4 in. (6.35 mm).
2.3.1.1.2 The strength of the breakage groove or breakage groove equivalent must not exceed
60% of the primary valve connection to the universal flange using the minimum published tensile
strength of the nozzle material (for a V-groove) or of the nozzle bolting material, and the minimum
published yield strength of the valve-to-universal flange bolting material. If the maximum tensile
strength of the nozzle bolting is known and used, then this connection strength may be equal to
the calculated valve-to-universal flange bolting strength based on minimum yield. Connection
strength for two load applications must be analyzedone with the load applied at the lowest point
of the nozzle assembly and one with the load applied at the nozzle breakage groove or equivalent
bolted connection or at the lowest point of the valve protective device. In both cases, the calculated
loads must be based on the combined tensile and shear stress.
11/2014 C-III [M-1002] 79

CHAPTER 2 M-1002
2.4 Shipper Requirements in Addition to DOT Requirements

2.4.1 Outage Requirements
Tank cars must be so loaded that sufficient outage is provided under conditions normal to
transportation. Consideration must be given to the volumetric expansion characteristics of the
liquid and the ambient temperatures to which it will be subjected in transit. Calculations must use
the reference temperatures and outage limits listed in DOT 173.24b (a).
2.5 Requirements for DOT/TC Tank Cars Weighing Over 263,000 lb GRL
2.5.1 All Class DOT/TC Tank Cars
Paragraph 2.5 applies to all Class DOT and TC tank cars ordered after December 31, 2003, when
the gross weight exceeds 263,000 lb.
2.5.1.1 Cars must comply with all requirements of the Office Manual of the AAR Interchange
Rules, latest version.
2.5.1.1.1 Cars must be in conformance with the truck requirements located in MSRP
Standard S-286 as required in the Office Manual of the AAR Interchange Rules, Rule 88.
2.5.1.2 Shippers are reminded that regulations limit the gross weight of Class DOT/TC tank cars
to 263,000 lb and that a federal exemption is required to operate these cars at heavier weights.
2.5.1.3 In addition to the design loads described in MSRP S-286, all REPOS loading, including
horizontal and vertical coupler loads, used for fatigue calculations must be increased by a factor of
1.09 above the loading used for 263,000 lb cars.
2.5.1.4 Car owner must identify appropriate areas of inspection for fatigue, corrosion, wear, etc.,
and must have a life-cycle maintenance plan for cars. This must identify inspection items,
inspection methods, acceptance criteria, and inspection frequencies. The car owner or designee
must have written procedures that ensure that work performed on cars conforms to federal and
AAR requirements.
2.5.1.5 New cars may not be equipped with reconditioned truck components.
2.5.1.6 Class DOT/TC cars with tanks constructed of aluminum or nickel plate with gross weight
over 263,000 lb are not authorized.
2.5.2 Class DOT/TC-111 Nonpressure Tank Cars
2.5.2.1 Class DOT/TC-111 cars must be equipped with top fittings protection in accordance with
Appendix E, paragraph 9.2.
2.5.2.2 Class DOT/TC-111 cars must be equipped with reclosing pressure relief devices, except
where the applicant can demonstrate that a non-reclosing device affords an equivalent level of
safety.
2.5.2.3 Class DOT/TC-111 cars with carbon steel tanks must meet one of the following minimum
criteria:
Tanks are constructed of normalized TC128 steel at least 7/16 in. thick and equipped with
steel jackets and 1/2 in. thick steel jacket heads.
Tanks are constructed of normalized TC128 steel at least 1/2 in. thick and equipped with
1/2 in. thick steel half-head shields.
Tanks are constructed of normalized ASTM A516 steel at least 1/2 in. thick and equipped
with steel jackets and 1/2 in. thick steel jacket heads.
Tanks are constructed of normalized ASTM A516 steel at least 5/8 in. thick and equipped
with 1/2 in. thick steel half-head shields.
C-III [M-1002] 80 11/2014

M-1002 CHAPTER 2
Tank car heads must be normalized after forming, unless specific approval is granted for a
facilitys equipment and controls.
2.5.2.4 Class DOT/TC-111 cars with high-alloy steel tanks (111****W6 and 111****W7) must
have heads and shells at least 1/2 in. thick and be equipped with half-head shields if not jacketed.
Jacketed tanks must be at least 7/16 in. thick and be equipped with 1/2 in. thick jacket heads.
2.5.3 Class DOT/TC Pressure Cars
2.5.3.1 In addition to the requirements of paragraph 2.5.1, Class DOT/TC-105, 112, 114, and 120
tank cars having a gross weight on rail over 263,000 lb must conform to paragraph 2.5.1 and be
equipped with a metal jacket and tank head protection.
2.5.3.2 Notwithstanding paragraph 2.5.3.1, if the federal regulations authorize the use of a tank
car without a metal jacket, the AAR requirement for a metal jacket is waived, if not required by
car specification, provided that the tank heads and shell are constructed from normalized AAR
TC128 Grade B steel and the required thickness of the tank heads and shell is increased by at
least 1/16 in. over minimum specification thickness. Tank head protection is required.
2.5.4 Class DOT/TC-113 Cryogenic Cars
Class DOT/TC-113 cryogenic cars with gross weight over 263,000 lb must meet the requirements
of paragraph 2.5.1.
2.5.5 Class DOT/TC-115 Nonpressure Tank Cars (tank within a tank)
In addition to the requirements of paragraph 2.5.1, Class DOT/TC-115 cars with gross weight over
263,000 lb must meet the requirements of paragraphs 2.5.2.1 and 2.5.2.2.
2.6 Top Fittings Protection Requirements for Nonpressure Cars
For protection of top fittings against rollovers and accidental horizontal loads, all new nonpressure
Class DOT/TC tank cars ordered after July 1, 2010, used to transport Packing Group I (high
hazard) and Packing Group II (medium hazard) materials must be equipped per paragraph 9.2.1
of Appendix E.
2.7 Requirements for Cars Built for the Transportation of Packing Group I and II
Materials with the Proper Shipping Names Petroleum Crude Oil, Alcohols, n.o.s.,
and Ethanol and Gasoline Mixture
2.7.1 Cars ordered after October 1, 2011, for the transportation of packing Group I and II
materials with the proper shipping names petroleum crude oil, alcohols, n.o.s., and ethanol
and gasoline mixture must comply with the following requirements.
2.7.2 Top Fittings Protection
2.7.2.1 Class 111 tank cars used to transport packing Group I and II materials with the proper
shipping names petroleum crude oil, alcohols, n.o.s., and ethanol and gasoline mixture must
be equipped per Appendix E, paragraph 9.2.1.
2.7.3 Pressure Relief Devices
Class 111 tank cars used to transport packing Group I and II materials with the proper shipping
names petroleum crude oil, alcohols, n.o.s., and ethanol and gasoline mixture must be
equipped with reclosing pressure relief devices. Upon approval of Pipeline and Hazardous Safety
Administration (PHMSA), a non-reclosing device can be used where the applicant demonstrates
that a non-reclosing device is required and affords an equivalent level of safety.
11/2014 C-III [M-1002] 81

CHAPTER 2 M-1002
2.7.4 Tank Material and Thickness

2.7.4.1 Class 111 tank cars used to transport packing Group I and II materials with the proper
shipping names petroleum crude oil, alcohols, n.o.s., and ethanol and gasoline mixture must
have heads and shells constructed of normalized TC128 Grade B steel or normalized
ASTM A516-70 steel. Tank car heads must be normalized after forming, unless approval is
granted by the AAR Executive Director of Tank Car Safety on the basis that a facility has
demonstrated that its equipment and controls provide an equivalent level of safety. For tanks
constructed of normalized TC128 Grade B steel, non-jacketed tanks must be at least 1/2 in. thick
and jacketed cars must be at least 7/16 in. thick. For tanks constructed of normalized
ASTM A516-70 steel, non-jacketed cars must be at least 5/8 in. thick and jacketed cars must be at
least 1/2 in. thick. In all cases the cars must be equipped with at least 1/2 in. half-head shields.
2.7.4.2 Class DOT-111 cars with high-alloy steel tanks (111 ****W6 and 111 ****W7) used to
transport packing Group I and II materials with the proper shipping names petroleum crude oil,
alcohols, n.o.s., and ethanol and gasoline mixture must have heads and shells at least 1/2 in.
thick and be equipped with at least 1/2 in. half-head shields if not jacketed. Jacketed tanks must
be at least 7/16 in. thick and be equipped with 1/2 in. thick jacket heads at a minimum.
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M-1002 CHAPTER 3
CHAPTER 3
SPECIFICATIONS FOR AAR TANK CAR TANKS
CONTENTS
3.1 (AAR.100) Specifications Applicable to Class AAR-203W and AAR-211W Tank Car Tanks. . . . . . . . C-III85
3.1.1 (AAR.100-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.2 (AAR.100-2) Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.3 (AAR.100-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.4 (AAR.100-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.5 (AAR.100-11) Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.6 (AAR.100-16) Gauging Devices, Top Loading and Unloading Devices, Venting Devices, and Air
Inlet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.7 (AAR.100-17) Bottom Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III85
3.1.8 (AAR.100-18) Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.1.9 (AAR.100-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.1.10 (AAR.100-25) Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.1.11 (AAR.100-26) Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.2 (AAR.200) Specifications Applicable to Class AAR-204W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III86
3.2.1 (AAR.200-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.2.3 (AAR.200-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III86
3.2.4 (AAR.200-5) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.5 (AAR.200-6) Bursting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.6 (AAR.200-8) Thickness of Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.7 (AAR.200-11) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.9 (AAR.200-18) Test of Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.10 (AAR.200-20) Pressure Relief Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III87
3.2.11 (AAR.200-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III88
3.2.13 (AAR.200-26) Certification of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III88
3.3 (AAR.300) Specifications Applicable to Class AAR-206W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III88
3.3.1 (AAR.300-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III88
3.3.3 (AAR.300-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III88
3.4 (AAR.400) Specifications Applicable to Class AAR-207W Pressure Differential Covered Hopper
Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III89
3.4.1 (AAR.400-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III89
11/2014 C-III [M-1002] 83
CHAPTER 3 M-1002

3.4.3 (AAR.400-3) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III89
3.4.4 (AAR.400-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III89
3.4.6 (AAR.400-6) Thickness of Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III90
3.4.7 (AAR.400-7) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III91
3.4.8 (AAR.400-8) Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III91
3.4.9 (AAR.400-9) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III91
3.4.11 (AAR.400-11) Car Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III92
3.4.12 (AAR.400-12) Hatch Nozzles, Covers, and Openings in Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III92
3.4.13 (AAR.400-13) Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III92
3.4.14 (AAR.400-14) Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III92
3.4.15 (AAR.400-15) Gauging Devices, Bottom Outlet Valve Operating Rods, Venting and Air Inlet
Devices, and Loading and Unloading Pipes Extending Through the Shell. . . . . . . . . . . . . . . . . . C-III92
3.4.17 (AAR.400-17) Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III93
3.4.18 (AAR.400-18) Tests of Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III93
3.4.22 (AAR.400-22) Qualification and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III94
3.4.23 (AAR.401) Individual Specification Requirements Applicable to Class AAR-207W Pressure
Differential Covered Hopper Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III94
3.5 (AAR.500) Specifications Applicable to Class AAR-208 Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.1 (AAR.500-1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.3 (AAR.500-3) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.5 (AAR.500-5) Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.6 (AAR.500-6) Tank Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.7 (AAR.500-7) Manway, Filling, and Discharge Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.8 (AAR.500-8) Tank Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III96
3.5.9 (AAR.500-9) Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III97
3.5.10 (AAR.500-10) Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III97
3.5.11 (AAR.500-11) Bottom Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III97
3.5.13 (AAR.500-13) Test of Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III97
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M-1002 CHAPTER 3
CHAPTER 3. SPECIFICATIONS FOR AAR TANK CAR TANKS

3.1 (AAR.100) Specifications Applicable to Class AAR-203W and AAR-211W Tank Car
Tanks
3.1.1 (AAR.100-1) General
Class AAR-203W and AAR-211W tanks must be built in accord with the applicable DOT-103W or
DOT-111W specification (e.g., AAR211A100W1 = DOT111A100W1, AAR211A100ALW1 =
DOT111A100ALW1, etc.) except as provided in the following paragraphs. See Table 1.1 for a
complete listing of AAR specifications.Where AAR paragraph numbers are omitted, the provisions
of DOT 179.200 and 179.201 apply. The weight limitations of 179.13 do not apply to Class
AAR-211W tank cars.
Table 3.1 DOT specifications for Class AAR-203W and AAR-211W tanks
AAR Specification Applicable DOT Specification
AAR-203W DOT-103W
AAR-203DW DOT-103DW
AAR-211A60W1 DOT-111A60W1
AAR-211A60ALW1 DOT-111A60ALW1
AAR-211A100W1 DOT-111A100W1
AAR-211A100W6 DOT-111A100W6
AAR-211A100ALW1 DOT-111A100ALW1
3.1.2 (AAR.100-2) Approval
For the procedure for securing approval, see paragraph 1.4.
3.1.3 (AAR.100-4) Insulation
3.1.3.1 If insulation is applied, insulating material must be approved.
3.1.3.2 Insulation must be covered with a jacket made of approved material that is applied so as
to be weather tight.
3.1.3.3 The exterior surface of a carbon steel tank and the inside surface of a carbon steel jacket
must be given a protective coating.
3.1.4 (AAR.100-10) Welding
3.1.4.1 Radioscopic examination of welded joints of carbon steel or alloy steel tanks is not a
requirement of this specification.
3.1.4.2 Welded joints of aluminum tanks must be radioscoped in accord with Appendix W.
3.1.5 (AAR.100-11) Postweld Heat Treatment
The portions of carbon steel tanks to which anchorage or draft sills are attached must be postweld
heat treated in accord with Appendix W.
3.1.6 (AAR.100-16) Gauging Devices, Top Loading and Unloading Devices, Venting
Devices, and Air Inlet Devices
When gauging devices, top loading and unloading devices, and venting and air inlet devices are
installed, protective housing is not required.
3.1.7 (AAR.100-17) Bottom Outlets
Bottom outlets on AAR specification tank cars must conform to DOT-179.200-17 except that
external valves may be of any approved design.
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3.1.8 (AAR.100-18) Pressure Relief Devices

3.1.8.1 Tank cars used to transport commodities that give off flammable vapors at or below
150 F (65.6 C), as determined by Tagliabues open-cup tester per ASTM D1310, must be
equipped with pressure relief valves. Tank cars used to transport other commodities must be
equipped with pressure relief valves or rupture disc devices, except as provided in paragraph 2.1.7
of this specification.
3.1.8.2 Rupture disc devices, if applied, must be at least 1 3/4 in. (44.4 mm) inside diameter.
Vents must be closed with rupture discs of suitable material. Means for holding disc in place must
not cause distortion or damage to disc. Rupture disc device closures must be chained or otherwise
fastened to prevent misplacement.
3.1.9 (AAR.100-24) Stamping
To certify that the tank complies with all specification requirements, each tank head must be
stamped as follows:
3.1.9.1 If a tank is built in compliance with all requirements of DOT 179.200, it must be stamped
in accord with DOT 179.200-24.
3.1.9.2 If tank shell and head welds are not radiographed or is not postweld heat treated, the
tank must be stamped in accord with DOT 179.200-24, except that the AAR specification number
must be stamped in lieu of DOT specification number, and stamping is required on the B end of
the car only.
3.1.10 (AAR.100-25) Stenciling
The tank, or jacket if the tank is insulated, must be stenciled in accord with DOT 179.22, except
that the AAR specification number must be stenciled in lieu of the DOT specification number.
3.1.11 (AAR.100-26) Certificate of Construction
See paragraph 1.4.4.
3.2 (AAR.200) Specifications Applicable to Class AAR-204W Tank Car Tanks
3.2.1.1 These tank cars are for use in the transportation of liquid argon, liquid nitrogen, or liquid
oxygen.
3.2.1.2 Tank cars built under these specifications must meet the requirements of DOT 179.400
except as provided in the following paragraphs. Where AAR paragraph numbers are omitted, the
provisions of DOT 179.400 shall apply. The weight limitations of 179.13 do not apply to Class
AAR-204W tank cars.
The insulation system must be such that the normal evaporation rate (NER) will be less than
0.75% per 24-hour day of the full liquid nitrogen payload, with an ambient temperature of 70 F
(21.1 C).
For tank cars used to transport oxygen, the insulation may not sustain combustion in a 99.5%
oxygen atmosphere at atmospheric pressure when contacted with a continuously heated, glowing
platinum wire.
The vacuum-insulated tank car must be provided with a connection for a vacuum gauge to indicate
the absolute pressure within the insulation space.
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M-1002 CHAPTER 3
3.2.4 (AAR.200-5) Materials

Plate material used to fabricate the inner container and appurtenances must comply ASTM
Specification A240, Type 304 or 304L, as specified in Appendix M, paragraph 3.3.1. The plate must
be in the annealed condition prior to fabricating, forming, and fusion welding.
3.2.5 (AAR.200-6) Bursting Pressure
The minimum required bursting pressure of the inner container is 240 psi (1655 kPa).
3.2.6 (AAR.200-8) Thickness of Plates
The wall thickness after forming of the inner container shell and heads must be not less than
3/16 in. (4.76 mm) nor the thickness calculated by the appropriate formula in DOT 179.400-8.
3.2.7 (AAR.200-11) Welding
Impact test specimens of the inner container must be removed from the welded test plate (see
Fig. W.1 Sketch B) and subjected to the tests specified in Appendix W, paragraph 8.0. The test
temperature must be 320 F (195.6 C).
Postweld heat treatment of the inner container is not a requirement of this specification.
3.2.9 (AAR.200-18) Test of Tank
The tank must be tested in accord with DOT 179.400-18. The inner container test pressure must
be 60 psi (414 kPa).
3.2.10.1 Rupture disc device. The inner container must be equipped with a rupture disc device
without an intervening shut-off valve and be designed to function at a pressure of not more than
60 psi (414 kPa). The rupture disc device capacity must be sufficient to limit the pressure within
the inner container to not over the test pressure during all conditions of operation, both normal
and abnormal, including fire with loss of vacuum when the insulation space is filled with air or
gaseous lading at atmospheric pressure.
3.2.10.2 Transport pressure relief valve. The inner container must be equipped with a
pressure relief valve without an intervening shut-off valve. The transport pressure relief valve
must have a start-to-discharge pressure of 25 psi 3 psi (152 to 193 kPa). The transport pressure
relief valve must be vapor-tight at a pressure of 20 psi (138 kPa). The transport pressure relief
valve capacity must be sufficient to limit the pressure within the inner container to a maximum of
35 psi (241 kPa) when the insulation space is filled with air or gaseous lading at atmospheric
pressure and the outer shell is at 130 F (54.4 C). The required capacity of the transport pressure
relief valve must be calculated in accord with Appendix A, paragraph 7.2.2.
3.2.10.3 Transport pressure control valve. In addition to the transport pressure relief valve,
a pressure control device having a lower set pressure may be mounted in parallel with the
transport pressure relief valve. This pressure control device must not be set at a pressure lower
than 15 psig (103 kPa). When used, this transport pressure control valve need not be retested nor
should a stencil be used.
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3.2.10.4 Off-loading pressure relief valve. For the purpose of allowing transfer of lading at a
pressure higher than the transport pressure relief valve setting, a second pressure relief valve,
hereinafter called the off-loading pressure relief valve, is permitted, provided an approved safety
interlock is installed in such a way as to automatically provide an unrestricted discharge path
from the inner container to the transport pressure relief valve at all times when the tank car is in
transportation. The design must be such that the safety interlock must not affect the discharge
path of the off-loading pressure relief valve at any time. The off-loading pressure relief valve shall
be set to a start-to-discharge pressure no higher than 35 psi 3 psi (221 to 262 kPa). The capacity
of this off-loading pressure relief valve must be sufficient to limit the pressure within the inner
container to a maximum of 45 psi (310 kPa) when the insulation space is filled with air or gaseous
lading at atmospheric pressure and the outer shell is at 130 F (54.4 C). When used, the
off-loading pressure relief valve need not be retested nor should a stencil be used.
3.2.11 (AAR.200-24) Stamping
To certify that the tank complies with all specification requirements, each tank must be stamped
in accord with DOT 179.400-24, except that the AAR specification number must be stamped in lieu
of the DOT specification number.
The outer shell must be stenciled in accord with DOT 179.400-25, except that the AAR
specification number must be stenciled in lieu of the DOT specification number.
3.2.13 (AAR.200-26) Certification of Construction
3.3 (AAR.300) Specifications Applicable to Class AAR-206W Tank Car Tanks
Tanks built under these specifications must meet the requirements of DOT 179.220 and 179.221,
except as provided in the following paragraphs. Where AAR paragraph numbers are omitted, the
provisions of DOT 179.220 and 179.221 apply.
3.3.3 (AAR.300-10) Welding
Radioscopic examination of welded joints of the inner container is not a requirement of this
specification.
Tank cars used to transport nonregulated commodities that give off flammable vapors at or below
150 F (65.6 C), as determined by Tagliabues open-cup tester per ASTM D1310, must be
equipped with pressure relief valves. Tank cars used to transport other commodities must be
equipped with pressure relief valves or rupture disc devices.
3.3.5 (AAR.300-25) Stamping
To certify that the tank complies with all specification requirements, each tank must be stamped
as follows:
3.3.5.1 If the tank is built in compliance with all requirements of DOT 179.220, the tank must be
stamped in accord with DOT 179.220-25.
3.3.5.2 If the tank is not radioscoped, it must be stamped in accord with DOT 179.220-25, except
that the AAR specification number must be stamped in lieu of the DOT specification number.
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M-1002 CHAPTER 3

The outer shell, or the jacket if the outer shell is insulated, must be stenciled in accord with DOT
179.220-26, except that the AAR specification number must be stenciled in lieu of the DOT
specification number.
3.4 (AAR.400) Specifications Applicable to Class AAR-207W Pressure Differential
Covered Hopper Cars
Cars built under these specifications for the transportation of granular commodities that are
unloaded pneumatically using pressures of 15 psig or greater must meet the following
requirements.
3.4.3 (AAR.400-3) Type
3.4.3.1 Cars built under this specification must be fusion-welded and be of approved
cross-section.
3.4.3.2 Any portion of the car shell not circular in cross-section must have walls of such thickness
and be so reinforced that the stresses in the wall caused by a given internal pressure are no
greater than the circumferential stresses that would exist under the same internal pressure in the
wall of a shell of circular cross-section designed in accordance with paragraph 3.4.6 (AAR.400-6).
3.4.3.3 When a car is divided into compartments, each compartment must be treated as a
separate entity.
Insulation is not a requirement of this specification.
The minimum required bursting pressure is listed in paragraph 3.4.23 (AAR.401).
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3.4.6 (AAR.400-6) Thickness of Plates

3.4.6.1 The wall thickness of the car shell and of 2:1 ellipsoidal heads shall be not less than that
specified in paragraph 3.4.23 (AAR.401) nor that calculated by the following formula:
Pd
t = ------------ (conventional units)
2SE
where
d = inside diameter in inches
E = welded joint efficiency = 0.9E1 where E1 is the joint efficiency shown in Table 3.2
P = minimum required bursting pressure in psi
S = minimum tensile strength of plate material in psi, as prescribed in Table M.10
t = minimum design thickness of plate in inches, after forming
Pd
t = ---------------------- (SI units)
2000SE
where
d = inside diameter, millimeters
E = welded joint efficiency = 0.9E1 where E1 is the joint efficiency shown in Table 3.2
P = minimum required bursting pressure, kPa
S = minimum tensile strength of plate material, MPa, as prescribed in Table M.10
t = minimum design thickness of plate after forming, millimeters
Table 3.2 Values of E1 joint efficiency

Degree of Radioscopy
Type of Joint Full Partial* None
Double-welded butt joint 1.00 0.85 0.70
Single-welded butt joint using backing strip 0.90 0.80 0.65
Double-full-fillet lap joint ...... ...... 0.55
* See paragraph 3.4.9.3 [AAR.400-9(c)]
3.4.6.2 The thickness, after forming, of a flanged and dished head must be not less than that
specified in paragraph 3.4.23 (AAR.401) nor that calculated by the following formula:
5PL
t = ------------ (conventional units)
6SE
where
E = welded joint efficiency as defined in Table 3.2 [AAR.400-6(a)]
L = main inside radius to which head is dished, measured on concave side in inches
P = minimum required bursting pressure in psi
S = minimum tensile strength of plate material in psi as prescribed in Table M.10
t = minimum design thickness of plate in inches, after forming
5PL
t = ---------------------- (SI units)
6000SE
where
E = welded joint efficiency as defined in Table 3.2
L = main inside radius to which head is dished, measured on concave side, millimeters
P = minimum required bursting pressure, kPa
S = minimum tensile strength of plate material, MPa, as described in Table M.10
t = minimum design thickness of plate after forming, millimeters
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M-1002 CHAPTER 3
3.4.6.3 If plates are clad with material having tensile strength properties at least equal to the
base plate, the cladding may be considered a part of the base plate when determining thickness. If
cladding material does not have tensile strength at least equal to the base plate, the base plate
alone must meet the thickness requirements.
3.4.7 (AAR.400-7) Materials
3.4.7.1 Carbon steel plate used to fabricate car shell, hatch nozzles, and, if subjected to internal
pressure, hopper sheets, must be as specified in Appendix M, paragraph 3.1 or 3.7.
3.4.7.2 Aluminum alloy plate used to fabricate car shell, hatch nozzles and, if subject to internal
pressure, hopper sheets, must be as specified in Appendix M, paragraph 3.2.
3.4.7.3 Alloy steel used to fabricate car shell, hatch nozzles and, if subjected to internal pressure,
hopper sheets, must be as specified in Appendix M, paragraph 3.3.1.
3.4.7.4 All parts and items of construction in contact with the lading must be made of a material
compatible with plate material and not subject to rapid deterioration by the lading or be coated or
lined with suitable corrosion-resistant material.
3.4.7.5 All external projections that may be in contact with the lading and all castings, forgings,
or fabrications used for fittings or attachments to the shell that may be in contact with the lading
must be made of material to an approved specification. See Appendix M, paragraph 4.5 for
approved casting material specifications for fittings.
3.4.8 (AAR.400-8) Heads
3.4.8.1 Heads must be of approved contour and may be flanged and dished or ellipsoidal, convex
outward.
3.4.8.2 Flanged and dished heads must have a main inside radius not exceeding 10 ft (3050 mm)
and an inside knuckle radius not less than 6% of the main inside radius.
3.4.8.3 Ellipsoidal heads must be an ellipsoid of revolution in which the major axis must equal
the diameter of the shell adjacent the head and the minor axis must be one half the major axis.
3.4.9 (AAR.400-9) Welding
3.4.9.1 All joints must be fusion-welded in compliance with Appendix W. Welding procedures,
welders, and fabricators must be approved.
3.4.9.2 Radioscopic examination of welds is not required provided appropriate reduction is made
in joint efficiency as specified in Table 3.2.
3.4.9.3 Partial radioscopy must include not less than one radiograph of each intersection of all
longitudinal and circumferential butt joints, single or double welded; one radiotape of at least 6 in.
for each 50 ft (152 mm for every 15200 mm) or fraction thereof of circumferential single- or
double-welded butt joint; and one radiotape of at least 6 in. for each 50 ft (152 mm for every
15200 mm) or fraction thereof of longitudinal single- or double-welded butt joint. In addition, at
least one radiotape of at least 6 in. (152 mm) must be made from any 10 ft (3050 mm) of completed
butt weld of each procedure and thickness made by each welder or welding operator. A spot
examined may coincidentally represent one procedure, one thickness, one welder or welding
operator, any 10 ft (3050 mm) of weld, and one 50 ft (15200 mm) interval of weld.
3.4.9.3.1 For each intersection that is radiographed, one required radiotape of a longitudinal or
circumferential weld may be omitted as long as each procedure and thickness made by each welder
or welding operator is represented by at least one radiograph or radiotape.
3.4.9.3.2 Radiography of intersections must be as required in Appendix W, paragraph 18.3.4.
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CHAPTER 3 M-1002
3.4.9.3.3 When a radiograph of a longitudinal or circumferential weld does not comply with the
acceptance standards, two additional areas adjacent to the defective welding must be
radiographed. When the welding and the adjacent areas comply with the acceptance standards,
the defective area must be repaired and radiographed. When the welding of the adjacent area does
not comply with the acceptance standards, then the entire length of all butt joints of the tank shell
must be radiographed.
3.4.9.4 Welding is not permitted on or to ductile iron or malleable iron fittings.
Postweld heat treatment of welded joints is not a requirement of this specification.
3.4.11 (AAR.400-11) Car Structure
See the Manual of Standards and Recommended Practices, Section C, Part II, Specifications for
Design, Fabrication, and Construction of Freight Cars, Specification M-1001, Chapter 6.
3.4.12 (AAR.400-12) Hatch Nozzles, Covers, and Openings in Shell
3.4.12.1 Hatch nozzles must be of approved design of cast, forged, or fabricated metal.
3.4.12.2 At least one hatch nozzle must be at least 16 in. (406 mm) inside diameter to serve as a
manway.
3.4.12.3 All hatch covers not hinged to the shell must be attached to the outside of the shell by at
least a 3/8 in. (9.52 mm) chain or its equivalent.
3.4.12.4 All joints between manway covers and their seats must be made tight against leakage by
the use of gaskets of suitable material.
3.4.12.5 Openings in the shell for hatches and other fittings must be reinforced in accord with
Appendix E.
3.4.13 (AAR.400-13) Internal Structure
Any structure, such as baffles, hopper plates, slope sheets, troughs, conduits, air ducts, aerator
devices, conveyors, or any other structure introduced as a permanent attachment in the shell to
contain or move the lading by any means, must be designed to adequately support the lading
during loading, transit, and unloading.
3.4.14 (AAR.400-14) Outlets
3.4.14.1 Outlets must be designed to withstand car test pressure and must be equipped with
dust-type closures.
3.4.14.2 Outlets and associated fittings, piping, and other external projections on the bottom of
the shell must comply with minimum rail clearance requirements of Appendix E.
3.4.15 (AAR.400-15) Gauging Devices, Bottom Outlet Valve Operating Rods, Venting
and Air Inlet Devices, and Loading and Unloading Pipes Extending Through the Shell
Class AAR-207 cars do not require the inclusion of gauging devices, bottom outlet valve operating
rods, venting and air inlet devices, or loading and unloading pipes extending through the shell.
When installed, however, these devices must be of approved design and be tightly closed. Interior
unloading pipes must be securely anchored within the shell.
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3.4.16.1 Each car or compartment thereof must be equipped with one or more pressure relief
valves or rupture disc devices of approved design. See Appendix A.
3.4.16.2 At least one pressure relief device must be mounted on top of the car.
3.4.16.3 Pressure ratings of pressure relief devices must comply with paragraph 3.4.23
(AAR.401) and must be not affected by any auxiliary closure.
3.4.16.4 Total discharge capacity of pressure relief valves must be not less than 1200 cfm
(0.566 m3/s) at standard conditions.
3.4.16.5 The minimum size of a rupture disc device is 2 in. (50.8 mm) diameter.
3.4.17 (AAR.400-17) Pressure Test
3.4.17.1 Each car must be tested hydrostatically or pneumatically to the test pressure prescribed
in paragraph 3.4.23 (AAR.401). The car must hold the prescribed pressure for at least 10 minutes
without leakage or evidence of distress. All closures except pressure relief devices must be in place
when the test is made. Appurtenances mounted in the shell to direct the flow of lading, such as
fabric or mechanisms that do not contribute to containing pressures, may be removed during the
test.
3.4.17.2 Insulated cars must be tested before insulation is applied.
3.4.18 (AAR.400-18) Tests of Pressure Relief Valves
Each valve must be tested by air or gas for compliance with paragraph 3.4.23 (AAR.401) before
being put into service.
3.4.19 (AAR.400-19) Stamping
To certify that the tank complies with all specification requirements, each car must be plainly and
permanently stamped in letters and figures at least 3/8 in. (9.52 mm) high into the metal near the
center of both outside heads as follows:
Table 3.3 Stamping requirements for Class AAR-400

Example of Required Stamping
Specification AAR-207A60W
Material ASTM A516-70
Cladding material (if any) ASTM A240-304 CLAD
Car builders initials ABC
Date of original test 00-0000
Car assembler (if other than car builder) DEF
Capacity 0000 CU FT (or 0000 CU FT and 000 CU M)
The car must be stenciled in compliance with Appendix C except as noted below.
3.4.20.1 Capacity in cubic feet (or cubic feet and cubic meters) must be stenciled on each head in
lieu of gallonage (or gallonage and liter) capacity.
3.4.20.2 Total air discharge capacity of pressure relief device or devices in cfm (or cfm and m3/s)
at standard conditions must be stenciled on the car near the air inlet connection in letters and
figures at least 1 1/2 in. (38.1 mm) tall.
11/2014 C-III [M-1002] 93

CHAPTER 3 M-1002

3.4.22 (AAR.400-22) Qualification and Maintenance
Cars built under this specification must have repairs made in accordance with Appendices B, D, R,
T, and W.
3.4.23 (AAR.401) Individual Specification Requirements Applicable to Class AAR-207W
Pressure Differential Covered Hopper Cars
3.4.23.1 (AAR.401-1) Individual Specification Requirements
In addition to AAR.400 (see paragraph 3.4), the individual specification requirements are shown
in Table 3.4.
C-III [M-1002] 94 11/2014

11/2014
M-1002
Table 3.4 Individual specification requirements applicable to Class AAR-207W pressure differential covered hopper cars)
AAR Specification 207A20W 207A28W 207A40W 207A40W6 207A48ALW 207A48W 207A60ALW 207A60W 207A80ALW 207A80W
Material [see paragraph 3.4.7 (AAR.400-7)] Steel Steel Steel Alloy Steel Al Alloy Steel Al Alloy Steel Al Alloy Steel
Insulation [see paragraph 3.4.4 Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional
(AAR.400-4)]
Bursting Pressure, psi (kPa) 50 (345) 70 (483) 100 (689) 100 (689) 120 (827) 120 (827) 150 (1034) 150 (1034) 200 (1379) 200 (1379)
[see paragraph 3.4.5 (AAR.400-5)]
Minimum Plate Thickness, in. (mm)

[see paragraph 3.4.6 (AAR.400-6)]
ShellBottom Sheets 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 3/8 (9.52) 3/8 (9.52)
Top Sheets 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 3/16 (4.76) 1/4 (6.35) 1/4 (6.35)
Heads 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 5/16 (7.94) 3/8 (9.52) 3/8 (9.52)
Test Pressure, psi (kPa) 20 (138) 28 (193) 40 (276) 40 v 48 (331) 48 (331) 60 (414) 60 (414) 80 (552) 80 (552)
[see paragraph 3.4.17 ( AAR.400-17)]
C-III [M-1002] 95
Pressure relief Valve: 15 (82.7 21 (117 30 (186 30 (186 36 (228 36 (228 45 (290 45 (290 60 (393 60 (393
Start-to-Discharge Pressure, to 124) to 165) to 228) to 228) to 269) to 269) to 331) to 331) to 434) to 434)
psi 3 psi (kPa range)
[see paragraph 3.4.16 ( AAR.400-16)]
Valve Flow Rating Pressure, 18 (124) 24 (165) 33 (228) 33 (228) 40 (276) 40 (276) 50 (345) 50 (345) 66 (455) 66 (455)
psi (kPa) (maximum)
Vapor-Tight Pressure 12 (83) 17 (117) 24 (165) 24 (165) 29 (200) 29 (200) 36 (248) 36 (248) 48 (331) 48 (331)
(minimum) psi (kPa)
Vent Bursting Pressure, Maximum 15 (103) 21 (145) 30 (207) 30 (207) 36 (248) 36 (248) 45 (310) 45 (310) 60 (414) b b
psi (kPa) [see paragraph 3.4.16
(AAR.400-16)]
CHAPTER 3
CHAPTER 3 M-1002
3.5 (AAR.500) Specifications Applicable to Class AAR-208 Tank Car Tanks

Tanks built under these specifications having lined, coated, or treated wooden-stave metal-hooped
tanks must meet the following requirements.
3.5.3 (AAR.500-3) Type
Tanks built under this specification must be cylindrical with flat heads inserted inside the ends of
the tank in rabbets. The tank must have at least one manway and at least one filling and
discharge opening in the top of the tank. The tank may have a bottom outlet opening and may be
provided with a recess cut in the bottom of the inside of the tank not over 12 in. (305 mm) in
diameter and 1 in. (25.4 mm) deep to form a well or sump to facilitate unloading.
Not specified.
3.5.5 (AAR.500-5) Material
3.5.5.1 All tank staves and heads must be made of No. 1 grade, well-dried cypress or Douglas fir
tank lumber of a minimum thickness of 4 in. (102 mm) stock size, straight-grained and free from
shakes and knots.
3.5.5.2 Lumber, when used for closure of filling and discharge openings, must be a minimum of
4 in (102 mm) stock size.
3.5.5.3 Tank hoops and tie-rods must be made of suitable metal and must be not less than 1 in.
(25.4 mm) in diameter.
3.5.6 (AAR.500-6) Tank Heads
Tank heads must be made flat of one or more thicknesses of lumber.
3.5.7 (AAR.500-7) Manway, Filling, and Discharge Openings
3.5.7.1 At least one manway of at least 18 in. (457 mm) inside diameter must be provided. The
manway must be provided with a 1/4 in. (6.35 mm) thick stainless steel or other approved metal
cover hinged to the tank, made tight against leakage, and securely fastened in place.
3.5.7.2 The manway cover may be provided with the filling and discharge opening securely
closed.
3.5.7.3 The tank must be equipped with a vacuum relief valve of approved design when bottom
outlet is applied.
3.5.8 (AAR.500-8) Tank Mounting
3.5.8.1 The tank must be secured to the underframe by tank bands at each bolster and by
intermediate tank bands attached to center sill saddles. The car structure must also provide
suitable fore-and-aft anchors applied to tank heads and attached to the underframe.
3.5.8.2 Tank car structure must comply with design requirements of the Manual of Standards
and Recommended Practices, Section C, Part II, Specifications for Design, Fabrication, and
Construction of Freight Cars, Specification M-1001, Chapter 6.
3.5.8.3 See also paragraph 5.2.2 in this specification.
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M-1002 CHAPTER 3
3.5.9 (AAR.500-9) Lining

The entire interior of the tank must be lined with No. 1 grade well-dried tongue-and-groove
cypress or Douglas fir tank staves.
3.5.10 (AAR.500-10) Painting
All outside wooden and metal parts of the tank must be finished with an acid-resistant varnish or
paint.
3.5.11 (AAR.500-11) Bottom Outlets
3.5.11.1 Bottom outlet flanges must be stainless steel and must be bolted with stainless steel
bolts using a suitable gasket material.
3.5.11.2 On newly built and empty cars, the extreme projection of the bottom outlet equipment
must be at least 12 in. (305 mm) above the top of rail on level track, and, in addition, must comply
with the vertical curve clearance requirements of Appendix E. All bottom outlet reducers and
closures and their attachments must be secured to the car by at least 3/8 in. (9.52 mm) chain or its
equivalent.
3.5.11.3 Bottom outlet must be of approved construction and must be provided with a liquid-tight
closure at its discharge end.
Not required.
3.5.13 (AAR.500-13) Test of Tanks
Each tank must be tested hydrostatically by attaching to the filling opening a pipe of such length
that a hydrostatic head of at least 3 ft (915 mm) is established by filling the tank and pipe with
water having a temperature not exceeding 100 F (37.8 C). Tank must hold the water for not less
than 30 minutes without leakage or evidence of distress.
3.5.14 (AAR.500-14) Stamping
To certify that the tank car complies with all specification requirements, each tank must be plainly
and permanently stamped in letters and figures at least 3/8 in. (9.52 mm) tall into the lumber near
the center of both outside heads as follows:
Table 3.5 Stamping requirements for Class AAR-500

Example of Required Stamping
Specification AAR-208
Material DOUGLAS FIR
Lining DOUGLAS FIR
Tank builders initials ABC
Date of original test 00-0000
Water capacity 0000 GAL (or 0000 GAL and 00 000 L)
Stenciling in compliance with Appendix C must be applied to plates attached to the car structure.
11/2014 C-III [M-1002] 97

CHAPTER 3 M-1002
C-III [M-1002] 98 11/2014

M-1002 CHAPTER 4
CHAPTER 4
RESERVED
11/2014 C-III [M-1002] 99

CHAPTER 4 M-1002
C-III [M-1002] 100 11/2014

M-1002 CHAPTER 5
CHAPTER 5
GENERAL DESIGN AND TEST REQUIREMENTS
CONTENTS

5.1 Requirements for Tank and Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III102
5.1.1 Welding Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III102
5.1.2 Heater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III102
5.1.3 Welding Stud Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III103
5.1.4 Plate Thickness and Material Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III103
5.1.5 Openings in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.1.6 Placard Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.1.7 Safety Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.1.8 Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.1.9 Lifting Provision Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.2 Tank Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.2.1 Anchors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III104
5.2.2 Tank Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III107
5.3 Head Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III107
5.3.1 Design and Test Requirements for Head Shield Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III107
5.4 Auxiliary Compressed Gas Containers on Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III108
5.4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III108
5.4.2 Supply Containers and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III108
5.4.3 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III109
5.4.4 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III109
5.4.5 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III110
5.4.6 Engine and Heater Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III110
5.4.7 Vaporizers for Liquefied Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III110
5.4.8 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III111
11/2014 C-III [M-1002] 101

CHAPTER 5 M-1002
CHAPTER 5. GENERAL DESIGN AND TEST REQUIREMENTS

5.1 Requirements for Tank and Appurtenances
5.1.1 Welding Certification
Welding procedures, welders, and fabricators must be approved. See Appendices B, R, and W.
5.1.2 Heater Systems
Designs of heater systems for installation on new or existing tanks must be approved.
5.1.2.1 Interior Heater Systems
In addition to the requirements of DOT 179.12, interior heater systems must meet the following
requirements:
5.1.2.1.1 Materials and Dimensions
5.1.2.1.1.1 Interior heater systems and plug flanges, if welded to tank or dome, must be cast,
forged, or fabricated metal and be of good weldable quality in conjunction with the metal of the
tank or dome.
5.1.2.1.1.2 Piping must be not less than 2 in. IPS. Tubing must be not less than 2 3/8 in. outside
diameter, and the wall thickness must be at least equivalent to the corresponding pipe size.
5.1.2.1.1.3 Material specifications and nominal wall thicknesses are listed in Appendix M.
5.1.2.1.1.4 Systems may be fabricated of other materials and of other than circular cross-section,
if approved.
5.1.2.1.2 Joints and Fittings
5.1.2.1.2.1 Welded butt joints are preferable.
5.1.2.1.2.2 Bolted joints with flanges welded to piping may be used if welded butt joints are not
feasible or to facilitate tank interior cleaning or application of linings.
5.1.2.1.2.3 Return bends shall be forged or made by bending the pipe.
5.1.2.1.2.4 Cast, forged, or fabricated manifolds of approved design may be used.
5.1.2.1.2.5 Inlets and outlets of heater systems shall be equipped with valve cock, cap, or plug.
5.1.2.1.2.6 Caps and plugs shall be secured by chain.
5.1.2.1.3 Application to Tank
5.1.2.1.3.1 Interior heater systems shall be so constructed that the breaking off of their external
connections will not cause leakage of the contents of the tank.
5.1.2.1.3.2 Inlets and outlets may be located in any portion of the dome, shell, heads, or
steam-jacketed outlet provided proper drainage of the heater system is accomplished.
5.1.2.1.3.3 If ends of coils are not attached to a manifold or steam-jacketed outlet, they shall be
attached to pads or reinforcements. Such reinforcements must be attached to the tank in
compliance with the requirements of the tank specification.
5.1.2.1.3.4 Outside pipe connections to steam coils shall not be an integral part of the interior
coils and shall be screwed or welded, or both, into outside pads or reinforcements.
5.1.2.1.3.5 All piping shall be secured so as to permit necessary expansion and contraction.
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M-1002 CHAPTER 5
5.1.2.2 Exterior Heater Systems

Exterior heater systems must be made of approved materials secured to the tank by approved
means and are subject to tests without leakage.
5.1.3 Welding Stud Attachment
If welding studs are used for attachment of appurtenances or jacket supports and are applied by
the stud welding process, they must be applied to an area twice the diameter of the stud, which
must be clean and reasonably free of loose mill scale, heavy oxides, or other material that would be
detrimental to weld quality. Studs must be low-carbon steel having properties not exceeding
ASTM A108, Grade C1020. If studs are used, they must be applied by the stud welding process
prior to postweld heat treatment.
5.1.4 Plate Thickness and Material Identification
5.1.4.1 If the calculated thickness of plate furnished for tanks is greater than the minimum
thickness prescribed in applicable tables, the actual thickness of the plate must be not less than
0.01 in. (0.254 mm) under the calculated thickness. If the calculated thickness of plate furnished
for tanks is less than the minimum thickness prescribed in the applicable tables, the actual
thickness of the plate must be not less than the minimum required thickness less allowable ASTM
tolerances; however, in no case must the actual thickness be less than 0.01 in. (0.254 mm) under
the calculated thickness.
5.1.4.2 Plate material for tank heads, shells, nozzles, and sumps should be laid out so that when
the tank is completed prior to painting, insulating, or lining, one complete set of the original
identification markings required in the specifications for the material will be plainly visible. In
case the original identification markings are unavoidably cut out or the material is divided into
two or more parts, either one set must be accurately transferred prior to cutting by the tank
manufacturer to a location where the marking will be visible on the completed tank, or a coded
marking must be used to ensure identification of each piece of material during fabrication and
subsequent identification of the markings on the completed tank. In either case, an as-built sketch
or a tabulation of materials must be made, identifying each piece of material with the mill test
report and the coded marking. Except as indicated in paragraph 5.1.4.3, material may be marked
by any acceptable method.
5.1.4.3 Where the service conditions prohibit die stamping for material identification, and when
so specified by the user, the materials manufacturer and the tank fabricator must mark the
required data on the plates in a manner that will allow positive identification upon delivery. The
markings must be recorded so that each plate will be positively identified in its position in the
finished tank. Transfer of markings for material that is to be divided must be done as in
paragraph 5.1.4.2.
5.1.4.4 When material is formed into shapes by anyone other than the manufacturer of the
completed tank, and the original markings as required by the applicable material specification are
unavoidably cut out, or the material is divided into two or more parts, one set must be accurately
transferred by the manufacturer of the shape. The mill certification of the physical and chemical
requirements of this material, in conjunction with the above modified marking requirements, is
considered sufficient to identify these shapes.
5.1.4.5 For plates, the tank manufacturer must obtain the mill test reports or certificates of
compliance as provided for in the material specification and must examine those reports and
certificates for compliance with the material specification and/or special material ordering
requirements.
5.1.4.6 For all other product forms, the material will be accepted as complying with the material
specification if the material specification provides for the marking of each piece with the
specification designation, including grade, type, and class, if applicable, and each piece is so
marked.
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5.1.4.7 All material used in the construction of a tank car must be examined before and during
fabrication for the purpose of detecting possible defects that would affect the safety of the tank.
5.1.5 Openings in Tank
Openings in tanks for manway nozzle, dome opening, or other fittings must be reinforced as
required in Appendix E.
5.1.6 Placard Holders
5.1.6.1 Each tank car must be equipped with at least four metal placard holders, permanently
attached by suitable brackets, located one at each end and each side of tank car, placed toward the
right and preferably near to and below the DOT and AAR stencils. Tank cars used exclusively for
the transportation of commodities for which DOT regulations do not require placards do not
require placard holders. Tank cars that are in dedicated product service for the transportation of
commodities for which DOT regulations require placards may display permanent placards (decal
or stencil) and do not require placard holders.
5.1.6.2 Holders must be designed to provide for secure attachment for each application, removal,
or reversal of the placards prescribed by the DOT regulations and must be of sufficient size to
permit placards to be applied with opposite points of the diamond in vertical or horizontal
positions, respectively. For design of an approved placard holder, see Appendix E. Holder brackets
must be designed to minimize transmission of vibration to placard holders.
5.1.7 Safety Appliances
Safety appliances must be in accord with Appendix S.
5.1.8 Stenciling
Stenciling must comply with individual specification requirements and Appendix C.
5.1.9 Lifting Provision Test
This test refers to the lifting provision requirements shown in the Manual of Standards and
Recommended Practices, Section C, Standard S-234. Each design of a tank car lifting provision is
subject to a test by loading at least one of the lifting provisions as follows:
5.1.9.1 The vertical component of the load applied to each lifting provision tested must be a
minimum of 25% of the gross weight (mass) on rail.
5.1.9.2 The direction of the applied load must be at 45 from the vertical and as near as possible
to a vertical plane parallel to the longitudinal centerline of the car and extending through the
center of the lifting provision.
5.1.9.3 After application and release of the required load, visual inspection must reveal no
evidence of permanent deformation in the tank car tank, bolster, or lifting provision, except that
local deformation is permitted in the hook bearing area.
5.2 Tank Anchors
5.2.1 Anchors, General
5.2.1.1 Anchor design must comply with Appendix E, paragraph 11.0. Anchors must be attached
to tank shells by fusion welding. They must be attached to center sills or to members attached to
center sills by means of rivets, two-piece rivets, or bolts. Rivets and two-piece rivets must comply
with Appendix M, paragraph 4.4. Bolts must comply with the current issue of ASTM A325 or
ASTM A490. Nuts must meet specifications compatible with threaded parts. Washers, if used,
must be hardened steel. After installation, all bolts must be mechanically deformed to prevent
loosening of the nuts.
5.2.1.2 Anchors for aluminum tanks must be aluminum.
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M-1002 CHAPTER 5
5.2.1.3 A single-piece anchor is one having two longitudinal members.

5.2.1.4 A multiple-piece anchor is one having more than two longitudinal members.
5.2.1.5 When steel tank cars are constructed without reinforcing plates between the anchor and
tank, the tank material in the anchor area must be fine-grain steel.
5.2.1.6 Calculations
5.2.1.6.1 The anchor-to-underframe connection must be designed as a shear connection. The
shear strength of the fasteners connecting a single-piece anchor to a center sill or to members
attached to a center sill must be not less than Su, where
R W 1 250 000
S u = -------------------------------------------------------- , lb (conventional units)
R
where
R = Rail load limit, lb
W = Weight of trucks plus underframe, lb
R W 5 560
S u = ------------------------------------------ , kN (SI units)
R
where
R = Rail load limit, kg
W = Mass of trucks plus underframe, kg
5.2.1.6.2 When a multiple-piece anchor is used, the minimum requirement must be 120% of the
requirement for a single-piece anchor.
5.2.1.6.3 The bearing strength of the connections with respect to the webs of the anchor and sill
must be greater than the shear strength of the fasteners. For aluminum anchors, the allowable
bearing stress of the web plates must be twice the tensile strength (unwelded condition) for
purposes of computing the bearing strength of the joint. For steel anchors, the allowable bearing
stress must be 2.25 times the tensile strength. The interfastener buckling stress must be
computed by the following formula. Critical buckling stress (cr) must be equal to or greater than
the maximum compressive stress in the member (anchor or sill) due to Su. The thickness of the
connected elements of the anchor and sill must be not less than 7/16 in. (11.1 mm).
0.076 u 2 b 2
cr = u ----------------------------
- ---

E t
where
cr = critical buckling stress, psi (MPa)
u = compressive strength of anchor or sill material, psi (MPa)
E = modulus of elasticity, psi (MPa)
b = fastener spacing, in. (mm)
t = thickness of anchor or sill material, in. (mm)
5.2.1.6.4 When the anchor welded to the tank is attached by means of driven rivets, two-piece
rivets, or bolts to another member that is attached to the underframe by means of driven rivets,
two-piece rivets, or bolts, both connections must comply with the minimum shearing and bearing
requirements. Only one connection (the weaker connection, either the anchor-to-intermediate
member or intermediate member-to-underframe) need be used as a reference when calculating the
required shear strength of the welded connection between the tank and the anchor in accord with
paragraph 5.2.1.6.5.
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CHAPTER 5 M-1002
5.2.1.6.5 The shear strength of the welded connection (using the weld efficiencies defined in
Appendix E, paragraph 5.1) between the tank and the anchor must be at least 1.4 times the shear
strength of the fasteners securing the anchor to the underframe and not less than the values listed
in Table 5.1.
Table 5.1 Minimum connection shear strength

Rail Load LimitConventional Units
177,000 lb Over 177,000 lb Over
or less to 220,000 lb 220,000 lb
Minimum shear strength, lb 1,320,000 1,650,000 1,980,000
Rail Load LimitSI Units

80 285 kg Over 80 285 kg Over
or less to 99 790 kg 99 790 kg
Minimum shear strength, N 5 872 7 340 8 807
5.2.1.6.6 For computing ASTM A502 Gr. 1 rivet shear and bearing areas, the diameter of the
reamed hole is used. The diameter of the reamed hole must not exceed the nominal diameter of the
rivet by more than 1/16 in. (1.59 mm).
For computing two-piece rivet shear and bearing areas, the nominal diameter of the rivet is used.
Locking grooves are not allowed in the shear plane. The diameter of the reamed hole must not
exceed the nominal diameter of the two-piece rivet by more than 1/16 in. (1.59 mm).
For computing bolt shear and bearing areas, the nominal diameter of the bolt is used. Threads are
not allowed in the shear plane. Bolt holes must be finish drilled or reamed to size. The diameter of
the finished hole must not exceed the nominal diameter of the bolt by more than 1/16 in.
(1.59 mm).
5.2.1.6.7 For calculating connection values, the design ultimate shear strength of the fastener in
the installed (driven) condition must be used as listed in Table 5.2.
Table 5.2 Fastener shear strength values

Design Ultimate
Shear Strength
Fastener ksi (MPa)
ASTM A502 Gr. 1 rivet 50 (345)
ASTM A325 (1/2 in. 1 in. ) bolt 87 (600)
ASTM A490 (1/2 in. 1 1/2 in. ) bolt 103 (710)
Two-piece rivet, 5060 ksi shear ultimate, undriven 63 (434)
Two-piece rivet, 126157 ksi ultimate tensile, undriven 84 (579)
5.2.1.6.8 Where the anchor is fabricated by welding or is attached by welding to a tank

reinforcing plate, the shear strength of the welded connection must be at least equal to the
minimum shear strength required for the anchor fasteners.
C-III [M-1002] 106 11/2014

M-1002 CHAPTER 5
5.2.2 Tank Bands

5.2.2.1 Each tank that is designed to be mounted on a separable underframe must have at least
two bands (one at each bolster) or other approved securement means of equal strength and
security. If more than two bands are used, their location is optional.
5.2.2.2 The section area of the tank band must be at no place less than 1 in.2 (645 mm2). A
threaded end 1 1/8 in. or more in diameter, with body consisting of a flat band 2 in. by 1/2 in.
(50.8 mm by 12.7 mm), or round iron 1 1/8 in. (28.6 mm) in diameter, will be accepted as meeting
this requirement.
5.2.2.3 Cars having tanks fusion-welded to body bolsters and multiunit tank car tanks do not
require tank bands.
5.3 Head Shields
5.3.1 Design and Test Requirements for Head Shield Attachments
When head shields are required in accord with the provisions of DOT 173.31(b)(3), the attachment,
design calculations, and test results must meet the following requirements and be approved by the
Tank Car Committee.
5.3.1.1 Design Conditions
The attachments must be designed so that under the most severe conditions imposed by the
following combinations of forces, the calculated stresses will not exceed the minimum yield
strength of the material.
Conventional Units SI Units

Impact Environment:
7,500,000h- F vertical = 9.8W s 1 + 3 402 000h-
Vertical F vertical = W s 1 + ----------------------------- -----------------------------
Wc L Wc L
combined with
1,250,000W 5 560 000W
Longitudinal F longitudinal = ----------------------------------s- F longitudinal = ----------------------------------s-
W W
In-Train Environment:
Vertical F vertical = 3W s F vertical = 29.42W s
combined with
Lateral F lateral = 1.25W s F lateral = 12.26W s
where
F = Uniformly distributed load acting on head shield, lb (N)
Ws = Weight (mass) of head shield including attachments thereto, lb (kg)
W = Light-weight (tare) of car, lb (kg)
h = Vertical distance between centerline of coupler and center of gravity of empty car, ft (mm)
Wc = Light-weight of car (W) less weight of trucks, lb (kg)
L = Length over tank heads, ft (mm)
11/2014 C-III [M-1002] 107

CHAPTER 5 M-1002
5.3.1.2 Test Requirements

A qualification impact test must be performed for a new and untried design of head shield
attachment in accord with the following conditions:
5.3.1.2.1 Head shields with attachments thereto must be applied to both ends of the car.
5.3.1.2.2 Strain gauges must be applied to both ends of the car at the critical locations. Critical
locations are to be determined by stress analysis.
5.3.1.2.3 The test car, empty and free to roll, must be impacted by a car of 70 ton nominal
capacity, loaded to allowable gross weight (mass) on rail, in increments of 2 mph (3.22 km/h),
starting at 6 mph (9.66 km/h), until a coupler force of 1,250,000 lb (5560 kN), or as close as
practical thereto, has been reached.
5.3.1.2.4 Both ends of the test car must be impacted, unless the head shields and attachments
are identical at each end.
5.3.1.2.5 The measured strains must be converted to stresses using the idealized true
stress-strain curves of the materials involved. The peak stress may not exceed the yield strength of
the material as defined by the 0.2% offset method. If the test is discontinued before the specified
coupler force is attained, the measured stresses must be extrapolated to determine peak stress at
1,250,000 lb (5560 kN).
5.3.1.2.6 A visual inspection of the head shield attachments and head shield must be made
during and after each of the tests. Any damage will be sufficient cause for disapproval of the
design.
5.4 Auxiliary Compressed Gas Containers on Tank Cars
5.4.1 Scope
These requirements apply when it is necessary to mount compressed gas cylinders or fuel supply
containers on tank cars to provide a source of gas vapors to blanket the tank contents, to inhibit or
retard chemical reaction, to provide an odorant, or to supply fuel to an internal combustion engine
or heater. Fuel gases generally will be carried in a liquefied form, while blanketing gases will be
carried in a nonliquefied form.
Containers must be demountable from the tank car tank or car structure. For reference, see the
Manual of Standards and Recommended Practices, Section C, Recommended Practice RP-229,
Requirements for Installation and Use of Liquefied Petroleum Gases on Freight and Passenger
Cars.
5.4.2 Supply Containers and Installation
5.4.2.1 Supply Containers
Containers for liquefied compressed gas must be cylinders conforming to DOT Specification 4B,
4BA, or 4BW. Containers for nonliquefied compressed gas must be in accord with DOT 173.302(a).
The cylinder valve outlets must comply with ANSI B57.1.
5.4.2.2 Installation
5.4.2.2.1 Supply containers must be mounted on the car, outside of the tank, in a place and
manner that will minimize the possibility of mechanical damage.
5.4.2.2.2 Supply containers must be mounted within the limiting outline to which the car is built.
5.4.2.2.3 Suitable shielding or protection must be provided for containers when any portion
extends below the centerline of draft.
C-III [M-1002] 108 11/2014

M-1002 CHAPTER 5
5.4.2.2.4 Supply containers must be secured by attachments that will withstand, without
permanent deformation, uncombined accelerations of 20 times force of gravity longitudinal, 10
times force of gravity vertical, and 5 times force of gravity transverse, based on the weight of
container and attachments plus contents.
5.4.2.2.5 Welding to the shell, head, or any part of the container is prohibited except when
performed by a container manufacturer.
5.4.2.2.6 Metal boxes or shields protecting containers must be painted white and must be
stenciled FLAMMABLE GAS in letters not less than 1 1/2 in. (38.1 mm) tall. When the contents
are nonflammable, the stenciling must be NONFLAMMABLE GAS in letters not less than
1 1/2 in. (38.1 mm) tall.
5.4.3 Valves
5.4.3.1 Valves on cars must be in the following sequence from supply container to outlet where
gas is to be used: supply container shut-off valve, excess flow valve (for flammable compressed
gases), back-flow check valve (where more than one container is used), manual shut-off valve, and
a pressure regulating system.
5.4.3.2 An excess flow valve must be installed in a flammable gas supply container outlet
connection to prevent flow of gas in case of breakage of the manual shut-off valve or piping. Other
excess flow valves must be installed as required by the design of the piping system so that a break
at any point in the system between the supply container and point of use will cause the excess flow
valve to function.
5.4.3.3 The manual shut-off valve must be located so as to be accessible in case of emergency and
must be stenciled or marked GAS SHUT-OFF VALVE.
5.4.3.4 Where more than one supply container is installed, a back-flow check valve also must be
installed.
5.4.3.5 The pressure regulating system must consist of one of the following arrangements:
5.4.3.5.1 A high-pressure or first-stage regulator and a low-pressure or second-stage regulator to
control flow of gas to engine, heater, or other use.
5.4.3.5.2 A single-stage regulator to control flow of gas from supply container to engine, heater, or
other use.
5.4.3.5.3 A single-unit two-stage regulator to control flow of gas from supply container to engine,
heater, or other use.
5.4.4 Piping
5.4.4.1 Piping from supply container to first-stage regulator must be not less than Schedule 80
steel, brass, or copper pipe; or seamless copper, brass, or steel tubing. Steel pipe or tubing shall be
adequately protected against exterior corrosion. Copper tubing must be Type K or equivalent,
having a minimum wall thickness of 0.049 in. (1.24 mm).
5.4.4.2 Aluminum pipe or tubing are prohibited.
5.4.4.3 Welded pipe joints must be used wherever possible.
5.4.4.4 Brazed copper tubing joints must be of brazing material joined at not less than 1,000 F
(538 C) and must be of such properties so as not to decrease in strength when threaded joints are
used.
5.4.4.5 Cast iron or aluminum fittings are prohibited.
5.4.4.6 Suitable provision must be made to compensate for thermal expansion and contraction.
11/2014 C-III [M-1002] 109

CHAPTER 5 M-1002
5.4.4.7 For nonflammable compressed gases, stainless braided PTFE hose may be used.
5.4.5 System
5.4.5.1 All parts of the system must be adequately protected from loose objects propelled from the
roadbed.
5.4.5.2 Container and piping system must be arranged for a single car function. Extension of the
piping system to an adjacent car is not authorized.
5.4.5.3 All piping and connections on each side of an excess flow valve must have a greater flow
capacity than the rated flow capacity of the excess flow valve.
5.4.5.4 All hose subject to container pressure must be designed for a minimum bursting pressure
of 1,250 psi (8618 kPa). Hoses used on the low-pressure side of a regulator must be designed for a
bursting pressure of five times the pressure setting of the regulator. Hoses must be resistant to
action of the gas in its liquid and vapor phases.
5.4.5.5 After installation, the piping, valves, fittings, and accessories must be tested and proved
tight at a pressure equal to one and one-half times the normal pressure at 60 F (15.6 C) at which
the system will operate.
5.4.5.6 Pipes, fittings, and accessories must be clamped and fastened to protect them from
vibration, strain, or wear from the usual freight car motions and impacts.
5.4.5.7 A pressure relief valve must be installed between any two shut-off valves or any condition
in the piping where liquid may be trapped.
5.4.5.8 Vents or discharge lines for pressure relief valves must be sized so as not to restrict the
flow of gas from the pressure relief valve when the relief valve is fully opened. When flexibility is
necessary, flexible hose may be used. Vents or discharge lines from relief valves must be located as
far as practical from sources of ignition. A rain cap or other protector must be used to keep water
and dirt from entering the pipe or valve.
5.4.5.9 Regulating equipment and controls must be protected by metal cabinets or shields to
prevent damage or tampering and to give protection from the weather. Car framework may be
used where practical to form part of this shielding.
5.4.5.10 All valves and accessories between the tank and first-stage regulator must have a
minimum design pressure of 250 psi (1724 kPa).
5.4.6 Engine and Heater Fittings
5.4.6.1 Exhaust pipes must be insulated or shielded and positioned to prevent injury to
personnel.
5.4.6.2 An automatic shut-off device must be provided to shut off the fuel to the gas-air mixer
when the engine is stopped.
5.4.6.3 An automatic shut-off valve must be provided to shut off the flow of fuel in the event the
pilot light is extinguished or the combustion air (for systems with other than gravity air supply) is
insufficient for proper combustion.
5.4.7 Vaporizers for Liquefied Gases
5.4.7.1 For liquid withdrawal utilizing a vaporizer, there must be a regulator in accord with
paragraph 5.4.3.5 to control the flow of gas from the fuel container to the engine or heater.
5.4.7.2 Vaporizers must have a minimum design pressure of 250 psi (1724 kPa).
5.4.7.3 Combustion exhaust gases must not be used as a direct means of heat supply for the
vaporization of fuel.
C-III [M-1002] 110 11/2014
M-1002 CHAPTER 5
5.4.8 Inspection and Maintenance

5.4.8.1 Inspection and repairs to the system must be made by qualified personnel.
5.4.8.2 The following inspection should be made at time of filling or pre-trip inspection:
5.4.8.2.1 All systems must be visually inspected for loose parts.
5.4.8.2.2 LP-gas system must be checked for leaks at each filling by noting any characteristic
odor of gas. If a leak is indicated, a bubble test should be conducted and proper repairs made.
5.4.8.2.3 LP-gas systems must be tested to certify operation of automatic shut-off devices.
5.4.8.3 Periodic testing of the supply containers must be arranged for by the car owner, lessee, or
operator in accord with applicable DOT regulations. Periodic testing and inspection of systems,
including necessary dismantling, cleaning, and testing of valves, controls, and regulators, must be
performed by the car owner or owners representative at intervals not longer than the retest period
for the supply container.
5.4.8.4 A supply container that has been damaged to an extent likely to cause it to be in unsafe
condition or to an extent where such a condition is suspected must be removed from service and
tested under the applicable DOT regulations.
11/2014 C-III [M-1002] 111

CHAPTER 5 M-1002
C-III [M-1002] 112 11/2014

M-1002 CHAPTER 6
CHAPTER 6
CAR STRUCTURE DESIGN AND TEST REQUIREMENTS
The tank car structure design and test requirements are located in the Manual of Standards and
Recommended Practices, Section C, Part II, Specifications for Design, Fabrication, and
Construction of Freight Cars, Specification M-1001, Chapter 6.
11/2014 C-III [M-1002] 113

CHAPTER 6 M-1002
C-III [M-1002] 114 11/2014

M-1002 APPENDIX A
APPENDIX A
TANK CAR VALVES AND FITTINGS
CONTENTS

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III117
2.0 Specifications for Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III117
2.1 Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III117
2.2 Nonmetallic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III117
2.3 Stem Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
2.4 Cast Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
3.0 Specifications for Design and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
3.1 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
3.2 Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
3.3 Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III119
3.4 Valve Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III121
3.5 Aspiration of Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III121
3.6 Resetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III121
3.7 Rupture Disc Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III121
3.8 Combination Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III121
3.9 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III122
3.10 Vacuum Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III122
3.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III122
3.12 Sampling Line Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III122
3.13 Electrical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III123
3.14 Pneumatic Valve Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III123
3.15 Bottom Outlet Valve Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
3.16 Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
3.17 Internal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
3.18 Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
3.19 Gauging Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
3.20 Process Protection Valves and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III124
4.0 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.1 Set Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.2 Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.3 Rupture Discs Used in Rupture Disc Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.4 Qualification of Rupture Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.5 Breaking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III125
4.6 Pressure Regulator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III126
4.7 Qualification of Surge Suppression Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III126
5.0 Flow Capacity Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III127
5.1 Test Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III127
5.2 Flow Rating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III127
11/2014 C-III [M-1002] 115
APPENDIX A M-1002

5.3 Test Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III128
6.0 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III128
6.1 Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III128
6.2 Rupture Disc Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III129
6.3 Liquid and Vapor Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III129
6.4 Liquid Level Control and Gauging Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III129
6.5 Vacuum Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III130
6.6 Excess Flow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III130
6.7 Pressure Regulator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III130
7.0 Formula for Flow Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III131
7.1 Tank Cars without an Inner Container Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III131
7.2 Tank Cars with an Inner Container Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III133
8.0 Derivation of Formula for Flow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III134
8.1 Derivation of Equation 7.2.1 and Equation 7.2.2Conventional Units . . . . . . . . . . . . . . . . . . . . . C-III138
C-III [M-1002] 116 11/2014

M-1002 APPENDIX A
APPENDIX A
TANK CAR VALVES AND FITTINGS
1.0 INTRODUCTION
Appendix A describes AAR requirements for the design, testing, materials, and marking of tank
car valves and fittings:
Pressure relief devices, including the determination of relieving capacity requirements
Liquid and vapor valves, including bottom loading and unloading valves
Vacuum relief valves
Liquid level control and gauging devices
Temperature sensing equipment and thermowells
Bottom washouts
Accessories and special appurtenances related to handling the lading
2.0 SPECIFICATIONS FOR MATERIALS
2.1 Metals
All devices covered by this appendix must be fabricated from materials that are resistant to
corrosive or solvent action of the lading in the liquid or gas phase and are suitable for the service
temperature.
2.2 Nonmetallic Materials
Cars Built to
All Other 49 CFR
Non-Regulated Flammable Specified Regulated Subpart C
Commodities Liquids Corrosives Commodities (Pressure Cars)
Primary Prohibited Prohibited Allowed Prohibited Prohibited
Closures See
paragraphs 2.2.1
and 2.2.4
Secondary Allowed Prohibited Allowed Allowed Prohibited
Closures See See See
paragraphs 2.2.2, paragraphs 2.2.2 paragraphs 2.2.2,
2.2.3, 2.2.4, and 2.2.5 and 2.2.4 2.2.3, 2.2.4, and 2.2.5
Gaskets, See See See See See
O-Rings, paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4
and Seals
2.2.1 Except for components that are used in aluminum sulfate, ammonium chloride, ferric
chloride, hydrochloric acid, hydrofluosilicic acid, sulfuric acid, or phosphoric acid service,
nonmetallic material must not be used for any primary pressure-containing parts of any device
covered by this appendix. Gaskets, O-rings, valve seat seals, or rupture discs are exempted,
provided the requirements of paragraph 2.2.4 are met. Nonmetallic rupture disc devices may be
used as primary closures, provided they meet the requirements of paragraphs 2.2.4 and 2.2.5.
11/2014 C-III [M-1002] 117

APPENDIX A M-1002
2.2.2 Nonmetallic material may be used for any secondary pressure-containing parts of any
device covered by this appendix, provided the requirements of paragraphs 2.2.4 and 2.2.5 are met.
Nonmetallic material, except for gaskets and seals, may not be used for any secondary pressure-
containing parts for cars used to transport flammable liquids. Nonmetallic plugs and caps may not
be used on any car built to the requirements of 49 CFR Part 179 Subpart C (pressure cars). A
nonmetallic component may not be combined with a metallic component when the interface of the
components is an NPT thread. Examples would be a cap/plug, siphon pipe/cap, or a blind
flange/plug but would not include any threaded connections designed to Figs. E.18 through E.18.3
(bottom outlet caps) Nonmetallic material may be used for secondary pressure-containing parts of
any device that is used in aluminum sulfate, ammonium chloride, ferric chloride, hydrochloric acid,
hydrofluosilicic acid, sulfuric acid, or phosphoric acid service without meeting the requirements of
paragraph 2.2.5. The material used to construct these components must be compatible with the
product, and the component must be designed and tested to the appropriate pressure.
2.2.3 For newly designed metallic pressure retaining components or devices, the use of
nonmetallic protective coverings for metal parts is permissible, provided such coatings do not
interfere with proper operation of the device. Protection against ignition arising out of static
current buildup must be addressed in all newly designed nonmetallic pressure retaining
components or devices.
2.2.4 It is the shippers responsibility to ensure that all nonmetallic materials are compatible
with the lading and the service temperature.
2.2.5 When required in paragraphs 2.2.1 and 2.2.2, components manufactured of nonmetallic
materials (including design changes to existing devices) must be tested in a manner that is
representative of the operating environment in which they are intended to be used without
showing signs of leakage or distress. Testing shall as a minimum include, but not be limited to, the
following:
Pressure Identification TestEach device design shall be tested at a pressure one and one
quarter the maximum operating pressure (33% of the burst pressure of the car class on
which it is intended to be used) for a minimum period of 10 minutes. Pressure test must be
performed at ambient, 150 F (65.5 C) or a higher temperature as determined by the
manufacturer, and 30 F (34.4 C).
Torque TestingWhen applicable (e.g., cap, plugs, etc.), each device shall be torque tested
in an appropriate manner that represents the application and removal of said device to the
car. Torque test must be performed at ambient, 150 F (65.5 C) or a higher temperature
as determined by the manufacturer, and 30 F (34.4 C).
Product Compatibility TestRepresentative samples of the material(s) of construction of
the device shall be tested for resistance to corrosion and/or solvent action of the lading in
the liquid and gas phase at temperatures to which the device will be exposed in service.
Testing should be performed per ASTM D543 or an equivalent nationally recognized
standard.
Life expectancyThe life expectancy of the component shall be determined by the
component manufacturer. Consideration should be given to but not be limited to the
results of UV exposure test under maximum expected atmospheric conditions, expansion
and contraction, creep, and all of paragraph 2.2 at both the minimum and maximum
operating conditions too which the component will be exposed.
Note: Test results must be submitted with the application for approval to the Tank Car Committee.
The manufacturer must have procedures in its quality program to ensure that nonmetallic
production parts are physically identical, within established tolerances, to the parts that were
qualification tested.
2.2.6 The manufacturer of nonmetallic components used in a device or the manufacturer of
nonmetallic devices is subject to the facility certification and quality assurance requirements of
Appendix B.
C-III [M-1002] 118 11/2014

M-1002 APPENDIX A
2.3 Stem Materials

Stem materials for pressure relief valves set at 75 psig (517 kPa) or more must comply with the
following requirements:
2.3.1 No free machining metal (i.e., having more than 0.07% sulfur, lead, phosphorus, bismuth,
or selenium) may be used.
2.3.2 Cold drawn materials may not be used, unless the stresses due to cold working have been
relieved.
2.3.3 For stems that are in tension, impact strength must be at least 25 ft lbf (33.9 J) Charpy
V-notch at 20 F (28.9 C) or the design temperature of the container to which the valve
assembly is attached, whichever is lower.
2.3.4 No part or whole assembly may be made from cast materials.
2.4 Cast Materials
Cast materials for valves and fittings normally in contact with the lading are restricted to those
listed in Appendix M.
3.0 SPECIFICATIONS FOR DESIGN AND APPLICATION
3.1 Type
For single-unit tank car tanks, the net free-flow area through any part of the pressure relief device
must be not less than 1/2 in.2 (323 mm2) except as provided in paragraph 7.2.2 of this appendix.
Pressure relief valves must be spring-loaded and must be of approved design. Valves must have
direct access to the vapor space in the tank. This access must be no lower than 6 in. (152 mm)
below the inside top of the tank and must be of sufficient area to provide the full flow-rated
capacity of the valve.
3.2 Pressure Rating
Pressure-containing parts of all devices covered by this appendix must be designed for a pressure
not less than the maximum pressure to which the devices will be exposed.
3.3 Design Considerations
3.3.1 Pressure relief devices must be so designed and constructed that the failure of any part
cannot reduce the flow capacity of the device.
3.3.2 Maximum allowable stress in unthreaded sections of stems must be 50% of the yield stress.
3.3.3 Section changes in the stem of a pressure relief valve below the seat must be joined with a
fillet not smaller than 1/4 in. (6.35 mm) radius.
3.3.4 A pressure relief valve in a typical mounting must be designed to withstand horizontal
acceleration of 20 times the force of gravity without causing the valve to fail or to not comply with
the start-to-discharge and vapor-tight pressure requirements, and without stressing any parts
beyond the yield point of materials used in their assembled condition.
3.3.5 Where welded multiple-piece stems are used in pressure relief valves set at 75 psig
(517 kPa) or more, dye penetrant or magnetic particle tests are required, with no imperfections
acceptable.
11/2014 C-III [M-1002] 119

APPENDIX A M-1002
3.3.6 All primary and secondary fittings and closures, except pressure relief devices, must be
designed to be leak-tight.
3.3.6.1 All liquid and vapor valves must have pipe plugs, pipe caps, quick disconnect closures, or
blind flanges on the outlets to prevent escape of product in case of leakage. All liquid and vapor
valving that utilizes tongue-and-groove flange facing shall conform to Figs. E.19 through E.19.9,
except that 3 in. full-port ball valves used on nonpressure cars may, as an option, use ANSI B16.5
large tongue design as shown in Fig. E.19.24.
3.3.6.2 The control valve on top of a gauging device must have, on the discharge side of the valve,
a solid (not cored) pipe plug, with or without an orifice, or an orifice in the valve body to restrict
flow. Orifice size in the plug or valve body must be no larger than No. 54 drill size [0.055 in.
(1.397 mm)].
For alterations to remove bottom fittings after August 1, 2005, that will utilize a welded primary
closure (other than alterations that apply a tank shell insert), Appendix R, paragraph 14.6 must
be followed.
3.3.6.3 For new construction after July 1, 1976, all liquid and vapor closures used in normal
loading and unloading operations, except gauging device plugs or sampling valve plugs, must be
fastened by an approved means to prevent misplacement under conditions incident to
transportation or use.
3.3.6.4 For new construction or modification after August 1, 2005, except for tank shells with no
bottom opening, bottom flanges for future application of bottom fittings must include primary and
secondary closures.
3.3.6.5 For new construction after July 1, 1976, all liquid and vapor closures used in normal
loading and unloading operations, except gauging device plugs or sampling valve plugs, must be
fastened by an approved means to prevent misplacement under conditions incident to
transportation or use.
3.3.7 When a pressure relief device is mounted on a hinged manway cover, the design must be
approved and must incorporate sufficient clearance to preclude damage to the device as the
manway cover is swung to the full open position.
3.3.8 Effective January 1, 1989, for new construction and effective January 1, 1991, for all rebuilt
cars, cars receiving 150 man-hours or more of repairs or for new fittings added to cars during
alteration or conversion, the following applies:
3.3.8.1 Means must be provided for use of 1/8 in. diameter cable-type railroad seal to prevent
access to tank interiors resulting from casual vandalism. (Removal of valves, caps, quick-
disconnect caps, plugs, flanges, and other closures, or any operation requiring the use of tools, is
not casual vandalism. Destruction of the 1/8 in. diameter cable-type railroad seal or an equivalent
means of securement is visual evidence of tampering.) Care must be exercised in the design not to
inhibit emergency response team action.
3.3.8.2 Primary closures (access to tank) must have seal provision. Vacuum relief valves are
exempt from this sealing requirement.
3.3.8.3 Operating valves and fittings must have provision for sealing the operating mechanism or
be enclosed in a protective housing with seal provision.
3.3.8.4 Protection of rupture disc devices may be provided by weather covers with seal provision.
3.3.8.5 Effective July 1, 2013, new valves and fittings must be traceable to the location at
which the valve or fitting was applied. This can be accomplished either by physical means of a
station stencil tag or lead seal attached by use if rivets, cable, wire, or other suitable means
or by an alternative electronic means tied to the serial number on the fitting.
C-III [M-1002] 120 11/2014

M-1002 APPENDIX A
3.3.9 On cars ordered built new after July 1, 2013, the use of tapered pipe threads such as
American National Standard taper pipe threads (NPT) (ANSI B1.20.1) to attach a primary fitting
having a connection 1 in. or greater in size is prohibited. When non-taper pipe threads are used as
means of attachment and the primary fitting has a secondary closure, a mechanical stop must be
employed to prevent rotation of a fitting. When a hole 1 in. or greater in size is reduced to less than
1 in. by means of a bushing or threaded insert, the bushing or threaded insert must be seal-
welded.
3.3.10 On cars ordered built new after July 1, 2013, the use of tapered pipe threads such as
American National Standard taper pipe threads (NPT) (ANSI B1.20.1) to attach a primary closure
having a connection 1 in. or greater in size is prohibited.
3.4 Valve Configuration
The configuration of a valve and its components must minimize the possibility of trapping and
collecting dirt or residue, which adversely affect the operation of the valve.
3.5 Aspiration of Liquid
When a pressure relief valve extends 6 in. (152 mm) or more below the inside top of the tank shell,
the total cross-section of all areas through which liquid could aspirate must not exceed 3.5% of the
vapor inlet area.
3.6 Resetting
If the operating conditions of a pressure relief valve are changed so as to require a higher or lower
set pressure, the valve may not be reset more than 10% above nor 10% below the marked set
pressure. If the operating conditions of a valve are changed so as to require a new spring for a
different pressure, the valve must be adjusted and remarked by the manufacturer (or by the car
owner with the valve manufacturers permission).
3.7 Rupture Disc Device
3.7.1 A rupture disc device must be so designed that the means for holding the rupture disc in
place will prevent distortion or damage to the disc when properly applied. Rupture disc device
closures must be chained or otherwise fastened to prevent misplacement.
3.7.2 Tank cars built or converted after January 1, 1978, must not be equipped with rupture disc
devices having a rupture disc retained by a threaded component that directly contacts the rupture
disc unless the rupture disc device was manufactured after May 1, 1994. Such devices on tank cars
built prior to January 1, 1978, may remain in service, but, if defective, must not be replaced in
kind.
3.7.3 When a rupture disc device is used, means for inspection of the top portion of the disc
without releasing clamping pressure on the disc must be provided.
3.7.4 Tank cars ordered built, converted, or rebuilt after May 1, 1994, that are equipped with
rupture disc devices and are placed in regulated commodity service must be equipped with a surge
pressure reduction device.
3.7.5 All non-pressure tank cars that are equipped with rupture disc devices, excluding
combination devices, and that are placed in regulated commodity service, except for molten sulfur,
acrylamide, and Class 9 elevated temperature materials, must be equipped with a surge pressure
reduction device at their next qualification after July 1, 2013.
3.8 Combination Devices
If a pressure relief valve is used in combination with a rupture disc, provision must be made to
detect any accumulation of pressure between the disc and the valve. The detection device must be
a needle valve, trycock, tell-tale indicator, or other approved device. The detection device must be
closed during transportation.
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APPENDIX A M-1002
3.9 Application
Except where multiple pressure relief devices are equipped with an approved three-way selector
valve, there must be no intervening valve between the pressure relief device and the vapor space of
the tank.
3.10 Vacuum Relief Valve
3.10.1 Gravity-actuated vacuum relief valves must not be applied or replaced in kind.
3.10.2 Vacuum relief valves installed prior to July 1, 2013, must be designed to seal bubble-tight
down to the start-to-open pressure and up to 100 psi (689 kPa) positive pressure. The integrity of
the seal must not be affected after opening the valve against 100 psi (689 kPa) positive pressure.
The minimum start-to-open pressure must be designed for negative 0.75 psig (5.17 kPag).
3.10.3 Effective July 1, 2013, for new tank car construction or at the time of the next qualification
of existing tank cars, vacuum relief valves must meet the following conditions:
Must be designed to seal bubble-tight down to the start-to-open pressure and up to
165 psig (1138 kPag).
The minimum start-to-open pressure must be designed for negative 0.75 psig (5.17 kPag).
Must be designed so that they cannot be manually actuated from the outside.
Must be within the permissible tolerance for start-to-open pressure as follows:
Range for Start-to-Open Permissible Tolerance Example of Tolerance

(psig) (psig) Applied to STO
and up to 1 and +0 psig Given psig, range is to 1
1 and up to 5 psig Given 2 psig, range is 1 to 2
Greater vacuum than 5 psig 1 psig Given 6 psig, range is 5 to 7
3.10.4 Effective July 1, 2013, manually actuated vacuum relief valves must not be replaced in
kind.
3.11 Maintenance
3.11.1 Repair work on pressure relief devices involving machining, grinding, welding, or other
alterations or modifications can be performed only by the valve manufacturer, or by the car owner
or user with the valve manufacturers permission, except as listed below.
3.11.2 If a trained specialist is available, the seating surfaces of metal-to-metal seat valves may
be lapped. The flat gasket face on the valve body mounting surface, or the gasket tongue, may be
machined to remove nicks and burns. The tolerances on the gasket tongue must not be exceeded.
3.12 Sampling Line Device
A sampling line valve, when used, must be constructed of austenitic or ferritic stainless steel. A
needle valve may have integral male threads that attach directly to the cover plate, provided the
threaded portion has a minimum Schedule 80 thickness. If a needle valve is attached using a pipe
nipple, the nipple must be made of Schedule 80 austenitic stainless steel pipe. Valves not so
equipped must be retrofitted not later than the next pressure relief valve or tank qualification
date, or at the time of any fitting repair or modification, whichever occurs first.
C-III [M-1002] 122 11/2014

M-1002 APPENDIX A
3.13 Electrical Devices

3.13.1 Electrical Requirements
3.13.1.1 A car-mounted electrical device must be intrinsically safe for those parts of the device
normally exposed to the lading, and intrinsically safe or explosion-proof for those parts of the
device not normally exposed to the lading, if the lading is a flammable liquid, a flammable
compressed gas, or an oxidizing material. Intrinsically safe electrical devices must conform to
Underwriters Laboratories Standard UL 913 or Factory Mutual Standard FM-3610/3611.
3.13.1.2 Each electrical system must include testing features and/or procedures that will assure
the operator that the system is operating normally at the beginning of the operation cycle and may
be expected to complete the cycle. Additionally, each system must safeguard against power or
connection failures during an operation cycle as follows: The electrical system must activate an
alarm if connections between a car-mounted device and off-car equipment, normally connected to
the car-mounted device at the time of use, are interrupted at any time. Electrical systems that are
powered by batteries must have an indicator that is automatically operated when battery energy
is less than that required for one loading cycle.
Electrical systems that are powered by connection to an AC power distribution system must have
a power on indicator that is readily visible to the operator. The term electrical systems as used
in this paragraph includes, in addition to the car-mounted device, any off-car equipment normally
connected to the car-mounted device at the time of use.
3.13.2 Environmental Requirements
3.13.2.1 Parts of devices mounted inside the tank must perform within their rated accuracy over
the full temperature range of the lading. All parts of devices not exposed to the lading must
perform within specified accuracy over the temperature range of -20 F to 170 F (28.8 C to
76.7 C), or the service conditions, whichever is most severe.
3.13.2.2 A car-mounted electrical device must operate normally and within its rated accuracy
following a three-axis acceleration impact of 15 times the force of gravity, half sine wave, 11 msec
duration. For the test procedure, see MIL-STD 810, latest revision.
following a four-part vibration test over the following frequency, amplitude, and acceleration
range: 5 to 20 Hz with double amplitude of 0.1 in. (2.54 mm); 20 to 30 Hz at 2 times the force of
gravity; 30 to 70 Hz with double amplitude of 0.036 in. (0.914 mm); and 70 to 2000 Hz at 10 times
the force of gravity. For the test procedure, see MIL-STD 810, latest revision.
following a thermal shock of the magnitude encountered in unloading and loading commodities in
which the device is used.
during normal environmental variations.
3.13.3 Materials of Construction
All materials must be resistant to corrosive or solvent action if exposed to the liquid or vapor
phases of the lading in normal circumstances of loading, unloading, or transit.
3.14 Pneumatic Valve Operators
The train air brake system must not be tapped for any pneumatically operated valve system or
device without the approval of the Braking Systems Committee. See Chapter 1, paragraph 1.4.2.7.
11/2014 C-III [M-1002] 123

APPENDIX A M-1002
3.15 Bottom Outlet Valve Attachments

When auxiliary bottom unloading fittings are to be used, in-line valving of an approved design is
acceptable, when installed below the shear-plane, provided the rail clearance limits of Appendix E,
paragraph 7.0, are maintained. The closure must meet DOT 179.200-17(a)(6). Only the minimum
number of fittings and only close nipples may be used. On auxiliary valves, all hand wheels and all
operating handles having a lever arm in excess of 6 in. (152.4 mm) must be removed when the car is
in transit. Elbowed or teed horizontal extensions of piping from outlet center line are prohibited.
3.16 Profile
The projection of pressure relief devices and other fittings and nozzles on nonpressure cars must
be kept to a minimum compatible with their proper operation. Appendix E, Figs. E.25.1 through
E.25.12, illustrate maximum profile guidelines that should not be exceeded without justification.
These guidelines apply to new cars and to nozzles added to existing cars. The guidelines do not
apply to addition of fittings to nozzles not originally built to these criteria. These figures apply
to cars with up to 6 in. (152.4 mm) of insulation and two-board platforms.
3.17 Internal Fittings
When a thermometer well or a gauging device is attached by a welding process to the underside of
a cover plate, the welding must be performed by a certified facility (see Appendix B). Welding must
be done by a qualified welder and using a qualified weld procedure in accordance with
Appendix W. The weld must have an effective throat equivalent to the thickness of the part being
welded.
3.18 Ball Valves
Screwed-end ball valves of the external wrenching tailpiece type must not be used unless the
tailpiece is secured to the adjacent body in accord with the valve manufacturers
recommendations. Valves of this type without secured tailpiece must be replaced with AAR-
approved valves or modified per manufacturers recommendations at next car shopping, but no
later than July 1, 2012.
3.19 Gauging Devices
3.19.1 Each manufacturer of gauging devices or components shall make installation,
maintenance, and operating instructions available for each device or component.
3.19.2 It is the car owners responsibility, at the time of next repaint or qualification, to mark all
cars equipped with gauging devices with a set of operating instructions, in an appropriate location,
to facilitate operation of the device. Visual gauge bars are not subject to this requirement.
3.20 Process Protection Valves and Fittings
When stripping, preparing, or applying an exterior protective coating, affected valves and fittings
must be removed or effectively protected.
3.21 External Bottom Outlet Ball Valves
External bottom outlet ball valves must have a handle interface on the valve stem or valve stem
adapter (as specified in Appendix E, paragraph 9.1.2.8.2.6).
C-III [M-1002] 124 11/2014

M-1002 APPENDIX A
4.0 PRESSURE SETTINGS

4.1 Set Pressure
The set pressure of a pressure relief valve, or the burst pressure of a rupture disc or breaking pin,
must be as specified in the applicable federal and AAR specifications.
4.2 Tolerance
4.2.1 The permissible tolerance for the start-to-discharge pressure of a pressure relief valve must
be 3%, or 3 psi (21 kPa), whichever is larger. Each new pressure relief valve must be tested by
the manufacturer before being put into service. Documentation must be provided to the owner
certifying that test results were within these start-to-discharge tolerances and regulatory vapor-
tight requirements. Use of the Certificate of Test Form (see Fig. D.4) is not required for such
documentation.
4.2.2 The permissible tolerance for the burst pressure of a rupture disc must be 0% to 15%.
4.2.3 The permissible tolerance for the burst pressure of a breaking pin must be 15 psi
(103 kPa).
4.3 Rupture Discs Used in Rupture Disc Devices
The procedure for the determination of the burst pressure of a rupture disc, including a disc with
breather hole, is to test one from each lot of up to 100 discs of the same design and made from the
same piece of material. The test procedure must employ a pressure rise that reaches 50% of the
rated burst pressure within 2 seconds and then continues at a rate of 1 to 4 psi per second (6.9 to
28 kPa per second) to burst. If the tolerance specified in paragraph 4.2.2 above is exceeded, two
additional discs must be tested, and both must meet specifications or the lot must be rejected.
Rupture discs must be tested at a temperature between 70 F and 75 F (21.1 C and 23.9 C)
unless otherwise specified.
4.4 Qualification of Rupture Discs
Each rupture disc design, for each design burst pressure and for each material of construction,
must be subjected to a qualification test (in its vacuum support system, if required). The test must
consist of 25 pressure cycles from 8 psig (55.2 kPa) to 75% of the rated burst pressure. The
duration of each cycle must not exceed 5 seconds. After cycling the disc, it must be subjected to a
pressure test consisting of a pressure rise that reaches 50% of the rated burst pressure within
2 seconds and continues at a rate of 1 to 4 psi per second (6.9 to 28 kPa per second) to burst. Discs
must be tested at a temperature between 70 F and 75 F (21.1 C and 23.9 C) unless otherwise
specified. Five discs must be tested and all five discs must rupture within the required burst
pressure tolerance.
4.5 Breaking Pins
The procedure for determination of the burst pressure of a breaking pin is to test one pin from a lot
of 16 or less made from one piece of material. If the tolerance specified in paragraph 4.2.3 above is
exceeded, two more pins must be tested and both must meet specifications or the lot must be
rejected.
11/2014 C-III [M-1002] 125

APPENDIX A M-1002
4.6 Pressure Regulator Valves

The procedure for determining the nominal standard set pressure for Class 105A500W tank cars
shall be determined using the flow method and definitions described in table Table A.1. Each
regulator shall be tested by an AAR-qualified shop, documented as required in paragraph 5.3,
Test Reports, and marked as required in paragraph 6.0, Marking.
Table A.1 Pressure regulator valve settings

Pressure Regulator
Valve Pressure Setting at Tolerance Start-to-Open Pressure
Marked Pressure Flow 10 scfm Air (Note 1) () (5%) Reclosing Pressure
300 310 1 scfm Note 2 Note 3
Notes:
1. Pressure regulator valve pressure setting at 10 scfm air is the pressure 10 psig higher than the
start-to-open pressure. The regulator is adjusted and set to a flow of 10.0 scfm 1.0 scfm of air
at this pressure.
2. Pressure regulator valve start-to-open pressure is the marked pressure at which the flow is
0.2 scfm to 0.6 scfm of air as measured with a flow meter or by collecting a timed volume of air
by the displacement of water. (This is for reference only, not for adjusting the regulator valve.)
3. Pressure regulator valve reclosing pressure is the pressure with a flow of less than 0.1 scfm and
is nearly bubble-tight. The lower limit for an acceptable reclosing pressure is 80% of the start-
to-open pressure.
4.7 Qualification of Surge Suppression Devices
The effect on flow rate of a surge suppression device used in series with a rupture disc device must
be considered when determining the overall flow capacity of the pressure relief system. Each
manufacturer of a surge suppression device must determine the discharge flow coefficient of the
device at pressures of 88 psi and 181.5 psi (110% of 80 psi and 165 psi, respectively) in typical
nozzle installations (2 in., 3 in., and 6 1/2 in. configurations). The applicant must test three devices
that are representative of production. The rated capacity of each device will be the average of the
three devices tested. The flow capacity of each device must not deviate more than 5% from the
average rating of the three devices in each configuration.
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M-1002 APPENDIX A
5.0 FLOW CAPACITY TESTS

5.1 Test Required
The flow capacity of each pressure relief device design must be determined by flow tests, except
that rupture disc devices incorporating an orifice diameter of 4 in. or greater need not be flow
rated. The following are modifications that affect the flow capacity and that will require a flow
rating test:
Changes in spring material that change the spring constant
Changes in the orifice diameter or huddle chamber
Changes to the approach and/or discharge channel (such as addition of a surge suppression
device)
5.2 Flow Rating Test
5.2.1 Tests must be conducted at the expense and responsibility of the applicant at a place where
approved equipment and personnel are available to conduct flow capacity tests. Tests must be
made in the presence of, and certified by, an authorized independent observer. The place,
personnel, equipment, and the authorized independent observer must be approved by the AAR or
ASME Boiler and Pressure Vessel Committee or by the National Board of Boiler and Pressure
Vessel Inspectors.
5.2.2 The flow capacity of pressure relief devices must be determined at the flow rating pressures
specified in 49 CFR 179.15(b)(4). If pressure relief valves are used in combination with breaking
pin or rupture disc devices, the required flow rating pressures must be the same as those for
corresponding valves without such devices.
5.2.3 Flow tests may be conducted using steam, air, natural gas, or the lading for which the
device is intended to be used. When saturated steam is used, correction for moisture content of the
steam must be made.
5.2.4 Tests must be made on pressure relief valves to determine the start-to-discharge pressure,
vapor-tight pressure, and relieving capacity for each size, design and pressure setting. Tests must
be made on a set of three pressure relief valves that are representative of production. The flow
capacity for each combination of design, size, and test pressure must be the average capacity
rating of the three valves tested. The flow capacity of each valve must not deviate more than 5%
from the average rating of the three valves.
5.2.5 After December 31, 2004, the flow capacity of a rupture disc pressure relief system must be
determined as specified in paragraphs 5.2.5.1 through 5.2.5.4. This applies to new construction or
alterations to add a rupture disc device. The flow capacity must be determined for each pressure
setting.
5.2.5.1 Each manufacturer must test the flow capacity of a rupture disc device as an ideal
conduit, without the rupture disc or any surge suppression device installed, to determine the
actual flow capacity of the device. The manufacturer must test three devices that are
representative of production. The rated capacity of each rupture disc device will be the average of
the three devices tested. The flow capacity of each device must not deviate more than 5% from the
average rating of the three devices. The presence of an observer (see paragraph 5.2.1) is not
required.
5.2.5.2 The flow capacity derived from paragraph 5.2.5.1 must be multiplied by 0.70 to provide
for an allowance for any structural member of the rupture disc that remains in place after disc
burst (this assumes a 2.2 in. I.D. minimum holder). Alternatively, each applicant may test the flow
capacity of a rupture disc device with the rupture disc installed, and all other provisions of
paragraph 5.2.5.1 apply. The rated capacity obtained is applicable only to that device and that
rupture disc design.
11/2014 C-III [M-1002] 127

APPENDIX A M-1002
5.2.5.3 When installing surge suppression devices, the flow capacity derived from
paragraph 5.2.5.2 must be multiplied by an appropriate discharge flow coefficient, determined by
the surge suppression device manufacturer, to provide for an allowance for restricted flow. See
paragraph 4.7. This is the rated flow capacity of the pressure relief system.
5.2.5.4 If there is a change in the rupture disc device or any installed surge suppression device
that affects the flow capacity, the tank car owner must recalculate the flow capacity of the pressure
relief system as stated above.
5.2.6 For the purpose of the test, each device must have a mounting that approximates a typical
approach channel and has, at the outlet, a passage that approximates a typical discharge channel.
5.3 Test Reports
5.3.1 The flow capacity must be reported in cubic feet per minute (or cubic feet per minute and
cubic meters per second) of air at standard conditions.
5.3.2 The official flow capacity of a device established under paragraph 5.2.4 above must be taken
as the average of tests of three devices of the same design, size, and pressure setting.
5.3.3 The official flow capacity of a rupture disc device is the smallest capacity of the devices
tested, as determined in paragraph 5.2.5 above.
5.3.4 Flow rating, materials of construction, general arrangement, and assembly data in
sufficient detail to determine compliance with the requirements of Appendix A must be submitted
with Form AAR 4-3 to the Director and the Tank Car Committee.
5.3.5 Pressure regulator valves shall be tested in accordance with Table A.1 and documented
with Form AAR 4-3, Application for Approval of Pressure Relief Device (see Fig. 1.3 in
Chapter 1).
6.0 MARKING
6.1 Pressure Relief Valves
6.1.1 Each pressure relief valve must be plainly and permanently marked by the valve
manufacturer or reconditioner with the required data.
6.1.2 The marking on each pressure relief valve may be placed on the valve or on a plate or plates
securely fastened to the valve. The marking must include the following and must be maintained
for the life of the valve:
The name or identifying mark of the manufacturer
Manufacturers design or type number
Serial number (effective for valves built after December 31, 2003)
Set pressure, psi (or psi and kPa)
Official flow capacity, cubic feet per minute (or cubic feet per minute and cubic meters per
second) of air at standard conditions
Flow rating pressure, psi (or psi and kPa)
C-III [M-1002] 128 11/2014

M-1002 APPENDIX A
6.2 Rupture Disc Devices

6.2.1 For rupture disc devices used on tanks specified in DOT 173.314, 179.200, and 179.220 and
in Chapter 3, paragraphs 3.1, 3.2, 3.3, and 3.4, the rupture disc or a metal tab attached to the
rupture disc must be marked to indicate the following:
Burst pressure, psi (or psi and kPa)
The lot number
6.2.2 For rupture disc devices built after December 31, 2003, the device must be marked on the
flange or on a nameplate permanently secured to the device as follows:
The manufacturers design or type number and the serial number
The flow rating pressure, psi (or psi and kPa)
6.2.3 On discs for which orientation in holder is important, mark TOP on discharge side.
6.3 Liquid and Vapor Valves
6.3.1 Each device with a net free-flow area of more than 1/2 in.2 (323 mm2) must be marked to
indicate the following:
Serial number (effective for valves built after July 1, 2013)
Type of trim
Pressure-temperature limitations
6.3.2 All pressure-retaining valve body castings shall be marked in accordance with the
appropriate ASTM specification, including material identification with the grade symbols (e.g.,
WCB, WC9, CF8M, etc.), heat numbers, or a lot number traceable to either a heat number or
month poured.
6.3.3 For valve bodies constructed with more than one pressure-retaining casting, each casting
must comply with the applicable ASTM marking requirement. This does not apply to bonnets,
yokes, or body inserts.
6.3.4 Marking requirements of paragraphs 6.3.2 and 6.3.3 above become effective for castings
manufactured after December 1, 2001.
6.4 Liquid Level Control and Gauging Devices
6.4.1 Each device must be marked to indicate the following:
Pressure rating
6.4.2 For all gauging devices, when removed from a car, each separable component that affects
gauging accuracy must be identified to ensure proper reinstallation.
6.4.3 For all gauging devices manufactured after December 31, 2003, the manufacturer must
ensure that each device indicates, when applicable, the specific gravity for which it is intended.
11/2014 C-III [M-1002] 129

APPENDIX A M-1002
6.5 Vacuum Relief Valves

Each device must be marked to indicate the following:
Type of trim and body material
Vacuum set pressure
6.6 Excess Flow Valves
For threaded device (not welded to manway cover), a serial number (effective for valves
built after July 1, 2013)
6.7 Pressure Regulator Valves
Nominal standard set pressure
Serial number
AAR-approval number as of the date of manufacture
C-III [M-1002] 130 11/2014

M-1002 APPENDIX A
7.0 FORMULA FOR FLOW CAPACITY

To determine the total required flow capacity of a pressure relief device, which may be regarded as
the sum of the individual capacities of several devices, use one of the following equations:
7.1 Tank Cars without an Inner Container Tank
7.1.1 Conventional Units
0.82
633,000FA
Q a = ------------------------------------ ZT
------- Equation 7.1.1a
LC M
0.82
Qa = Gu A (for F=1, see Table A.5) Equation 7.1.1b
0.82
Q a = 2G i UA (for F<1, see Table A.5) Equation 7.1.1 c
where
A = the total outside surface area of the tank or inner container (ft2)
C = the gas constant that is a function of the ratio of specific heats at standard conditions. For liquids, if this
variable is unknown, 315 is a safe value (see Table A.4)
F = the environmental factor, equal to 1.0 for noninsulated tank cars, or calculated as follows for insulated
tank cars or thermally protected tank cars, provided the overall system will remain effective at
temperatures up to 1200 F:
1,200 t -
F = 8U
---------------------------------
34,500 Equation 7.1.1 d
Gi = the gas factor for insulated containers (see Table A.5)
Gu = the gas factor for noninsulated containers (see Table A.5)
L = the latent heat of vaporization in Btu per pound at flowing conditions
M = the molecular weight of the product
Qa = the minimum rate of discharge in cubic feet per minute of free air at standard conditions
T = the temperature of product at flowing conditions, R (Rankine)
t = the temperature of gas at flowing conditions, F
U = the overall thermal conductance of the insulating material at 100 F, Btu/h-ft2-F
Z = the compressibility factor at flowing conditions. For liquids, if this variable in unknown, 1 is a safe value.
7.1.1.1 Minimum Flow Capacity
When the physical properties of a liquid product are not known, the minimum flow capacity of a
pressure relief device may be calculated as follows:
P 85
Q min = Q a 1 + 1/4 -------------------- Equation 7.1.1.1a
85
where P is the flow rating pressure (psig) per 49 CFR 179.15(b)(4), and Qa is calculated
using the following physical properties:
C = 325 L = 130 Btu/lb
t = 190 F M = 63
T = 650 R Z = 0.864
This paragraph is applicable only for pressure relief devices with a start-to-discharge pressure less
than or equal to 165 psig.
11/2014 C-III [M-1002] 131

APPENDIX A M-1002
7.1.2 SI Units
0.82
6,500FA ZT-
Q a = ------------------------------ ------ Equation 7.1.2a
LC M
0.82
Qa = Gu A (for F=1, see Table A.5) Equation 7.1.2b
0.82
Q a = 2G i UA (for F<1, see Table A.5) Equation 7.1.2 c
where
A = the total outside surface area of the tank or inner container (m2)
C = the gas constant that is a function of the ratio of specific heats at standard conditions. For liquids, if this
variable is unknown, 315 is a safe value (see Table A.4)
F = the environmental factor, equal to 1.0 for noninsulated tank cars, or calculated as follows for insulated
tank cars or thermally protected tank cars, provided the overall system will remain effective at
temperatures up to 648.88 C:
649 t -
F = 8U
----------------------------
391,800
Gi = the gas factor for insulated containers (see Table A.5)

Gu = the gas factor for noninsulated containers (see Table A.5)
L = the latent heat of vaporization in kJ/kg per pound at flowing conditions
M = the molecular weight of the product
Qa = the minimum rate of discharge in cubic meters per second of free air at standard conditions
T = the temperature of product at flowing conditions, K (Kelvin)
t = the temperature of gas at flowing conditions, C
U = the overall thermal conductance of the insulating material at 37.8 C, kJ/h-m2-C
Z = the compressibility factor at flowing conditions. For liquids, if this variable in unknown, 1 is a safe value.
7.1.2.1 Minimum Flow Capacity
When the physical properties of a liquid product are not known, the minimum flow capacity of a
pressure relief device may be calculated as follows:
P 586
Q min = Q a 1 + 1/4 ----------------------- Equation 7.1.2.1a
586
where P is the flow rating pressure (psig) per 49 CFR 179.15(b)(4), and Qa is calculated
using the following physical properties:
C = 325 L = 302 kJ/kg
t = 87.8 C M = 63
T = 361 K Z = 0.864
This paragraph is applicable only for pressure relief devices with a start-to-discharge pressure less
than or equal to 1138 kPa.
7.1.3 Alternate Flow Capacity
As an option to the requirements of paragraph 7.1 above, any tank car transporting a non-
regulated material, Class 8 material, or other material for which the regulations permit the use of
a non-reclosing pressure relief device [ref. DOT 173.31(b)(2)] requires a pressure relief device with
a flow capacity not less than 1,100 scfm, providing that the start-to-discharge pressure does not
exceed 165 psi. This paragraph applies whether the car is equipped with a rupture disc device or a
pressure relief valve. This paragraph does not apply to any material requiring a flow capacity, as
calculated per paragraph 7.1, that exceeds 19A0.82 (conventional units) or 0.06A0.82 (SI units),
where A is the same value used in the paragraph 7.1 calculation.
C-III [M-1002] 132 11/2014

M-1002 APPENDIX A
7.2 Tank Cars with an Inner Container Tank

The formulas presented below are for liquefied gases in tanks consisting of an inner container
suspended in an outer shell. Such tanks are built under Specification AAR-204W or Class DOT-
113.
7.2.1 The rupture disc device capacity must be sufficient to limit the pressure within the inner
container to not exceed the test pressure during all conditions of operation, both normal and
abnormal, including fire with loss of vacuum, when the insulation space is filled with air or
gaseous lading (whichever requires the greater capacity) at atmospheric pressure:
0.82
Qa = Gi Uc A (conventional or SI units) Equation 7.2.1a
7.2.2 In addition to the requirement of paragraph 7.2.1 above, the pressure relief valve capacity
must be sufficient to limit the pressure within the inner container to the flow rating pressure
specified in the tank specification when the insulation space is filled with air or gaseous lading
(whichever requires the greater capacity) at atmospheric pressure and the outer shell...
...is at 130 F:
130 t 2
Q a = ------------------------------- G i U c A (conventional units) Equation 7.2.2a
4 1,200 t 2
...is at 54.4 C:
0.382 54.4 t 2
Q a = --------------------------------------- G i U c A (SI units) Equation 7.2.2b
649 t 2
Notes:
1. In paragraphs 7.2.1 and 7.2.2 above, Uc is the overall thermal conductance of the insulating
material filled with air or gaseous lading, at atmospheric pressure, whichever provides the
greater thermal conductance.
2. In paragraph 7.2.2 above, the value of Uc at the average temperature of the insulation may be
used. For liquid hydrogen, the value of Uc must be chosen on the basis that the insulation space
is filled with gaseous hydrogen at one atmosphere.
3. The net free flow area through any part of the pressure relief valve must be not less than
3/16 in.2 (1.21 cm2).
4. The Gi values for ethylene and hydrogen in Table A.5 are given for both rupture disc device and
pressure relief valve settings of Class DOT-113 cars used for these commodities.
11/2014 C-III [M-1002] 133

APPENDIX A M-1002
8.0 DERIVATION OF FORMULA FOR FLOW CAPACITY

Under conditions of adiabatic and reversible flow (isentropic), the capacity of a pressure relief
valve for vapor and gas relief can be calculated using the following ASME Code equation:
W = CKAp M
----- Equation 8.0a
T
where
W = the mass flow rate of gas or vapor, lb/h
C = the constant for gas or vapor, a function of the ratio of specific heats, k=Cp/Cv (with dimension)
K = the coefficient of discharge, dimensionless
A = the actual area of discharge orifice or nozzle area, in.2
p = the upstream pressure (the set pressure multiplied by 1.10) plus atmospheric (flow rating pressure)
M = the molecular weight of the gas or vapor
T = the temperature of the gas at flowing conditions, R
For real gases, an empirical correction can be made to Equation 8.0a by using the equation of
state:
pv = ZRT Equation 8.0b
where
v = the gas specific volume in ft3/lb
R = the gas constant
Z = the compressibility factor
Equation 8.0a then becomes

M-
W = CKAp ------ Equation 8.0 c
ZT
For a tank engulfed in fire under quasi-steady state conditions, the heat absorbed by the liquid is
used to vaporize it, and the vapor generated is expelled through the pressure relief valve. The
vapor flow through the pressure relief valve is given by the following equation:
W = Q L lb h Equation 8.0d
where
Q = the amount of heat absorbed by the liquid cargo, Btu/h
L = the latent heat of vaporization at flowing conditions, Btu/lb
Assume that a given relief valve is tested with dry air at 60 F (520 R), the pressure differential is
sufficient for critical flow. For this case, Equation 8.0c can be written as follows:
Ma
W a = C a KAp ------------
- Equation 8.0 e
Za Ta
C-III [M-1002] 134 11/2014

M-1002 APPENDIX A
Solving for KAp,

Wa Za Ta
KAp = -------- ------------
- Equation 8.0 f
Ca Ma
where
Ca = 356 (for air K=1.4)
Ma = 28.97
Ta = 520 R
Za = 1.0
C is calculated using the following equation:

k+1
------------
2 k1
C = 520 k ------------ Equation 8.0g
k + 1
where
C
k = ------p- Equation 8.0 h
Cv
Substituting these values into Equation 8.0f, we obtain the following:

Kap = 0.0119W a Equation 8.0 i
Because this pressure relief valve is designed for vapor relief on a liquid container, the air rated
capacity of the valve (at 60 F) can be determined by substituting Equation 8.0d and Equation 8.0i
in Equation 8.0c as follows:
Q ZT
W a = ------------------------ ------- Equation 8.0 j
0.0119LC M
where
Wa = the air rated equivalent capacity in lb/h at 60 F inlet temperature
Because we want Wa to be expressed in ft3/min at standard conditions, the following conversion is

made:
Wa vo
cfm a = -------------
- Equation 8.0k
60
where
vo = 13.1 ft3/lb, specific volume of air at 60 F, 14.7 psia
60 = the conversion factor from hours to minutes
Substituting Equation 8.0j into Equation 8.0k,

18.34Q ZT
cfm a = Q a = ------------------ ------- Equation 8.0 l
LC M
11/2014 C-III [M-1002] 135

APPENDIX A M-1002
When the specific heat ratio k from which C is calculated is not known, a value of C=315 is
considered a conservative value.
The fundamental equation used in calculating the amount of heat absorbed by a liquid cargo
container exposed to fire can be expressed as follows:
Q = qFEA w Equation 8.0 m
where
Q = the rate of heat absorption by the liquid, Btu/h
q = the heat flux from the fire (per unit wetted area completely exposed to fire), Btu/h-ft2
F = the dimensionless fire exposure factor
Aw = the total wetted surface area of the container, ft2
E = the fraction of surface of vessel exposed to fire
Substituting Equation 8.0m into Equation 8.0l, we obtain the following:

18.34qFEA w
Q a = --------------------------------- ZT
------- Equation 8.0 n
LC M
Experimental data indicate that the heat flux q from a free-burning hydrocarbon fire can reach
values up to 34,500 Btu/h ft2 to bare container surfaces. Substituting this value for q in Equation
8.0n gives the following:
633,000FEA w
Q a = ----------------------------------- ZT
------- Equation 8.0 o
LC M
It should be noted that Equation 8.0o breaks down near the critical point of the mixture, where L
approaches zero. For this reason, this equation should not be used where values of L are less than
50 Btu/lb.
Factor E is defined as the fraction of the wetted surface of the vessel exposed to fire. Fire test data
(Cummings) indicate that as the size of a vessel increases, the fraction of the wetted surface
exposed decreases in accordance with the following expression:
1 -
E = ----------- Equation 8.0p
0.18
A
where
A = the total area of container in ft2
To include a factor of safety, if the total wetted surface area of the container Aw in Equation 8.0o is
to equal A, then the product
0.82
Ea w = EA = A Equation 8.0q
C-III [M-1002] 136 11/2014

M-1002 APPENDIX A
Substituting Equation 8.0q into Equation 8.0o,

0.82
633,000FA ZT
Q a = ------------------------------------ ------- Equation 8.0 r
LC M
The definition for F can be typically expressed by the following equation:

U t1 t2
F = -----------------------
- Equation 8.0 s
q
where
F = the environmental factor that can vary between 0 and 1
U = the overall thermal conductance BTU/h-ft2 at 100 F
t1 = the assumed external surface temperature under the fire conditions = 1200 F
t2 = the temperature of the gas (liquid) at flowing conditions
q = the heat flux from the fire/unit wetted area exposed to fire = 34,500 BTU/h-ft2
The equation becomes the following:

U 1,200 t 2
F = --------------------------------
- Equation 8.0 t
34,500
Note the following:

Because thermal conductivity is difficult to find at elevated temperatures, U is defined as
the overall thermal conductivity at 100 F (37.77 C) multiplied by 2 for a safety factor.
Assuming that the insulation is rendered 50% ineffective in a fire, the result, again, is
multiplied by 2 for a safety factor.
It is assumed that the heat transfer through the metal connections and fittings projecting
through the insulation is approximately equal to the transfer through the insulated area.
To compensate for this, the temperature is, again, multiplied by 2 for a safety factor.
The product of the three factors of U is equal to eight, and Equation 8.0t becomes the following:
8U 1,200 t 2
F = -----------------------------------
- Reference Equation 7.1.1d
34,500
For a noninsulated container (bare tank), F = 1. For all other cases (insulation, thermal protection,
and linings), the value of F should be calculated and used in Equation 8.0r.
11/2014 C-III [M-1002] 137

APPENDIX A M-1002
8.1 Derivation of Equation 7.2.1 and Equation 7.2.2Conventional Units

In the case of paragraph 7.2.1 above, the tank construction consists of an inner container
suspended within an outer shell, and there is no need to apply a factor for heat loss through metal
connections. The overall thermal conductance is also defined for the insulating material filled with
air or gaseous lading and is denoted as Uc. The environmental factor then becomes the following in
this case:
4U c 1,200 t 2
F = --------------------------------------
- Equation 8.1a
34,500
Multiplying and rearranging into Equation 7.1.1a,

0.82
73.4U c 1,200 t 2 A
Q a = ----------------------------------------------------------- ZT
------- Equation 8.1b
LC M
To simplify use of the formula for commonly encountered gases and pressures, set
73.4 1,200 t 2 ZT
G i = --------------------------------------- ------- Equation 8.1 c
LC M
Substituting,
0.82
Qa = Gi Uc A Reference Equation 7.2.1a
The derivation of Equation 7.2.2a is based on an outer shell temperature of 130 F. The weight of
lading vaporized is given by the following:
U c A 130 t 2
w = ----------------------------------- , lb/h Equation 8.1d
L
From Compressed Gas Associations (CGAs) Basic Consideration for Pressure Relief Device
standards,
13.1wC a ZTM a
Q a = ---------------------- -----------------
- Equation 8.1 e
60C Za Ta M
where subscript a indicates values for air.

Substituting the expression for w and the known values for air,
13.1 U c A 130 t 2 356 ZT 28.97
Q a = ----------------------------------------------------------------- --------------------------
- Equation 8.1 f
60CL 1.0 520 M
and
18.3 130 t 2 ZT
Q a = ---------------------------------- -------U c A Equation 8.1g
LC M
From the definition of Gi,
ZT Gi
------- = --------------------------------------------------
- Equation 8.1 h
M 73.4 1,200 t 2 LC
C-III [M-1002] 138 11/2014

M-1002 APPENDIX A
Substituting,
130 t 2
Q a = ------------------------------- G i U c A Reference Equation 7.2.2a
4 1,200 t 2
Table A.2 Common pressure relief valve settings

Start-to-Discharge Flow Rating Vapor-Tight (minimum)
psi (nominal) kPa psi kPa psi kPa
15 103 26 179 12 83
25 172 35 241 20 138
30 207 40 276 24 165
35 241 45 310 28 193
45 310 55 379 36 248
75 517 85 586 60 414
100 690 110 758 80 552
115 793 125 862 95 655
150 1034 165 1138 120 827
165 1138 182 1251 132 910
225 1551 247.5 1706 180 1241
247 1703 272 1873 198 1362
255 1758 280.5 1934 204 1407
280 1931 308 2124 224 1544
300 2068 330 2275 240 1655
330 2275 363 2503 264 1820
375 2586 412.5 2844 300 2068
350 3103 495 3413 360 2482
500 3447 550 3792 400 2758
Notes to Table A.2:
a. For range of allowable pressure relief valve settings, see 49 CFR 179.15.
b. For DOT 113 and AAR 204 cars (cryogenic), use Equation 7.2.1 and Equation 7.2.2.
c. For DOT 107 seamless steel tank cars and AAR 207 PD covered hopper cars, see specifications.
d. For 113C120 and 113D120 (cryogenic liquid) tank car specifications, alternative pressure relief
valve, if used in lieu of rupture disk, start-to-discharge 90 psi (621kPa), flow rating 100 psi (689kPa),
vapor tight 72 psi (496 kPa). See also 49 CFR 179.401.
11/2014 C-III [M-1002] 139

APPENDIX A M-1002
Table A.3 Common combination pressure relief device settings

Rupture Disc Pressure Relief Valve
Burst Start-to-Discharge Flow Rating Vapor-Tight (minimum)
psi (nominal) kPa psi kPa psi kPa psi kPa
35 241 31 214 45 310 25 171
75 517 70 483 85 586 56 386
100 690 93 641 110 758 74 513
150 1034 140 965 154 1062 112 772
165 1138 153 1055 168 1160 122 844
225 1551 210 1448 231 1593 168 1158
247 1703 231 1593 254 1752 185 1274
255 1758 238 1641 262 1805 190 1313
280 1931 261 1800 287 1980 209 1440
300 2069 280 1931 308 2124 224 1544
330 2275 310 2137 341 2351 248 1710
375 2586 351 2420 386 2662 281 1936
450 3103 422 2910 464 3201 338 2328
495 3413 465 3206 512 3527 372 2565
500 3447 470 3241 517 3565 376 2593
Notes to Table A.3:
a. For DOT 113 and AAR 204 cars (cryogenic), use Equation 7.2.1 and Equation 7.2.2.
b. For DOT 107 seamless steel tank cars and AAR 207 PD covered hopper cars, see specifications.
c. For 113C120 and 113D120 (cryogenic liquid) tank car specifications, alternative pressure relief valve, if used in lieu of
rupture disk, start-to-discharge 90 psi (621kPa), flow rating 100 psi (689kPa), vapor tight 72 psi (496 kPa). See also
49 CFR 179.401.
d. For range of allowable PRD settings, see 49 CFR 179.15.
Table A.4 Constant C vs. specific heat ratio k

k C k C k C
1.00 315a 1.26 343 1.52 366
1.02 318 1.28 345 1.54 368
1.04 320 1.30 347 1.56 369
1.06 322 1.32 349 1.58 371
1.08 324 1.34 351 1.60 372
1.10 327 1.36 352 1.62 374
1.12 329 1.38 354 1.64 376
1.14 331 1.40 356 1.66 377
1.16 333 1.42 358 1.68 379
1.18 335 1.44 359 1.70 380
1.20 337 1.46 361 2.00 400
1.22 339 1.48 363 2.20 412
1.24 341 1.50 364
a As k approaches 1.00, C approaches a limiting value of 315.
+ 1-
k-----------
Cp 2 k1
k = ------- ; C = 520 k ------------ When C is not shown, 315 is a safe value.
Cv k+1
C-III [M-1002] 140 11/2014

M-1002 APPENDIX A
Table A.5 Values of Gu and Gi for commodities

at commonly used flow rating pressures (page 1 of 4)
Start-to- Flow
Discharge Rating Gua Gia
Pressure Pressure
Conv. SI Conv. SI
Commodity psi kPa psia kPa units units units units
Acetic acid 75 517 85 586 42.9 0.1421 4.10 0.0007
Acetone 75 517 85 586 35.70 0.1183 3.91 0.0006
Acrylonitrile 75 517 85 586 33.12 0.1097 3.42 0.0005
Acrylonitrile 165 1138 181.5 1252 35.44 0.1170 3.40 0.0005
Ammonia, anhydrous 225 1551 247.5 1706 21.34 0.0707 2.678 0.0004
Ammonia, anhydrous 247.5 1706 270 1862 21.63 0.0716 2.693 0.0004
Ammonia, anhydrous 280.5 1934 306 2110 21.93 0.0726 2.726 0.0004
Ammonia, anhydrous 300 2068 330 2275 22.22 0.0736 2.749 0.0004
Ammonia, anhydrous 330 2275 360 2482 22.26 0.0737 2.754 0.0004
Argon, refrigerated liquidb 60 414 60 414 55.7 0.1845 9.5 0.0015
Benzene 75 517 85 586 40.80 0.1351 4.18 0.0007
Benzoic acid 75 517 85 586 38.01 0.1254 2.48 0.0004
Butadiene 75 517 85 586 39.73 0.1316 4.905 0.0008
Butadiene 225 1551 247.5 1706 49.89 0.1652 5.689 0.0009
Butadiene 247.5 1706 270 1862 51.33 0.1700 5.806 0.0009
Butadiene 255 1758 280.5 1934 52.02 0.1723 5.862 0.0009
Butadiene 280.5 1934 306 2110 53.72 0.1779 6.001 0.0010
Butadiene 300 2068 330 2275 55.37 0.1834 6.136 0.0010
Carbon dioxide 375 2586 412.5 2844 48.56 0.1608 6.621 0.0011
Carbon dioxide 450 3103 495 3413 52.53 0.1737 7.07 0.0011
Carbon disulfide 225 1551 247.5 1706 47.85 0.1579 4.74 0.0008
Chlorine 225 1551 247.5 1706 49.8 0.1649 6.12 0.0010
Chlorine 375 2586 412.5 2844 55.7 0.1845 6.56 0.0011
Chlorodifluoromethane (R22) 247.5 1706 270 1862 65.89 0.2183 8.22 0.0013
Chloroform 165 1138 181.5 1252 54.82 0.1809 5.53 0.0009
Cyclohexane 75 517 85 586 43.26 0.1433 4.41 0.0007
Decene (Decylene) 75 517 85 586 50.81 0.1683 4.03 0.0006
Dichlorodifluoromethane 225 1551 247.5 1706 77.10 0.2554 9.34 0.0015
Dichlorodifluoromethane 255 1758 280.5 1934 80.56 0.2668 9.66 0.0016
Dichlorodifluoromethane 300 2068 330 2275 85.75 0.2840 10.14 0.0016
Difluoroethane 225 1551 247.5 1706 53.16 0.1761 6.441 0.0010
Difluoroethane 300 2068 330 2275 60.66 0.2009 7.18 0.0012
Difluoromonochloroethane 75 517 85 586 53.66 0.1777 6.707 0.0011
Difluoromonochloroethane 225 1551 247.5 1706 66.19 0.2192 7.696 0.0012
Difluoromonochloroethane 300 2068 330 2275 73.41 0.2431 8.324 0.0013
Dimethylamine, anhydrous 225 1551 247.5 1706 42.77 0.1417 4.86 0.0008
Dimethylamine, anhydrous 247.5 1706 270 1862 44.08 0.1460 4.97 0.0008
11/2014 C-III [M-1002] 141

APPENDIX A M-1002

Start-to- Flow
Pressure Pressure
Conv. SI Conv. SI
Dimethylamine, anhydrous 280.5 1934 306 2110 46.08 0.1526 5.14 0.0008
Dimethylamine, anhydrous 300 2068 330 2275 47.71 0.1580 5.28 0.0009
Dimethylamine, anhydrous 330 2275 360 2482 49.78 0.1649 5.46 0.0009
Dimethyl ether 225 1551 247.5 1706 42.68 0.1414 5.161 0.0008
1-Dodecene 75 517 85 586 40.07 0.1322 2.80 0.0004
Dowtherm A 165 1138 181.5 1252 54.02 0.1789 2.60 0.0004
Ethyl acrylate 75 517 85 586 46.21 0.1531 4.56 0.0007
Ethyl alcohol 75 517 85 586 23.71 0.0785 2.54 0.0004
Ethylene oxide 75 517 85 586 31.54 0.1045 3.80 0.0006
Ethylene, refrigerated liquid 75 517 85 586 35.9 0.1189 5.30 0.0009
Ethylene, refrigerated liquid 90 621 100 689 36.7 0.1216 5.40 0.0009
Ethylene, refrigerated liquidb 120 827 120 827 37.7 0.1249 5.53 0.0009
Fertilizer ammoniating solution 75 517 85 586 9.54 0.0316 1.21 0.0002
Fertilizer ammoniating solution 225 1551 247.5 1706 10.79 0.0357 1.37 0.0002
Fertilizer ammoniating solution 375 2586 412.5 2844 11.88 0.0393 1.51 0.0002
Hydrogen, refrigerated liquid 30 207 40 276 44.4 0.1471 8.3 0.0013
Hydrogen, refrigerated liquidb 60 414 60 414 47.5 0.1573 9.0 0.0015
Hydrogen chloride 450 3103 495 3413 51.68 0.1712 6.87 0.0011
Liquefied petroleum gasc 75 517 85 586 40.85 0.1353 5.085 0.0008
Liquefied petroleum gasc 225 1551 247.5 1706 50.29 0.1666 6.260 0.0010
Liquefied petroleum gasc 247.5 1706 270 1862 51.42 0.1703 6.355 0.0010
Liquefied petroleum gasc 280.5 1934 306 2110 54.98 0.1821 6.733 0.0011
Methyl alcohol 75 517 85 586 20.84 0.0690 2.29 0.0004
Methyl chloride 225 1551 247.5 1706 42.78 0.1417 5.149 0.0008
Methyl mercaptan 225 1551 247.5 1706 37.99 0.1258 4.264 0.0007
Methyl methacrylate 75 517 85 586 48.52 0.1607 4.74 0.0008
Monochlorodifluoromethane 225 1551 247.5 1706 60.5 0.2004 7.6 0.0012
Monochlorodifluoromethane 300 2068 330 2275 66.3 0.2196 8.1 0.0013
Monoethanolamine 165 1138 181.5 1252 26.00 0.0858 2.03 0.0003
Monoethylamine (ethylamine) 247.5 1706 270 1862 39.65 0.1313 4.35 0.0007
Monoisopropanolamine 165 1138 181.5 1252 31.33 0.1034 2.54 0.0004
Monoisopropylamine 225 1551 247.5 1706 41.48 0.1369 4.39 0.0007
C-III [M-1002] 142 11/2014

M-1002 APPENDIX A

Start-to- Flow
Pressure Pressure
Conv. SI Conv. SI
Monoisopropylamine 280.5 1934 306 2110 47.60 0.1571 4.90 0.0008
Monomethylamine, anhydrous 225 1551 247.5 1706 31.47 0.1042 3.71 0.0006
Monomethylamine, anhydrous 247.5 1706 270 1862 32.25 0.1068 3.78 0.0006
Monomethylamine, anhydrous 280.5 1934 306 2110 33.30 0.1103 3.87 0.0006
Monomethylamine, anhydrous 300 2068 330 2275 34.12 0.1130 3.94 0.0006
Monomethylamine, anhydrous 330 2275 360 2482 35.11 0.1163 4.03 0.0007
Nitrogen fertilizer solution 75 517 85 586 9.54 0.0316 1.21 0.0002
Nitrogen fertilizer solution 225 1551 247.5 1706 10.79 0.0357 1.37 0.0002
Nitrogen fertilizer solution 375 2586 412.5 2844 11.88 0.0393 1.51 0.0002
Nitrogen, refrigerated liquidb 60 414 60 414 54.7 0.1812 9.4 0.0015
Nitrosyl chloride 225 1551 247.5 1706 56.99 0.1888 6.707 0.0011
Oxygen, refrigerated liquidb 60 414 60 414 50.6 0.1676 8.6 0.0014
Phenol solution 75 517 85 586 36.50 0.1209 2.95 0.0005
Phenol solution 165 1138 214.5 1479 43.02 0.1425 3.05 0.0005
Phosphorus trichloride 225 1551 247.5 1706 64.40 0.2133 6.10 0.0010
Styrene monomer 75 517 85 586 43.97 0.1456 3.78 0.0006
Sulfur dioxide 150 1034 165 1138 37.28 0.1235 4.54 0.0007
Sulfur dioxide 225 1551 247.5 1706 39.58 0.1311 4.69 0.0008
Sulfur dioxide 375 2586 412.5 2844 43.66 0.1446 4.97 0.0008
Tertiary butyl mercaptan 225 1551 247.5 1706 57.72 0.1912 5.42 0.0009
1,1,1,2-Tetrafluoroethane 300 2068 330 2275 77.69 0.2573 9.30 0.0015
Toluene Diisocyanate 375 2586 412.5 2844 45.79 0.1511 1.78 0.0003
Trichlorosilane 375 2586 412.5 2844 98.84 0.3274 9.67 0.0015
Trifluorochloroethylene 225 1551 247.5 1706 63.4 0.2100 8.2 0.0013
Trifluorochloroethylene 300 2068 330 2275 84.59 0.2802 10.00 0.0016
Trimethylamine, anhydrous 225 1551 247.5 1706 59.26 0.1963 6.66 0.0011
Trimethylamine, anhydrous 247.5 1706 270 1862 61.36 0.2032 6.84 0.0011
Trimethylamine, anhydrous 280.5 1934 306 2110 65.34 0.2164 7.20 0.0012
Trimethylamine, anhydrous 300 2068 330 2275 68.63 0.2273 7.50 0.0012
Trimethylamine, anhydrous 330 2275 360 2482 73.43 0.2432 7.94 0.0013
Vinyl chloride 150 1034 165 1138 42.45 0.1406 5.116 0.0008
Vinyl chloride 225 1551 247.5 1706 46.36 0.1535 5.404 0.0009
Vinyl chloride 247.5 1706 270 1862 47.43 0.1571 5.485 0.0009
Vinyl chloride 255 1758 280.5 1934 47.94 0.1588 5.524 0.0009
Vinyl chloride 280.5 1934 306 2110 49.18 0.1629 5.620 0.0009
11/2014 C-III [M-1002] 143

APPENDIX A M-1002

Start-to- Flow
Pressure Pressure
Conv. SI Conv. SI
Vinyl chloride 300 2068 330 2275 50.37 0.1668 5.712 0.0009
Vinyl fluoride 450 3103 495 3413 64.94 0.2151 8.336 0.0014
Vinyl methyl ether 75 517 85 586 38.64 0.1280 4.709 0.0008
Vinyl methyl ether 225 1551 247.5 1706 46.94 0.1555 5.301 0.0009
Notes to Table A.5:
a When lower flow rating pressures than those shown are used, the values of Gu and Gi are on
the safe side and may be used as shown or may be calculated using the prescribed formulas.
For higher flow rating pressures than shown, the values must be calculated. Wherever specific
Gi and Gu values are listed, they must be used to calculate flow rate requirements.
b Values are for sizing the rupture disc device flow capacity. For argon, nitrogen, and oxygen,
these values may also be used to calculate (conservatively) the flow capacities of pressure
relief valves.
c The same value must be used for liquid hydrocarbon gas.
C-III [M-1002] 144 11/2014

M-1002 APPENDIX B
APPENDIX B
CERTIFICATION OF TANK CAR FACILITIES
CONTENTS

1.0 Administrative Provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III146
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III146
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III146
1.3 Objective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III146
2.0 Certification Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III147
2.1 Tank Car Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III147
2.2 Material Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III148
2.3 Facility Minimum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III148
2.4 Quality Assurance Program Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III150
2.5 Car Builder Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III150
2.6 Minimum Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III150
2.7 Subcontract Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III151
3.0 Procedures for Certification Application and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III151
3.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III151
3.2 On-Site Inspection for Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III152
3.3 Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III152
3.4 Mobile Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III153
3.5 Maintaining Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III153
3.6 AAR M-1002 AND M-1003 Certification Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III154
3.7 Recertification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III154
3.8 Denial of Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III154
3.9 Revocation of Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III154
3.10 Facilitys Changes to Current Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
3.11 Right of Appeal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
3.12 Facilitys Withdrawing Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
3.13 Fees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
3.14 Certification Status Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
3.15 Facilities That Are Certified in Accord with Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III155
Exhibit B1 Subcontractor Evaluation Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III157
Exhibit B2 AAR Tank Car Facility Inspection and Evaluation Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III158
Exhibit B3 AAR Tank Car Facility Inspection and Evaluation Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III167
Exhibit B3A Certification Additional Information Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III170
11/2014 C-III [M-1002] 145

APPENDIX B M-1002
APPENDIX B
CERTIFICATION OF TANK CAR FACILITIES
1.0 ADMINISTRATIVE PROVISIONS
1.1 Introduction
This specification has been formulated by the Tank Car Committee of the Association of American
Railroads. Each tank car facility that performs tank car activities requiring certification to this
specification should note that there are other sections of the AAR Manual of Standards and
Recommended Practices (MSRP), the Field Manual of the AAR Interchange Rules, and the Office
Manual of the AAR Interchange Rules that contain additional requirements. S-2034 certification is
required for tank car facilities certified to manufacture and/or assemble tank cars. The MSRP
sections are outlined in the To The User and Preface section of this specification (Section C,
Part III, Specifications for Tank Cars, Manual of Standards and Recommended Practices (MSRP)
of the AAR, Specification M-1002).
1.2 Scope
Appendix B describes the process and procedures that tank car facilities must follow to obtain and
maintain certification from AAR. Appendix B outlines those activities performed by tank car
facilities that require tank car facility certification. Tank car activities performed by tank car
facilities must comply with all applicable AAR specifications and federal regulations. Appendices
referenced in this specification refer to those in M-1002 unless otherwise specified. Depending
upon the facilitys total scope of work, the facility may be subject to other AAR technical
certifications and/or QA commodity code requirements.
1.3 Objective
AAR M-1002 certification requires an evaluation of a tank car facilitys ability to meet the
requirements outlined in this appendix. The evaluation is followed by certification. Annual
evaluations are conducted to maintain the certification.
C-III [M-1002] 146 11/2014

M-1002 APPENDIX B
2.0 CERTIFICATION ELEMENTS

2.1 Tank Car Activities
2.1.1 Table B.1 lists those tank car activities that require certification in accord with the AAR
Manual of Standards and Recommended Practices, Section C, Part III (M-1002), Appendix B. The
activity code and tank car activity align with the commodity specified in the AAR Manual of
Standards and Recommended Practices, Section J (M-1003), Appendix A. Tank car activity codes
are not all inclusive, i.e., no single tank car activity code covers multiple tank car activities. For
example, A19 does not include B78, B81, B85, or any other activity code that may be associated
with the manufacturing of a tank car.
Table B.1 Tank car activities requiring certification
Activity Codes Tank Car Activity
A19 Manufacture of tank cars
B24 Repair of tank cars
B78 Assemble of tank cars
B79 Alteration of tank cars
B80 Conversion of tank cars
B81 Qualification of tank cars
B82 Manufacture of tank car tanks, including support structure, that are moved to and from the facility without
trucks (running gear)
B83 Repair tank car tanks that are moved to and from the facility without trucks (running gear)
B84 Qualification of tank car tanks that are moved to and from the facility without trucks (running gear)
B85 Manufacturer of pressure-retaining tank components that are moved to and from the facility without
trucks (running gear).
B86 Repair of pressure-retaining tank components that are moved to and from the facility without trucks
(running gear).
C4 Manufacture of tank car service equipment
C5 Recondition/repair and qualification of tank car service equipment
C6 Removal and replacement of tank car service equipment (including changing of gaskets)
C7 Removal of interior linings and coatings in tank cars
C8 Installation of interior linings and coatings in tank cars
C9 Qualification of interior linings and coatings in tank cars
C10 Repair of interior linings and coatings in tank cars
C11 Inspection of interior linings and coatings in tank cars
2.1.2 Regarding Activity Code C6, the following activities do not require certification; replacing
in-kind rupture disks, bottom outlet valve caps, nonpressure hinged manway gaskets and/or fill-
hole cover gaskets, bottom outlet valve cap gaskets, magnetic gauging device rods, O-rings in
gauging device caps, O-rings in thermometer well housing tubes, secondary closures, chains, and
flanges external to valves.
2.1.3 Regarding Activity Codes C7, C8, C9, C10, and C11, certification is required only when the
facility installs, inspects, qualifies, removes, and/or repairs interior linings and coatings in tank
cars that transport materials that are corrosive to the tank as defined in Appendix L,
paragraph 7.0, or that are reactive to the tank as defined in 49 CFR 180.503.
2.1.4 If a facility is certified to activity code C8 and/or C10, the facility would require activity
code C9.
11/2014 C-III [M-1002] 147

APPENDIX B M-1002
2.2 Material Groups

See Appendix M.
Table B.2 Material groups
Group Reference Material
Group 1 Appendix M, paragraph 3.1 Carbon steel plate
Appendix M, paragraph 3.6 Manganese-molybdenum steel plate
Appendix M, paragraph 3.7 Manganese-silicon steel plate
Group 2 Appendix M, paragraph 3.2 Aluminum alloy plate
Group 3 Appendix M, paragraph 3.3 High alloy steel plate (stainless steel)
Group 4 Appendix M, paragraph 3.4 Nickel plate
Group 5 Open
Group 6 Open
Group 7 Appendix M, paragraph 3.5 Nickel alloy steel plate
2.3 Facility Minimum Requirements

2.3.1 Certified facilities must be capable of performing, or arranging to have performed in accord
with this specification, all associated tank car activities incident to the activity code(s) for which
they are certified. Certified facilities must be in compliance with the AAR specifications, federal
regulations, and AAR interchange rules.
2.3.2 Each facility that is to perform welding on tank car tanks must be certified by the AAR
specifically for one or more of the material groups in Table B.2 by performance of the appropriate
welding procedure qualification tests in accord with Appendix W, and must weld only on tanks of
material groups for which the facility is certified. Welded repairs, alterations, or conversions must
be performed in accord with Appendix R.
2.3.3 For a facility to obtain certification for A19 and/or B82, the facility must demonstrate the
ability to manufacture a tank car tank.
2.3.4 For a facility to obtain certification for activity codes A19 and/or B24, the facility must also
obtain certification for activity code B81, and vice versa.
2.3.5 For a facility to obtain certification for activity code B82 and/or B83, the facility must also
obtain certification for activity code B84, and vice versa.
2.3.6 For a facility to obtain certification to activity codes B24 and/or B83, the facility must
demonstrate, at a minimum, repair level RL1 as described in paragraph 2.3.8 using a material
from a material group for which the facility seeks certification. The inspector will evaluate RL1
capability during an on-site inspection and during each annual evaluation. If the facility does not
maintain, at a minimum, repair level RL1, the facilitys certification to activity code(s) B24 and/or
B83 will be revoked; and the facility must reapply for certification for those activity codes.
2.3.7 For a facility to obtain certification to repair level RL2 to activity code(s) B24 and/or B83,
the facility must demonstrate as described in paragraph 2.3.9 using a material from a material
group(s) for which the facility seeks certification. The inspector will evaluate this capability during
an on-site inspection. The repair level capability will be evaluated during each annual evaluation.
C-III [M-1002] 148 11/2014

M-1002 APPENDIX B
2.3.8 Demonstration of repair level RL1 capability requires, at a minimum, a welder qualified by
the facility in accord with Appendix W using the facilitys qualified welding procedure
specifications (WPS) per Appendix W. This capability can be demonstrated by performing a
welded repair to a tank car tank or by a test plate. This welded repair must be witnessed during
the on-site inspection. If the demonstration is performed on a tank car tank, the qualified welder
must perform a welded repair in accord with Appendix R. If the demonstration is performed on a
test plate, it must be performed in accord with paragraph 2.3.10. The facility is required to
perform and document both nondestructive testing using NDT methods MT or PT and postweld
heat treatment as prescribed in Appendix R. During the on-site inspection, the inspector must
witness the NDT examination and verify the documentation; and at a minimum, witness only the
setup of postweld heat treatment.
2.3.9 Demonstration of repair level RL2 capability requires, at a minimum, a welder qualified by
the facility in accord with Appendix W using the facilitys qualified welding procedure
specifications (WPS) per Appendix W. This capability can be demonstrated by performing a defect
repair (insert or through shell/head crack) to a tank car tank or using a test plate. If the
demonstration is performed on a tank car tank, the qualified welder must perform the repair in
accord with Appendix R. If the demonstration is performed on a test plate, it must be performed in
accord with paragraph 2.3.11. During the on-site inspection, the inspector must witness the NDT
examination and verify the documentation; and at a minimum, witness only the setup of postweld
heat treatment.
2.3.10 In lieu of a tank car facility demonstrating repair level RL1 capability on a tank car, a
facility is permitted to use a test plate provided that the test plate material is from the listed
materials in the material group(s) identified in the application for certification. The test plate
must be the contour of a tank car tank and be a minimum size of 4 ft (1.2 m) in width and 4 ft
(1.2 m) in height. The qualified welder must perform a fillet weld that simulates a weld
attachment using a material from a material group for which the facility seeks certification. The
fillet weld size must be a minimum 5/16 in. (8 mm), and the length must be a minimum of 12 in.
(305 mm).
2.3.11 In lieu of a tank car facility demonstrating repair level RL2 capability on a tank car, a
facility is permitted to use a test plate provided that the test plate material is from the listed
materials in the material group(s) identified in the application for certification. The test plate
must be the contour of a tank car tank and be a minimum size of 4 ft (1.2 m) in width and 4 ft
(1.2 m) in height. The qualified welder must perform a double-weld butt joint on a tank shell insert
with 1 in. (25.4 mm) minimum corner radius. The insert must restore original contour. The
minimum size of the insert must be at least 1 ft2 (.092 m2) in size. The qualified welder must
demonstrate, at a minimum, horizontal position 2G and vertical position 3G butt welds.
Table B.3 Repair levels for activity codes B24 and/or B83
Repair Level Description
RL1 Demonstrate proficiency in performing welding to tank car tank material, NDT method MT or PT, and post-weld
heat treatment. This level excludes repairing a through-the-tank-car tank defect (insert or through-the-shell/
head crack). This demonstration must be performed on a tank car tank or test plate and must be performed
on a material from a material group for which the facility seeks certification.
RL2 Demonstrate proficiency in performing welding to tank car tank material, NDT, and post-weld heat treatment.
This level includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This
demonstration must be performed on a tank car tank or test plate and must be performed on a material from
a material group for which the facility seeks certification.
2.3.12 Tank car facility certification is not required for facilities that manufacture and/or repair
pressure-retaining tank component(s) on behalf of the certified tank car facilities as long as the
certified facility adheres to paragraph 2.3.15.
11/2014 C-III [M-1002] 149

APPENDIX B M-1002
2.3.13 Tank car facility certification is required for facilities that manufacture and/or repair
pressure-retaining tank component(s) to their own controlled designs and specifications.
2.3.14 Tank car facility certification is required for facilities that manufacture and/or repair
pressure-retaining tank component(s) to controlled designs and specifications of a non-certified
tank car facility.
2.3.15 Each certified tank car facility that authorizes work using services and/or equipment as
described in paragraph 2.7.1 requires an Exhibit B-1 and must verify that the work is in
compliance with all applicable specifications and regulations.
2.3.16 The facility must possess the latest published issues of MSRP M-1002 Specifications for
Tank Cars, Field Manual of the AAR Interchange Rules, and Office Manual of the AAR
Interchange Rules, and any other current applicable AAR publications covering tank car work it
certifies as meeting AAR requirements, including a current file of Safety and Operations
publications (Circular Letters). The facility must also have the applicable federal regulations. A
listing of current AAR publications is shown on the preface page of this manual. Information on
where to obtain AAR publications can be found in the Ordering Information section of M-1002 or
online at http://www.aarpublications.com.
2.4 Quality Assurance Program Certification
Each facility wishing to obtain certification by the AAR Tank Car Committee in accord with this
specification must also obtain certification in accord with the AAR Manual of Standards and
Recommended Practices, Section J, Specification for Quality Assurance (M-1003).
2.5 Car Builder Certification
Each facility wishing to obtain certification by the AAR Tank Car Committee in accord with this
specification for activity code A19 (manufacture of tank cars) and/or B78 (assemble tank cars)
must also obtain certification in accord with MSRP Section C, Standard S-2034, Car Builder
Certification.
2.6 Minimum Personnel Qualifications
2.6.1 Welders and Welding Operators
2.6.1.1 All personnel engaged in welding on tank car tanks must be performance-qualified in
accord with Appendix W. Welders certified per Appendix W shall be considered to meet the
requirements of AAR Manual of Standards and Recommended Practices, Section C Part II (M-
1001), paragraph 5.1.8.2.
2.6.1.2 All other welders at a certified facility must be qualified per AAR Manual of Standards
and Recommended Practices, Section C Part II (M-1001), paragraph 5.1.8.2.
2.6.2 Inspection PersonnelWelding, Nondestructive Testing, and Coating/Lining
Inspection
2.6.2.1 All certified facilities performing nondestructive testing or coating/lining inspection must
have available at least one person qualified and certified in the inspection method in accordance
with the companys written practice, as applicable per Appendix L or Appendix T.
2.6.2.2 Those facilities that do not employ personnel with the above qualifications must submit a
list of those companies they intend to use for those services by utilizing an Exhibit B-1. The
certified facility must verify in writing that these companies utilize personnel with the above
qualifications and that inspections will be made in accord with applicable requirements.
C-III [M-1002] 150 11/2014

M-1002 APPENDIX B
2.7 Subcontract Requirements

2.7.1 When a facility subcontracts any of the following services and/or equipment, the facility
must verify the service using an Exhibit B-1:
Interior coating / lining applicator and inspector per Appendix L
Welding inspector (AWS CWI), NDT technicians, NDT level III per Appendix T
PWHT per Appendix R and Appendix W
Hardness testing per Appendix W
Measuring and test equipment and welding machine calibration
Manufacture and/or repair of pressure-retaining tank components from a facility that is
not certified
Internal QA M-1003 audits performed by subcontractors
2.7.2 A company representative who is responsible for the activity must attest on the Exhibit B-1
form that the subcontractor uses the appropriate personnel, process, or equipment to meet the
requirements of the specification. Exhibit B-1 forms are valid for 1 year and must be renewed.
Each facility shall 1) ensure on a continuing basis that its subcontractors perform work in
accordance with the specification; and 2) renew the Exhibit B-1 form when a change to personnel,
process, or equipment invalidates the current Exhibit B-1 form.
2.7.3 For clarity, the following do not require an Exhibit B-1 form:
Tank interior cleaning services
Exterior paint application services
Head shield repairs (including inserts)
Jacket repairs
Purchase of new service equipment
Purchase and/or repair of parts common to all freight cars
An M-1002 certified tank car facility
3.0 PROCEDURES FOR CERTIFICATION APPLICATION AND MAINTENANCE
3.1 Application
3.1.1 The original and one copy of the application package, as defined per paragraph 3.1.2 of this
appendix, must be submitted when applying for initial certification and recertification to
425 Third Street SW, Suite 1000
Phone: 202-639-2262
3.1.2 The application package shall consist of the following:
Exhibit B-3
Exhibit B-3A (including additional documentation as directed within the B-3A)
Exhibit B-1 form(s), as applicable
Fee (refer to paragraph 3.13)
3.1.3 Upon receipt of the application package, the Executive DirectorTank Car Safety will
provide for review. The Executive Director or agent may request that the facility furnish additional
information.
3.1.4 If the applicant furnishes an incomplete application package or if not all required
information requested is provided, the Executive Director or agent will advise the applicant.
11/2014 C-III [M-1002] 151

APPENDIX B M-1002
3.1.5 Once the application package has been reviewed and it is deemed to consist of all required
information, the Executive Director or agent will appoint an individual or team representing the
Tank Car Committee to inspect the facility requesting certification. The on-site inspection for
initial certification as outlined in paragraph 3.2 of this appendix.
3.2 On-Site Inspection for Certification
3.2.1 An inspector (individual or team) assigned by the Executive Director representing the Tank
Car Committee will inspect the facility requesting certification.
3.2.2 The inspector will contact the facility and determine if the facility deems itself capable of
demonstrating the applicable proficiencies of those tank car activities outlined in the application.
If the facility is ready, an on-site inspection will be scheduled. If the facility is not ready, it must
advise the inspector when it is ready, at which time the on-site inspection will be scheduled.
3.2.3 The on-site inspection for certification will be performed during the same scheduled
timeframe as the required QA audit outlined in AAR Manual of Standards and Recommended
Practices, Section J, Quality Assurance Program Specification (M-1003).
3.2.4 The Exhibit B-2 will be used to document the on-site inspection and will indicate the results
of the on-site inspection.
3.2.5 Upon completion of the on-site inspection, the inspector will provide the completed Exhibit
B2 to the Executive Director.
3.3 Certification
3.3.1 Approval under this specification applies only to one facility. If a company desires that more
than one facility be approved, each facility must be approved independently.
3.3.2 Approval of a facility to any activity code(s) is based upon the Exhibit B2.
3.3.3 Upon receipt of the completed Exhibit B-2, the inspector will review, and if no deficiencies
were noted, the report will be provided to the Executive Director for final review prior to providing
the Exhibit B-2 to the Tank Car Committee for action.
3.3.4 Any deficiencies noted during the on-site inspection will be provided to the facility by the
inspector. The facility must provide a written response to the inspector within 10 business days
from the date of correspondence, with the corrective actions addressing the deficiencies. The
written response may be sent via email as an attachment.
3.3.5 In the event that the facility fails to respond within 10 business days from the date of
correspondence on the deficiencies to the inspector, the inspector will notify the Executive Director
or agent.
3.3.6 Upon acceptance of corrective actions by the inspector, the Exhibit B-2 will be forwarded to
the Executive Director or agent for final review prior to providing the Exhibit B-2 to the Tank Car
Committee for action.
3.3.7 Upon approval by the Tank Car Committee, the Executive Director will provide the facility
with the certification letter and the Exhibit B-2.
3.3.8 Certification to this specification is in effect for a period of 6 years, subject to an annual
evaluation.
C-III [M-1002] 152 11/2014

M-1002 APPENDIX B
3.4 Mobile Operations

3.4.1 Each certified facility may operate mobile units as necessary, but the mobile unit must
remain under the direction and control of the certified facility. Mobile units must be based and
operate from the certified facility. The mobile unit shall be permitted to perform all activities that
the certified facility is certified to perform, provided that the employees are identified and function
in accordance with the certified facilitys Quality Assurance Program. Mobile units are not
permitted to manufacture or assemble tank car tanks.
3.4.2 The mobile unit(s) must be physically present at the time of M-1003 QA audits and in-plant
inspections, and there must be objective evidence that the mobile unit is operating under the
certified facilitys M-1003 Quality Assurance Program.
3.4.3 If a mobile unit operates outside of paragraphs 3.4.1 and 3.4.2 of this appendix, it must
obtain independent certification.
3.5 Maintaining Certification
3.5.1 To maintain certification, annual evaluations are performed by an inspector (individual or
team assigned by the Tank Car Committee). The inspector will use the Exhibit B-2 during an
annual evaluation and will furnish the complete Exhibit B-2 to the Executive Director for review.
3.5.2 For a facility to maintain certification to activity code(s) B24 and/or B83, the facility must
demonstrate, at a minimum, repair level RL1 capability annually per paragraph 2.3.8.
3.5.3 For a facility to maintain certification to repair level RL2 for activity code(s) B24 and/or
B83, the facility must provide objective evidence that an RL2 repair has been performed at least
once within the first 3 years of certification and again at least once between year 3 and
recertification. If an RL2 repair is not performed on a tank car tank within these intervals, then
the facility, at a minimum, must perform an RL2 repair (either on a tank car tank or test plate) for
evaluation during the year 3 annual on-site inspection and again for recertification.
3.5.4 Any deficiencies noted during the annual evaluation by the inspector will be provided to the
facility. The facility must provide a written response to the inspector within 10 business days, from
the date of correspondence, with the corrective actions addressing the deficiencies. Once the
inspector has completed the Exhibit B-2, it will be provided to the Executive Director for final
review and handling.
3.5.5 In the event that the facility fails to respond within 10 business days from the date of
correspondence on the deficiencies to the inspector, the inspector will notify the Executive Director
or agent.
3.5.6 Upon receipt of the completed Exhibit B-2, the Executive Director will review and if no
deficiencies are noted, the facility will maintain its certification and be provided a letter and the
Exhibit B-2.
3.5.7 The annual evaluation will be performed during the same scheduled timeframe as the
required QA audit outlined in AAR Manual of Standards and Recommended Practices, Section J,
Quality Assurance Program Specification (M-1003).
3.5.8 The Committee reserves the right to inspect certified facilities at any time to ensure
maintenance of certification standards. This right also includes unannounced on-site inspections;
the inspectors will furnish reports of any deficiencies in writing to the Tank Car Committee.
3.5.9 Car owners and certified facilities have the right and responsibility to report improper
repairs to the Executive Director for review by the Tank Car Committee. The Executive Director
may authorize an unannounced on-site inspection of a facility and may request copies of repair
records on subject cars from the involved parties.
11/2014 C-III [M-1002] 153

APPENDIX B M-1002
3.6 AAR M-1002 AND M-1003 Certification Cycle

Each tank car facility (M-1002) certification is in effect for a period of 6 years subject to annual
evaluations. Each Quality Assurance Program (M-1003) certification is in effect for a period of
3 years subject to annual compliance audits. Both M-1002 on-site inspections/evaluations and
M-1003 audits will be performed during the same scheduled timeframe with one another for all
tank car activities requiring certification. Table B.4 provides the M-1002 certification and M-1003
certification cycle alignment.
Table B.4 Alignment of M-1002 and M-1003 certification for all tank car activity codes
Year M-1002 Certification M-1003 Certification
1 Initial Certification Initial Certification
2 Annual Evaluation Compliance Audit
4 Annual Evaluation Recertification
7 Recertification Recertification
3.7 Recertification
3.7.1 Recertification follows the same process as initial certification. Refer to paragraph 3.0 of
this appendix.
3.7.2 Each M-1002-certified facility must be recertified at intervals of 6 years from the original
certification date.
3.7.3 It is the responsibility of the facility to initiate the recertification proceedings 6 months
prior to the expiration date of the current certification.
3.7.4 Recertification is not automatic and can be denied if the tank car facility no longer complies
with AAR Manual of Standards and Recommended Practices, Section C Part III, Specification of
Tank Cars (M-1002) and federal regulations.
3.8 Denial of Certification
In the event the Tank Car Committee finds that the applicants facility is not suitable for
certification, the applicant may request that an additional on-site inspection be performed at the
facility. The applicant must bear all expenses of this additional on-site inspection. If the results of
the additional on-site inspection are not suitable for certification, the matter may be appealed to
the Association of American Railroads Assistant Vice President, Environment and Hazardous
Materials.
3.9 Revocation of Certification
3.9.1 Facility certification will be revoked if the facility fails to maintain AAR M-1003 Quality
Assurance certification.
3.9.2 A facility may have certification revoked by formal action of the Tank Car Committee for
documented evidence of failure to meet the requirements of M-1002. In such cases, the facility
management must prove that sufficient corrective remedies and quality assurance measures have
been implemented before any written reapplication is eligible for approval. This must be verified
by an on-site inspection by an inspector (individual or team assigned by the Tank Car Committee).
Reapplication must be in accord with specified procedures for an original application.
C-III [M-1002] 154 11/2014

M-1002 APPENDIX B
3.10 Facilitys Changes to Current Certification

3.10.1 Any of the following changes to a facilitys current certification requires written
notification, prior to making the change(s), to the Executive Director using the Exhibit B-3 form: a
change in location, a request to change the station stencil, the addition or removal of activity
codes, the addition or removal of a material group, or the change in repair level capability.
Depending upon the scope of the facilitys change request, the facility may be subject to an
inspection to validate the change request.
3.10.2 It is the responsibility of the new owner to notify the Executive Director within 30 days of
the change in ownership. This notification will initiate the Tank Car Committee consideration of
the transfer of approval.
3.11 Right of Appeal
At all times, the applicant will have the right to appeal or make further submissions until such
time as all issues have been resolved for granting the certification by the Committee. Appeals shall
be made to the Association of American Railroads Assistant Vice President, Environment and
Hazardous Materials. Such appeal may be accompanied by any comments, explanations, or
evidence in support of such appeal that the applicant desires to submit.
3.12 Facilitys Withdrawing Certification
In the event that a facility ceases tank car activities requiring certification in accord with this
specification for a period exceeding 6 months, the facility must provide written notification to the
Executive Director. Written notification must be on company letterhead and include, at a
minimum, the facility name, location, and station stencil.
3.13 Fees
3.13.1 An application package for initial certification and recertification must be accompanied by
an initial payment that applies toward technical review and administrative expenses, payable to
the Association of American Railroads.
3.13.2 Upon completion of the on-site inspection, an invoice will be issued for the current facility
inspection fee and any expenses incurred.
3.13.3 The tank car service fees are listed in the Office Manual of the AAR Interchange Rules,
Appendix E.
3.14 Certification Status Report
AAR will periodically publish listings of certified facilities. The listing will include the following:
Company name, facility location, station stencil, facility activity code(s), material group(s), repair
level (if applicable), and expiration date of certification.)
3.15 Facilities That Are Certified in Accord with Appendix B
3.15.1 Facilities that are certified to perform work in accord with this specification are published
periodically as described in paragraph 3.14. Prior to authorizing any tank car activities requiring
certification that is not listed, contact the Executive Director to determine if appropriate
certification of the facility will be in effect at the time of the performance of the work.
425 Third Street SW, Suite 1000
Phone: 202-639-2262
Fax: 202-639-2930
E-mail: kdorsey@aar.org
11/2014 C-III [M-1002] 155

APPENDIX B M-1002
3.15.2 In lieu of physically mailing and/or faxing written notification to the Executive Director,
the written notification can be in electronic format (i.e., MS Word or PDF file) and sent via email to
the Executive Director.
3.15.3 Exhibits
Exhibit B1 Subcontractor Evaluation Sheet
Exhibit B2 AAR Tank Car Facility Inspection and Evaluation Form
Exhibit B3 Application for Tank Car Facility Technical Certification and Change
Notification Form
Exhibit B3A Certification Additional Information Form
C-III [M-1002] 156 11/2014

M-1002 APPENDIX B
EXHIBIT B1
SUBCONTRACTOR EVALUATION SHEET

Each facility shall complete and retain a copy of this form for each subcontractor required by Appendix B. A company
representative responsible for the activity shall attest that the subcontractor uses appropriate equipment, procedures, and
personnel to meet the requirements of this specification. This form expires one year after the date verified below.
Part 1: Subcontractor
1 Company Name
2 Address 3 City
4 State/Province 5 Zip/Postal Code 6 Country
Part 2: Primary Subcontractor Contact
7 Name 8 Title
9 Office Phone 10 Cell Phone 11 Fax
12 Email Address
Part 3: Subcontractor Activity
13 Select the applicable activities provided to the Certified Facility :
Personnel Process Equipment Service Product
For each activity identified above, explain how the company representative responsible for that activity verifies that the
subcontractor understands and conforms to the requirements of the Association of American Railroads Manual of
Standards and Recommended Practices, Section C Part III, Specification for Tank Cars (M-1002).
14 Personnel
15 Processes
16 Equipment
17 Service
18 Product
Part 4: Company Representative
19 Company Name
20 Name 21 Title
25 Address 26 City
30 Signature (Attesting)
31 Date Verified [MM/DD/YYYY] 32 Date of Expiration [MM/DD/YYYY]
Save Print Reset
AAR Manual of Standards and Recommended Practices M-1002

Page 1 of 1
Exhibit B1 (Rev. January 2014)
11/2014 C-III [M-1002] 157

APPENDIX B M-1002
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C-III [M-1002] 166 11/2014

M-1002 APPENDIX B
EXHIBIT B3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
This form is both the application for AAR Technical Certification for a single tank car facility and used as change
notification as required by paragraph 3.10. This application must be accompanied by an initial payment as required by
paragraph 3.13. This form is part of the application package (see paragraph 3.1.2), which must be submitted to

425 Third Street, SW Suite 1000
Part 1: General Application Information
1 Application for Initial Certification Inspection Recertification Inspection Change Notification
2 Application Date [MM/DD/YYYY]
3 Do you have a valid M-1003 Quality Assurance Program Certification? Yes No

If No, the facility must apply for M-1003 QAP certification. (NOTE: In addition to technical certification, QA
certification is required in order to perform any tank car activity listed in Part 4 of this application and in Appendix B
Table B.2.)
4 Applicable to facilities requesting certification for manufacturing (A19) and/or assembling (B78) tank cars: Do you
have a valid S-2034 Car Builder Certification? Yes No
If No, the facility must apply for S-2034 Car Builder Certification.
5 If you are an existing AAR Registered Tank Car Facility, provide the following:
What is your Station Stencil?
Do you prefer to keep the same Station Stencil? Yes No
Part 2: Tank Car Facility Information
6 Station Stencil (Assigned by AAR; however Station Stencil request can be made in field 36 Comments)
7 Company Name
8 Address 9 City
10 State/Province 11 ZIP/Postal Code 12 Country

Part 3: Primary Contact at Facility
13 Name 14 Title
18 Email Address
Part 4: Applicant
19 Is the applicant the contact identified in Part 3 and located as identified in Part 2?
Yes (if so, skip this part) No
20 Company Name
21 Name 22 Title
23 Address 24 City
31 Email Address
Part 5: Recipient of Certification from AAR
32 Select the Recipient (NOTE: This facility must have the ability to produce the certification letter upon request.)
Applicant (Part 4) Primary Contact (Part 3)
AAR Manual of Standards and Recommended Practices M-1002 Page 1 of 3

Exhibit B3 (Rev. March 2014)
11/2014 C-III [M-1002] 167

APPENDIX B M-1002
EXHIBIT B3
Part 6: Facility Certification Information
NOTE: Certified facility must be capable of performing, or arrange to have performed, all associated tank car activities for
which the facility is certified.
33 Select activity codes that apply:
A19 Manufacturer of tank cars
B82 Manufacture of tank car tanks, including support structure, that are moved to and from the facility without trucks
(running gear)
B85 Manufacturer of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
B86 Repair of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
C4 Manufacturer of tank car service equipment
C5 Reconditioner/repair and qualification of tank car service equipment
34 Select each applicable material group (1, 2, 3, 4, 7) or N/A:

MG 1 TC-128 Included MG 2 MG 3 MG 4 MG 7(s) N/A
35 Select a repair level capability if applying for B24 and/or B83:
RL1Demonstrate proficiency in performing welding to tank car tank material, NDT method MT or PT, and postweld heat
treatment. This level excludes repairing a through-the-tank-car tank defect ( insert or through-the-shell/head crack). This
demonstration must be performed on a tank car tank or test plate and must be performed on a material from a material group for
which the facility seeks certification.
RL2Demonstrate proficiency in performing welding to tank car tank material, NDT, and postweld heat treatment. This level
includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This demonstration must be
performed on a tank car tank or test plate and must be performed on a material from a material group for which the facility
seeks certification.
Part 7: Fee Information

36 Is the initial payment, as required by paragraph 3.13 of Appendix B, attached? Yes
(NOTE: AAR will not process application without initial payment)

C-III [M-1002] 168 11/2014

M-1002 APPENDIX B
EXHIBIT B3
37 Comments
This is to attest that the information provided in this application meets all requirements of M-1002, Appendix B, and that
all information required by M-1002, Appendix B, Form B-3A, has been included.
38 Applicants Name 39 Applicants Signature
40 Company 41 Signature Date [MM/DD/YYYY]
42 Title
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11/2014 C-III [M-1002] 169

APPENDIX B M-1002
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C-III [M-1002] 170 11/2014

M-1002 APPENDIX B
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11/2014 C-III [M-1002] 171

APPENDIX B M-1002
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C-III [M-1002] 172 11/2014

M-1002 APPENDIX B
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11/2014 C-III [M-1002] 173

APPENDIX B M-1002
C-III [M-1002] 174 11/2014

M-1002 APPENDIX C
APPENDIX C
MARKING OF TANK CARS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III176
2.0 Stenciling of Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III176
2.1 New Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III176
2.2 Repainted Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III176
2.3 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III176
3.0 Tank Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III181
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III181
3.2 Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III182
4.0 Placard Holder or Permanent Placards (Decal or Stencil). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III182
4.1 When Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III182
4.2 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III182
5.0 AAR Commodity Marking Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III183
5.1 Tank Cars without Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III183
6.0 Load Limit Stencil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III183
7.0 Bolted and Hinged Manway Style Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III183
8.0 Retroreflective Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III184
8.1 Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III184
8.2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III184
8.3 Retroreflective Surface Area per Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III184
8.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III185
11/2014 C-III [M-1002] 175

APPENDIX C M-1002
APPENDIX C
MARKING OF TANK CARS
1.0 INTRODUCTION
1.1 Scope
This appendix describes AAR requirements for marking of tank cars, including stenciling and
stamping. It supplements the general requirements of the Manual of Standards and
Recommended Practices, Section L, Standard S-910.
2.0 STENCILING OF TANK CARS
2.1 New Tank Cars
New tanks and new car structures, or new tanks for existing cars, must be stenciled as required by
the applicable specification and the following notes. All required markings for tank cars must be in
English (required information also may be displayed in a second language). The stenciling is
shown in Fig. C.2 and Fig. C.3. When stenciling is prescribed on tank and tank is insulated, the
stencils must be applied on the jacket.
2.2 Repainted Tank Cars
When existing cars are repainted and restenciled, all required markings for tank cars must be in
English (required information also may be displayed in a second language) and stenciling must
comply with the following notes:
2.3 Notes
See Fig. C.2 and Fig. C.3.
2.3.1 Tanks
2.3.1.1 Initials and number of DOT, TC, or AAR specifications applicable to the tank cars
operating specification must be stenciled on both sides of the tank in letters and numerals at least
1 1/2 in. (38.1 mm) high.
2.3.1.2 Water capacity in U.S. gallons and liters must be stenciled on tank cars as follows:
Pressure and nonpressure tank cars: shell-full volume on both heads of the tank or the
jacket.
Compartment tank cars: shell-full volume of each compartment, on both sides of the
tank or jacket, near manway. The capacity of each compartment may also be stenciled on
the heads of the tank or the jacket. Compartments must be identified numerically,
beginning with the B-end compartment as No. 1 and numbering consecutively toward the
A-end. The compartment identification stencil must be located immediately below the
capacity stencil for each compartment, be of the same size, and consist of the number only.
2.3.1.3 When tanks are designed and are authorized for transportation of a particular commodity
only, (NAME OF COMMODITY), or such other wording as may be required to indicate the limits
of usage of the car, must be marked in letters at least 1 in. (25.4 mm) high on each side of the tank.
For those commodities listed in DOT 172.330, the name of the commodity must be marked on each
side of the tank in letters at least 3.9 in. (100 mm) high and at least 0.24 in. (6.0 mm) wide.
2.3.1.4 When tanks are converted from one class to another or when a conversion results in a
change in tank qualification interval, the date of conversion must be stenciled below the tank built
date.
2.3.1.5 When exterior thermal coatings are applied, see Field Manual of the AAR Interchange
Rules, Rule 80.E.1 for marking requirements.
2.3.1.6 A qualification stencil is to be applied at the time that the tank is qualified.
C-III [M-1002] 176 11/2014

M-1002 APPENDIX C
2.3.1.7 Tanks made of clad plates must have stenciled on the tank (MATERIAL) CLAD TANK.
These marks must be in letters at least 1 1/2 in. (38.1 mm) high and placed immediately below the
car specification stencil.
2.3.1.8 DOT-112S and 114S cars in anhydrous ammonia service must be painted or cleaned every
5 years to functionally restore the original white appearance. Year painted or cleaned must be
stenciled on the car.
2.3.1.9 When cars are equipped with exterior heater coils with inlet or outlet pipe caps removed,
they must be stenciled EXTERIOR HEATER PIPES-NO INLET OR OUTLET PIPE CAPS
REQUIRED in letters at least 1 in. (25.4 mm) high.
2.3.1.10 Stub sill, nonpressure, nonexterior-coiled tank cars built prior to July 1, 1974, that
qualify for defect card protection under Field Manual of the AAR Interchange Rules, Rule 95 must
be stenciled AAR CERTIFIED SS NUMBER XX in 1 1/2 in. (38.1 mm) letters below the light
weight stencil on each side of the tank. Certified status number is as assigned by the Equipment
Engineering Committee.
2.3.1.11 If the load limit is restricted or reduced for any reason, a 3 in. (76.2 mm) star symbol
must be added immediately to the left of the load limit stencil. See Field Manual of the AAR
Interchange Rules, Rule 70.
2.3.1.12 Stencil carbon dioxide (CO2) tank cars with the stencils specified in Chapter 2,
paragraph 2.1.1.
2.3.1.13 If the commodity is designated a poison-inhalation hazard, the sides of the tank car tank
or jacket must be stenciled INHALATION HAZARD in 3.9 in. (100 mm) minimum letters near
the commodity stencil location.
2.3.1.14 Tank cars with interior lining or coating are to be marked per paragraph 2.3.3.3 below.
2.3.2 Running Gear
2.3.2.1 On cars equipped with center sills, reporting marks must be stenciled on the underframe,
center sills or side sills, and both truck bolsters. On stub sill cars, reporting marks must be
stenciled on both truck bolsters.
2.3.2.2 The consolidated stencil for lubrication and air brakes is to be applied in accord with Field
Manual of the AAR Interchange Rules, Rule 80.
2.3.2.3 When the owner desires cars to be marked to provide information with respect to
couplers, brake beams, wheels, raised wheel seat axles, heater systems, or volume of the tank,
such marks must be stenciled on the heads of the tank in letters at least 1 1/2 in. (38.1 mm) high.
For long travel springs, see Field Manual of the AAR Interchange Rules, Rule 50. For
abbreviations, see paragraph 2.3.4.7 below.
2.3.2.4 The brake lever diagram metal badge plate must be located as shown in Figs. C.2 and C.3.
See Field Manual of the AAR Interchange Rules, Rule 88.
2.3.2.5 When tank cars have been inspected in accord with Field Manual of the AAR Interchange
Rules, Rule 88B.2, they must be stenciled in accord with paragraph 2.3.3.4 below.
2.3.2.6 Tank cars equipped with high-friction brake shoes must be stenciled 00 INCH HF COMP
SHOES in letters at least 1 1/2 in. (38.1 mm) high on the side sill at each corner of the car.
11/2014 C-III [M-1002] 177

APPENDIX C M-1002
2.3.3 Inspection and Test

2.3.3.1 Tank Qualification
2.3.3.1.1 The year in which a tank is qualified and the qualification due date must be applied
and/or maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9) in
letters and numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.1.2 For tank cars with an interior lining/coating (acting as a barrier between the base metal
of the tank car tank and the commodity, including for product purity purposes), a tank thickness
test is required at the time of application and removal/replacement of the interior lining/coating.
The year in which a tank thickness test is performed, the due date, and a station stencil must be
applied and/or maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9)
in letters and numerals at least 1 in. (25.4 mm) high. For tank cars with an interior coating/lining
program, it is allowed to enter LNG RMVL under the column DUE to denote that the thickness
test is required at the time of coating or lining removal/replacement.
2.3.3.2 Service Equipment Qualification
2.3.3.2.1 The year in which the service equipment (except items covered in paragraphs 2.3.3.2.2,
2.3.3.2.3, and 2.3.3.2.4 below) is qualified and the qualification due date must be applied and/or
maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9) in letters and
numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.2.2 The type of pressure relief device must be applied and/or maintained in the location
specified on the qualification stencil (Fig. C.5 or Fig. C.9) in letters and numerals at least 1 in.
(25.4 mm) high. For tank cars not equipped with a pressure relief device (total containment), the
identification stencil should read NONE. The identification stencil for a valve-disc combination
device should read COMB PRD on cars so equipped. A station stencil is required.
2.3.3.2.2.1 The start-to-discharge pressure of a reclosing pressure relief device or the burst
pressure of a rupture disk or breaking pin must be applied and/or maintained in the location
specified on the qualification stencil (Fig. C.5 or Fig. C.9) in letters and numerals at least 1 in.
(25.4 mm) high. When a rupture disk or breaking pin device is used in combination with a relief
valve, the start-to-discharge pressure to be stenciled is that of the rupture disk (or breaking pin
device).
2.3.3.2.2.2 The year in which a reclosing pressure relief device is qualified and the qualification
due date must be applied and/or maintained in the location specified on the qualification stencil
(Fig. C.5 or Fig. C.9) in letters and numbers at least 1 in. (25.4 mm high). Station stencil of facility
applying the device is required.
2.3.3.2.3 Tank cars with interior heater systems must have the stencil INT HTRS applied
letters at least 1 in. (25.4 mm) high.
2.3.3.2.3.1 The year in which the interior heater system is qualified and the qualification due
date must be applied and/or maintained in the location specified on the qualification stencil
(Fig. C.5 or Fig. C.9) in letters and numerals at least 1 in. (25.4 mm) high. A station stencil is
required.
2.3.3.2.3.2 Exterior heater systems do not require requalification.
2.3.3.2.4 Tank cars with a sparger system must have the stencil SPGR applied and/or
maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9) in letters at
least 1 in. (25.4 mm) high.
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M-1002 APPENDIX C
2.3.3.2.5 When service equipment qualification occurs at more than one facility, the station
stencil block shall show the station stencil for the facility that finalizes the qualification. For
example, if the excess flow valves and eduction pipes are qualified at one facility, and then the
liquid and vapor valves are qualified later at another facility, then the station stencil of the latter
facility shall appear in the station stencil block.
2.3.3.2.6 Valves and fittings may be replaced in kind on tank cars without changing the
qualification dates marked on the tank when performed by a certified facility. The facility
replacing the valve or fitting shall maintain records of the valve or fitting replacement throughout
the qualification interval.
2.3.3.2.7 When installing a valve or fitting on a tank car, including new cars, existing cars, and at
the time of qualification, the facility installing the valve or fitting must follow the requirements of
Appendix A, paragraph 3.3.8.5.
2.3.3.3 Coating/Lining Qualification
2.3.3.3.1 Lining applicator, type of lining, and year applied shall be marked on the tank (or
jacket) in the general area of the consolidated stencil in letters and numerals at least 1 in.
(25.4 mm) high. For linings used for product purity only, enter PP and NONE for the
qualification and due dates on the qualification stencil. A station stencil is required.
2.3.3.3.2 The year in which the coating or lining is inspected and the inspection due date must be
in letters and numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.4 88.B.2 Inspection
The year in which a Rule 88.B.2 inspection is performed and the inspection due date must be
in numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.5 Stub Sill Inspection
The year in which a stub sill inspection is performed and the inspection due date must be applied
numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.4 General
2.3.4.1 The location, sizes, and spacing of letters and numerals must be as shown in Figs. C.2 and C.3.
2.3.4.2 The reporting mark assigned by the AAR must be stenciled as shown on car sides and
ends. The reporting mark and number may be stenciled on top of the car on or near the
longitudinal center line at the B-end, reading from B-end to A-end. If so stenciled, the size and
spacing must be the same as on the side of the tank or jacket.
2.3.4.3 Arrangement of the reporting mark, load limit, and light weight must be as shown, except
that the entire arrangement may be moved, if necessary, to suit the construction of the car. For
example, the light weight stencil may be applied on the same line as the load limit stencil.
2.3.4.4 When a tank car has a consolidated stencil applied, the date built new (month and year) is
not required to be stenciled on the right side of the tank as shown in Fig. C.2 and Fig. C.3. See
Field Manual of the AAR Interchange Rules, Rule 80. The date converted or rebuilt (month and
year), if applicable, must be stenciled as shown. For separate built dates for car structure and
tank, see Field Manual of the AAR Interchange Rules, Rule 88B.1.d.
2.3.4.5 The sum of the load limit and the car light weight must not exceed the rail load limit,
based on axle capacity.
11/2014 C-III [M-1002] 179

APPENDIX C M-1002
2.3.4.6 All cars having dimensions exceeding Plate B in MSRP Section C, Standard S-2026, must
have the appropriate stencil shown in the AAR Manual of Standards and Recommended Practices,
Section L, Standard S-913, applied directly to the right of the reporting marks.
2.3.4.7 The following optional abbreviations may be used for tank car stenciling. Abbreviations
should not be used when the meaning would be made unclear or awkward. They should be used
when stenciling information referenced in paragraph 2.3.2.3 above; for example, No. 18 BR BM
for Number 18 brake beam.
Table C.1 Optional abbreviations for tank car stenciling
Abbreviation Definition Abbreviation Definition Abbreviation Definition
BM Beam FRA AIP FRA Alternative PP Product purity
BOT Bottom Inspection and Test PRD Pressure relief device
BR Brake Procedure PSI Pounds per square
BLT Built GAL Gallons inch
CAPY Capacity GR Gear PVC Polyvinyl Chloride
COMB PRD Combination pressure HF High friction RSD Raised
relief device HTR Heater RPKD Repacked
COMP Composition IDT In Date Test REQ Required
CONT Controls INT Interior SPGR Sparger
CONV Converted KG Kilograms SPRG Spring
CPL Coupler L Liters SP Special Permit
CTC Canadian Transport LB Pounds SR Safety PermitRail
Commission LNG RMVL Lining removal ST Service Trial
CUFT Cubic Feet LT Light STL Steel
DOT Department of LMT Limit STNLS Stainless
Transportation LD Load TC Transport Canada
DFT Draft LUB Lubricated THERMO Thermometer
E Exemption MAG Magnetic W Wear, Wrought
ELEC Electric MO Month WT Weight
EXS Extended service NO Number WHLS Wheels
EXT Exterior OPR Operated
2.3.4.8 Unless otherwise specified in a special permit, competent authority, approval, or AAR
service trial, the special permit, competent authority, approval, or AAR service trial number must
be marked as shown in Fig. C.2 or Fig. C.3. When a Federal Railroad Administration-approved
alternative inspection program authorizes an extended interval, the letters FRA AIP must
appear as shown in Fig. C.2 or Fig. C.3. The marking must have a width of at least 0.24 in.
(6.0 mm) and a height of at least 3.9 in. (100 mm).
2.3.4.9 If operation of the tank car is restricted for any reason under 49 CFR 215.203(a), the
symbol -R, of the same size as the reporting mark, must be stenciled immediately thereafter,
followed by a term or terms identifying the restriction in letters at least 1 in. (25.4 mm) high. See
also 49 CFR 215.303.
2.3.4.10 If desired by car owner or lessee, a stencil indicating LEASED TOCOMPANY may be
placed on both sides of the tank or jacket, near the ladder or near the bottom outlet, in letters at
least 1 in. (25.4 mm) high.
C-III [M-1002] 180 11/2014

M-1002 APPENDIX C
2.3.4.11 Special instructions related to tank cleaning, special fittings, or other items affecting the
use and service of the tank car (e.g., emergency numbers, trust agreements, restrictions on air
pressure used) may be marked, at the owners option, on both sides near the center of the tank,
near the bottom outlet, or on or near the manway. Additional information may be added to the
qualification stencil at the owners or shippers option.
2.3.4.12 For dual (conventional and metric) stenciling, required on new and repainted tank cars
after January 1, 1982, see the AAR Manual of Standards and Recommended Practices, Section L,
Standard S-914.
2.3.4.13 Whenever a year is required to be marked on a tank, it must be marked using four
characters (e.g., 2003). Whenever the month and year are required to be marked on a tank, they
must be marked using six characters (e.g., 01 2003).
2.3.4.14 When a tank car is approved for extended service status, the tank car must be marked
EXS after the reporting mark and number (e.g., ABCX 0000 EXS) on both sides.
3.0 TANK IDENTIFICATION PLATES
3.1 General
3.1.1 After July 25, 2012, to certify compliance with federal requirements, the tank manufacturer
must install two identical permanent identification plates in accord with 49 CFR 179.24.
3.1.2 Plates are to be unpainted and of a size suitable to contain the following items of text.
Letters must be a minimum of 3/16 in. high and be clearly stamped, etched, or embossed on the
plates.
Carbuilders Name Full name of the carbuilder as shown on the Certificate of

Construction
Builders Serial Number Builders serial number for the specific car
Certificate of Construction/ Number of the AAR Certificate of Construction under which
Exemption the car was built or exemption number if constructed under an
exemption
Tank Specification Constructed tank specification from line 7 of the Certificate of
Construction
Tank Shell Material/Head Material ASTM or AAR specification of the material used to construct
the tank shell and heads. In the case of Class DOT-113W, DOT-
115W, AAR-204W, and AAR-206W cars, the materials used to
construct the outer tank will be listed. In the case of aluminum
tanks, only the alloy (e.g., 5154) need be listed. In the case of
stainless steel tanks, only the type (e.g., 304L or 316L) need be
listed. Normalized steel material may be identified with
NORM or N following the material specification.
Insulation Materials Generic names of thermal protection and insulation materials
Insulation Thickness Thermal protection and insulation thicknesses in inches
Underframe/Stub Sill Type Stub sill type designation used in the SS-3 inspection database
Date Built Month and year of construction. If the underframe has a
different built date than the tank built date, both dates must
be shown.
11/2014 C-III [M-1002] 181

APPENDIX C M-1002
3.1.3 See Fig. C.1 for an example of the marking on an identification plate.
CARBUILDERS NAME: KEN DORSEY TANK CAR COMPANY
BUILDERS SERIAL NUMBER: 0000-00-001
CERTIFICATE OF CONSTRUCTION/EXEMPTION: A049006/E-13195
TANK SPECIFICATION: DOT-111A100W1
TANK SHELL MATERIAL/HEAD MATERIAL; TC128B/A516
INSULATION MATERIALS; CERAMIC FIBER/FIBERGLASS
INSULATION THICKNESS: 0.5 IN./3.5 IN.
UNDERFRAME/STUB SILL TYPE: PGK 001
DATE BUILT: OCT 2003
Fig. C.1 Marking on an identification plate

3.1.4 The tank car owner must replace any illegible or missing identification plates. The car
owner must use the information on the tank specification plate attached to the opposite end of the
car, or from reconstructed information if both plates are missing.
3.1.5 When a modification to the tank changes any of the information shown on the tank
identification plate, the car owner or the tank car facility making the modification must install an
additional variable identification plate on the tank in accord with 49 CFR 179.24 (a)(3).
3.1.6 Tank car owners may apply the tank identification plate on any tank car built before July
25, 2012, in accord with 49 CFR 179.24.
3.1.7 The identification plates and, when required, a variable specification plate must be
permanently affixed by welding or by use of stainless steel mechanical fasteners. If bolts are used
for mounting, the threads must be deformed to prevent loss of the plates.
3.2 Conversions
A pressure car tank that is permanently converted to a lower pressure specification must have the
new specification and conversion date stamped on the outside of the manway nozzle or flange, in
3/8 in. (9.52 mm) letters, on the left side of the car.
4.0 PLACARD HOLDER OR PERMANENT PLACARDS (DECAL OR STENCIL)
4.1 When Required
4.1.1 All cars used to transport commodities classed as hazardous by the DOT must have metal
placard holders or display permanent placards (decal or stencil). Metal placard holders or
permanent placards must be applied to both sides toward the right end, preferably near to and
below the DOT and AAR stencils, and to both ends. Placard holders or permanent placards must
be located such that product spillage or dirt and water are not directed to the placards from the
cars wheels.
4.1.2 All cars required to be placarded for subsidiary hazards must have dual metal placard
holders or display permanent placards (decal or stencil). Metal placard holders or permanent
placards must be applied to both sides toward the right end, preferably near to and below the DOT
and AAR stencils, and to both ends. Placard holders or permanent placards must be located such
that product spillage or dirt and water are not directed to the placards from the cars wheels.
4.2 Design
See Chapter 5, paragraph 5.1.6, and Appendix E.
C-III [M-1002] 182 11/2014

M-1002 APPENDIX C
5.0 AAR COMMODITY MARKING REQUIREMENTS

When required by a Department of Transportation or Transport Canada regulation, exemption,
special permit, special authorization, or Competent Authority exemption or approval, single-unit
tank cars must be marked with a commodity name in accord with the requirements of the
applicable regulation.
5.1 Tank Cars without Pressure Relief Devices
Tank cars without pressure relief devices must be marked with the commodity name on both sides
of the tank or jacket in 4 in. (102 mm) minimum letters and NO PRESSURE RELIEF DEVICE
in 2 in. (50 mm) minimum letters beneath the commodity name.
6.0 LOAD LIMIT STENCIL
6.1 Effective January 1, 1985, the load limit (instead of nominal capacity) is to be stenciled on all
tank cars built new.
6.2 The load limit stencil will replace the nominal capacity stencil on all tank cars when
reweighed, repainted, retested, shopped for repair, or restenciled for any reason, effective January
1, 1997.
6.3 Any tank car not stenciled with a load limit must have a load limit stencil applied and the
nominal capacity stencil removed.
6.4 Load limit is the difference between the total weight on rail for the journal size and the scale
light weight of the car. See Field Manual of the AAR Interchange Rules, Rule 70.B.3.b.
6.5 For commodities having regulated car loadings (Chlorine, Bromine), the metric conversion for
load limit must be made to the nearest lower kilogram instead of to the nearest 50 kg otherwise
required by Field Manual of the AAR Interchange Rules, Rule 70.
For a 90 ton Chlorine car, the starred 180,000 lb load limit converts to 81 648 kg, not
81 650 kg.
For a 110,000 lb maximum load Bromine car, the starred load limit converts to 49 895 kg,
not 49 900 kg.
7.0 BOLTED AND HINGED MANWAY STYLE MARKING
7.1 For manway styles identified in Tables D.5 through D.11, at the next tank test, tank or
pressure relief device qualification, or owners shopping, a manway style decal/stencil per Fig. C.4
shall be applied to an operating platform corner post, on top of the manway cover, or on any other
unobstructed location near the manway on all cars equipped with bolted and hinged manways.
7.2 The manway style decal/stencil shall state the following in letters and numerals at least
1/4 in. (6.35 mm) high:
MANWAY STYLE: XXXX-123
The Xs indicate the manufacturers identification and the numbers indicate the style number
assigned by the manufacturer.
7.3 New cars ordered after July 1, 1996, must be equipped with manway style decals/stencils per
Fig. C.4. Manways designed to accommodate the AAR standard gasket, as defined in Appendix E,
paragraph 3.3.5.3, are to be designated MANWAY STYLE: AAR-1.
7.4 Manway cover gasket dimensions may also be shown on the manway style decal/stencil. If
shown, the gasket dimensions must be in 1/4 in. (6.35 mm) minimum height letters and numbers
and must be the same gasket dimensions as shown in the applicable Manway Style Chart or as
determined to be appropriate by the car owner or shipper.
11/2014 C-III [M-1002] 183

APPENDIX C M-1002
8.0 RETROREFLECTIVE SHEETING

This paragraph applies to the installation of retroreflective sheeting to tank cars. As used in this
standard, the term reflector shall refer to individual strips of retroreflective sheeting that complies
with the requirements of paragraph 8.1. For new applications of reflectors to cars with existing
stenciling and for cars whose construction does not permit compliance with paragraphs 8.4.1
through 8.4.4, the minimum area of retroreflective sheeting specified in paragraph 8.3 shall be
applied. The reflectors shall be applied in a manner that complies as closely as possible with these
requirements.
8.1 Material
Retroreflective sheeting material shall comply with the application and environmental resistance
requirements of AAR Manual of Standards and Recommended Practices, Section L, Specification
M-947, paragraphs 4.1, 4.5.1, 4.5.1.1, 4.5.2, 4.5.3, 4.5.4, and 4.6, and shall comply with the
requirements of ASTM D4956-04 for Type V sheeting if metalized or Type VII sheeting if non-
metalized. The characters FRA-224 constitute the manufacturers certification that the
retroreflective sheeting conforms to the requirements of this standard in addition to the
requirements of Title 49, Code of Federal Regulations, Part 224.103. The characters shall appear
at least once on the exposed surface of each sheeting in the final application, shall be a minimum
of 3 mm high, and shall be permanently stamped, etched, molded, or printed within the product;
and each certification shall be spaced no more than 4 in. apart. Retroreflective sheeting shall be
yellow or fluorescent yellow.
8.2 Size
Individual reflectors are to be 4 in. 18 in. or 4 in. 36 in., as practicable. Reflectors may be
separated into 4 in. 9 in. strips if necessary and applied on either side of discontinuous surfaces,
appurtenances, or existing or other required car markings.
8.3 Retroreflective Surface Area per Car
Each side of each car, including each unit of multi-unit cars, shall be equipped with no less than
the following total surface area.
Minimum Area of
Retroreflective Sheeting Equivalent Number of
Car Length over End Sills per Side 4 in. 18 in. Reflectors
Up to 50 ft 3.5 ft2 7
Over 50 ft to 60 ft 4.0 ft2 8
Over 90 ft to 100 ft* 6.0 ft2 12
* Cars over 100 ft long must be equipped with an additional 0.5 ft2
of retroreflective sheeting on each side for every additional 10 ft
of length.
C-III [M-1002] 184 11/2014

M-1002 APPENDIX C
8.4 Location
8.4.1 Reflectors are to be oriented vertically. Reflectors are not to be applied over existing or
required car stencils and markings.
8.4.2 Individual reflectors are to be spaced along the length of the car, with one reflector applied
at least every 12 ft, as practicable. If existing stencils, appurtenances, or discontinuous surfaces
make it impracticable to apply reflectors at least every 12 ft, they shall be applied at the smallest
interval greater than 12 ft that is practicable.
8.4.3 Two 4 in. 18 in. reflectors, one above the other, or one 4 in. 36 in. reflector is to be
applied as close to each car end as is practicable. Reflectors are not to be applied in the portion of
the car side occupied by safety appliances.
8.4.4 The reflectors are to be centered vertically on the horizontal centerline of the tank, or as
near as practicable. If it is not practicable to safely apply the reflectors centered vertically about
the horizontal centerline of the tank, the reflectors may be applied with their top edges no lower
than the horizontal centerline of the tank.
8.4.5 Reflectors are not to be applied in the splash zone beneath the manway. The splash zone is
a vertical band 2 ft minimum, 4 ft preferred, on each side of the manway centerline.
8.4.6 Reflectors, decals, and stenciling are not to be overlapped.
11/2014 C-III [M-1002] 185

A ABCX 00000 G F
B I Y Z
C H J
APPENDIX C
N
HORIZONTAL
CENTERLINE
OF TANK O
9" DOT XXXXX
ABCX 00000R (RESTRICTION) COMMODITY (MATERIAL) CLAD TANK

LD LMT 00000 LB 00 000 KG C INHALATION HAZARD P
1" AAR STXXXX SEE FIGURE
3" LT WT 00000 LB 00 000KG
DOTE OR SRXXXX C4
AAR CERTIFIED S S (NUMBER) 7'0" MAX
3" LETTERS
3" SPACES BLT XX-XXXXX
CONV XX-XXXXX
E
6'10 " MAX

4"10 " MIN
BLT XX-XXXXX ABCX 00000
CONV XX-XXXXX
D
TOP OF RAIL S
ELEVATION
K Q L R M
T
U
ABCX 00000
CAPY 00000 GAL Typical placement of retroreflective sheeting per paragraph 8.0 in this specification.
CAPY 00 000 L
C-III [M-1002] 186

Placement window for typical application of retroreflective sheeting
V
______________
______________
CL HEAD W Notes:
1. See paragraph 8.4.4 for placement of reflectors.
2. Reflectors are not to be applied in the splash zone beneath the manway of any tank
E car. The splash zone is a vertical band 2 ft minimum, 4 ft preferred, on each side of
the manway centerline.

3. Stenciling, decals, and reflectors are to be applied such that they do not overlap.
ABCX 00000
X
STENCIL B-END OF CAR AS SHOWN
STENCIL A-END OF CAR IN SAME MANNER
Fig. C.2 DOT and AAR stencil requirements for qualified tank cars
11/2014
M-1002
M-1002 APPENDIX C
Call Out Paragraph Reference Call Out Paragraph Reference
A 2.3.4.2 ABCX 00000 N 2.3.1.11 1/2 in. minimum
B 2.3.4.3, 2.3.4.5, and 2.3.4.9 O 2.3.1.71 1/2 in. minimum
C 2.3.1.11 P Fig. C.5 or Fig. C.9 Qualification stencilblank

(see Fig. C.8 for sample of completed stencil)
D 2.3.1.101 1/2 in.
Q 2.3.1.4, 2.3.4.41 in. minimum
E 4.1
R 2.3.2.2consolidated stencil
F Fig. C.4
S 2.3.2.6
G 2.3.4.6
T 2.3.4.24 in. minimum
H 2.3.1.2(compartment cars) 1 1/2 in. minimum
U 2.3.1.21 1/2 in. minimum
I 2.3.3.3.1Lining application
V DOT Part 1793/8 in. letters stamped in both
J Remarks c. and e. heads.
K 2.3.4.4See remark f.1 1/2 in. minimum W 2.3.2.3
L 2.3.2.4Brake lever badge plate (BL only) X 2.3.2.11 1/2 in. minimum
M 2.3.2.1(center sill cars only1 1/2 in. Y 2.3.1.3, 5.0commodity name

minimum)
Z 2.3.4.8exemptions, safety permits, service
trials
Remarks (paragraph references are to this appendix):

a. For thermal coatings, see paragraph 2.3.1.5.
b. For painting, see paragraph 2.3.1.8.
c. When exterior heater coils are applied, see paragraph 2.3.1.9.
d. For CO2 stencils, see paragraph 2.3.1.12.
e. For leasing stencil, see paragraph 2.3.4.10.
f. For separate built dates of tank and underframe, stencil as shown. Otherwise, built date is part of consolidated
stencil. See paragraph 2.3.4.4 and paragraph 2.3.2.2.
g. Stencils are applied to both sides of car unless otherwise indicated.
h. For inhalation hazard stencil, see paragraph 2.3.1.13.
i. Pressure units on existing cars are not required to be changed from lb to psi until they are repainted.
j. For extended service, mark the tank car with EXS after the car number using the same size of letters.
Fig. C.2 DOT and AAR stencil requirements for qualified tank cars (concluded)
11/2014 C-III [M-1002] 187

A ABCX 00000 G F OMIT ON CARS NOT EQUIPPED
WITH INTERNAL HEATER PIPES
B AA AB
C H J
M
APPENDIX C
N
HORIZONTAL DOT XXXXX O
CENTERLINE (MATERIAL) CLAD TANK
OF TANK DISC 000 PSI
SAFETY VALVE 000 PSI P
TESTED 20XX DUE 20XX
9" TANK 000 PSI
TESTED 20XX DUE 20XX
ABCX 00000R (RESTRICTION) COMMODITY HEATER PIPES 000 PSI
LD LMT 00000 LB 00 000 KG C INHALATION HAZARD TESTED 20XX DUE 20XX
1" AAR STXXXX (MATERIAL) LINED TANK R
3" LT WT 00000 LB 00 000KG APPLIED MO/YR
DOTE OR SRXXXX
AAR CERTIFIED S S (NUMBER) PRESSURE TEST NOT REQ'D U
3" LETTERS 7'0" MAX
3" SPACES BLT XX-XXXXX
CONV XX-XXXXX
E
6'10 " MAX

4"10 " MIN
BLT XX-XXXXX ABCX 00000
CONV XX-XXXXX
D
TOP OF RAIL
T
ELEVATION
I Q K S L
Typical placement of retroreflective sheeting per paragraph 8.0 in this specification.
V
W Placement window for typical application of retroreflective sheeting
ABCX 00000
CAPY 00000 GALS
CAPY 00 000 L
C-III [M-1002] 188

*This figure applies to cars that are tested in accordance with Appendix D, to tank cars
X that are subject to qualification requirements of part 180 but have not yet reached their
______________
______________ implementation date, and to cars that are painted and marked in kind.
CL HEAD Y
Notes:
1. See paragraph 8.4.4 for placement of reflectors.
2. Reflectors are not to be applied in the splash zone beneath the manway of any tank
E
car. The splash zone is a vertical band 2 ft minimum, 4 ft preferred, on each side of
the manway centerline.

ABCX 00000 3. Stenciling, decals, and reflectors are to be applied such that they do not overlap.
Z
STENCIL B-END OF CAR AS SHOWN
STENCIL A-END OF CAR IN SAME MANNER
Fig. C.3 DOT and AAR stencil requirements for other tank cars*
11/2014
M-1002
M-1002 APPENDIX C
Call Out Paragraph Reference Call Out Paragraph Reference

A 2.3.4.2 ABCX 00000 O 2.3.3.2.2.1
B 2.3.4.3, 2.3.4.5, and 2.3.4.9 P 2.3.3.1, 2.3.3.21 in. minimum
C 2.3.1.11 Q 2.3.1.4, 2.3.4.41 in. minimum
D 2.3.1.101 1/2 in. R 2.3.3.3.12 in. minimum
E 4.1 S 2.3.2.2 consolidated stencil
F Fig. C.4 T 2.3.2.6
G 2.3.4.6 U 2.3.1.61 in. minimum
H 2.3.1.2(compartment car) 1 1/2 in. minimum V 2.3.4.24 in. minimum
I 2.3.4.4See remark f.1 1/2 in. minimum W 2.3.1.21 1/2 in. minimum
J Remarks c. and e. X DOT Part 1793/8 in. letters stamped in both

heads.
K 2.3.2.4Brake lever badge plate (BL only)
Y 2.3.2.3
L 2.3.2.1(Center sill cars only 1 1/2 in.
minimum) Z 2.3.2.11 1/2 in. minimum
M 2.3.1.11 1/2 in. minimum AA 2.3.1.3, 5.0commodity name
N 2.3.1.71 1/2 in. minimum AB 2.3.4.8exemptions, safety permits, service

trials
Remarks (paragraph references are to this appendix):

a. For lined or coated tanks, see paragraph 2.3.1.5.
b. For painting, see paragraph 2.3.1.8.
c. When exterior heater coils are applied, see paragraph 2.3.1.9.
d. For CO2 stencils, see paragraph 2.3.1.12.
e. For leasing stencil, see paragraph 2.3.4.10.
f. For separate built dates of tank and underframe, stencil as shown. Otherwise, built date is part of consolidated
stencil. See paragraph 2.3.4.4 and paragraph 2.3.2.2.
g. Stencils are applied to both sides of car unless otherwise indicated.
h. Station stencil is required for retest dates. See paragraph 2.3.3.1.1.
i. For inhalation hazard stencil, see paragraph 2.3.1.13.
j. Retest stencil for valve-disc safety device should read Comb Safety Device.
k. Pressure units on existing cars are not required to be changed from lb to psi until they are repainted.
l. For tank, pressure relief valve, and interior heater system test stencil requirements, see the 1/1/96 release of
M-1002, Appendix C.
m. For lining stencil requirements, see the 1/1/96 release of M-1002, Appendix C.
n. For extended service, mark the tank car with EXS after the car number using the same size of letters.
Fig. C.3 DOT and AAR stencil requirements for other tank cars* (concluded)
11/2014 C-III [M-1002] 189

APPENDIX C M-1002
REQUIRED MANWAY STYLE
OPTIONAL GASKET SIZE: ELASTOMERIC

HARD
Blank Decal
REQUIRED MANWAY STYLE: GATX #3
OPTIONAL GASKET SIZE: ELASTOMERIC 21 7/8" OD 19" ID 1/4" THK

HARD 21 5/8" OD 19" ID 1/4" THK
Example
Fig. C.4 Manway style decal stencil
41 11
------
16
41 -----3- 1
16 --- Typ.
4
16 15
------
24"
16
1
8 1--- 1
--- Typ. 8 8 8 --- Typ.
2 4 4
STATION STENCIL QUALIFIED DUE 2

1
TANK QUALIFICATION 2 6 --4-
THICKNESS TEST 2
1 1--- SERVICE EQUIPMENT 2
2
5 18 1--- 18 3---
PRD: 3
4 4
1 1--- LINING 2
2
88.B.2 INSPECTION 2 6 1---
2
STUB SILL INSPECTION 2
Fig. C.5 Qualification stencilblank

(see Fig. C.8 for sample of completed stencil)
C-III [M-1002] 190 11/2014

M-1002 APPENDIX C
STATION STENCIL QUALIFIED DUE

TANK QUALIFICATION
THICKNESS TEST
SERVICE EQUIPMENT
PRD:
LINING
88.B.2 INSPECTION
STUB SILL INSPECTION
Fig. C.6 Qualification stencilshown with added lines for additional information
(reference paragraph 2.3.4.11 above)

TANK QUALIFICATION 2.3.3.1.1 2.3.3.1.1 2.3.3.1.1
THICKNESS TEST 2.3.3.1.2 2.3.3.1.2 2.3.3.1.2
SERVICE EQUIPMENT 2.3.3.2.1 2.3.3.2.1 2.3.3.2.1
PRD:2.3.3.2.2 2.3.3.2.2.1 2.3.3.2.2.2 2.3.3.2.2.2 2.3.3.2.2.2
2.3.3.2.3 2.3.3.2.4 2.3.3.2.3.1 2.3.3.2.3.1 2.3.3.2.3.1
LINING 2.3.3.3 2.3.3.3 2.3.3.3
88.B.2 INSPECTION 2.3.3.4 2.3.3.4 2.3.3.4
STUB SILL INSPECTION 2.3.3.5 2.3.3.5 2.3.3.5
Fig. C.7 Qualification stencilshown with paragraph references for required items

TANK QUALIFICATION ABC-1 1999 2009
THICKNESS TEST ABC-1 2000 2010
SERVICE EQUIPMENT ABC-1 1999 2004
PRD:VALVE 75 PSI DEF-1 1999 2004
INT HTR SPGR FGL-1 1999 2004
LINING ABC-1 PP NONE
88.B.2 INSPECTION ABC-1 1999 2009
STUB SILL INSPECTION ABC-1 1999 2009
Fig. C.8 Qualification stencilsample of completed form
11/2014 C-III [M-1002] 191

APPENDIX C M-1002
41 11
------
16
41 -----3- 1
16 --- Typ.
4
16 15
------
24"
16
1
8 1--- 1
--- Typ. 8 8 8 --- Typ.
2 4 4
STATION STENCIL QUALIFIED DUE 2

TANK QUALIFICATION (INNER) 2 6 1---
4
THICKNESS TEST (INNER) 2
TANK QUALIFICATION (OUTER) 2
4
THICKNESS TEST (OUTER) 2
22 1--- 23
1 1--- SERVICE EQUIPMENT 2 2
2
5
PRD: 3
1 1--- LINING 2
2
88.B.2 INSPECTION 2 6 1---
2
STUB SILL INSPECTION 2
Fig. C.9 Qualification stencilblank

This is an alternative to Fig. C.5 for tank cars with an inner tank
(see Fig. C.8 for sample of completed stencil with the exception
of the additional tank and thickness)
C-III [M-1002] 192 11/2014

M-1002 APPENDIX D
APPENDIX D
RETEST AND QUALIFICATION REQUIREMENTS
CONTENTS

2.0 Qualification and Maintenance Requirements for DOT Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . C-III194
2.1 AAR Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III194
3.0 AAR Maintenance and Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III200
3.1 Supplemental AAR Maintenance and Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . C-III200
3.2 Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III202
3.3 Certificate of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III203
3.4 Elastomeric Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III203
3.5 Retest or Qualification Stencils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III203
3.6 Bottom Outlet Caps and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III203
3.7 Securement of Manway Covers, Protective Housings, Valves, and Fittings for Pressure and
Nonpressure Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III204
3.8 Placard Holder Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III205
4.0 Pressure Relief Valve and Hydrostatic Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III205
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III205
4.2 Hydrostatic Tank Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III205
4.3 Procedure for Retesting Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III208
4.4 Procedure for Retest of Interior Heater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III208
4.5 Test Gauge Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III209
5.0 Certificate of Test Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III211
6.0 Hinged and Bolted and Strap-Style Manway Cover Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . C-III214
6.1 Manway Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III214
6.2 Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III214
6.3 Manway Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III214
6.4 Eyebolts and Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III215
6.5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III215
6.6 Tightening of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III215
6.7 Strap-Style Manway Straps, Tee Bolt, and Screw Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III216
11/2014 C-III [M-1002] 193

APPENDIX D M-1002
APPENDIX D
RETEST AND QUALIFICATION REQUIREMENTS
1.0 INTRODUCTION
Appendix D describes AAR and DOT requirements for retest and qualification of tank car tanks.
2.0 QUALIFICATION AND MAINTENANCE REQUIREMENTS FOR DOT TANK CAR
TANKS
Qualification and maintenance requirements for tanks built under DOT specifications are set
forth in 49 CFR Part 180, Subpart F.
2.1 AAR Tank Car Tanks
2.1.1 Applicability
This program establishes the minimum acceptable framework for an owners qualification
program for AAR Class tank cars and components not subject to federal regulations. AAR Class
tank cars subject to the hazardous material regulations must comply with the regulations in
49 CFR 180.500.
2.1.1.1 Owners shall follow this program in developing their written procedures (work
instructions), as required by 49 CFR 179.7(d), for use by tank car facility employees. The owners
qualification program for each tank car, or a fleet of tank cars, must identify where to inspect, how
to inspect, and the acceptance criteria. Tank car facilities must incorporate the owners
qualification program into their quality assurance program, as required by 49 CFR 179.7(a)(2),
(b)(3), and (b)(5).
2.1.1.2 This section applies to any person who manufactures, fabricates, marks, maintains,
repairs, inspects, or services tank cars to ensure continuing qualification.
2.1.1.3 Any person who performs a function prescribed in this program shall perform that
function in accordance with this program.
2.1.2 Quality Assurance Program
The quality assurance program requirements of the AAR Manual of Standards and Recommended
Practices, Section J, Specification M-1003, apply.
2.1.3 Requirements for Qualification
Each tank car owner shall ensure that a tank car facility does the following:
Inspects and tests (examines) each item
Evaluates each item according to the acceptable results of inspection and test
Marks each tank car as specified
Prepares the documentation as required
2.1.4 Conditions Requiring Qualification of Tank Cars
Without regard to the qualification compliance date requirements, an owner shall ensure that a
qualification of the tank is performed if
the tank bears evidence of damage caused by fire; or
the Tank Car Committee requires it, based on the existence of probable cause that a tank
car or a class or design of tank cars may be in an unsafe operating condition.
C-III [M-1002] 194 11/2014

M-1002 APPENDIX D
2.1.5 Frequency of Qualification

2.1.5.1 For the inner container of Class AAR-206 tank cars, the tank car must have a hydrostatic
pressure test and internal visual inspection conforming to the requirements of this appendix.
2.1.5.2 For Class AAR-204 tank cars, the tank car tank does not require a periodic pressure test;
however, pressure relief devices on AAR-204 tank cars must be tested every 5 years.
2.1.5.3 Tank cars with fusion welds must be qualified and maintained in accordance with Table
D.1. All qualification requirements need not be done at the same time.
Table D.1 Frequency of qualification

Retest and Qualification
Requirements Description Maximum Interval
2.1.6 Visual inspection 10 years
2.1.7 Structural integrity inspection 10 years
2.1.8 and 2.1.9 Thickness test See paragraph 2.1.8
2.1.10 Safety systems 10 years
2.1.11 Lining or coating Per owners program
2.1.12 Leakage pressure test After reassembly
2.1.13 Service equipment (including pressure relief devices) 10 years
2.1.6 Visual Inspection

Each tank car owner shall ensure qualification of the tank through an external and internal
inspection. At a minimum, the visual inspection must include the following:
2.1.6.1 Except in areas where insulation, internal coatings, or internal linings preclude it, an
internal and external inspection of the tank shell and heads for abrasion, corrosion, cracks, dents,
distortions, defects in welds, or other condition that could make the tank car unsafe for
transportation; for AAR-206, an inspection of the interior of the inner container and an inspection
of the exterior outer shell and heads.
2.1.6.2 Non-coated tank cars shall have a visual inspection at the time of the tank qualification.
2.1.6.3 Prior to the application of an internal coating, an internal inspection of the tank shell and
heads for abrasion, corrosion, cracks, dents, distortions, defects in welds, and any other condition
that could make the tank car unsafe for transportation.
2.1.6.4 An inspection of the service equipment, in accordance with the owners maintenance
program, for indications of conditions that could make the tank car unsafe for transportation.
2.1.6.5 An inspection for missing or loose bolts, nuts, and other fasteners that could make the
tank car unsafe for transportation.
2.1.6.6 An inspection of all bolted, threaded, and quick-disconnect closures on the tank car for
conditions that could make the tank car unsafe for transportation.
2.1.6.7 An inspection of the required markings for legibility.
11/2014 C-III [M-1002] 195

APPENDIX D M-1002
2.1.7 Structural Integrity Inspection and Test

Each tank car owner shall ensure qualification of the fatigue-critical structural elements on the
tank. These elements may include one or more of the following:
2.1.7.1 All transverse fillet welds greater than 0.25 in. (0.64 cm) within 4 ft (121.92 cm) of the
bottom longitudinal centerline, except the body bolster pad attachment welds.
2.1.7.2 The termination of longitudinal fillet welds greater than 0.25 in. (0.64 cm) within 4 ft
(121.92 cm) of the bottom longitudinal center line.
2.1.7.3 Tank shell butt welds within 2 ft (60.96 cm) of the bottom longitudinal centerline that
have structural discontinuities and/or terminations of reinforcements within 12 in. (30.48 cm) of
the weld.
2.1.7.4 The owner must maintain all supporting documentation used to make such
determination at its principal place of business and make the data available to AAR and FRA upon
request.
2.1.7.5 For Class AAR-206 tanks, paragraphs 2.1.7.1, 2.1.7.2 and 2.1.7.3 apply only to the outer
shell fillet welds and to the (non-reinforced) exposed outer shell butt welds.
2.1.7.6 Each tank car facility shall inspect and test the identified elements by one or more of the
following methods:
Dye penetrant
Radiography
Magnetic particle
Ultrasonic flaw detection
Direct and/or remote visual inspection
Acoustic emission testing
2.1.7.7 Perform weld inspection per the requirements of paragraph 3.1.2.1 below.
2.1.7.8 Perform truck and draft component inspection per the requirements of paragraph 3.1.2.2
below.
C-III [M-1002] 196 11/2014

M-1002 APPENDIX D
2.1.8 Thickness Tests

2.1.8.1 When required, each tank car facility shall measure the thickness of the shell, heads,
sumps, domes, and nozzles on each tank car by using a device capable of accurately measuring the
thickness to within 0.002 in. (0.05 mm).
2.1.8.2 Each tank car tank shall have a thickness test measurement
at least once every 10 years for non-lined/coated cars; or
prior to the application of an internal lining or internal coating.
ADDITIONAL THICKNESS
10-YEAR INSPECTION INTERVAL
F
5-YEAR INSPECTION INTERVAL
LOCALIZED REDUCTIONS ONLY G
A B C D E
Fig. D.1 Tank shell thickness qualification frequencies

where
A = As-built tank shell thickness, with additional thickness.
B = Required minimum tank shell or head thickness after forming per Part 179 (see Appendix X, parts
179.100-6, 179.200-6, 179.101-1, 179.201-1, etc.).
C = Inspection frequency adjustment point (required minimum shell or head thickness, minus 1/2 of the
table value in paragraph 2.1.9 below).
D = Condemning limit for general corrosion (required minimum shell or head thickness, minus the table
value in paragraph 2.1.9 below).
E = Condemning limit for localized corrosion [required minimum shell or head thickness, minus the table
value in paragraph 2.1.9 below, minus 1/16 in. (1.58 mm)]. See Note 1 in paragraph 2.1.9 below for
diameter limitations and minimum separation distances.
F = Allowable shell thickness reduction (table value in paragraph 2.1.9 below).
G = Additional thickness reduction for localized areas.
2.1.8.2.1 For tank cars with a lining/coating program, thickness testing is not required. The
lining/coating program must include a documented inspection procedure.
2.1.8.3 For a localized repair of an internal lining or internal coating, a qualified individual shall
verify conformance with paragraph 2.1.9 by measuring the shell or head in the area of the repair.
The thickness test applies only to the non-lined or non-coated repair area and is not a qualification
event. Modification of the tank car stencil is not required.
2.1.8.4 Each tank car owner shall ensure that a tank car will not operate below the condemning
limit for general corrosion or the condemning limit for localized corrosion, as shown in Fig. D.1.
2.1.8.5 For sumps, domes, nozzles, and nozzle reinforcements, the tank car owner shall determine
if any reduction in the wall thickness affects the design levels of reliability and safety built into the
sump, dome, tank nozzle, or nozzle reinforcement. Each tank car owner must maintain at its
principal place of business documentation describing the allowable thickness reductions for
sumps, domes, nozzles, and nozzle reinforcements. This documentation must be available to AAR
and FRA upon request.
2.1.8.6 After repairs, alterations, conversions, modifications, or blasting of a tank car that results
in a reduction in tank thickness, a qualified individual shall measure the thickness of the tank in
the area of reduced thickness to ensure that the thickness of the tank conforms to paragraph 2.1.9.
11/2014 C-III [M-1002] 197

APPENDIX D M-1002
2.1.9 Service Life Shell Thickness Allowance

If a qualified individual finds a tank with a head or shell thickness below the required minimum
thickness (after forming for its specification), as stated in the AAR specifications, the tank may
continue in service if any reduction in the required minimum thickness is not more than that
provided in the following table.
Table D.2 Allowable shell thickness reductions

Marked Tank Test Pressure Top Shell and Tank Head Bottom Shell
< 200 psig 1/8 in. (3.17 mm) 1/16 in. (1.58 mm)
200 psig 1/32 in. (0.79 mm) 1/32 in. (0.79 mm)
NOTES:
1. A TANK CAR OWNER MAY ADD AN EXTRA 1/16 IN. (1.58 MM) TO THE VALUES IN THE TABLE FOR LOCAL REDUCTIONS. LOCAL
REDUCTIONS ARE THOSE THAT DO NOT EXCEED 8 LINEAR INCHES (20.32 LINEAR CENTIMETERS), MEASURED AT THE
LONGEST DIMENSION, AND ARE SEPARATED FROM OTHER LOCAL REDUCTIONS BY AT LEAST 16 IN. (40.64 CM).
2. ANY REDUCTION IN THE TANK CAR SHELL THICKNESS MAY NOT AFFECT THE STRUCTURAL STRENGTH OF THE TANK CAR TO
THE EXTENT THAT THE TANK CAR NO LONGER CONFORMS TO MSRP SECTION C-II, SPECIFICATION M-1001.
3. SHELL THICKNESS REDUCTIONS APPLY ONLY TO THE OUTER SHELL FOR CLASS AAR-206 TANK CARS. THERE IS NO SHELL
OR HEAD THICKNESS REDUCTION AUTHORIZED FOR THE INNER TANK.
2.1.10 Safety System Inspection

Each tank car owner shall ensure qualification of the tank car safety systems.
2.1.11 Lining and Coating Inspection and Test
All interior linings and/or coatings shall be inspected per the lining or coating owners written
program.
2.1.12 Leakage Pressure Test
2.1.12.1 Unless the design of the service equipment arrangement precludes it (e.g., there is no
fitting to pressurize the tank), each tank car facility shall ensure that tank, service equipment,
and closures installed on the tank are leak tested.
2.1.12.2 The test may be conducted with the lading in the tank.
2.1.12.3 The written procedure and test method for leak testing must ensure the sensitivity and
reliability of the test method to ensure the serviceability of components.
2.1.12.4 This section does not apply to facilities that remove closures for the sole purpose of
loading or unloading the lading (e.g., blind flanges, pipe plugs, quick-disconnects, etc.).
2.1.13 Service Equipment Inspection and Test
2.1.13.1 Each tank car owner shall ensure that qualification of tank car service equipment is
performed at least once every 10 years.
2.1.13.2 Each tank car facility shall qualify service equipment, including reclosing pressure relief
devices and interior heater systems, in accordance with this appendix.
2.1.14 Qualification Compliance Date for Tank Cars
After July 1, 2005, each AAR Class tank car in nonregulated, nonhazardous commodity service
shall be qualified and maintained in accordance with this section no later than the date the tank
car would require a periodic hydrostatic pressure test (i.e., the marked due date on the tank car for
the hydrostatic test).
C-III [M-1002] 198 11/2014

M-1002 APPENDIX D
2.1.15 Acceptable Results of Inspections and Tests

Provided it conforms to other applicable requirements of M-1002, a tank car is qualified for use if
it successfully passes the following inspections and tests conducted in accordance with
paragraph 2.1:
2.1.15.1 Visual inspection: A tank car successfully passes the visual inspection when the
inspection shows no structural defect that may cause leakage from or failure of the tank before the
next inspection and test interval.
2.1.15.2 Structural integrity inspection and test: A tank car successfully passes the
structural integrity inspection and test when it shows no structural defect that may initiate cracks
or propagate cracks and cause failure of the tank before the next inspection and test interval.
2.1.15.3 Service life shell thickness: A tank car successfully passes the service-life shell
thickness inspection when the tank shell and heads show no thickness reduction below that
allowed in paragraph 2.1.9 above.
2.1.15.4 Safety system inspection: A tank car successfully passes the safety system inspection
when each coupler vertical restraint system and system used to protect discontinuities on the tank
car conforms to M-1002.
2.1.15.5 Lining and coating inspection: Per owners written program.
2.1.15.6 Leakage pressure test: A tank car successfully passes the leakage pressure test when
all product piping, fittings, and closures show no indication of leakage.
2.1.15.7 Service equipment inspection and test: The tank car service equipment successfully
passes the service equipment inspection and test when there are no signs of corrosion, cracks,
dents, distortions, or other defects that would cause a failure prior to the next qualification event.
2.1.16 Repairs, Alterations, Conversions, Modifications, and Maintenance
2.1.16.1 All work must be performed in facilities having the appropriate level of AAR certification
and must comply with all applicable requirements of M-1002.
2.1.16.2 When converting a car from AAR to DOT, the owner must have written documentation
that the car conforms to all DOT manufacturing and maintenance requirements.
2.1.17 Markings
When a tank car passes the required inspection and test with acceptable results, the tank car
facility shall mark the date qualified and the next qualification date (due date) on the tank car in
accordance with Appendix C.
2.1.18 Reporting and Record Retention Requirements
2.1.18.1 Each owner of a specification tank car shall retain the certificate of construction (Form
AAR 4-2) and documents (e.g., General Arrangement, Tank Arrangement, Fittings Arrangement,
etc.) certifying that the manufacture of the specification tank car identified in the documents is in
accordance with the applicable specification.
2.1.18.2 The builders signature on the certificate of construction, and marking of the tank with
the tank specification, affirms that all of the appropriate inspections and tests were performed to
qualify the tank for continued use.
2.1.18.3 The builder must retain the inspection and test reports to affirm that the tests and
inspections required under this specification were performed.
2.1.18.4 The owner shall retain the documents throughout the period of ownership.
2.1.18.5 Upon a change of ownership, the requirements of Chapter 1, paragraph 1.3.15 of this
specification apply.
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APPENDIX D M-1002
2.1.19 Inspection and Test Reporting

2.1.19.1 Each in-service tank car that is inspected and tested as specified in paragraph 2.1 must
have a written or electronic report, in English, according to this paragraph.
2.1.19.2 The owner must retain a copy of the inspection and test reports until successfully
completing the next inspection and test of the same type. The inspection and test report must
include the following:
Type of inspection and test performed (a checklist is acceptable)
The results of each inspection and test performed
Reporting mark and number
Tank specification
Inspection and test date (month and year)
Location and description of defects found and method used to repair each defect
The name and address of the tank car facility and the name of the inspector(s)
3.0 AAR MAINTENANCE AND QUALIFICATION REQUIREMENTS
In addition to the maintenance and qualification requirements specified in the federal regulations,
the following AAR requirements apply. For the purposes of this section, "federal regulations"
means 49 CFR Part 180 and Transport Canada (TC) TP14877.
3.1 Supplemental AAR Maintenance and Qualification Requirements
3.1.1 These supplemental requirements apply to all railroad tank cars marked to indicate
compliance with an AAR, TC, or DOT specification. Each tank car owner is responsible for the
following:
3.1.1.1 Performing a visual inspection of the exterior surface of the tank car, including the outer
shell (jacket) and jacket heads of DOT-113, DOT-115, and AAR-204 tank cars;
3.1.1.2 Performing a structural integrity inspection at all locations susceptible to damage that
could reduce the reliability of the tank, welded attachments, and nozzles. At a minimum the
inspection must include the following:
All transverse fillet welds with design dimensions greater than 0.25 in. (0.64 cm) within
121.92 cm (4 ft) of the bottom longitudinal centerline;
The termination of longitudinal fillet welds with design dimensions greater than 0.25 in.
(0.64 cm) within 4 ft (121.92 cm) of the bottom longitudinal center line; and
The tank shell butt welds within 2 ft (60.96 cm) of the bottom longitudinal centerline.
3.1.1.3 For Class DOT-113, DOT-115, and AAR-204 tank cars, this section applies only to the
outer shell (jacket) fillet welds and to the non-reinforced exposed outer shell (jacket) butt welds.
3.1.1.4 Inspecting the welds attaching the bolster to the sill and those attaching the draft sill to
the sill pad, inboard and outboard of the body bolsters. At a minimum, the inspection must include
the following:
All transverse fillet welds with design dimensions greater than 0.25 in. (0.64 cm) within
4 ft (121.92 cm) of the bottom longitudinal centerline
The termination of longitudinal fillet welds with design dimensions greater than 0.25 in.
(0.64 cm) within 4 ft (121.92 cm) of the bottom longitudinal centerline
For cars incorporating a metal jacket, removal of portions of the tank jacket is required, except
when using fiber optics, acoustic emissions, or equivalent inspection techniques.
3.1.1.5 Inspecting the trucks and draft components per Field Manual of the AAR Interchange
Rules, Rule 88.B.2.
The various inspections and maximum intervals are summarized in Table D3.
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M-1002 APPENDIX D
3.1.2 All of the inspections mentioned herein shall be conducted in accord with the requirements
of 49 CFR Part 180 and AAR Specification M-1002, Appendix T.
3.1.2.1 Acceptable methods for use during tank qualification are as shown in Appendix T, Table
T.1. The applicability of any particular method for a given inspection area shall be determined by
the NDT Level III. Additional inspection methods may be employed if any uncertainty arises.
3.1.2.2 Thickness tests shall be performed as follows:
Thickness readings shall be taken at the bottom, one side (90), and the top of the tank
shell within 6 in. of each circumferential weld seam on each side of the circumferential
weld seam. One thickness reading shall be taken at the center of each tank head. Two
thickness readings shall be taken on each tank nozzle and one at the sump, when so
equipped.
When corrosion or other damage that reduces shell thickness is found either by thickness
readings or other inspection, additional readings shall be taken to map the thinned area.
Shell thickness measurements on rubber-lined and coated tanks must be taken at the time
of lining/coating application.
Table D.3 Required tank car qualifications/inspections
Where Required Description Maximum Interval
49 CFR Part 180, Visual inspection 10 years
49 CFR Part 180, Structural integrity inspection 10 years
49 CFR Part 180, Thickness test 180.509 (f)
49 CFR Part 180, Safety systems 10 years
49 CFR Part 180, Lining or coating (for materials corrosive to the tank) 180.509 (i)
49 CFR Part 180, Leakage pressure test After assembly
49 CFR Part 180, Service equipment (including pressure relief devices) 180.509 (c)
Field Manual Rule 88.B.2 Thorough inspection of load-carrying members, end 10 years, or as required by
sills, side sills, draft systems, trucks, tank car jackets, Note 1
and hand brakes
AAR Circular Stub draft sills, sill pads, sill attachments welds At tank qualification or mileage
CPC-1094 (outboard of bolsters) limit
AAR M-1002, Appendix D, Stub draft sills, sill pads, sill attachments welds With structural integrity
paragraph 3.1.1.4 (inboard of bolsters) inspection
Note 1. Tank cars released into service after rebuilding or after heavy repair must receive an inspection in accordance with
the Field Manual of the AAR Interchange Rules, Rule 88.B.2.b. The term "heavy repair" means that the total labor hours on a
tank car exceed 85 hours because of accidental damage. Accidental damage means a physical defect in the tank parent metal
or tank jacket caused by fire, natural disaster, or contact with another object during the operation of the tank, and is not limited
to abrasion, buckling, corrosion, cracks, cuts, dents, distortions, defects in welds, gouging, and any painting, coating, and lining
associated thereto. Tank and component qualifications required by 49 CFR Part 180 and Transport Canada (TC) TP14877,
including any purging, cleaning, and water testing associated with qualification, are not included in the 85 hours, nor are interior
coating repairs included in the 85 hours when the tank interior is coated for the sole purpose of product purity.
11/2014 C-III [M-1002] 201

APPENDIX D M-1002
3.2 Valves and Fittings

This paragraph applies to the maintenance and qualification of valves and fittings used on tank
cars.
3.2.1 Maintenance and Qualification of Valves and Fittings
3.2.1.1 Each valve and fitting owner is responsible for the development or adoption of a
maintenance and qualification program to ensure that valve and fittings meet a performance
specification.
When cracked pressure relief valve stems or springs are found during maintenance or
qualification inspections, the valve, the commodity service history and the valve repair history
should be reviewed with the valve manufacturer to determine the cause of failure.
3.2.1.2 Maintenance procedures for valves and fittings must include the following elements:
Work instructions to include removal of existing station stencil tags, disassembly, cleaning,
and reassembly
Acceptance criteria, including threaded components
Selection and application of materials
Torque specifications, when required, for assembly of components (e.g., face plates)
Requirements for marking the station stencil on a metal tag or a lead seal that clearly
identifies the facility that resealed, rebuilt, or remanufactured the valve or fitting, and the
means for affixing the tag or seal to the valve or fitting. See Appendix C,
paragraph 2.3.3.2.7 for the station stencil marking requirements of facilities that install
valves and fittings following maintenance.
When a liquid or vapor valve is replaced and has damaged closure threads, the closure
itself must be replaced.
All threads shall be inspected for excessive wear, corrosion, pitting, or any other defect.
3.2.1.3 In addition to paragraph 3.2.1.2, qualification procedures for valves and fittings must
include the following elements:
A facility that reseals, rebuilds, or remanufactures valves and fittings not integral to the
tank must perform a bench test to the valve and fitting to ensure that the performance
requirements are met.
A facility that applies a valve or fitting not integral to the tank must perform a leak test to
ensure the performance requirements are met.
A facility that reseals, rebuilds, or remanufactures a valve or fitting not integral to the
tank must mark the product to ensure traceability.
A facility that reseals or rebuilds valves and fittings integral to the tank (e.g., top-operated
bottom outlet valve) must perform a leak test to ensure that the performance requirements
are met.
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M-1002 APPENDIX D
3.2.1.4 Valves and fittings may be replaced in kind on tank cars without changing the
qualification dates marked on the tank when performed by a facility that is certified to activity
code C6. The facility replacing the valve or fitting shall maintain records of the valve or fitting
replacement throughout the qualification interval.
In te g ra l to ta n k
S ta r t
New
R e s ea l
F a il
P a ss
R e b uild Le a k T e st P a ss / F a il S to p
C o m p o n e n t M a in te n an c e C o m p o ne n t Q ua lific a tio n
Fig. D.2 Valve and fitting qualification process

3.3 Certificate of Test
See paragraph 5.0 below for the suggested format and instructions for a certificate of test of tank,
pressure relief valve, and heater system.
3.4 Elastomeric Materials
Elastomeric materials that are used for pressure relief valve gaskets or gasket seals and that are
normally exposed to the lading must be replaced when the device is tested.
3.5 Retest or Qualification Stencils
Retest or qualification stencils must be applied in accordance with Appendix C.
3.6 Bottom Outlet Caps and Nozzles
3.6.1 At the time of service equipment qualification, all bottom outlet caps and nozzles must have
the threaded surfaces inspected for wear per the requirements of Appendix E, Figs. E.18 through
E.18.5. Caps or nozzles worn beyond these limits must be removed from service. Typical NoGo
gauges are shown in Figs. E.18.6 through E.18.9. These gauges also may be used to verify the
integrity of threads on hose connections used at loading and unloading sites. At the time of retest,
all elastomeric materials used as gaskets in these devices must be renewed.
3.6.1.1 Cap depth (X) with no gasket and nozzle length (Y) must be measured. In order to achieve
gasket compression, the cap depth (X) must not be greater than the nozzle length (Y). Dimensions
X and Y are as shown in Figs. E.18.6 through E.18.9.
3.6.1.2 Cap depth (X) with no gasket must not be less than 1 5/8 in. (41.3 mm) for the 4 in. cap or
1 1/2 in. (38.1 mm) for the 6 in. cap.
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APPENDIX D M-1002
3.6.1.3 A single cap gasket of 1/4 in. (6.35 mm) maximum thickness must be used. Multiple gaskets
must not be used.
3.6.2 Thread surfaces and gasket seating surfaces must be visually inspected for corrosion and/or
mechanical damage. Parts that are unsuitable must be removed from service.
3.7 Securement of Manway Covers, Protective Housings, Valves, and Fittings for
Pressure and Nonpressure Cars
3.7.1 To ensure that every car is inspected once, this section will remain in effect until April 1,
2006.
3.7.2 At the time of the first tank test or qualification for existing equipment after April 1, 1996,
each tank car shall have the bolts, studs, and nuts securing pressure-retaining parts inspected for
proper engagement.
3.7.3 As a minimum, two fasteners from each bolt circle shall be inspected. Where all
engagements are the same in a bolt circle, any two fasteners may be inspected. Where all
engagements are not the same, the largest and smallest engagements shall be inspected (i.e., the
tallest and shortest stud projections, or the longest and shortest projections of bolts or studs
through nuts).
3.7.4 If inspection of the initial lot demonstrates that those fasteners meet the requirements of
paragraphs 3.7.4.4 and 3.7.4.5 below, then the remaining fasteners do not have to be inspected. If
the initial lot does not meet the requirements of paragraphs 3.7.4.4 and 3.7.4.5, the remaining
fasteners must be inspected and any noncompliant fasteners must be adjusted or replaced to bring
them into compliance.
3.7.4.1 If fittings are disassembled at the time of the tank test, this inspection must be conducted
during or after reassembly.
3.7.4.2 Engagement depth of studs may be determined by physical or ultrasonic measurement. If
ultrasonic testing is used, ASTM E797-87 or ASME 797 procedures may be used for reference.
3.7.4.3 The engagement depth must be calculated using the following formulae:
3.7.4.3.1 For studs securing manway cover plates on pressure cars (or similar type arrangements on
nonpressure cars):
3- (in.)
l e = l s l a + t p + -----
16
3.7.4.3.2 For studs securing all other closures and fittings:

le = ls la
where
le = engagement depth
ls = stud length
la = length of stud above the cover plate as physically measured
tp = thickness of the manway cover plate
3.7.4.4 le must be equal to or greater than the nominal stud diameter.
3.7.4.5 As a minimum, nuts must be fully engaged; that is, no nut threads may be showing.
3.7.4.6 Bolts, studs, and nuts applied after April 1, 1996, shall conform to Appendix M,
paragraphs 1.2.3 and 4.2 (for pressure cars), or Appendix M, paragraph 4.2.3 (for nonpressure
cars).
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M-1002 APPENDIX D
3.8 Placard Holder Brackets

At the time of the next qualification of existing tank cars, the placard holder brackets and their
attachments must be brought into conformance with Chapter 5, paragraph 5.1.6.2, and Field
Manual of the AAR Interchange Rules, Rules 53.D.3 and 81.E.12.
4.0 PRESSURE RELIEF VALVE AND HYDROSTATIC TEST PROCEDURE
4.1 General
4.1.1 Facilities that are currently authorized to perform retesting in accord with this appendix
are periodically published as prescribed per Appendix B. Prior to authorizing any tank car
activities requiring certification that is not listed, contact the Executive DirectorTank Car
Safety, Association of American Railroads, 425 Third Street SW, Suite 1000, Washington, DC,
20024, to determine if appropriate certification of the facility will be in effect at the time of the
performance of the work (phone 202-639-2260; fax 202-639-2930; email kdorsey@aar.org).
4.2 Hydrostatic Tank Testing Procedure
4.2.1 This procedure is applicable to pressure and nonpressure tank car tanks, pressure relief
valves, and interior heater systems. It does not apply to cryogenic cars and their fittings nor to
electric heater coil systems, which utilize special procedures not covered herein.
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APPENDIX D M-1002
4.2.2 Steps Common to Both General Purpose Tanks and Pressure Car Tanks
Step Action
1. Determine the tanks last contents.
2. Observe safety procedures and protective clothing requirements in effect for the test
location and environment. Determine suitability for safe testing.
(CAUTION: Valves, fittings, and tanks may retain harmful product residues.)
3. Remove pressure relief devices and blank off the openings.
4. Remove or open all heater system, thermowell, and sealed gauging device closures during
the test period.
5. Install a certified test gauge (see paragraph 4.5 below for gauge standards).
6. Fill the tank completely with test liquid to the top of the manway nozzle. Vent gases while
filling.
7. Apply tank specification hydrostatic test pressure.
8. Disconnect the pressure source from the tank.
9. Test gauge must be open to tank during the holding period, as follows:
Noninsulated car 10 minutes

Insulated car 20 minutes
10. During the holding period, inspect the tank shell, or jacket, and all closures for leakage.
11. If test liquid is to be removed, removal should be continuous. Provide positive venting
while draining.
12. If internal inspection is not to be performed, skip to step 16.
13. Prior to vessel entry, safety procedures shall be observed. Tank interior is to be dried by
suitable means. Remove loose dirt, scale, rust, and sludge.
(CAUTION: Tank atmospheres and residues can be hazardous.)
14. Results of visual internal inspection shall be reported to car owner in writing.
15. When tank shell thickness readings are indicated, they shall be determined by an
appropriate nondestructive test method.
16. Observe recommended practice per paragraph 3.2 above for valves and fittings.
17. After retest, the reassembled tank must be subjected to at least 15 psi (103.421 kPa)
internal pressure and connections tested for leakage. Closures and handles are to be in
serviceable condition and properly attached.
18. Stencil car as required in accord with Appendix C, paragraph 2.3.3.
19. Prepare a Certificate of Test Form (see paragraph 5.0 below) or documentation as required
by DOT per 180.517(b) and send to car owner.
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M-1002 APPENDIX D
4.2.3 Steps Unique to Pressure Tanks (When Manway Covers Are Removed)
Step Action
1. Carefully clean manway nozzle gasket mating surfaces and inspect for cuts, corrosion,
cracks, warping, and other damage. Contact car owner for corrective action if defects exist.
2. Remove valves, fittings, and gaskets from the manway cover.
3. Inspect excess flow valves. Check for seat tightness if required.
4. Clean the manway cover assembly and thoroughly inspect it for corrosion, bent or broken
piping, weld defects, warping, etc. Contact car owner for corrective action if defects exist.
5. Carefully inspect thermowell and gauging device attachment welds for undercuts, cracks,
and other weld-related defects. If it is necessary to repair them, contact the car owner to
ensure use of proper securement design and approved welding procedures. After repair,
test to ensure their ability to retain tank test pressure.
6. Inspect studs for corrosion, improper insertion, or other defects. Insert studs to full depth,
with specification stamping exposed. Studs must comply with Appendix M, paragraphs
1.2.3 and 4.2.
7. Apply a new manway cover gasket and install the assembly. Care must be taken to avoid
gasket displacement and damage to gaskets, grooves, eduction pipes, or stud threads.
8. Tighten nuts per paragraph 3.2.1 above and Fig. D.3.
9. Install valves and fittings to manway cover and tighten per paragraph 3.2.1 above.
10. Inspect valves and fittings for compliance with provisions of 49 CFR 179.100-17(a), and
Appendix A, paragraph 3.15.
11. Perform the steps listed in paragraph 4.2.2 above, steps 17 through 19, to complete the
process.
4.2.4 Steps Unique to Nonpressure (General Purpose) Tanks
Step Action
1. Inspect the manway nozzle, cover, and old gasket for indication of warping or out-of-round
conditions.
2. Remove the manway cover gasket, carefully clean the gasket mating surface, and inspect
it for cuts, corrosion, cracks, warping, or other damage. Contact the car owner if defects
exist.
3. Apply a new manway cover gasket and, when applicable, apply in accord with
paragraph 6.0 below. Care must be taken to avoid gasket displacement or damage to the
gasket, seat, or groove.
4. Inspect all eyebolt lug attachment welds for evidence of corrosion or condition that would
affect serviceability. Repair as necessary.
5. Inspect the manway eyebolt assemblies for serviceability and compliance with pressure
release provisions of 49 CFR 179.201-6.
6. Tighten the manway cover per paragraph 3.2.1 above and Fig. D.3, limiting tightening
force to avoid cutting the gasket and/or distorting the cover. Use of a wrench with a 12 in.
handle is recommended.
7. Inspect valves and fittings after reapplication for compliance with the provisions of
49 CFR 179.200-16(b) and Appendix A, paragraph 3.15.
8. Perform the steps listed in paragraph 4.2.2 above, steps 17 through 19, to complete the
process.
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APPENDIX D M-1002
4.3 Procedure for Retesting Pressure Relief Valves
Step Action
1. Remove the pressure relief valve from the car.
2. Cover the nozzle opening to avoid introducing contaminants to the car.
3. Carefully clean the gasket mating surfaces and inspect them for cuts, cracks, corrosion,
warping, or other damage. Contact the car owner or lessee for corrective action if defects
exist.
4. Inspect the valve for product damage and for missing, bent, or broken parts.
5. Inspect the valve per manufacturers guidelines and replace unusable parts. Repair work
shall be limited per Appendix A, paragraph 3.11.
6. Elastomeric materials used for gaskets or gasket seals must be replaced. Observe
dimensional and compatibility provisions of paragraph 3.2 above.
7. Reassemble per manufacturers guidelines. Avoid introducing foreign matter to the valve
interior.
8. Install the valve to the test rack using a suitable gasket.
9. Using a certified test gauge per paragraph 4.5 below, apply the specified test pressure with
suitable gas.
10. Note the pressure at which the valve starts to discharge (STD).
11. Reduce the pressure slowly and note the pressure when the valve is bubble-tight [vapor-
tight pressure (VTP)].
12. If the valve does not function within prescribed pressure ranges as defined in Table D.4,
the cause shall be determined and corrected and the valve retested.
13. Stencil cars as required in accord with Appendix C, paragraph 2.3.3.
14. Prepare documentation as required by DOT and send to car owner.
4.4 Procedure for Retest of Interior Heater Systems
Step Action
1. Fill completely with test liquid. Vent while filling.
2. Install certified test gauge (see paragraph 4.5 below for gauge standards).
3. Apply 200 psig hydrostatic test pressure.
4. Disconnect the pressure source from the heater system.
5. Inspect for leakage while under test pressure. Determine that no leakage occurs. Maintain
test for 10 minutes.
6. Remove test liquid completely.
7. Stencil car as required in accord with Appendix C, paragraph 2.3.3.
8. Complete documentation as required by DOT and send to the car owner.
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M-1002 APPENDIX D
4.5 Test Gauge Standards

4.5.1 Gauges preferably shall be at least 4 in. in diameter and shall be graduated over a range of
approximately twice the maximum test pressure. Gauges shall be of grade 1A (1.0% of span,
excluding friction) accuracy per ANSI/ASME B40.1. Gauges may be equipped with static (lazy)
hands.
4.5.2 Gauges must be recalibrated at least once each six months or at any time there is reason to
believe they are in error. Tests are to be by deadweight or master gauge method, and gauges shall
be date-tagged accordingly.
Table D.4 Allowable pressure relief valve pressure tolerances
Maximum
Nominal Gauge Gauge
STDa/ (psig) Tolerance Minimum Maximum Minimum Rangee/ Incremente/
b/ (+/-)c/ (psig) STD (psig) STDa/ (psig) VTPd/ (psig) (psig) (psig)
35 3 32 38 28 0100 1
75 3 72 78 60 0150/160 1
150 4.5 145.5 154.5 120 0300 2
225 6.75 218.25 231.75 180 0400 5
247.5 7.4 240.1 254.9 196 0400 5
255 7.7 247.3 262.7 204 0400 5
280.5 8.4 272.1 288.9 224 0500 5
300 9 291 309 240 0500 5
330 10 320 340 264 0500 5
375 11.25 363.75 386.25 300 0600 10
450 13.5 436.5 463.5 360 0750 10
For tank tests to 60 psig 0150/160 1
For tank tests above 60 psig to 200 psig 0400 5
For tank tests between 200 psig and 400 psig 0600 10
For tank tests over 400 psig 01000 20
Internal Heater Systems 0400 5
Notes:
a/ STD = start-to-discharge.
b/ Valves should be set or reset to NOMINAL STD pressure.
c/ DOT requirements for tolerances are given at 49 CFR 179.15. Pressure tolerances listed
above have been shown here to assist testing personnel and are not intended to alter any DOT
requirements.
d/ VTP = vapor-tight pressure
e/ Digital or dial gauges of greater range may be used if accuracy and sensitivity levels are equal
to or better than required above.
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APPENDIX D M-1002
Fig. D.3 Recommended sequence and tightening procedures for resecuring tank car tank manway covers, valves,
fittings, and flanges
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M-1002 APPENDIX D
5.0 CERTIFICATE OF TEST FORM

5.1 The retesting of tank car tanks, pressure relief valves, and heater systems, either singly or
any combination thereof, must be reported by the party making the tests. Reports must be
submitted to and retained by the tank car owner. Submittal of the report may be on Fig. D.4,
Certificate of Test Form, or other equivalent form that will certify that all tests and pertinent
information are reported in accordance with DOT 180.517(b). Use either conventional or SI units.
5.2 The following instructions must be followed by the party or facility reporting tests to ensure
that all required information will be furnished, regardless of the form used:
Line Instruction
1. The reporting marks and car numbers must be those that are or will be recorded in the
Official Railway Equipment Register covering the cars being tested. Fig. D.4, Certificate of
Test Form, allows one car to the form.
2. Show the tank specification to which the tank is presently certified. (This item must be
known to make sure that the tank is tested to the required pressure, in lieu of any lower
pressure indicated by the stenciled specification.)
3. When the car is being operated under another specification, the stenciled specification
must be entered here.
4. Show the capacity in U.S. gallons (liters). For nonpressure cars, record shell-full volume.
For pressure cars, record shell-full volume plus the volume of the manway nozzle.
5. Show the pressure to which the tank was tested.
6. Show the pressure to which the interior heater system was tested. [Minimum to be not less
than 200 psi (1379 kPa)].
7. This item is divided into two identical sections to record the following data for one or more
pressure relief valves as required by car design. Pressure relief valves are numbered from
the B-end or the BL-side.
a. Show the name and location of the company testing the pressure relief valve.
b. Show the name and location of the company applying the pressure relief valve.
c. Show the pressure relief valve manufacturer and the model number.
d. Show the serial number of the specific valve tested.
e. This item must show the start-to-discharge pressure of the valve being tested and must
be within the tolerance for the given valve setting in DOT 179.15(b)(5). Note: For a
pressure relief valve used in combination with a breaking pin or rupture disc, the
requirements of DOT 179.15(e)(3) apply, and the pressure relief valve tests at the
reduced test pressure must be shown.
f. This item must show the vapor-tight condition of the valve being tested and must not
be less than the minimum for the given valve setting in the applicable retest table.
Note: For a pressure relief relief valve used in combination with a breaking pin or rup-
ture disc, the requirements of DOT 179.15(e)(3) apply, and at least the minimum
reduced vapor-tight pressure must be shown.
g. This item indicates whether or not the elastomeric valve seals have been replaced.
Enter a yes or no.
h. If the answer to item g. is yes, indicate the material of construction of the new
elastomeric seals.
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APPENDIX D M-1002
Line Instruction
8. This item is divided into two parts for the information required when the pressure relief
valve is equipped with a combination device (breaking pin or rupture disc).
a. Show the pressure rating of the rupture disc.
b. Show the pressure to which the complete breaking pin device was tested with the lower
diaphragm in place.
Note: See Appendix C, paragraph 2.3.3.2, for stenciling requirements for tank cars
equipped with combination pressure relief devices.
9. This item is divided into two parts to describe the rupture disc devices on the car.
a. Indicate the number of rupture disc devices on the car.
b. Indicate the pressure rating of the rupture disc applied to the tank car after test.
10. Certify that the excess flow valves have been checked for tightness.
11. This item must record the components being tested and the corresponding dates they were
last tested.
Note: A pressure relief valve applied from stock that was tested within six months of
installation and protected from deterioration may be considered as having been tested on
the date of installation and may be so stenciled.
12. This item records the built/conversion date of the car, as well as the date of the last test, if
different.
13. This item is divided into three parts to indicate the year stenciled on the car that the tank,
pressure relief valve, and/or interior heater system will be due for next test.
a. Tank (date stenciled on car)
b. Pressure relief valve (date stenciled on car)
c. Interior heater system (date stenciled on car)
14. Record the name and location of the facility that performed the tank and/or heater system
test.
The individual responsible for certification attests to the accuracy of the tests indicated
above by signing and dating at the bottom of the form.
C-III [M-1002] 212 11/2014

M-1002 APPENDIX D

1. Reporting marks and car number
2. Tank specification
3. Stenciled specification
4. Tank capacity in gallons (liters)
5. Tank test pressure, psi (kPa)a/
6. Interior heater system test pressure, psi (kPa)a/
7. Pressure relief valve (PRV) No. 1 No. 2
a. Name and location of company performing test of PRV
b. Name and location of company applying PRV
c. Manufacturer and model/type number
d. Serial number
e. Start-to-discharge pressure, psi (kPa)b/
f. Vapor-tight pressure, psi (kPa)b/
g. Valve seals replaced (Y/N) (only those exposed to product)
h. New seal material
8. Combination device
a. Rupture disc pressure, psi (kPa)
b. Breaking pin lower diaphragm tight at psi (kPa)
9. Rupture disc device
a. Number of rupture disc devices
b. Rupture disc pressure, psi (kPa)
10. Excess flow valve seat tightness checked (Y/N)
11. Test date (date stenciled on car)
12. Tank built/conversion date
13. Test due stencil
14. Name and location of company performing tank and/or heater
system test
a/ Tested with hydrostatic pressure shown, for the required time period, without leaks or evidence of distress.
b/ Valve has been set to start-to-discharge and is vapor-tight at pressure shown. For combination devices, the
start-to-discharge and vapor-tight pressures of the valve portion is shown.
I HEREBY CERTIFY THAT TESTS PERFORMED TO TANK CAR TANKS, PRESSURE RELIEF VALVES
AND/OR HEATER SYSTEMS WERE DONE IN ACCORD WITH THE DEPARTMENT OF TRANSPORTATION
REGULATIONS AND THE AAR SPECIFICATIONS FOR TANK CARS AND REPORTED CORRECTLY.
Date (Signed) Owner/Tester

Fig. D.4 Certificate of Test Form
11/2014 C-III [M-1002] 213

APPENDIX D M-1002
6.0 HINGED AND BOLTED AND STRAP-STYLE MANWAY COVER MAINTENANCE

At each tank qualification, the following inspections, maintenance operations, and tests shall be
performed on each hinged and bolted nonpressure car manway assembly.
6.1 Manway Cover
6.1.1 Clean and visually inspect the gasket seating surface for defects. The surface is to be
smooth and may have machining marks and/or 1/32 in. deep concentric or spiral grooves machined
into surface. Gouges, nicks, and other defects are acceptable up to 1/8 in. in diameter and 1/32 in.
deep, provided all surrounding high spots are removed. Larger defects, or those suspected to
impair sealing, shall be repaired by welding (except on covers made of ductile or malleable iron)
and/or remachining, or by replacement. Machined gasket seating surfaces shall be smooth within
125500 microinches RMS maximum roughness. Corroded or rusted gasket surfaces shall be
cleaned to expose noncorroded or nonrusted metal. Surfaces that cannot be cleaned up shall be re-
machined or replaced.
6.1.2 Inspect cover operation. With the gasket removed, close the cover lightly and check that the
hinge pin is free. Free up, if necessary. With a new gasket installed, close the cover lightly and
check that at least 1/8 in. clearance exists at all possible contact interference points, such as at
dimension A on the applicable manway style chart (Tables D.5 through D.10). Check cover for
centering.
6.2 Gaskets
6.2.1 Exercise care when removing the old gasket and any gasket cement from the gasket seating
surface before installing a new gasket. Install a new gasket compatible with the commodity as
required in Appendix A, paragraph 2.2.4.
6.2.2 Gasket size must correspond to the following:
The Manway Style Chart (Tables D.5 through D.10 and D.12); or
A manway nozzle rim style gasket shown in Table D.11, provided the gasket seats and
seals properly; or
A gasket designed to conform to the requirements of Appendix E, paragraph 3.3.5.3.
6.3 Manway Nozzle
6.3.1 Inspect the gasket seating surface for gouges, nicks, and other defects. File, grind, or
machine raised displaced metal as detected by a straight edge. After removing raised metal,
defects that are deeper than 1/32 in. and are continuous across the gasket seating surface are not
acceptable. Repair defects by welding and grinding/filing or by machining. The gasket seating
surface shall be smooth within 125500 microinches RMS maximum roughness with no defects
deeper than 1/32 in. continuous across the gasket surface.
6.3.2 Inspect eyebolt and hinge lugs on the nozzle. Repair any distortion, corrosion, or cracks
found.
C-III [M-1002] 214 11/2014

M-1002 APPENDIX D
6.4 Eyebolts and Nuts

6.4.1 Inspect eyebolts for corrosion, damaged threads, excess paint, and residual commodity. Any
defect that prevents the required nut engagement by hand is cause for cleaning, repair, or
replacement.
6.4.2 Gauge the major diameter of the external eyebolt threads over the nut clamping surface
using a calibrated GO/NO-GO gauge per ANSI/ASME B1.2, Table 1, or an equivalent calibrated
gauge. The limiting dimension shall be the Class 1A minimum major diameter thread size.
6.4.3 Inspect eyebolt hinge pins. Pins are to be replaced if wear or corrosion exceeds 25% of
original thickness.
6.4.4 Inspect to ensure that all manway eyebolt nuts on a given car are of the same configuration
and size (i.e., heavy square or heavy hex).
6.4.5 Inspect safety eyebolts to ensure the cover cannot be opened while the tank is under
pressure.
6.5 Testing
6.5.1 Any repairs to gasket seating surfaces or cover replacement require the manway to be gas
tested for leaks at 15 psig minimum unless a hydrostatic tank retest is performed, subjecting the
tank cars manway cover and gasket to tank test pressure.
6.5.2 If the manway securement fails the above testing, the manway nozzle should be checked for
out-of-round condition, which may prevent a proper gasket seal.
6.6 Tightening of Bolts
6.6.1 Tightening sequence is to be as follows:
Fig. D.5 Bolt tightening sequence

6.6.2 Determine that thread surfaces are clean.
6.6.3 Tighten nuts finger-tight.
6.6.4 Tighten nuts by wrench in sequential order per the appropriate bolt pattern.
6.6.5 After sequentially tightening, use rotational tightening and reverse rotational tightening
until stable.
11/2014 C-III [M-1002] 215

APPENDIX D M-1002
6.7 Strap-Style Manway Straps, Tee Bolt, and Screw Coupling

6.7.1 Inspect the strap assembly, including hinge pin, for corrosion, wear, cracks, and
deformation. Repair per manufacturers instructions.
6.7.2 Inspect the tee bolt and screw coupling for corrosion, damaged threads, excess paint, and
residual commodity. Any defect that prevents the required screw coupling engagement by hand is
cause for cleaning, repair, or replacement.
6.7.3 It is recommended to lubricate the straps inner surface with a dry lubricant, and lubricate
the tee bolt and screw coupling threads with a light coating of thread lubricant.
6.7.4 Inspect the safety latch to ensure that the cover cannot be opened while the tank is under
pressure.
Fig. D.6 Kelso strap-style manway
C-III [M-1002] 216 11/2014

M-1002 APPENDIX D
Table D.5 Manway Style Chart for ACF Industries, Inc.a/

(page 1 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD ID THbtK) Diagramc/
Elastomeric A
ACF-1
18"/8
(3152118)
Hard 19 1/4" 17" 1/8"
Elastomeric A
ACF-2
20"/8
(3156812)
Hard 21 1/4" 18 7/8" 1/8"
ACF-3 Elastomeric 19" 16 3/4" 1/8" A

(3156932) 18"/8
(3-A-0670) Hard 19 1/4" 16 7/8" 1/8"
Elastomeric 20 1/2" 17" 1/8" A

ACF-4
18"/8
(417-25270)
Hard 20 1/2" 17" 1/8"
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at A for gasket compression before tightening bolts.
11/2014 C-III [M-1002] 217

APPENDIX D M-1002

(page 2 of 3)
25 1/4" 22 7/8" 1/8" A

Elastomeric
ACF-5 25 1/4" 22 7/8" 1/4"
24"/8
(41-74527)
Hard
25 1/4" 22 7/8" 1/8"
21 7/8" 19 1/2" 1/8"

Elastomeric A
ACF-6
20"/8
(3-C-6848) 21 7/8" 19 1/2" 1/8"
Hard
A
Elastomeric 21 1/2" 18 3/4" 1/4"
ACF-7
20"/8
(3-A-5299C)
Hard 21 5/8" 18 7/8" 1/8"
Elastomeric A
ACF-8
18"/8
(3-N-3680)
Hard 19 1/2" 16 7/8" 1/8"
C-III [M-1002] 218 11/2014

11/2014 Specifications for Tank Cars
M-1002 APPENDIX D

(page 3 of 3)
Elastomeric A
ACF-9
20"/8
(3-F-6077)
Hard 21 1/4" 18 7/8" 1/8"
Elastomeric 21 7/8" 18 7/8" 1/8"

A
ACF-10
20"/8
(3-A-5299G) Hard 21 7/8" 18 7/8" 1/8"
21 7/8" 18 7/8" 1/4"
Elastomeric 21 7/8" 18 7/8" 1/8" A

ACF-11
(5-K-2375) 20"/6
Hard 21 7/8" 18 7/8" 1/8"
(5-K-4404)
21 7/8" 18 7/8" 1/4"
Elastomeric 21 1/8" 19 3/4" 1/4" A

ACF-12
20"/8
(3-D-5271)
Hard
11/2014 C-III [M-1002] 219

APPENDIX D M-1002
Table D.6 Manway Style Chart for General American Transportation Companya/
(page 1 of 3)
Manway Style Number of Boltsb/ Gasket Type (OD ID THK) Diagramc/

GATX #1 20"/6
Hard 22" 19" 1/4"

GATX #2 20"/6
Hard 21 1/2" 19 1/4" 1/4"
Elastomeric 21 7/8" 19" 1/4"

A
GATX #3 20"/6
Hard 21 5/8" 19" 1/4"
Elastomeric 21 1/2" 18 5/8" 1/4"

A
GATX #4 20"/6
Hard 21 1/2" 18 3/4" 1/4"
C-III [M-1002] 220 11/2014

M-1002 APPENDIX D
(page 2 of 3)
Elastomeric 22 1/4" 19 1/4" 3/16" A

GATX #5 20"/6
Hard 22 1/8" 19 3/8" 1/8"

GATX #6 20"/8
Hard 21 5/8" 19" 1/4"

GATX #7 18"/8
Hard 19 3/8" 17" 1/4"
Elastomeric 21 1/2" 19 1/4" 1/4"

A
GATX #8 20"/8
Hard 21 11/16" 19 5/8" 1/4"
11/2014 C-III [M-1002] 221

APPENDIX D M-1002
(page 3 of 3)
Elastomeric 19 5/8" 17 1/2" 1/4"

GATX #9 18"/8 A
Hard 19 5/8" 17 1/2" 1/4"
Elastomeric 21 1/4" 19 5/8" 1/4"

A
GATX #10 20"/10
Hard 21 1/4" 19 7/8" 1/4"
Table D.7 Manway Style Chart for General Electric Railcar Servicesa/
A
GE-1 18"/8 Elastomeric 19 3/8" 17" 1/8"
A
GE-2 20"/8 Elastomeric 21 3/8" 19" 1/8"
C-III [M-1002] 222 11/2014
M-1002 APPENDIX D
Table D.8 Manway Style Chart for Trinity Industries, Inc.a/

Elastomeric 21 1/2" 19 1/4" 1/4" A

TRN-1 20" ID/6
Hard 21 11/16" 19 5/8" 1/8"
Elastomeric 21 1/2" 19 1/4" 1/4" A

TRN-2 20" ID/8
Hard 21 11/16" 19 5/8" 1/8"
Elastomeric 21 1/2" 18 7/8" 1/8" A

TRN-3 20" ID/8
Hard 21 1/2" 18 7/8" 1/8"
Elastomeric 22 1/4" 19 1/4" 1/8" A

TRN-4 20" ID/10
Hard 22 1/16" 19 7/16" 1/8"
11/2014 C-III [M-1002] 223

APPENDIX D M-1002
Table D.9 Manway Style Chart for Union Tank Car Companya/
(page 1 of 3)
Elastomeric 21 1/2" 19 7/16" 1/8" A

UTC-1 20"/8
Hard 21 12" 19 7/16" 1/8"
A
Elastomeric 19 1/2" 17 7/16" 1/8" A

UTC-2 18"/6
Hard 19 1/2" 17 7/16" 1/8"
A
Elastomeric 19 1/2" 17 7/16" 1/8" A

UTC-3 18 1/2"/6
Hard 19 1/2" 17 7/16" 1/8"
A
Elastomeric 21 7/16" 19 3/4" 1/4" A

UTC-4 20"/8
Hard
A
Elastomeric 21 1/8" 19 3/4" 1/4" A

UTC-5 20"/8
Hard
A
Elastomeric 21 5/16" 20 3/16" 1/4" A

UTC-6 20"/8
Hard
A
d/ RTC denotes cars originally built by Richmond Tank Car Company.
C-III [M-1002] 224 11/2014

M-1002 APPENDIX D
(page 2 of 3)

SOFT
UTC-7 20"/8
Hard 21 13/16" 19 9/16" 1/8"
A
HARD
A
Elastomeric 20 1/8" 17" 1/4"
SOFT
UTC-8 18"/6
Hard 19 13/16" 17 9/16" 1/8" A
HARD
A
Elastomeric 23" 20 5/16" 1/8"
UTC-9 21"/8
Hard 23" 20 1/2" 1/8"
Elastomeric 21 1/2" 19 5/16" 1/8" A

UTC-10 20"/8
Hard 21 1/2" 19 5/16" 1/8"
Elastomeric 21 1/2" 19 1/2" 1/4" A

UTC-11 20"/6
Hard 21 1/4" 19 1/2" 1/8"
A
Elastomeric 19 1/2" 17 1/2" 1/4" A

UTC-12 18"/4
Hard 19 1/4" 17 1/2" 1/8"
A
11/2014 C-III [M-1002] 225

APPENDIX D M-1002
(page 3 of 3)
Elastomeric 19" 18 1/2" 1/4" dia.

UTC-13 18"/8
Hard
Elastomeric 19" 18 1/2" 1/4" dia.

UTC-14 18"/8
Hard
Elastomeric 21 5/8" 18 3/4" 1/4" A

RTC-1d/ 20"/8 Hard 21 5/8" 18 3/4" 1/8"
21 5/8" 19" 1/4"
A
Elastomeric 21 5/8" 18 3/4" 1/4" A

RTC-2d/ 20"/6 Hard 21 5/8" 18 3/4" 1/8"
21 5/8" 19" 1/4"
RTC-3d/ 18"/8 Elastomeric 19" 16 3/4" 1/8" dia.

A
Table D.10 Manway Style Chart for AAR Standard Gasketsa/

Elastomeric 21 11/16" 19 1/2" 1/4"

See Figs. E.26A, B, and C for typical
AAR-1 20"/6-8-10
manway cover gasket grooves.
Hard 21 5/8" 19 1/2" 1/8"
C-III [M-1002] 226 11/2014

M-1002 APPENDIX D
Table D.11 Manway Style Chart for Alternate Manway Gasket Styles
Manway Style Number of Boltsa/ Gasket Type (OD ID THK) Diagramb/
See Manway Style

GATX #3, 6, 7 Elastomeric Bevel groove style
Chart
GASKET
20"/6
GASKET
GATX #3,6 with 5/8"wall Elastomeric Nozzle rim style
nozzle
20" I.D.
NOZZLE
20"/6-8-10
Elastomeric GASKET
Various with 5/8" wall Nozzle rim style
or hard
nozzle
20" I.D.
NOZZLE
18"/6-8-10
Elastomeric GASKET
Various with 5/8" wall Nozzle rim style
or hard
nozzle 18" I.D.
NOZZLE
a/ Recommend manway eyebolts be lightly lubricated.

b/ Check for interference between nozzle rim gasket and shear ring on manway cover.
Table D.12
Manway Style Number of Boltsa/ Gasket Type (OD ID THK) Diagramb/
21 5/8" 19 1/2" 1/8"
Elastomeric 21 5/8" 19 1/2" 3/16"
21 5/8" 19 1/2" 1/4"
Klincher 20"/1
Hard 21 11/16" 19 5/8" 1/8"
a/ Recommend manway eyebolts be lightly lubricated.

b/ Check for interference between nozzle rim gasket and shear ring on manway cover.
11/2014 C-III [M-1002] 227

APPENDIX D M-1002
C-III [M-1002] 228 11/2014

M-1002 APPENDIX E
APPENDIX E
DESIGN DETAILS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III231
1.2 Dimensions and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III231
1.3 Tolerance for Single-Unit Tank Car Tank Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III232
1.4 Ellipsoidal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III232
2.0 Reinforcement of Head and Shell Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III233
2.1 Acceptable Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III233
2.2 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III233
2.3 Reinforcement Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III233
2.4 Dome Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III234
2.5 Openings in Knuckle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III234
2.6 Nozzle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III234
3.0 Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III234
3.1 DesignCovers for Pressure Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III234
3.2 Openings in Pressure Car Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III235
3.3 DesignCovers for Nonpressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III236
3.4 Openings in Protective Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III237
3.5 Pressure Car Manway Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III237
4.0 Pressure Relief Device Connections for Nonpressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III237
4.1 Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III237
5.0 Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III238
5.1 Joint Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III238
5.2 Plug Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III238
5.3 Design Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III239
5.4 Abutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III239
5.5 Transition Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III239
6.0 Compartment Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III240
6.1 Inserted Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III240
6.2 Compartments Constructed as Separate Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III240
7.0 Vertical Curve Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III241
8.0 Protection of Bottom Discontinuities on Class 105A, 109A, 112A, 114A, and 120A Tank Car Tanks C-III242
9.0 Protection of Bottom and Top Discontinuities on Nonpressure Tank Car Tanks . . . . . . . . . . . . . . . . C-III243
9.1 Bottom Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III243
9.2 Top Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III245
10.0 Noncircular Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III246
11.0 Anchor Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III249
12.0 Head-to-Sill Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III250
13.0 Bottom Outlet Valve and Nozzle Arrangements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III251
11/2014 C-III [M-1002] 229
APPENDIX E M-1002

14.0 Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III251
14.1 Requirements for Use of Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III251
14.2 Design of Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III251
15.0 Tank Bottom Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III252
C-III [M-1002] 230 11/2014

M-1002 APPENDIX E
APPENDIX E
DESIGN DETAILS
1.0 INTRODUCTION
1.1 Scope
Appendix E describes AAR requirements for certain design details on tank cars and tank car
tanks.
1.2 Dimensions and Tolerances
1.2.1 The illustrations in this appendix are intended to indicate the degree of standardization
and interchangeability required and are not construction drawings. Methods of dimensioning and
geometric characteristics such as concentricity, roundness, and symmetry should conform to ANSI
Y14.5, Dimensioning and Tolerancing.
1.2.2 The following notes apply to illustrations in Figs. E.5 through E.13 and E.19 through
E.19.25:
1.2.2.1 Unless otherwise specified, standard tolerances for decimal dimensions are 0.005 in. and
standard tolerances for fractional dimensions are 1/64 in.
1.2.2.2 Unless otherwise specified, the fit of screw threads is Class 2A and 2B (ANSI B1.1).
1.2.2.3 Standard tolerance on taper pipe threads is 1 thread.
1.2.2.4 Engagement of taper pipe threads conforms to American Standard Taper Pipe Threads
(NPT) (ANSI B2.1).
Table E.1 Engagement of taper pipe threads

Size of Length of
Thread Normal Hand Engagement Effective Thread
1 1/4 0.420 0.707
2 0.436 0.757
2 1/2 0.682 1.138
3 0.766 1.200
3 1/2 0.821 1.250
11/2014 C-III [M-1002] 231

APPENDIX E M-1002
1.2.2.5 Recommended drills for taps are as follows:
Table E.2 Recommended drills for taps

Thread Size Drill Size
3/4 in.10 21/32 in.
7/8 in.9 49/64 in.
1 1/4 in. NPT 1 1/2 in.
2 in. NPT 2 7/32 in.
2 1/2 in. NPT 2 5/8 in.
3 in. NPT 3 1/4 in.
3 1/2 in. NPT 3 3/4 in.
1.2.2.6 Bolt holes are equally spaced 1/64 in.
1.2.2.7 Chlorine service requires 3A and 3B fit for the tap end and 2A and 2B fit for the nut end
of the stud (ANSI B1.1).
1.2.2.8 For stud holes, the stated depth of the thread is the minimum full thread engagement,
and the stated depth of the hole is the maximum depth.
1.2.3 The following notes apply to Figs. E.18 through E.18.9 for bottom outlet caps and nozzles:
1.2.3.1 The thread dimensions on the bottom outlet connections in Figs. E.18 through E.18.9 are
standardized to conform with ANSI B1.1, except nozzle threads, only, have dimensions reduced by
0.020 in. (0.508 mm) to allow for product build-up and corrosion.
1.2.3.2 To identify manufactured parts conforming with this standard, E18 is to be cast or steel
stamped on a surface not subject to wear.
1.3 Tolerance for Single-Unit Tank Car Tank Heads
1.3.1 The inner surface of a torispherical (flanged and dished) or ellipsoidal head must not
deviate outside of the specified shape by more than 1.25% of D nor inside the specified shape by
more than 0.625% of D, where D is the nominal inside diameter of the head skirt (straight flange)
at point of attachment to the shell. Such deviation must be measured perpendicular to the
specified shape and must not be abrupt. The knuckle radius must not be less than specified.
1.3.2 Measurements for determining the tolerances must be taken from the surface of the base
metal and not from the welds.
1.3.3 The skirts of heads must be sufficiently true to round so that the difference between the
maximum and minimum diameters will not exceed 1% of the nominal diameter.
1.4 Ellipsoidal Heads
Heads formed to an approximate ellipsoidal shape are acceptable as ellipsoidal heads, provided the
resulting formed shape falls within the envelope created when the tolerances established in
paragraph 1.3 above are applied to the shape specified for a true ellipsoidal head.
C-III [M-1002] 232 11/2014

M-1002 APPENDIX E
2.0 REINFORCEMENT OF HEAD AND SHELL OPENINGS

2.1 Acceptable Designs
The following requirements apply to openings in shells or heads, except that openings in the
knuckle area of heads must conform to paragraph 2.5 below. The openings shown in Figs. E.20
through E.20.12 are approved. Other designs may be submitted for approval.
2.2 Calculations
Reinforcement for tank openings must be calculated by the following method:
Area available within the rectangle abcd (see Figs. E.20 through E.20.12)
Area required for nonpressure tanks = 2Dte
Area required for pressure tanks = 2.2Dte
Excess Area = area available minus area required
where
D = diameter of finished opening in the plane of the cut-out, in. (mm)
e = 0.90 when opening is in solid plate or flued-type reinforcement
1.00 when opening intersects any joint in the tank shell
K = actual reinforcement pad thickness, in. (mm)
M = actual tank thickness, in. (mm)
N = actual dome or nozzle wall thickness, in. (mm)
R = corner radius of flued-type reinforcement, in. (mm)
t = calculated required head or shell thickness, in. (mm)
2.3 Reinforcement Zone
2.3.1 The boundary of reinforcement zone must be determined as follows: The length ac or bd
(see Figs. E.20 through E.20.12) must be equal to the diameter of the finished opening in the tank
shell on each side of the axis of the opening. For flued openings abutting the tank shell (Figs.
E.20.2 and E.20.6), the length ac or bd must be equal to twice the inside diameter of the dome or
nozzle.
The dimension ab or cd must not exceed 2 1/2 times the actual shell thickness, or 2 1/2 times the
dome shell (or nozzle) wall thickness plus the thickness of any added reinforcement, whichever is
less, above and below the tank shell, except that, for reinforcement flued from solid plate, this
dimension may be equal to the corner radius R above the reinforcement but must not exceed 3 in.
(76.2 mm). When the dome shell is located outside the reinforcement boundary abcd, as shown in
Fig. E.20.4, only 2 1/2 M must be used to determine the dimension above and below the tank shell.
2.3.2 The required reinforcement area must be provided in all planes passing through the center
of the opening and normal to the tank surface.
2.3.3 The reinforcement area available must be adjusted, if any material within the rectangle
abcd has an allowable stress value less than that of the tank shell material, by multiplying the
reinforcement area available by the ratio of the allowable stress value to that of the tank shell
material. No credit may be taken for additional strength of any reinforcement having a higher
allowable stress value than that of the tank itself.
2.3.4 Any weld metal within the boundary of reinforcement may be included as area available.
When so included, it must be credited with an allowable stress value equivalent to the weaker of
the materials connected by the weld.
2.3.5 No metal added as corrosion allowance may be considered as reinforcement.
11/2014 C-III [M-1002] 233

APPENDIX E M-1002
2.4 Dome Reinforcement

2.4.1 When the diameter of the opening in the tank shell within the dome exceeds 30 in.
(762 mm) and a flued type opening is not used, the dome shell must be reinforced as follows:
2.4.1.1 The dome shell reinforcement must be provided below a horizontal plane 4 in. (102 mm)
above the top of the tank shell down to the intersection between the dome shell and the tank shell.
This reinforcement must not be included in the reinforcement zone stated in paragraph 2.3.1
above when calculating the tank shell reinforcement.
2.4.1.2 The total thickness of the dome, within the boundaries defined in paragraph 2.4.1.1
above, must be not less than twice the larger of the thickness specified in DOT 179.200-6(a) (or
former reference 179.201-2) multiplied by 1 plus the ratio of the inside dome diameter (IDD)
divided by twice the inside tank diameter (ITD). See Fig. E.20.9 or Fig. E.20.10.
2.4.1.3 The dome shell thickness within the boundaries defined in paragraph 2.4.1.1 above must
consist of not more than two plates of the same material.
2.5 Openings in Knuckle Area
2.5.1 Any portion of an opening extending beyond the center 80% of the head diameter is
considered to fall within the knuckle area.
2.5.2 All requirements of paragraph 2.2 above must be met.
2.5.3 Diameters must be measured in the plane of the opening.
2.5.4 Not less than 50% of the required material must be on each side of the centerline of the
opening.
2.5.5 The ratio of the diameter along the major axis to the diameter along the minor axis must be
1.5, or less, measured in the plane of the opening.
2.6 Nozzle Connections
Nozzle reinforcements must be attached by welds having strengths no less than given by the
parameter W in Fig. E.16.
3.0 MANWAY COVERS
3.1 DesignCovers for Pressure Cars
3.1.1 The dimensions and tolerances for the standard 18 in. manway cover are shown in Figs.
Fig. E.5 and Fig. E.6. The dimensions and tolerances for the standard 20 in. manway cover are
shown in Figures Fig. E.7 and Fig. E.8. Modified designs may be submitted for approval.
3.1.2 For larger diameter manways, the diametral dimensions must be increased
commensurately.
3.1.3 The minimum thickness of a manway cover must conform to DOT 179.101-1(a).
C-III [M-1002] 234 11/2014

M-1002 APPENDIX E
3.1.4 If the thickness calculated by the following formula exceeds that listed in DOT
179.101-1(a), the calculated thickness is the required minimum.
t = d 0.3p
----------- + 1.78Whg
----------------------- t = d 0.0003p
-------------------- + 1.78Whg
-----------------------
S Sd
3 S Sd
3
where where
t = thickness of manway cover required at center, in. t = thickness of manway cover required at center, mm
d = mean diameter of gasket groove, in. d = mean diameter of gasket groove, mm
hg = 1/2 [manway bolt circle diameter minus d], in. hg = 1/2 [manway bolt circle diameter minus d], mm
p = pressure relief valve flow rating pressure shown in p = pressure relief valve flow rating pressure shown in
Appendix A, Table A.2 or A.3, psi Appendix A, Table A.2 or A.3, kPa
S = 1/3 minimum tensile strength value for cover S = 1/3 minimum tensile strength value for cover
material, as shown in Appendix M, psi material,as shown in Appendix M, MPa
W = 2 W = 2
0.3927d p + 0.7854dmp + 152,500 lb 0.3297d p- + 0.7854dmp
------------------------- ----------------------------- + 678 000 , N
m = 2.00 for 1/8 in. thick unfilled PTFE gasket, in. 1000 1000
or m = 50.8 for 3.18 mm thick unfilled PTFE gasket, mm
3.00 for spiral-wound stainless steel gasket,a/ in. or
76.2 for spiral-wound stainless steel gasket,a/ mm
a/ For other gasket materials, see ASME Code for Unfired Pressure Vessels, Section VIII,
Division 1.
3.1.5 For cars built after April 1, 1996, studs for pressure-retaining parts and protective housing
covers must engage for a minimum depth equal to the diameter plus 1/8 in. As a minimum, nuts
must be fully engaged; that is, no nut threads may be showing.
3.1.6 Cars built or altered after December 1, 2003, for transportation of Class 2 or PIH materials,
with the exception of those listed below, must have manway covers that are designed to
accommodate capping kits. Sufficient clearance for capping kits must exist above and around all
fittings. Accommodations must be made for closures and safety chains. Port openings must be of a
suitable size for capping kit brackets and must be oriented to facilitate capping. See Figs. E.29 and
E.30 for typical capping kit dimensions and clearance requirements. The following cars are
excepted from this requirement:
Cars transporting carbon dioxide
Class DOT-113 and AAR-204W cars
Cars altered to remove slip tube gauging devices under Chapter 1, paragraph 1.3.9.
3.2 Openings in Pressure Car Manway Covers
3.2.1 Manway covers may be equipped with openings as illustrated in Figs. E.19 through E.19.23,
inclusive, or other approved openings.
3.2.2 Openings less than 2 3/8 in. (60.3 mm) diameter need not be reinforced.
3.2.3 When two or more openings are spaced center-to-center closer than two times their average
diameter, reinforcement must be provided. To provide this reinforcement, the manway cover
thickness must be calculated by either of the following methods:
3.2.3.1 Assume a single opening, concentric with the cover gasket surface, of a diameter that will
circumscribe all through openings in the group, and calculate as provided in paragraph 3.2.4
below.
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APPENDIX E M-1002
3.2.3.2 Calculate as provided in paragraph 3.1.4 above, except that the quantity under the
square root sign in the equation must be doubled.
3.2.4 Manway covers having an opening greater than one half of dimension d must be designed
as a loose flange in accord with ASME Code for Unfired Pressure Vessels, Section VIII, Division 1.
3.3 DesignCovers for Nonpressure Cars
3.3.1 Flat manway covers for nonpressure cars must be designed in accord with ASME Code for
Unfired Pressure Vessels, Section VIII, Division 1, Part UG-34, except as provided in
paragraph 3.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part
UG-39.
3.3.2 Dished manway covers for nonpressure cars must be designed in accord with ASME Code
for Unfired Pressure Vessels, Section VIII, Division 1, Appendix 1-6, except as provided in
paragraph 3.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part UG-
37.
3.3.3 The following additions or exceptions to ASME Code must be used when calculating covers
in accord with paragraphs 3.3.1 and 3.3.2 above:
S = 1/3 minimum tensile strength value for cover material, as shown in the appropriate
ASTM or AAR specification
P = tank test pressure
When the bolt spacing exceeds 2a + t, the maximum flange moment must be multiplied by
the factor
bolt spacing-
----------------------------
2a + t
where
a = nominal bolt size
t = flange thickness
3.3.4 As an alternate to the requirements of paragraph 3.3.1 or 3.3.2 above, the cover may be
proven by testing as follows:
3.3.4.1 The closure must hold 1.25 times the prescribed tank test pressure for a minimum of
10 minutes without leakage or evidence of stress.
3.3.4.2 The test must be conducted with the closure secured to its typical mating components,
without special sealing techniques, using gaskets and bolting materials as intended for service.
3.3.4.3 Stresses in the closure must not exceed the materials specified minimum yield strength,
as shown in the appropriate ASTM or AAR specification.
3.3.5 Hinged manway covers applied to new tank cars after July 1, 1996, are to be designed to
retain, under normal operating conditions, the manway gaskets listed in paragraph 3.3.5.3 below
and designated as standard manway style AAR-1 (see appropriate manway style chart in
Appendix D, Tables D.5 through D.10 and D.12). Typical machined grooves are illustrated in
Fig. E.26. Other groove configurations or retention methods are acceptable provided that the
following criteria are met:
3.3.5.1 Elastomeric flat gaskets retained by the manway cover are to be retained by overlapping
the manway cover gasket groove on both the inside and outside edges. This overlap is to be 1/16 in.
on the inside and 1/32 in. on the outside, nominal dimensions. See Fig. E.26, item C.
3.3.5.2 Hard flat gaskets retained by the manway cover are to be retained by overlapping the
manway cover gasket groove on the inside or outside edges. This overlap is to be 1/16 in. nominal.
See Fig. E.26, items A and B.
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M-1002 APPENDIX E
3.3.5.3 Any gasket configuration that produces an effective seal and provides adequate retention
may be applied at the manway.
3.3.5.4 The hinged manway cover must also be able to properly retain and effectively seal when
equipped with the standard gaskets listed below:
Elastomerica/ gasket: 21 11/16 in. O.D. 19 1/2 in. I.D. 1/4 in. thick
Hard gasket: 21 5/8 in. O.D. 19 1/2 in. I.D. 1/8 in. thick
a/ Elastomeric refers to a solid rubber type material, such as EPDM, Viton,
Buna-N, or Neoprene, without any reinforcement or fibers.
3.3.5.5 Modified designs that are not in accord with the above criteria must be submitted for
approval.
3.3.6 Hinged manway covers are to be designed to allow machining so that the recommended
sealing surface finish for the service gasket may be achieved. The specifications presented below
are guidelines that will produce sealing surfaces compatible with the majority of gasket materials.
Other surface specifications may be submitted for approval.
3.3.6.1 Gasket sealing surfaces are to be machined to obtain a surface finish in the range of
63 microinches to 500 microinches, RMS.
3.3.6.2 Gasket sealing surface may be machined with concentric or spiral grooves. Grooving tool
should have a radius cutting surface.
3.3.7 For a new manway design or for a design not shown in the manway style charts in
Appendix D, Tables D.5 through D.10, design information and appropriate drawings are to be
submitted to AAR for inclusion in M-1002.
3.3.8 For cars built after April 1, 1996, studs for pressure-retaining parts and protective housing
covers must engage for a minimum depth equal to the diameter plus 1/8 in. As a minimum, nuts
must be fully engaged; that is, no nut threads may be showing.
3.4 Openings in Protective Housing Cover
When a weather cover designed for vertical discharge is required to cover an opening in a
protective housing cover, the weather cover must be of the self-closing type. See Fig. E.15 for
typical design.
3.5 Pressure Car Manway Seals
When required for U.S. Customs seal, two adjacent studs on a pressure car manway flange must be
1 1/4 in. longer than standard length and be provided with 3/8 in. seal holes 7/8 in. from the outer
end. The seal holes must be aligned to accept a 1/4 in. diameter by 6 in. long cable seal, Brooks
Cable Seal Lock Model B No. 8903106, or U.S. Customs-approved equivalent. See Figure Fig. E.17.
Sealing compounds may be used to retain stud orientation.
4.0 PRESSURE RELIEF DEVICE CONNECTIONS FOR NONPRESSURE CARS
4.1 Standard Connections
Standard pressure relief device connections are shown in Fig. E.21. Modified designs may be
submitted for approval.
11/2014 C-III [M-1002] 237

APPENDIX E M-1002
5.0 JOINT DESIGN

5.1 Joint Efficiency
For computing the thickness of parts or the strengths of various types of fusion-welded joints by
means of the applicable formulas given in this specification, the joint efficiency, to be used in
connection with the minimum tensile strengths in Appendix M, is as follows:
Table E.3 Joint efficiency

Maximum
Type of Jointa/ Joint Efficiencyb/
Double-welded butt 90
Single full fillet without plug welds End Weld 44
Side Weld 33
Single full fillet in combination with End Weld 52c/
plug welds (see Fig. E.4, item B) or Side Weld 39
single-welded butt with backup (see Fig. E.4, item
D)
Double full fillet End Weld 52
Single-welded butt Shear 36
with backup (see) Tension and
Fig. E.4, items C and D) Compression 81
a/ See Figs. E.3 and E.4.
b/ Values shown must be used, except when specified otherwise in the
individual tank car specifications.
c/ If fillet weld is less than a full fillet, joint efficiency must be 35%.
See Fig. E.4, item C.
5.2 Plug Welds
5.2.1 Plug welds must be used only in conjunction with fillet welds.
5.2.2 The shear value of each plug weld must be computed by the following formula:

2 2
L = 0.63 D 1--- S L = 0.63 D 6.35 S-
------------------------------------------
4 1000
where
D = diameter of the bottom of the hole in which the plug is made, in. (mm)
L = shear value for plug weld, lb (kN)
S = minimum tensile strength of the plate material, psi (MPa)
5.2.3 Plug weld holes must have a diameter not less than T + 1/2 in. (T + 12.7 mm) and not more
than 2 in. (50.8 mm), where T = thickness of plate or attached part in which hole is made.
5.2.4 See paragraph 6.1 below for plug welds on interior compartment heads.
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M-1002 APPENDIX E
5.3 Design Calculations

In the design calculations, using the above joint efficiencies for head-to-shell attachments, the
total shear load on the welded joint must be based on the minimum required bursting pressure of
the tank and must be equated to the shear value of the welded joint, which is the product of the
weld throat area, the minimum tensile strength of the plate material, and the appropriate joint
efficiency, given in the above table. In the case of combination welds making up a welded joint
(such as fillet welds with plug welds or single fillet welds with single-welded butt welds with
backup), the shear value of the welded joint must be the sum of the shear values of each weld.
5.4 Abutting Edges
5.4.1 A tapered transition section having a length not less than three times the offset between
the adjacent plate surfaces, as shown in Fig. E.2, must be provided at points between plates that
differ in thickness by more than one quarter of the thickness of the thinner plate or by more than
1/8 in. (3.18 mm). The transition section may be formed by any process that will provide a uniform
taper. The weld may be partly or entirely in the tapered section or adjacent to it. See Fig. E.2.
5.4.2 Abutting edges of plates at longitudinal joints must not, after being welded, have an offset
from each other at any point in excess of one quarter of the plate thickness of the joint, with a
maximum permissible offset of 1/8 in. (3.18 mm). This rule applies to all butt-welded joints in tank
and dome head.
5.4.3 Particular care should be taken in matching up the edges of cylindrical sections and heads
to ensure that all joints are properly aligned. Maximum permissible offset of the completed joint is
as follows:
For plates over 1/4 in. to 3/4 in. (6.35 mm to 19.0 mm) in thickness25% of plate thickness
For plates over 3/4 in. to 1 1/2 in. (19.0 mm to 38.1 mm) in thickness3/16 in. (4.76 mm)
5.5 Transition Joints
When the tank shape between heads is other than a single horizontal right circular cylinder, and
unreinforced transition joints without knuckle radii are employed, the change of slope in the
longitudinal direction across each transition joint must not be greater than the following:
90
= -------
d for nonpressure tanks
---
t
= 175
---------
d for pressure tanks
---
t
where
d = inside diameter of tank at transition joint, in. (mm)
t = design thickness of tank plate at transition joint, in. (mm)
= slope change across transition joint in degrees
11/2014 C-III [M-1002] 239

APPENDIX E M-1002
6.0 COMPARTMENT HEADS

6.1 Inserted Heads
6.1.1 Inserted heads must be secured by means of the following:
A single full fillet weld in combination with plug welds (see Fig. E.4, item B)
A single welded butt joint with backup in combination with a fillet weld (see Fig. E.4, items
C and D)
6.1.2 Plug welds must have a minimum diameter of 1 in. (25.4 mm). The minimum number of
uniformly spaced plug welds for each head must be as follows:
Table E.4 Minimum plug welds required

Minimum Number
Inside Diameter of Tank of Plug Welds
60 in. (1520 mm) or under 16
Over 60 to 78 in. (1520 to 1980 mm) 20
Over 78 to 96 in. (1980 to 2440 mm) 24
Over 96 to 112 in. (2440 to 2840 mm) 28
Over 112 through 122 in. (2840 through 3100 mm) 32
6.1.3 When used in combination with a full fillet weld, the minimum root opening of the single-
welded butt joint with backup must be 1/8 in. (3.18 mm). See Fig. E.4, item D. When used in
combination with other than a full fillet weld, the minimum root opening of the single-welded butt
joint with backup must be 1/2 in. (12.7 mm). See Fig. E.4, item C. Welds other than full fillet must
have minimum leg dimensions of 3/16 in. (4.76 mm).
6.2 Compartments Constructed as Separate Tanks
When compartments are formed from separate tanks, these must be joined together by a cylinder
attached to the head flange by a full fillet weld. The cylinder must contact the head flange for a
distance of at least twice the plate thickness, or 1 in. (25.4 mm), whichever is greater. Distance
from the head seam to the cylinder must be at least 1 1/2 in. (38.1 mm), or three times the plate
thickness, whichever is greater. See Fig. E.4, item A.
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M-1002 APPENDIX E
7.0 VERTICAL CURVE CLEARANCE REQUIREMENTS

7.1 Extreme projection of outlets, washouts, and other appurtenances must have rail clearance
equal to or exceeding that given by the following equation:

2 2 2 2
L 4z - L 4z -
y = 0.75 S W W- + V + 0.125
----- + V + 1.5
-------------------------------- y = 0.75 S ---- --------------------------------------
rn R rn R
where
y = minimum allowable vertical clearance in inches (millimeters) between rail and lowest portion of outlets,
washouts, or other appurtenances, measured on a straight horizontal track with the car new and empty
L = truck center dimension, ft (mm)
n = number of spring groups under car (e.g., four for two 4-wheel trucks)
R = 500 ft for cars with truck centers of 41 ft 3 in. or less, and 675 ft for cars with truck centers greater than 41 ft
3 in.
In SI units, R = 152 000 mm for cars with truck centers of 12 600 mm or less, and 206 000 mm for cars with
truck centers greater than 12 600 mm.
r = spring rate of one group of springs, lb/in. (kg/mm)
S = total spring travel, in. (mm)
V = total wear (3/4 in. [19.05 mm] for one-wear wheels, 1 1/2 in. [38.1 mm] for two-wear wheels, 2 in. [50.8 mm]
for multiwear wheels)
W = total weight (tare) on springs of empty car, lb (kg)
z = longitudinal distance from the centerline of the car to the outlet, washout, or other appurtenances, ft (mm)
7.2 y must not be less than 12 in. (305 mm) for outlets and washouts.
7.3 y must be not less than S W

----- + 4 3/4 in. for other appurtenances.
rn
In SI units, y must be not less than S W

----- + 121 mm for other appurtenances.
rn
7.4 Under any conditions of wear, the minimum clearance above top of rail of body-mounted
valves, caps, and other fixtures shall be 9 in. (229 mm) on an empty car and 7 in. (178 mm) on a
loaded car, excluding exterior heater coil caps, which must be left off in transit, and cap retaining
chains.
11/2014 C-III [M-1002] 241

APPENDIX E M-1002
8.0 PROTECTION OF BOTTOM DISCONTINUITIES ON CLASS 105A, 109A, 112A, 114A,

AND 120A TANK CAR TANKS
8.1 On new Class 105A, 109A, 112A, 114A, and 120A stub sill tank car tanks and on pressure
stub sill tank cars converted or altered to add bottom fittings, an approved method of protection
against impact must be provided for bottom discontinuities that project beyond the shell envelope,
such as bottom outlets, washouts, blind flanges, or sumps, but excluding those that have the
following characteristics:
Extend 1 in. (25.4 mm) or less beyond the shell envelope, measured on the longitudinal
bottom centerline.
Support safety or brake appliances or other appurtenances.
Incorporate a continuous longitudinal taper at a 1:3 ratio or shallower in the portion
extending beyond 1 in. (25.4 mm) from the shell envelope, measured on the longitudinal
bottom centerline.
Are capable of resisting the design conditions specified in paragraphs 8.2.1, 8.2.2, and 8.2.3
below, without rupturing the tank.
Are sumps of approved design that, on insulated tanks, are totally contained within the
jacket profile, are of a depth not to exceed the nominal thickness of the insulation, and do
not extend more than 2 1/2 in. (63.5 mm) below the tank shell. Sump reference here is to
weld cap type or pressed steel sumps (pressed into tank shell or a separate pressing
welded into or onto the tank shell). This exclusion does not include sumps formed of
straight nozzles with essentially flat cover plates.
8.2 For bottom discontinuities not excluded above, a protective device must be designed as
follows:
8.2.1 A load, normal to the slope of the protective device, whose vertical component equals the
rail load minus the weight (mass) of the trucks, must be applied.
8.2.2 The above load must be considered as concentrated on any transverse line on the protective
device.
8.2.3 The stresses in the tank shell, the protective device, and its connections to the tank shell
must not exceed the minimum tensile strength of the material. In addition, the combined stress in
the tank shell due to the load specified above and an internal pressure, equal to the pressure relief
valve start-to-discharge pressure, must not exceed the minimum tensile strength of the shell
material. The stresses in the webs of the protective device must not exceed the critical buckling
stress.
8.2.4 The longitudinal slope of the protective device must not exceed a ratio of 1:3.
8.2.5 Any vertical extension of the discontinuity below the protective device must be designed to
break off without rupturing the tank or releasing lading. The protective device must extend down
to, or below, the level of the discontinuity or its designed breaking point.
For bottom outlets, the skid should extend down to the breakage groove or to the extremity
of parts comprising the equivalent of a breakage groove.
For washouts and blind flange closures, the skid should extend down to the bottom of the
studs attaching the bottom closure.
For sumps, or other discontinuities not exempted in paragraph 8.1 above, the skid should
extend down to the extremity of the sump or discontinuity.
8.2.6 The skid, when used, must be of fabricated, cast, or forged design and be of material
compatible with that to which it is attached.
8.2.7 The design of the protective device must take into account any abrupt change in stiffness
from the long, rigid, protective device to the flexible tank shell.
C-III [M-1002] 242 11/2014

M-1002 APPENDIX E
8.2.8 Bottom outlet valve handles, unless stowed separately, must be designed to either bend or
break free on impact, or the handle in the closed position must be located above the bottom surface
of the skid.
8.2.9 Bottom profile of the protective device must provide a sliding surface without
discontinuities.
9.0 PROTECTION OF BOTTOM AND TOP DISCONTINUITIES ON NONPRESSURE
TANK CAR TANKS
9.1 Bottom Protection
9.1.1 On new nonpressure stub sill tank cars and on nonpressure stub sill tank cars converted or
altered to add bottom fittings, an approved method of protection against impact shall be provided
for bottom discontinuities that project beyond the shell envelope, such as bottom outlets,
washouts, blind flanges, or sumps, but excluding those discontinuities that have the following
characteristics:
Extend 1 in. (25.4 mm) or less beyond the shell envelope, measured on the longitudinal
bottom centerline.
Support safety or brake appliances or other appurtenances.
Incorporate a continuous longitudinal slope at a 1:3 ratio or shallower in the portion
extending beyond 1 in. (25.4 mm) from the shell envelope, measured on the longitudinal
bottom centerline.
Are capable of resisting the design conditions specified in paragraphs 9.1.2.1, 9.1.2.2, and
9.1.2.3 below, without rupturing the tank.
9.1.2 For bottom discontinuities not excluded above, a protective device must be designed as
follows:
9.1.2.1 A load, normal to the slope of the protective device, whose vertical component equals the
rail load minus the weight (mass) of the trucks, must be applied.
9.1.2.2 The above load must be considered as concentrated on any transverse line on the
protective device.
9.1.2.3 The stresses in the tank shell, protective device, and their connections must not exceed
the minimum tensile strength of the material. The stresses in the webs of the protective device
must not exceed the critical buckling stress.
9.1.2.4 The longitudinal slope of the protective device must not exceed a ratio of 1:3.
9.1.2.5 Any vertical extension of the discontinuity below the protective device must be designed
to break off without rupturing the tank or releasing lading. The protective device must extend
down to, or below, the level of the discontinuity or its designed breaking point.
For bottom outlets, the skid should extend down to the breakage groove or to the extremity
of parts comprising the equivalent of a breakage groove.
For washouts and blind flange closures, the skid should extend down to the bottom of the
studs attaching the bottom closure.
For sumps or other discontinuities not exempted in paragraph 9.1.1 above, the skid should
extend down to the extremity of the sump or discontinuity.
9.1.2.6 The skid, when used, must be of fabricated, cast, or forged design and be of material
compatible with that to which it is attached.
9.1.2.7 The design of the protective device must take into account any abrupt change in stiffness
from the long, rigid, protective device to the flexible tank shell.
11/2014 C-III [M-1002] 243

APPENDIX E M-1002
9.1.2.8 Bottom Outlet Actuation

9.1.2.8.1 For cars built new before July 1, 2015, bottom outlet valve handles, unless stowed
separately, must be designed to either bend or break free on impact, or the handle in the closed
position must be located above the bottom surface of the skid.
9.1.2.8.2 Cars built new on or after July 1, 2015, equipped with external bottom outlet ball valves
must have the interface end of the handle as specified in paragraph 9.1.2.8.2.6, and the handle
must meet one of the following configurations:
Handle that is stowed separately:
Provision must be made for handle stowage to prevent loss of handle due to stresses or
shocks incident to transportation when the handle is shipped with the car.
Handle that is located completely within the skid:
A handle can remain coupled to the valve provided it is completely within the skid when
in the closed position, and is equipped with a closed-position locking mechanism.
Handle must have a breakage groove.
Handle that is disengaged from the valve when in the closed position and located outside
the skid:
When in the closed position, must be equipped with a means to prevent unintended
engagement with the valve.
When in the open position, must remain engaged (coupled) with the valve and not
disengage without the valve being fully closed.
Alternate means of actuation are permitted and must meet the intent of this section and
be approved by the AAR Tank Car Committee.
9.1.2.8.2.1 If the handle interface is not rectangular, it must have a raised/recessed line formed
on the end. The long flats of the handle interface or raised/recessed line must be oriented parallel
to the direction of flow of the valve.
9.1.2.8.2.2 Fully closed valve position must be clearly discernible from the side of the car when
viewing at the bottom skid level.
9.1.2.8.2.3 A stencil must be located in the vicinity of the valve that shows what the valve should
look like with the valve in the closed position and how to operate the valve.
9.1.2.8.2.4 A security/tamper seal is required to keep the valve in the closed position.
9.1.2.8.2.5 The valve operating mechanism (handle, handle brackets, securement pin, etc.) must
ensure against the valve opening due to stresses or shocks incident to transportation. The valve
operating mechanism must be designed to prevent failure from wear of the mechanism that could
permit the valve to open (including wear due to stresses or shocks incident to transportation).
9.1.2.8.2.6 The valve stem at the valve stem/handle interface must be capable of being operated
by a commonly available socket or socket extension. The size of the socket or socket extension must
be included on the operating stencil in the lower left hand corner, for example 1" socket or
" extension.
9.1.2.8.2.7 Molten sulfur is exempt from the requirements of this section.
9.1.2.9 Cars equipped with a protective device and internal vertical piping must have piping
designed to avoid damage to the tank or fittings if the tank is deformed inwardly by the device.
9.1.2.10 Bottom profile of the protective device must provide a sliding surface without
discontinuities.
C-III [M-1002] 244 11/2014

M-1002 APPENDIX E
9.1.3 Sumps of approved design do not require protection when, on insulated cars, they are
totally contained within the jacket profile, do not exceed the nominal thickness of the insulation,
and do not extend more than 2 1/2 in. (63.5 mm) below the tank shell. Sump reference here is to
weld cap type or pressed steel sumps (pressed into tank shell or a separate pressing welded into or
onto the tank shell). This exclusion does not include sumps formed of straight nozzles with
essentially flat cover plates.
9.1.4 Class 207W pressure differential covered hopper cars are excluded from the requirements
of this section.
9.1.5 Levels of protection, as specified per 49 CFR 173.31(b)(5), are defined as follows:
9.1.5.1 Level A requires meeting the requirements of paragraphs 9.1.1, 9.1.2, and 9.1.3 above.
9.1.5.2 Level B requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 9.1.2 above.
For all bottom outlets extending more than 1 in. (25.4 mm) below the tank shell exterior
For all blind flanges and washouts (not having internal closure) that extend more than
2 5/8 in. (66.7 mm) below the tank shell exterior (inclusive of bolting)
For all internally closed washouts that extend more than 5 in. (127 mm) to the breakage
groove or shear plane measured from the bottom tank shell exterior
For sumps greater than 5 in. (127 mm) that are not contoured and contoured sumps made
of pipe caps or pressed steel that have a straight wall projection exceeding 1 3/4 in.
(44.5 mm) below the tank shell exterior.
9.1.5.3 Level C requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 9.1.2 above:
For all bottom discontinuities extending more than 5 in. (127 mm) below the tank shell
exterior (measurement to the shear plane, if any, and inclusive of bolting) with the
following exception: contoured sumps made of pipe caps of pressed steel, having a straight
wall projection below the tank shell exterior not in excess of 1 3/4 in. (44.5 mm).
9.2 Top Protection
9.2.1 When top fittings discontinuity protection is specified for nonpressure cars, the following
requirements must be met:
9.2.1.1 The protective structure must be as tall as the tallest fitting involved, must provide
protection for those fittings, without overstressing the tank shell and nozzles, when subjected to
forces of 1/2W in the vertical downward direction, 1W horizontal in the longitudinal direction, and
1/2W horizontal in the lateral direction.
W is defined as the designed gross rail load of the car, less trucks.
The forces are applied separately and uniformly over the projected plane of the protective
structure perpendicular to the direction of the force.
For horizontal loads, the projected plane extends from the top of the tank to the top of the
protective structure.
In the case of multiple nozzles, the forces are applied uniformly over their combined
projected area if the reinforcement zones of the nozzle, as defined in paragraph 2.3.1 of this
appendix, have a positive overlap. If there is no overlap of the reinforcement zones, each
nozzle must be protected so that it can withstand the applied loads independent of the
other nozzles.
Calculations should use the minimum specified tensile strength of the material for the
tank, nozzle(s), unprotected service equipment, and protective device (where applicable).
Stresses must not exceed the critical buckling stresses of the assembly under
consideration.
11/2014 C-III [M-1002] 245

APPENDIX E M-1002
9.2.1.2 The design stresses must not exceed the minimum specified tensile stress for the tank,
nozzle, and protective housing, provided that the critical buckling stresses are not exceeded.
9.2.1.3 The protective structure must not reduce the pressure relief device flow capacity below
the minimum required.
9.2.1.4 The protective structure must provide a means of drainage with a minimum flow area
equivalent to six 1 in. diameter holes (4.71 in.2).
9.2.1.5 The strength of the attachment of the protective structure to its base structure should not
exceed 70% of the attachment strength of the base structure to its base structure. For example, if
the protective structure is attached to the nozzle, the strength of the attachment of the protective
structure to the nozzle may not exceed 70% of the strength of the attachment of the nozzle to the
tank.
9.2.1.6 Individual fittings may be unprotected if there is no loss of lading when subjected to the
design loads in paragraph 9.2.1.1. If unprotected fittings are used in conjunction with a protective
structure, the design loads are shared in proportion to the projected areas of the protective
structure and the fittings.
9.2.1.7 Discontinuity protection is not required for manway covers that have internal or external
shear rings designed to resist the horizontal loads as defined in paragraph 9.2.1.1.
9.2.1.8 No discontinuity protection is required for internal safety relief valves, cover plates, blind
flanges, or plugs.
10.0 NONCIRCULAR NOZZLES
When noncircular nozzles are applied to a nonpressure tank car tank, the following conditions
must be met:
10.1 If the long dimension exceeds twice the short dimension, the resistance necessary to provide
against excessive distortion due to twisting moment must be verified, as provided in
paragraph 10.5 below.
10.2 If the long dimension is not parallel to the circumference of the shell, the design adequacy
must be verified, as provided in paragraph 10.5 below.
10.3 The nozzle must be designed to sustain bending stresses as determined by the following
steps:
10.3.1 Consider the flat portion of an unrestrained noncircular nozzle as a flat plate, fixed at the
vertical tangent points and simply supported at the top and bottom, and calculate the bending
stress f in the center of the flat portion. See Table E.5 and the following formula:

b 2 b 2
f = cp --- cp ---
t t
f = --------------------
1000
where
f = bending stress in the center of the flat portion of the nozzle

p = tank test pressure, psi (kPa)
c = proportionality factor (see Table E.5)
C-III [M-1002] 246 11/2014

M-1002 APPENDIX E
10.3.2 Calculate the bending stress c in the center of the curved portion by multiplying the
bending stress in the flat portion by the factor determined from Table E.6.
c = q f
where
c = bending stress in the center of the curved portion of the nozzle

q = proportionality factor (see Table E.6)
10.3.3 The computed stress must not exceed one third of the minimum tensile strength of the
nozzle material.
10.4 Only the nozzle thickness in excess of that required for the bending load can be considered
as available as reinforcement.
11/2014 C-III [M-1002] 247

APPENDIX E M-1002
10.5 As an alternative, or when the provisions of paragraphs 10.1 and 10.2 cannot be met, the
adequacy of a noncircular nozzle and its reinforcement may be verified using five 3-gauge rosettes,
applied as shown in Fig. E.22. When the tank is pressurized to its hydrostatic test pressure, the
measured stresses must not exceed the following:
Rosette
#1 #4 u
u
------ ------ where
3 3
= maximum principal stress, psi (MPa)
#2 u #5 u
------ ------ u = minimum tensile strength of the material, psi (MPa)
3 3 = maximum shear stress, psi (MPa)
#3 u
------
4
Table E.5 Proportionality factors for f

Aspect ratio a/ c1 c2
0.1 0.093 0.249
0.2 0.101 0.246
0.3 0.113 0.241
0.4 0.130 0.235
0.5 0.148 0.227
0.6 0.166 0.218
0.7 0.179 0.209
0.8 0.186 0.199
0.9 0.186 0.189
1.0 0.180 0.179
a/ If a < b, = a/b and c = c1
If b < a, = b/a and c = c2
Table E.6 Proportionality factors for c

b/d q
a
0 0.571
0.1 0.624
0.2 0.674
0.3 0.720
b
0.4 0.764
0.5 0.805
0.6 0.843
0.7 0.879
d 0.8 0.913
0.9 0.945
1.0 max 0.975
t
C-III [M-1002] 248 11/2014

M-1002 APPENDIX E
11.0 ANCHOR DESIGN

To minimize stress concentrations at the extreme ends of tank anchors, unless otherwise
approved, the attachment of the anchor to the tank must be designed as follows:
11.1 The nominal stress in the tank shell at the extreme ends of the anchor, calculated for the
design load W, must not exceed the yield strength of the tank shell material, for steel or stainless
steel tanks, or one third the yield strength of the tank shell alloy and temper for aluminum tanks,
calculated by the following formula
S b = Mc
6
-------- 10 Mc-
I S b = ----------------
I
where
W = design load (rail load limit less weight [mass] of trucks and underframe), uniformly distributed over the length
of the tank between heads, lb (kg)
Sb = nominal stress due to design load, psi (MPa)
M = moment at the extreme ends of the anchor, in. lbf (N m)
c = outside radius of tank shell, in. (mm)
I = moment of inertia of cross-section of tank shell at extreme ends of the anchor, in.4 (mm4)
11.2 The nominal stress in the tank shell at the extreme ends of the anchor, calculated for design
load with amplification factor and 1,250,000 lb (5560 kN) impact force, must not exceed the
minimum tensile strength of the tank shell material as given in Appendix M, calculated by the
following formula:

H-
S c = aS b + ------ S c = aS b + 500H
-------------
2A 2A
where
Sc = nominal stress due to impact, psi (MPa)

12Hhx- 1224Hhx-
a = amplication factor = 1 + ----------------
2
in conventional units or 1 + ----------------------
2
in SI units
WL WL
H = impact force = 1,250,000 lb (5560 kN)

h = vertical distance from centerline of draft to center of gravity of loaded car, ft (mm) (See the Manual of
Standards and Recommended Practices, Section C, Part II, Specifications for Design, Fabrication, and
Construction of Freight Cars, Specification M-1001, Chapter 6.)
x = distance from center of car to extreme end of anchor, ft (mm)
W = design load (rail load limit less weight [mass] of trucks and underframe), lb (kg)
L = inside length of tank between heads, ft (mm)
A = area equal to shell thickness multiplied by the sum of half the extreme anchor or saddle plate length plus the
extreme width over the top anchor flanges or saddle plate, in.2 (mm2)
11.3 Anchor designs must be verified by calculations or test to ensure that the tank will not
experience permanent deformation at the ends of the anchor under the imposition of impact loads
as specified in the Manual of Standards and Recommended Practices, Section C, Part II,
Specifications for Design, Fabrication, and Construction of Freight Cars, Specification M-1001,
Chapter 6.
11/2014 C-III [M-1002] 249

APPENDIX E M-1002
11.4 In lieu of designing to paragraphs 11.1 and 11.2 above, anchors on steel, stainless steel, and
aluminum cars may be constructed using reinforcing plates, placed between the anchor and the
tank, that conform to the following:
11.4.1 The thickness of the reinforcing plate must be not less than 0.5 in. (12.7 mm).
11.4.2 The reinforcing plate must extend transversely, beyond each leg of the anchor, for a
minimum distance of the outside radius of the tank divided by 10.
11.4.3 The length of the reinforcing plate, extending beyond the extreme ends of the anchor, must
be not less than
2 2
4 R t -
----------------------
L = --- 4 2
3 31
where
L = length of reinforcing plate beyond the extreme ends of the anchor, in. (mm)
R = outside radius of tank shell, in. (mm)
t = reinforcing plate thickness, in. (mm)
= Poissons ratio
11.4.4 The reinforcing plates must have corner radii not less than 2 1/2 in. (63.5 mm).
11.4.5 For aluminum tanks, the anchor reinforcement may be combined with the tank shell into
one plate, provided the thickness is at least 1/2 in. (12.7 mm) more than the minimum thickness
required for the shell in DOT 179.100-6 or 179.200-6, with the abutting edges tapered in accord with
this appendix.
11.4.6 Plate elements of an anchor section that conform to paragraphs 11.4.1 and 11.4.2 above,
and whose length, L, beyond the extreme ends of the anchor leg, conforms to paragraph 11.4.3
above, may be considered to be reinforcement plates.
12.0 HEAD-TO-SILL ATTACHMENTS
New stub sill tank cars that are equipped with head braces must be designed such that the
outboard edge distance of the tank head reinforcing pad, measured in the longitudinal direction
from the toe of the head brace-to-pad weld to the toe of the pad-to-tank weld is not less than l,
where l is determined by the following formula:
2 2
S up t p + S ut t t
l = 1.5 ---------------------------------- conventional or SI units
S yt t t
where
l = head brace pad edge distance, in. (mm)

Sup = tensile strength of reinforcing pad material, psi (MPa)
Sut = tensile strength of tank material, psi (MPa)
Syt = yield strength of tank material, psi (MPa)
tp = pad thickness, in. (mm)
tt = tank head thickness, in. (mm)
Cars constructed without head braces must comply with the edge distance requirements of
Chapter 6.
C-III [M-1002] 250 11/2014

M-1002 APPENDIX E
13.0 BOTTOM OUTLET VALVE AND NOZZLE ARRANGEMENTS

13.1 A nozzle, or a nozzle with an auxiliary valve, must have a breakage groove or breakage
groove equivalent that meets 49 CFR 179.200-17(a)(7).
13.2 The relative strength of the primary valve connection to the tank and the nozzle breakage
groove or breakage groove equivalent must comply with the following:
13.2.1 The strength of the breakage groove or breakage groove equivalent must not exceed 60% of
the strength of the primary valve connection to the universal flange, using the minimum
published tensile strength for the nozzle material (for a vee groove) or for the nozzle bolting
material, and using the minimum published yield strength of the primary valve-to-universal
flange bolting material. If the maximum tensile strength of the nozzle bolting is known and used,
then the nozzle connection strength may be equal to the calculated valve-to-universal flange
bolting strength, based on minimum yield.
13.2.2 Connection strength for two load applications must be analyzed: One with the load applied
at the lowest point of the nozzle assembly, and one with the load applied at the nozzle breakage
groove (or equivalent bolted connection), or at the lowest point of the valve protection device. In
both cases, the calculated strengths must be based on the combined tensile and shear stresses.
14.0 REINFORCING PADS
14.1 Requirements for Use of Reinforcing Pads
14.1.1 Attachment requirements for major structural components on tank car tanks are covered
in the sections of this manual that deal with those components. For other brackets and
attachments, reinforcing pads are required, if, when welded directly to tanks, they could cause
damage to the tanks, either through fatigue, over-stressing, or denting or puncturing in the event
of an accident.
14.1.2 Reinforcing pads are not required for the following attachments:
Thin attachments, such as exterior heater coils, drip ledges, and others that are easily
crushed in the event of an accident
Large, cast bottom outlet skids that are attached to tanks over a broad area and do not
constitute a puncture hazard in the event of an accident
Full-girth attachments, such as compartment car attachment rings and tank stiffening
rings, that are continuously attached to tanks
Tank bottom reinforcing plates or bars and attachments welded thereto
14.1.3 Tank attachments shall be designed to collapse or shear off, without loss of lading, in the
event of an accident.
14.2 Design of Reinforcing Pads
When reinforcing pads are used under brackets attached to tank car tanks, the following criteria
shall be observed:
14.2.1 Pads shall be not less than 1/4 in. thick and shall not exceed the thickness of the tank shell
to which they are welded by more than 15%. Use of pads less than 7/16 in. thick shall be restricted to
light structural applications.
14.2.2 Pads shall be attached by continuous fillet welds, except for venting provisions. The ultimate
shear strength of the bracket-to-pad weld shall not exceed 85% of the ultimate shear strength of the
pad-to-tank weld. Pad-to-tank fillet weld leg size shall not exceed tank shell thickness.
14.2.3 Pads shall have each corner rounded to a 1 in. minimum radius.
14.2.4 The distance between a bracket and the edge of the reinforcing pad to which it is attached
shall not be less than three times the thickness of the pad.
11/2014 C-III [M-1002] 251

APPENDIX E M-1002
15.0 TANK BOTTOM APPURTENANCES

When reinforcing pads, skids, washouts, and sumps are welded on the tank bottom longitudinal
centerline, the transverse ends must be no closer than 12 in. (304.8 mm) (measured longitudinally)
unless they are welded to each other or to a connecting pad that reinforces the tank shell between
them. The weld shall be designed to provide a smooth transition between the appurtenances. A
lesser distance may be used if it is determined to be acceptable by analysis or satisfactory service
experience.
3
"
16 1
8 "
3
" OPENING
16
1
8 "
3
" OPENING
16
SECTION AA
" R
"
IN
12
"M
10 12

10
"

"
"
"
A
" MAX 3
8 "R
A
2 16" MAX
1 " R
2 16" MIN
13
5
" R
2 8 " MAX
2 16" MIN
7
8 "R
2
"
2
"
5
"
1
" MAX " R

10
"

"M
" R
"

IN
10
METHOD OF ATTACHMENT
OPTIONAL
PLACARD OUTLINE
Fig. E.1 Limiting dimensions for metal placard holder

C-III [M-1002] 252 11/2014
M-1002 APPENDIX E
4.76 3.18
4.76 OPENING
3.18
4.76 OPENING
SECTION AA
19.0 R
8
31
IN
31
0M
8
27
26
3
6.35
6.35
A
12.7 MAX 9.52 R
A
38.1 R
71.4 MAX
58.7 MIN
19.0 R
66.7 MAX
55.6 MIN
22.2 R
57
.2
.2
57
.4
44
12.7 MAX. 6.35 R

26
0M
6.35
IN
19.0 R
27
METHOD OF ATTACHMENT
OPTIONAL
PLACARD OUTLINE
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.1.1 Limiting dimensions for metal placard holderSI units

11/2014 C-III [M-1002] 253
APPENDIX E M-1002
HEAD SHAPE
L
L TAPER MAY
BE INSIDE L
WELD OR OUTSIDE
SEE NOTE
PREFERRED
(CENTER LINES COINCIDE) PERMISSIBLE PREFERRED
NOTE:
LENGTH OF THE REQUIRED
TAPER L MAY INCLUDE
THE WIDTH OF THE WELD.
IN ALL CASES L SHALL BE
NOT LESS THAN THREE TIMES
THE OFFSET BETWEEN THE
ABUTTING PLATES.
Fig. E.2 Butt welding of plates of unequal thickness
C-III [M-1002] 254 11/2014

M-1002 APPENDIX E
PLANE IN SHEAR
END WELD
IN SHEAR
PLANE
SIDE WELD
SINGLE
Fig. E.3 Fillet welds
11/2014 C-III [M-1002] 255

APPENDIX E M-1002
INTERIOR TANK HEAD
NOT LESS THAN D 2 T1 MIN
FULL FILLET
INTERIOR TANK HEAD
D T1
TANGENT POINT
T T
FULL FILLET TANGENT POINT
WELD
3T MIN OR 2T MIN OR
1 " MIN 1'' MIN
JOINT A JOINT B
INTERIOR TANK HEAD

INTERIOR TANK HEAD
NOT LESS THAN 2T1 NOT LESS THAN 2T1
FILLET WELD
FULL FILLET
T1 T1
16" MIN
WELD
" MIN
1
8 " MIN
3
T T
TANGENT POINT TANGENT POINT

SINGLE WELDED
BUTT WITH BACKUP
SINGLE WELDED
BUTT WITH BACKUP
15 to 20 15 to 20
JOINT C JOINT D
Fig. E.4 Acceptable joints for interior heads of compartment tank cars
C-III [M-1002] 256 11/2014

M-1002 APPENDIX E
INTERIOR TANK HEAD

NOT LESS THAN D 2 T1 MIN
FULL FILLET
INTERIOR TANK HEAD
WELD
D
TANGENT POINT T1
T T
FULL FILLET
WELD TANGENT POINT
3T MIN OR 2T MIN OR
38.1 MIN 25.4 MIN
JOINT A JOINT B
INTERIOR TANK HEAD INTERIOR TANK HEAD

NOT LESS THAN 2T1 NOT LESS THAN 2T1
FILLET WELD
FULL FILLET
4.76 MIN
T1
T1
WELD
12.7 MIN 3.18 MIN
T T
TANGENT
TANGENT POINT POINT
SINGLE WELDED
BUTT WITH BACKUP SINGLE WELDED
BUTT WITH BACKUP
15 to 20 15 to 20
JOINT C JOINTD
Fig. E.4.1 Acceptable joints for interior heads of compartment tank carsSI units
11/2014 C-III [M-1002] 257

APPENDIX E M-1002
DRAIN PRESSURE RELIEF VALVE

TO MEET REQUIREMENTS
54 54
VENTING VALVE
SAMPLING VALVE (OPTIONAL)
1/4' PIPE TAP, TOP AND BOTTOM
3/4'' PIPE TAP, BOTTOM (OPTIONAL)
DRAIN
DRAIN
DRILL 1 5/16'' HOLES DRILL AND TAP FOR 3/4'' STUDS

FOR 1 1/8'' STUDS
.
AD
67
'R
/2'
/8'
71
'R
AD
LOADING AND DISCHARGING VALVE
.
LONGITUDINAL
CL OF TANK
23'' D
D.
IA. IA.
31'' D
RA
20 STUDS (BOLTS OPTIONAL FOR

73
/8''
GASES OTHER THAN CHLORINE)

/4'
71
'R
EQUALLY SPACED
AD
LOADING AND
.
DISCHARGING
DRAIN
13 1
VALVE
/2'' R
AD.
THERMOMETER WELL (OPTIONAL)

DRAIN 3/4'' PIPE TAP, TOP AND BOTTOM
DRILL AND TAP FOR

3/4'' STUDS
DRAIN HOLES 1'' DIA. (OPTIONAL SIZE AND LOCATION) GAUGING DEVICE (VENTING VALVE OPTIONAL)
DRAIN HOLES 13/16'' DIA.
Fig. E.5 Standard manway cover for 18 in. manway (see details in Fig. E.19 series)
C-III [M-1002] 258 11/2014

M-1002 APPENDIX E
DRAIN PRESSURE RELIEF VALVE

TO MEET REQUIREMENTS
54 54
VENTING VALVE
SAMPLING VALVE (OPTIONAL)
1/4' PIPE TAP, TOP AND BOTTOM
3/4'' PIPE TAP, BOTTOM (OPTIONAL)
DRAIN
DRAIN
DRILL AND TAP FOR 3/4'' STUDS
DRILL 1 5/16'' HOLES
FOR 1 1/8'' STUDS
.
AD
17
0R
5R
19
AD
.
LOADING AND DISCHARGING VALVE
LONGITUDINAL
CL OF TANK
D.
584
IA. DIA.
A
73817'' D
1R
20 STUDS (BOLTS OPTIONAL FOR
19
7R
GASES OTHER THAN CHLORINE)
18
EQUALLY SPACED
AD
.
LOADING AND
DISCHARGING
VALVE DRAIN
343
RAD
.
THERMOMETER WELL (OPTIONAL)

DRAIN 3/4'' PIPE TAP, TOP AND BOTTOM
DRILL AND TAP

FOR 3/4'' STUDS
GAUGING DEVICE (VENTING VALVE OPTIONAL)
DRAIN HOLES 1'' DIA. (OPTIONAL SIZE AND LOCATION)
DRAIN HOLES 13/16'' DIA.
Fig. E.5.1 Standard manway cover for 18 in. manway (see details in Fig. E.19 series)SI units
11/2014 C-III [M-1002] 259

APPENDIX E M-1002
33'' DIA.
31'' DIA.
25 " DIA.
DRILL 1 16" DIA. HOLES FOR 1 8 " DIA. STUDS

5 1
1
8 "
2" MIN.
1 "
3
8 " "R "
17" DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
19.238'' .010'' DIA.
19 " DIA.
1
" DIA. GROOVES
16
20'' DIA.
20.263'' .010'' DIA.
26'' DIA. (NOM.)

23'' DIA. B.C.
20.313'' .010'' DIA. 1 2

1
8 " GASKET
19" DIA. 1
16 " DIA. GROOVE
19.188'' .010'' DIA. 1 2

DRILL AND TAP THROUGH
1 8 " 7 UNC 2B
1
3
"
16
NOTE:
1 NEW CONSTRUCTION OR REPAIR

INCLUDING FULL FILL OF GROOVE
WITH WELDING:
.010'' AS MACHINED
.035'' AS CAR COMPLETED
18'' DIA. 2 TOLERANCES ARE NOT APPLICABLE

FOR FIELD INSPECTION OF EXISTING
CARS OR MINOR GROOVE REPAIRS.
Fig. E.6 Detail of cover and nozzle joint for 18 in. manway
C-III [M-1002] 260 11/2014

M-1002 APPENDIX E
838 DIA.
787 DIA.
648 DIA.
DRILL 1 5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
3.18
57.2 MIN.
44.4
6.35 R
6.35
438 DIA. 9.52 DRILL AND TAP THROUGH

3/4'' 10 UNC 2B
488.40 TO 488.89 DIA.
495 DIA.
1.59 DIA. GROOVES
508 DIA.
514.43 TO 514.93 DIA.
660 DIA. (NOM.)

584 DIA. B.C.
515.70 to 516.20 DIA. 1 3 3.18 GASKET
502 DIA. 1.59 DIA. GROOVE

487.13 to 487.62 DIA. 2 3
1 8" 7 UNC 2B
1
NOTE:

4.76
WITH WELDING:
515.70 TO 516.20 AS MACHINED.
515.07 TO 516.83 AS CAR COMPLETED.

WITH WELDING:
457 DIA. 486.49 TO 488.26 AS CAR COMPLETED.
3 TOLERANCES ARE NOT APPLICABLE

Fig. E.6.1 Detail of cover and nozzle joint for 18 in. manwaySI units
11/2014 C-III [M-1002] 261

APPENDIX E M-1002
DRAIN
54 54
DRAIN
DRAIN
201 16" DIA. HOLES

5
EQUALLY SPACED
ON 25'' DIA. B.C.
35'' DIA.
IA. 25'' D
33'' D IA.
IA.
'' D
1/2
27
DRAIN
DRAIN
20 HOLES DRILLED AND

TAPPED FOR 3/4'' STUDS
EQUALLY SPACED ON
33'' DIA. B.C.
61'' DIA. DRAIN HOLES ON 29'' DIA. B.C. 6 13 16" DIA. DRAIN HOLES
Fig. E.7 Standard manway cover for 20 in. manway (see details of openings in Fig. E.19 series)
C-III [M-1002] 262 11/2014

M-1002 APPENDIX E
DRAIN
54 54
DRAIN
DRAIN
201 16" DIA. HOLES

5
EQUALLY SPACED
ON 635 DIA. B.C.
889 DIA.
DIA. 635
838 DIA.
IA.
'D
698
DRAIN
DRAIN
20 HOLES DRILLED AND

TAPPED FOR 3/4'' STUDS
EQUALLY SPACED ON
838 DIA. B.C.
61'' DIA. DRAIN HOLES ON 737 DIA. B.C. 6 13 16" DIA. DRAIN HOLES
Fig. E.7.1 Standard manway cover for 20 in. manway (see details of openings in Fig. E.19 series)SI units
11/2014 C-III [M-1002] 263

APPENDIX E M-1002
35'' DIA.
33'' DIA.
27 " DIA.
DRILL 1
5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
1
8 "
2 " MIN.
1 "
3
8 " " R "
19 " DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
21.238'' .010'' DIA.
21 " DIA.
1
" DIA. GROOVES
16
22'' DIA.
22.263'' .010'' DIA.
28'' DIA. (NOM.)

25'' DIA. B.C. 1
" GASKET
16
22.313'' .010'' DIA. 1 2
21 " DIA. 1
" DIA. GROOVE
16
21.188'' .010'' DIA. 1 2 DRILL AND TAP THROUGH

1 8 " 7 UNC 2B
1
3
16 "
NOTE:
WITH WELDING:
.010'' AS MACHINED
.035'' AS CAR COMPLETED
2
TOLERANCES ARE NOT APPLICABLE
20'' DIA. FOR FIELD INSPECTION OF EXISTING
Fig. E.8 Detail of cover and nozzle joint for 20 in. manway
C-III [M-1002] 264 11/2014

M-1002 APPENDIX E
889 DIA.
838 DIA.
698 DIA.
DRILL 1
5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
3.18
57.2 MIN.
44.4
6.35 R
6.35
9.52 DRILL AND TAP THROUGH

489 DIA. 3/4'' 10 UNC 2B
539.20 TO 539.69 DIA.
546 DIA.
1.59 DIA. GROOVES
559 DIA.
565.23 TO 565.73 DIA.
711 DIA. (NOM.)
635 DIA. B.C. 3.18 GASKET

566.50 to 567.00 DIA. 1 3
552 DIA.
1.59 DIA. GROOVE
537.93 to 538.42 DIA. 2 3
1 8 " 7 UNC 2B
1
NOTE:

4.76 WITH WELDING:

WITH WELDING:
508 DIA.
Fig. E.8.1 Detail of cover and nozzle joint for 20 in. manwaySI units
11/2014 C-III [M-1002] 265

APPENDIX E M-1002
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
TAP " NPT TAP " NPT
VARIOUS DEVICES BY VARIOUS DEVICES BY

MANUFACTURERS MANUFACTURERS
(OPTIONAL) (OPTIONAL)
SAMPLE OPENING THERMOWELL OPENING
SECTION EE SECTION FF
27" DIA.
25" DIA. ANGLE VALVE INTERFACE
DRAIN HOLES 1" DIA. THROUGH SEE Fig. E.19.8 FOR DETAILS
ON 29" DIA. BOLT CIRCLE (3 PLACES)
LOCATED AS SHOWN
(6 PLACES)
F
E
E
F
36
36
R8
45

R7
45 45
LONGITUDINAL AXIS
OF TANK CAR

R6
36
36
45
33" DIA.
GAUGING DEVICE INTERFACE 31" DIA. BC
SEE Fig. E.19.25 FOR DETAILS
TWENTY 1 5 16" DIA. HOLES
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 25" DIA. BC
SEE Fig. E.10 FOR DETAILS
SAFETY VALVE INTERFACE
TWENTY HOLES DRILLED AND
TAPPED FOR "10 STUDS
EQUALLY SPACED ON 31" DIA. BC
Fig. E.9 Standard manway cover for 20 in. manwayVCM (see details of openings in Fig. E.19 series)
C-III [M-1002] 266 11/2014

M-1002 APPENDIX E
33" DIA.
31" DIA. BC
1
8 " 27" DIA.
25" DIA. BC
1 " 2 " MIN.
" 19 " DIA.

DRILL AND TAP FOR 3
" R "
"10 UNC2B THROUGH
8 21.238" .010 DIA.
EQUALLY SPACED 21 " DIA.
(20 PLACES) 22" DIA.
22.263" .010 DIA.
1 16" DIA. THROUGH
5
EQUALLY SPACED
(20 PLACES)
1
" DIA. GROOVES
16
1
" DEEP
32
28" DIA. (NOM.)

25" DIA. BC
1 2
22.313 .010 DIA.
21 " DIA.
1 2
21.188 .010 DIA.
20" DIA.
3
"
16
16" GASKET IN
1
THIS GROOVE
DRILL AND TAP THROUGH 1

" DIA. GROOVE
16
1 8 " 7 UNC2B
1
1
" DEEP
32
NOTE: 20 EQUALLY SPACED
WITH WELDING:
.010" AS MACHINED.
.035" AS CAR COMPLETED.

Fig. E.10 Detail for cover and nozzle joint for 20 in. manwayVCM
11/2014 C-III [M-1002] 267

APPENDIX E M-1002
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
TAP " NPT TAP " NPT
VARIOUS DEVICES BY VARIOUS DEVICES BY

MANUFACTURERS MANUFACTURERS
(OPTIONAL) (OPTIONAL)
SAMPLE OPENING THERMOWELL OPENING
SECTION EE SECTION FF
29" DIA.
DRAIN HOLES 1" DIA. THROUGH 27" DIA. ANGLE VALVE INTERFACE
ON 31" DIA. BOLT CIRCLE
LOCATED AS SHOWN (3 PLACES)
(6 PLACES)
45 S
)P LACE
. (2
T YP
F
E
F
E
36
36
45
R8

45 45
LONGITUDINAL AXIS
OF TANK CAR
5 8 "
R7
36
36
45
35" DIA.
GAUGING DEVICE INTERFACE
SEE Fig. E.19.25 FOR DETAILS 33" DIA. BC
TWENTY 1 16" DIA. HOLES

5
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 27" DIA. BC
SEE Fig. E.12 FOR DETAILS
SAFETY VALVE INTERFACE
TWENTY HOLES DRILLED AND
TAPPED FOR "10 STUDS EQUALLY
SPACED ON 33" DIA. BC
Fig. E.11 Standard manway cover for 22 in. manwayVCM (see details of openings in Fig. E.19 series)
C-III [M-1002] 268 11/2014

M-1002 APPENDIX E
35" DIA.
33" DIA. BC
1
8 " 29" DIA.
27" DIA. BC
1 " 2 " MIN.
" 21 " DIA.

DRILL AND TAP FOR 3
8 " R " 23.238" .010 DIA.
"10 UNC2B THROUGH
EQUALLY SPACED 23 " DIA.
(20 PLACES) 24" DIA.
24.263" .010 DIA.
1 16" DIA. THROUGH
5
EQUALLY SPACED
(20 PLACES)
1
" DIA. GROOVES
16
1
" DEEP
32
30" DIA. (NOM.)

27" DIA. BC
1 2
24.313 .010 DIA.
23 " DIA.
1 2
23.188 .010 DIA.
22" DIA.
3
16 "
16" GASKET IN
1
THIS GROOVE
DRILL AND TAP THROUGH 1

" DIA. GROOVE
16
1 8 " 7 UNC2B
1
1
" DEEP
32
NOTE: 20 EQUALLY SPACED
WITH WELDING:
.010" AS MACHINED.
.035" AS CAR COMPLETED.

Fig. E.12 Detail for cover and nozzle joint for 22 in. manwayVCM
11/2014 C-III [M-1002] 269

APPENDIX E M-1002
0.75"
34.00" +.00
-.25 FOR 20" MANWAY
+.00
36.00" -.25 FOR 22" MANWAY
13.50" .75
4.00" .25
5.00" .25
0.88" DIA. THROUGH FOUR HOLES
TWENTY HOLES EQUALLY SPACED
EQUALLY SPACED 27.50" DIA. MIN. FOR 20" MANWAY
STRADDLE 4" HOLES
29.50" DIA. MIN. FOR 22" MANWAY
Fig. E.13 Protective housing for 20 in. and 22 in. VCM tank car cover plates
C-III [M-1002] 270 11/2014

M-1002 APPENDIX E
STRAIGHT-TOP TANK, SINGLE NOZZLE
STRAIGHT-TOP TANK, MULTIPLE NOZZLES
SLOPING-TOP TANK
MULTIPLE COMPARTMENT CAR WITH SLOPING-TOP COMPARTMENTS

NOTE:
SHADED AREAS DENOTE "SHELL-FULL" AND
NONSHADED PORTIONS ARE VOID AREAS
Fig. E.14 Shell-full for typical tank car types
11/2014 C-III [M-1002] 271

APPENDIX E M-1002
TYPICAL WEATHER COVER

(SELF-CLOSING)
PROTECTIVE HOUSING COVER
MINIMUM OPENING
OPTIONAL EXHAUST FLUE
DISCHARGE CHANNEL
PRESSURE RELIEF VALVE
Fig. E.15 Detail for opening in protective housing cover for transporting liquefied flammable gases
C-III [M-1002] 272 11/2014

M-1002 APPENDIX E
C PAD DIA.
D
A F
G
A DIA.
D
B
J
B MEAN DIA.
T M H
E TN
C
W = load to be carried by welds, lb (kN)

S = specified minimum tensile strength of shell or head material, psi (MPa)
Sp = specified minimum tensile strength of the weaker of materials being joined, but not greater than S, psi (MPa)
Sn = specified minimum tensile strength of nozzle material, psi (MPa)
T = minimum calculated shell or head thickness, in. (mm)
Tn = actual nozzle wall thickness, in. (mm)
Strength of Connection Elements

A Inner fillet weld in shear = 1.57 AF (.49Sp) = 1.57 AF (.49Sp) 103
B Nozzle wall shear = 1.57 BTn (.70Sn) = 1.57 BTn (.70Sn) 103
C Groove weld tension = 1.57 AH (.74Sp) = 1.57 AH (.74Sp) 103
D Outer fillet weld in shear = 1.57 CG (.49 Sp) = 1.57 CG (.49 Sp) 103
E Groove weld tension = 1.57 AJ (.74 Sp) = 1.57 AJ (.74 Sp) 103
Explore possible paths of failure using W = (2t M) DS in conventional units or

W = (2t M) DS 103 in SI units:
Without Pad With Pad
1) A + B W 1) B + D W
2) A + C W 2) A + C + E W
3) C + D W
Fig. E.16 Nozzle attachment welds
11/2014 C-III [M-1002] 273

APPENDIX E M-1002
BROOKS CABLE SEAL

LOCK (MODEL B)
NO. 8903106
3.93" SPACING (20" COVER)

1 8 " DIA. STUD
1
4.24" SPACING (22" COVER)
3
8 " DIA. HOLE
" DIA. CABLE SEAL LOCK
TYPICAL
2 8"
5
HVY
HEX
COVER PLATE
7
8 "
3
8 " DIA. HOLE
1 "
TOP OF STANDARD
LENGTH STUD
Fig. E.17 Tank car safety seal for pressure cars
C-III [M-1002] 274 11/2014

M-1002 APPENDIX E
6'' REFERENCE
5.250''MIN. MAJOR DIAMETER
(MAX. NOT SPECIFIED)
PITCH DIA. 5.088"5.103" CHAMFER 45 TO
5 8 " DIAMETER
3
E18 STAMPED MINOR DIA. 4.979'' 5.017"
OR CAST (SEE NOTE 6)
3 " 4 " REF 1 8"

1
2 " REF
" 5 "
5 1
" OPTIONAL 125
4 8 " REF
8 16
"
1'' REF 3.00'' CORE REF 5
" REF
1
8
" 60
2.00'' CORE
1 8 " REF
3
45 1 " REF
125 45 REF
" SEE NOTE 1
MINOR DIA. 4.920''MAXIMUM
3 8 " REF
7
1 " (MIN. NOT SPEC.)
PITCH DIA. 5.052'' 5.064'' 4'' REF
MAJOR DIA. 5.203'' 5.226'' 6 " REF
NOZZLE E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE " HOLE
OF COMPLETED PART FOR CAR SEAL
(OPTIONAL)
OUTLET CAP
Notes:
1. Drill and tap 2 in. or 2 1/2 in. NPT as required.
2. Outlet cap and nozzle dimensions or configuration are to be manufacturers option, except for thread dimensions.
3. The 5 1/4 in.4 special 2A nozzle thread diameters are 0.020 in. less than the 5 1/4 in.4 UN 2A of ANSI B1.1 standard.
4. The 5 1/4 in.4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 5 1/4 in. O.D. 3 1/4 in. I.D. 1/8 in. thick.
6. Maximum minor diameter for hose couplings is 4.984 in. instead of 5.017 in.
7. If the cap or hose coupling thread minor diameter is worn to greater than 5.032 in. on any diameter at a depth greater than
1/2 in. (or accepts the No-Go gauge of Fig. E.18.7 to the 1/2 in. depth), the cap or hose coupling must be removed from
service.
8. If the nozzle thread major diameter is worn to less than 5.141 in. on any diameter for a length greater than 1 5/8 in. (or
accepts the No-Go gauge of Fig. E.18.6 to the 1 5/8 in. depth), the nozzle must be removed from service.
Fig. E.18 4 in. bottom outlet cap and nozzle thread standard
11/2014 C-III [M-1002] 275
APPENDIX E M-1002
152 REFERENCE
5.250'' MIN. MAJOR DIAMETER
(MAX. NOT SPECIFIED)
CHAMFER 45 TO
PITCH DIA. 5.088" 5.103" 137 DIAMETER
E18 STAMPED MINOR DIA. 4.979'' 5.017"
OR CAST ( SEE NOTE 8)
95.2 108 REF 28.6
57.2 REF
6.35 15.9 1.59 OPTIONAL138
105 REF
25.4 REF 76.2 CORE REF
15.9 REF
6.35 60
34.9 REF 50.8 CORE
45 31.8 REF
45 REF
6.35 SEE NOTE 1
MINOR DIA. 4.929'' MAXIMUM
(MIN. NOT SPEC.) 98.4 REF
44.4
PITCH DIA. 5.052'' 5.064'' 102 REF
MAJOR DIA. 5.203'' 5.226'' 159 REF
NOZZLE E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE 12.7 HOLE
OF COMPLETED PART FOR CAR SEAL
(OPTIONAL)
OUTLET CAP
Notes:
1. Drill and tap 2 in. or 2 1/2 in. NPT as required.
3. The 5 1/4 in.4 special 2A nozzle thread diameters are 0.020 in. less than the 5 1/4 in.4 UN 2A of ANSI B1.1 standard.
4. The 5 1/4 in.4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 133 O.D. 82.6 I.D. 3.18 thick.
6. All thread dimensions are shown in conventional units.
7. Appendix H must be followed when using SI units.
9. If the cap or hose coupling thread minor diameter is worn to greater than 5.032 in. on any diameter at a depth greater
than 1/2 in. (12.7 mm) (or accepts the No-Go gauge of Fig. E.18.7 to the 1/2 in. depth), the cap or hose coupling must
be removed from service.
10. If the nozzle thread major diameter is worn to less than 5.141 in. on any diameter for a length greater than 1 5/8 in.
(41.3 mm) (or accepts the No-Go gauge of Fig. E.18.6 to the 1 5/8 in. depth), the nozzle must be removed from service.
Fig. E.18.1 4 in. bottom outlet cap and nozzle thread standardSI units
C-III [M-1002] 276 11/2014
M-1002 APPENDIX E
9 " REF
8 " REF
MAJOR DIA. (MAX. NOT SPEC.)
45 CHAMFER TO 8.000'' MIN.
8 8 " DIAMETER
1
PITCH DIAMETER 7.837'' 7.858''
E18 STEEL MINOR DIAMETER 7.729'' 7.767"
STAMP (SEE NOTE 6)
OPTIONAL: 8 " HOLE (3) FOR
3
7'' REF " 8 "

5
LOCKING SET SCREWS
5
8 "
2 8 " REF
1 8 " REF
1
4 " REF
" REF 8'' 125 1''
7
8 " REF
5 1
" OPTIONAL
16
8 " REF 3 5 8 " CORE

5
OPTIONAL
REF
" 1 " REF " HOLE FOR
CAR SEAL
" 60 2'' CORE (OPTIONAL)
1 "
45 45 REF
125
SEE NOTE 1
"
MINOR DIA. (MIN. NOT SPEC.) 4 " REF
7.650''MAX 5'' REF
10'' REF
MAJOR DIAMETER 7.952'' 7.976''
NOZZLE
E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE
OF COMPLETED PART
Notes: OUTLET CAP

1. Drill and tap for 2 in., 2 1/2 in., or 3 in. NPT as required.
3. The 8 in.4 special 2A nozzle thread diameters are 0.020 in. less than the 8 in.4 UN 2A of ANSI B1.1 standard.
4. The 8 in.4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 8 in. O.D. 6 in. I.D. 1/8 in. thick.
7. If the cap or hose coupling thread minor diameter is worn to greater than 7.782 in. on any diameter at a depth greater than
7/16 in. (or accepts the No-Go gauge of Fig. E.18.9 to the 7/16 in. depth), the cap or hose coupling must be removed from
service.
8. If the nozzle thread major diameter is worn to less than 7.890 in. on any diameter for a length greater than 1 1/2 in. (or
accepts the No-Go gauge of Fig. E.18.8 to the 1 1/2 in. depth), the nozzle must be removed from service.
Fig. E.18.2 6 in. bottom outlet cap and nozzle thread standard
11/2014 C-III [M-1002] 277
APPENDIX E M-1002
241 REF
216 REF
MAJOR DIA. (MAX. NOT SPEC.)
45 CHAMFER TO 8.000'' MIN.
206 DIAMETER PITCH DIAMETER 7.837'' 7.858''
E18 STEEL MINOR DIAMETER 7.729'' 7.767"
STAMP (SEE NOTE 8)
OPTIONAL: 9.52 HOLE (3) FOR
178 REF 12.7 15.8 LOCKING SET SCREWS
15.9
73.0 REF
28.6 REF
121 REF
12.7 REF 203
15.9 REF 1.59 OPTIONAL
15.9 REF 92.1 CORE 25.5
REF OPTIONAL
12.7 31.8 REF
12.7 HOLE FOR
CAR SEAL
60 50.8 CORE (OPTIONAL)
19.0
45 45 REF
SEE NOTE 1
6.35 6.35
MINOR DIA. (MIN. NOT SPEC.) 114 REF
7.650''MAX 127 REF
254 REF
MAJOR DIAMETER 7.952'' 7.976''
NOZZLE
E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE
OF COMPLETED PART
Notes:
1. Drill and tap for 2 in., 2 1/2 in., or 3 in. NPT as required. OUTLET CAP
3. The 8 in.4 special 2A nozzle thread diameters are 0.020 in. less than the 8 in.4 UN 2A of ANSI B1.1 standard.
4. The 8 in.4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 203 O.D. 152 I.D. 3.18 thick.
6. All thread dimensions are shown in conventional units.
7. Appendix H must be followed when using SI units.
9. If the cap or hose coupling thread minor diameter is worn to greater than 7.782 in. on any diameter at a depth greater than 7/16 in.
(or accepts the No-Go gauge of Fig. E.18.9 to the 7/16 in. depth), the cap or hose coupling must be removed from service.
10. If the nozzle thread major diameter is worn to less than 7.890 in. on any diameter for a length greater than 1 1/2 in.
(38.1 mm) (or accepts the No-Go gauge of Fig. E.18.8 to the 1 1/2 in. depth), the nozzle must be removed from service.
Fig. E.18.3 6 in. bottom outlet cap and nozzle thread standardSI units
C-III [M-1002] 278 11/2014
M-1002 APPENDIX E
MAXIMUM MAJOR DIA.

5.250" MINIMUM NOT SPECIFIED (CAP)
MAJOR DIA. (CAP)
5.103" MAXIMUM
5.088" MINIMUM PITCH DIA. (CAP)
PITCH DIA. (CAP)
5.017" MAXIMUM
4.979" MINIMUM MINOR DIA. (CAP)
MINOR DIA. (CAP) (SEE NOTE 2)
MINIMUM CAP MAXIMUM CAP
INTERNAL THREAD INTERNAL THREAD
5 "4 UN ANSI B1.1 5 "4 UN ANSI B1.1
0.014" REF 0.029" REF

0.025" REF
0.012' REF
MAXIMUM NOZZLE MINIMUM NOZZLE

EXTERNAL THREAD EXTERNAL THREAD
5 "4 SPECIAL 2A 5 "4 SPECIAL 2A
(SEE NOTES) (SEE NOTES)
4.929" MAXIMUM MINIMUM MINOR DIA.

MINOR DIA. (NOZZLE) NOT SPECIFIED (NOZZLE)
0.012" 5.064" MAXIMUM 0.025" 5.052" MINIMUM

REF PITCH DIA. (NOZZLE) REF PITCH DIA. (NOZZLE)
5.226" MAXIMUM 5.203" MINIMUM

MAJOR DIA. (NOZZLE) MAJOR DIA. (NOZZLE)
MAXIMUM MATERIAL CONDITIONS MINIMUM MATERIAL CONDITIONS

MINIMUM LOOSENESS IS 0.024" ON DIAMETER MAXIMUM LOOSENESS IS 0.051" ON DIAMETER
NOTES:
1. THESE 5 " 4 SPECIAL 2A NOZZLE THREAD DIAMETERS ARE
0.020" LESS THAN THE 5 " 4 UN 2A OF ANSI B1.1 STANDARD.
2. MAXIMUM MINOR DIAMETER FOR HOSE COUPLINGS IS 4.984"

INSTEAD OF 5.017".
Fig. E.18.4 1/4 in.4 thread layout
11/2014 C-III [M-1002] 279

APPENDIX E M-1002
MAXIMUM MAJOR DIA.

8.000" MINIMUM NOT SPECIFIED (CAP)
MAJOR DIA. (CAP)
7.854" MAXIMUM
7.838" MINIMUM PITCH DIA. (CAP)
PITCH DIA. (CAP)
7.767" MAXIMUM
7.729" MINIMUM MINOR DIA. (CAP)
MINOR DIA. (CAP) (SEE NOTE 3)
MINIMUM CAP MAXIMUM CAP
INTERNAL THREAD INTERNAL THREAD
8"4 SPECIAL 8"4 SPECIAL
(SEE NOTE 1) (SEE NOTE 1)
0.014" REF 0.029" REF

0.026" REF
0.012" REF
MAXIMUM NOZZLE MINIMUM NOZZLE

EXTERNAL THREAD EXTERNAL THREAD
8"4 SPECIAL 2A 8"4 SPECIAL 2A
(SEE NOTE 2) (SEE NOTE 2)
7.679" MAXIMUM MINIMUM MINOR DIA.

MINOR DIA. (NOZZLE) NOT SPECIFIED (NOZZLE)
0.012" 7.814" MAXIMUM 0.026" 7.802" MINIMUM

REF PITCH DIA. (NOZZLE) REF PITCH DIA. (NOZZLE)
7.976" MAXIMUM 7.952" MINIMUM

MAJOR DIA. (NOZZLE) MAJOR DIA. (NOZZLE)
MAXIMUM MATERIAL CONDITIONS MINIMUM MATERIAL CONDITIONS

MINIMUM LOOSENESS IS 0.024" ON DIAMETERS MAXIMUM LOOSENESS IS 0.052" ON DIAMETERS
NOTES:
1. THESE 8"4 SPECIAL 2B CAP THREAD DIAMETERS ARE 2.000"
GREATER THAN THE 6"4 UN 2B OF ANSI B1.1 STANDARD.
2. THESE 8"4 SPECIAL 2A NOZZLE THREAD DIAMETERS ARE

1.9800" GREATER THAN THE 6"4 UN 2A OF ANSI B1.1 STANDARD.
3. MAXIMUM MINOR DIAMETER FOR HOSE COUPLINGS IS 7.734"

INSTEAD OF 7.767".
Fig. E.18.5 8 in.4 thread layout
C-III [M-1002] 280 11/2014

M-1002 APPENDIX E
7 8"
1
5.141"
(2) 1 8 " 45
1.750"
7 16" (OPTIONAL)
2 "
"
NO-GO GAUGE FOR
AAR 5 "4 THREAD NOZZLE
" (4) 32" 45

1 3
8 "
NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
2. ANY DIMENSIONALLY STABLE MATERIAL MAY BE USED.
Y 3. MANUFACTURING TOLERANCE: DECIMAL 0.005 IN.
(ref. Appendix D, 4. RECERTIFICATION TOLERANCE: DECIMAL 0.015 IN.
paragraph 3.6) 5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
6. MAY BE COMBINED WITH FIG. E.18.7 IN A SINGLE GAUGE CONFIGURATION.
Fig. E.18.6 Gauge for worn threads4 in. bottom outlet nozzle
6"
(4) 32" 45
1
1" 7 16" (OPTIONAL)
"
1 8"
3 NO-GO GAUGE FOR
AAR 5 "4 THREAD CAP OR COUPLING
0.625"
3
8 " 1 32"
5.032"
(2)1 8 " 45
X = 1 5/8" MINIMUM (ref. Appendix D, paragraph 3.6)
NOTES:
3. MANUFACTURING TOLERANCE: DECIMAL 0.005 IN.
4. RECERTIFICATION TOLERANCE: DECIMAL 0.015 IN.
5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
NOT IMPAIRED.
Fig. E.18.7 Gauge for worn threads4 in. bottom outlet cap or coupling
11/2014 C-III [M-1002] 281
APPENDIX E M-1002
10 "
7.890"
(2) 8 " 45
1
16" (OPTIONAL)
7
1.625"
2 "
NO-GO GAUGE FOR

7
8 " AAR 8"4 THREAD NOZZLE
9
"
16 3
8 "
(4) 32" 45
1
NOTES:
Y 3. MANUFACTURING TOLERANCE: DECIMAL 0.005 IN.
(ref. Appendix D, 4. RECERTIFICATION TOLERANCE: DECIMAL 0.015 IN.
paragraph 3.6) 5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
NOT IMPAIRED.
Fig. E.18.8 Gauge for worn threads6 in. bottom outlet nozzle
8 8"
3
13
"
16 16" (OPTIONAL)
7 (4)1 32" 45
11
"
1 8"
3
16
NO-GO GAUGE FOR
AAR 8"4 THREAD CAP OR COUPLING
0.563"
3
8 " 1 32"
7.782"
(2) 8 " 45
1
8 " DIA. (REF)
X = 1 " MINIMUM
NOTES:
3. MANUFACTURING TOLERANCE: DECIMAL 0.005 IN.
4. RECERTIFICATION TOLERANCE: DECIMAL 0.015 IN.
5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO
SUIT THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF
THE GAUGE IS NOT IMPAIRED.
Fig. E.18.9 Gauge for worn threads6 in. bottom outlet cap or coupling
C-III [M-1002] 282 11/2014

M-1002 APPENDIX E
1 1 88"
1
8"
3
7.515 .005 DIA
8.485 .005 DIA
10
5
8" DIA B.C. DRILL AND TAP FOR
3
8 - 4 - 10 UNC 28
STUDS
8.500 .005 DIA
7.500 .005 DIA
8"
5
DRILL 8" DIA HOLES

7
IN VALVE FLANGE
Fig. E.18.10 Detail for mounting condition of bottom outlet valves
11/2014 C-III [M-1002] 283

APPENDIX E M-1002
DRILL 7 8 " DIA. HOLES

IN VALVE FLANGE
"
1.505'' .003' DIA.

1 " DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' .003'' DIA.
3 " DIA. B.C. DRILL AND TAP FOR FOUR

'' 10 UNC 2A STUDS
2.255'' .003'' DIA.
1
" DIA. GROOVE
16 1
7
8 " DIA.
1.495'' .003'' DIA.
1
1
8 " DIA.
1
8 " GASKET
3
"
16
"
8
"
7
8
1
1
1''
DRILL AND TAP 1 " NPT

Fig. E.19 Detail of mounting conditions for 1 in. angle valve
C-III [M-1002] 284 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
38.16 TO 38.30 DIA.
44.4 DIA.
50.8 DIA. 1.59 DIA. GROOVES
56.95 TO 57.09 DIA.
88.9 DIA. B.C. DRILL AND TAP FOR FOUR

'' 10 UNC 2A STUDS
57.21 TO 57.35 DIA.
1.59 DIA. GROOVE 47.6 DIA.
37.90 TO 38.04 DIA.

3.18 GASKET
28.6 DIA.
4.76
22.2
28.6
25.4
DRILL AND TAP 1 " NPT

Fig. E.19.1 Detail of mounting conditions for 1 in. angle valveSI units
11/2014 C-III [M-1002] 285

APPENDIX E M-1002

IN VALVE FLANGE
"
3.255'' .003'' DIA.
3 " DIA.
3 " DIA.
1
"
16 DIA. GROOVES
3.995'' .003'' DIA.
DRILL AND TAP FOR FOUR

6 " DIA. B.C. '' 10 UNC 2A STUDS
4.005'' .003'' DIA.
" DIA. GROOVE 3 8 " DIA.

1 5
16
3.245'' .003'' DIA.
2'' DIA.
1
8 " GASKET
3
"
16
1 "
"
8
7
DRILL AND TAP 2'' NPT OR 2 " NPT
Fig. E.19.2 Detail of mounting conditions for 2 in. angle valve for tank with 2 in. eduction pipes
C-III [M-1002] 286 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
1.59 DIA. GROOVES 95.3 DIA.
101.40 TO 101.54 DIA.

159 DIA. B.C. '' 10 UNC 2A STUDS
101.66 TO 101.80 DIA.
82.35 TO 82.49 DIA.
50.8 DIA.
3.18 GASKET
4.76
22.2
31.8
DRILL AND TAP 2'' NPT OR 2 " NPT
Fig. E.19.3 Detail of mounting conditions for 2 in. angle valve for tank with 2 in. eduction pipesSI units
11/2014 C-III [M-1002] 287

APPENDIX E M-1002

IN VALVE FLANGE
"
3.255'' .003'' DIA.
3 " DIA.
1
" DIA. GROOVES
16
3 " DIA.
3.995'' .003'' DIA.

4.005'' .003'' DIA.
" DIA. GROOVE 3 8 " DIA.

1 5
16
3.245'' .003'' DIA. 1

8 " GASKET
"
3
"
1 "
8
16
7
1 18 "
EXCESS FLOW VALVE

2
5
8 " DIA. WELDED TO COVER
2.906'' DIA.
Fig. E.19.4 Detail of mounting conditions for 2 in. angle valve for tanks with 2 in. eduction pipes
C-III [M-1002] 288 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
1.59 DIA. GROOVES 95.3 DIA.
101.40 TO 101.54 DIA.
159 DIA. B.C. DRILL AND TAP FOR FOUR

'' 10 UNC 2A STUDS
101.66 TO 101.80 DIA.
82.35 to 82.49 DIA.

3.18 GASKET
22.2
4.76
31.8
28.6
EXCESS FLOW VALVE

66.7 DIA. WELDED TO COVER
73.81 DIA.
Fig. E.19.5 Detail of mounting conditions for 2 in. angle valve for tanks with 2 in. eduction pipesSI units
11/2014 C-III [M-1002] 289

APPENDIX E M-1002

IN VALVE FLANGE
"
3.255'' .003'' DIA.

3 " DIA.
3 " DIA. 1
"
16 DIA. GROOVES
3.995'' .003'' DIA.
6 "DIA. B.C. DRILL AND TAP FOR FOUR

'' 10 UNC 2A STUDS
4.005'' .003'' DIA.
3
5
8 " DIA. 1
"
16 DIA. GROOVE
3.245'' .003'' DIA.
2
15
16 " DIA. 1
8 " GASKET
3
"
"
16
8
1 "
7
7
" MIN.
16
DRILL AND TAP 3'' NPT OR 3 '' NPT

Fig. E.19.6 Detail of mounting conditions for 2 in. or 3 in. angle valve for tanks with 3 in. eduction pipes
C-III [M-1002] 290 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
101.40 TO 101.54 DIA.

'' 10 UNC 2A STUDS
101.66 TO 101.80 DIA.
92.1 DIA. 1.59 DIA. GROOVE
82.35 TO 82.49 DIA.
74.6 DIA. 3.18 GASKET
4.76
31.8
22.2
11.1 MIN.
DRILL AND TAP 3' NPT OR 3 '' NPT

Fig. E.19.7 Detail of mounting conditions for 2 in. or 3 in. angle valve for tanks with 3 in. eduction pipesSI units
11/2014 C-III [M-1002] 291

APPENDIX E M-1002

IN VALVE FLANGE
"
3.255'' .003'' DIA.
3 " DIA.
3 " DIA. 1
" DIA. GROOVES
16
3.995'' .003'' DIA.

4.005'' .003'' DIA.
3
5
8 " DIA. 1
" DIA. GROOVE
16
3.245'' .003'' DIA.
2
15
16 " DIA.
1
8 " GASKET
3
"
"
16
8
1 "
"
EXCESS FLOW VALVE

3.505'' DIA. WELDED TO COVER
Fig. E.19.8 Detail of mounting conditions for 2 in. or 3 in. angle valve for tanks with 3 in. eduction pipes
C-III [M-1002] 292 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
101.40 TO 101.54 DIA.

'' 10 UNC 2A STUDS
101.66 TO 101.80 DIA.
82.35 TO 82.49 DIA.
74.6 DIA. 3.18 GASKET

22.2
4.76
31.8
19.0
EXCESS FLOW VALVE

89.03 DIA. WELDED TO COVER
Fig. E.19.9 Detail of mounting conditions for 2 in. or 3 in. angle valve for tanks with 3 in. eduction pipesSI units
11/2014 C-III [M-1002] 293

APPENDIX E M-1002

IN VALVE FLANGE
"
1.505'' .003'' DIA.
1 " DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' .003'' DIA.

4
1
2.255'' .003'' DIA.
1
7
8 " DIA. 1
16 " DIA. GROOVE
1.495'' .003'' DIA. 1

8 " GASKET
3
"
16
1 " DIA.
"
8
1 "
DRILL AND TAP 1 '' NPT

Fig. E.19.10 Detail of mounting conditions for gauging device
C-III [M-1002] 294 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
38.16 TO 38.30 DIA.
44.4 DIA.
56.95 TO 57.09 DIA.

'' 10 UNC 2A STUDS
57.21 TO 57.35 DIA.

37.90 TO 38.04 DIA.
3.18 GASKET
4.76
31.8 DIA.
2.22
31.8
DRILL AND TAP 1 '' NPT

Fig. E.19.11 Detail of mounting conditions for gauging deviceSI units
11/2014 C-III [M-1002] 295

APPENDIX E M-1002

IN VALVE FLANGE
"
1.505'' .003'' DIA.
1 " DIA. B.C.
2'' DIA. 1
16 " DIA. GROOVES
2.245'' .003'' DIA.
4 8 " DIA. B.C.

1 DRILL AND TAP FOR FOUR
'' 10 UNC 2A STUDS
2.255'' .003'' DIA.
1 8 " DIA. " DIA. GROOVE

7 1
16
1.495'' .003'' DIA.

1
8 " GASKET
3
"
16
1 " DIA.
1 "
"
7
8
"
1.531'' DIA.
Fig. E.19.12 Detail of mounting conditions for gauging device
C-III [M-1002] 296 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
38.16 TO 38.30 DIA.
44.4 DIA.
56.95 TO 57.09 DIA.

'' 10 UNC 2A STUDS
57.21 TO 57.35 DIA.
37.90 TO 38.04 DIA.

3.18 GASKET
4.76
22.2
31.8 DIA.
31.8
19.0
38.89 DIA.
Fig. E.19.13 Detail of mounting conditions for gauging deviceSI units
11/2014 C-III [M-1002] 297

APPENDIX E M-1002

IN VALVE FLANGE
"
1.505'' .003'' DIA.

1 " DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' .003'' DIA.

'' 10 UNC 2A STUDS
2.255'' .003'' DIA.
1
7
8 " DIA. 1
16 " DIA. GROOVE
1.495'' .003'' DIA.

1
1
8 " DIA.
3
"
1
8 " GASKET
16
3
8 "
"
1 "
8
7
3
8 "R
1 " DIA.
Fig. E.19.14 Detail of mounting conditions for pressure relief valve
C-III [M-1002] 298 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
38.16 TO 38.30 DIA.
44.4 DIA.
56.95 TO 57.09 DIA.

'' 10 UNC 2A STUDS
57.21 TO 57.35 DIA.
37.90 TO 38.04 DIA.
28.6 DIA.
3.18 GASKET
4.76
9.52
22.2
31.8
9.52 R
44.4 DIA.
Fig. E.19.15 Detail of mounting conditions for pressure relief valveSI units
11/2014 C-III [M-1002] 299

APPENDIX E M-1002

IN VALVE FLANGE
"
4.005 .003'' DIA.
4 " DIA.
4 " DIA. 1
" DIA. GROOVES
16
4.745'' .003'' DIA.

'' 10 UNC 2A STUDS
4.755 .003'' DIA.
4 8 " DIA. " DIA. GROOVE

3 1
16
3.995 .003'' DIA.
2 8 " DIA.
7
1
8 " GASKET
3
"
16
"
"
1 "
3
"
8
8
7
3 8 " DIA.
3
C-III [M-1002] 300 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
101.66 TO 101.80 DIA.
108 DIA.
114 DIA. 1.59 DIA. GROOVES
120.45 TO 120.59 DIA.

120.71 TO 120.85 DIA.
101.40 TO 101.54 DIA.
73 DIA. 3.18 GASKET

4.76
12.7
22.2
31.8
9.52
85.7 DIA.
11/2014 C-III [M-1002] 301

APPENDIX E M-1002
DRILL 8 " DIA. HOLES

7
IN VALVE FLANGE
"
4.255 .003'' DIA.
4 " DIA.
4 " DIA. 1
" DIA. GROOVES
16
4.995 .003'' DIA.

'' 10 UNC 2A STUDS
5.005'' .003'' DIA.
4
5
8 " DIA. 1
" DIA. GROOVE
16
4.245'' .003'' DIA.
3 16" DIA.
1
3
"
16
1
8 " GASKET
"
"
1 "
"
8
3
7
3 "
C-III [M-1002] 302 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
108.01 TO 108.15 DIA.

114 DIA.
126.80 TO 126.94 DIA.

'' 10 UNC 2A STUDS
127.06 TO 127.20 DIA.
107.75 TO 107.89 DIA.
77.8 DIA.
4.76 3.18 GASKET
12.7
22.2
31.8
9.52
95.2
11/2014 C-III [M-1002] 303

APPENDIX E M-1002
DRILL 16" DIA. HOLES

15
IN VALVE FLANGE
"
6.005 .003'' DIA.

6 " DIA.
6 " DIA. 1
" DIA. GROOVES
16
6.745 .003'' DIA.

8'' DIA. B.C. 7
8 " 9 UNC 2A STUDS
6.755 .003'' DIA.
6
3
8 " DIA. 1
" DIA. GROOVE
16
5.995'' .003'' DIA.
5
5
8 " DIA.
1
8 " GASKET
3
"
1 8"
1"
16
3
C-III [M-1002] 304 11/2014

M-1002 APPENDIX E
DRILL 16" DIA. HOLES

15
IN VALVE FLANGE
6.35
152.46 TO 152.60 DIA.
159 DIA.
171.25 TO 171.39 DIA.

8 " 9 UNC 2A STUDS
7
171.51 TO 171.65 DIA.
152.20 TO 152.34 DIA.
143 DIA.
3.18 GASKET
25.4
4.76
34.9
11/2014 C-III [M-1002] 305

APPENDIX E M-1002

IN VALVE FLANGE
"
7.255'' .003'' DIA.
7 " DIA.
7 " DIA. 1
16 " DIA. GROOVES
7.995'' .003'' DIA.
DRILL AND TAP FOR EIGHT

8.005'' .003'' DIA.
7
5
8 " DIA. 1
" DIA. GROOVE
16
7.245'' .003'' DIA.
6
5
8 " DIA.
1
8 " GASKET
"
3
"
8
16
1 "
C-III [M-1002] 306 11/2014

M-1002 APPENDIX E

IN VALVE FLANGE
6.35
184.21 TO 184.35 DIA.
190 DIA.
203.00 TO 203.14 DIA.
DRILL AND TAP FOR EIGHT

203.26 TO 203.40 DIA.
183.95 TO 184.09
168 DIA.
3.18 GASKET
4.76
22.2
31.8
11/2014 C-III [M-1002] 307

APPENDIX E M-1002
DRILL " DIA. HOLES

IN VALVE FLANGE
"
4.25" .02"
5.00" .02"
6" DIA. BC DRILL AND TAP FOR

8 " 11 UNC 2A STUDS
5
5.06" .02"
4.19" .02" 1
8 " GASKET
0.19"
"
1"
AS REQUIRED
Fig. E.19.24 Detail of mounting condition for 3 in. full ported flanged ball valves for nonpressure tank cars using
ANSI B16.5 large tongue design
3 " DIA. BC
2.255" .003" DIA.

17
" DIA. 1 1 8 " DEEP
32
1 8 " DIA.
7
TAP
5
8 " 11 UNC2B " DEEP
EQUALLY SPACED 1.495 .003" DIA.
1
" DIA. GROOVE
16
(4 PLCS) 1
32" DEEP
3
"
16
1 " DIA.
"
1.531" DIA.
Fig. E.19.25 Gauging device interface VCM tank cars
C-III [M-1002] 308 11/2014

M-1002 APPENDIX E
SMALLER OF
a c .7N OR .7M
2N 2M
M
D
2M
b
d SMALLER OF
.7N OR .7M
D D
Fig. E.20 Reinforced openings in tank shellflued nozzle, lap welded
D N
a c SMALLER OF
2N K .7N OR .7M
2M
M
2M
b N
d
D D
Fig. E.20.1 Reinforced openings in tank shellbuilt-up nozzle with pad
D N
c
a
R 2N 2M
M
2M
b
d
D D
Fig. E.20.2 Reinforced openings in tank shellflued nozzle, butt-welded

11/2014 C-III [M-1002] 309
APPENDIX E M-1002
D N
SMALLER OF
" (6.35) OR .7N
a c
2N K 2M
M
2M
b
d SMALLER OF
D D M OR K
Fig. E.20.3 Reinforced openings in tank shellbuilt-up nozzle with reinforcement
D N
a c
2M
K M
2M SMALLER OF SMALLER OF
b M OR K .7N OR .7M
d
D D
Fig. E.20.4 Reinforced openings in tank shelldome shell outside reinforcement boundary
SMALLER OF
a c .7N OR .7M
R 2N
2M
D 2M
SMALLER OF
b .7N OR .7M
d
D D
Fig. E.20.5 Reinforced openings in tank shellflued nozzle, tapered, lap-welded

C-III [M-1002] 310 11/2014
M-1002 APPENDIX E
D N
a c
2N 2M
K M
2M
b
d .7 K
D D
Fig. E.20.6 Reinforced openings in tank shellflued opening abutting tank shell
D N
SMALLER OF
c " (6.35) OR .7N
a
2M
OR
2N M
2M
b
d
D D
Fig. E.20.7 Reinforced openings in tank shellbuilt-up nozzle, butt-welded
SMALLER OF
" (6.35) OR .7N
D N
a c
K 2N
2M
M
SMALLER OF
2M
M OR K
b
d SMALLER OF
.7M OR .7N = TW
D D
SMALLER OF
.7N OR .7K = TW
Fig. E.20.8 Reinforced openings in tank shellbuilt-up nozzle with reinforcement
11/2014 C-III [M-1002] 311

APPENDIX E M-1002
SMALLER OF
.7 N OR .7 L
IDD N SMALLER OF
" (6.35) OR .7N SMALLER OF
M OR K
L
c
a 4" (102) ON
K 2N 2M
LONG CL
SMALLER OF
2M M .7 N OR .7 L
b d
ITD IDD
IDD
IDD
2N ( 1 + 2ITD
)
WHERE N = SPECIFIED
DOME SHELL THICKNESS
(MAY BE ONE PIECE).
Fig. E.20.9 Reinforcement with internal ring for dome opening greater than 30 in. (762 mm)
SMALLER OF
N .7 N OR .7 L
SMALLER OF
IDD L M OR K
SMALLER OF
c " (6.35) OR .7L
a 4" (102) ON
K 2N 2M
LONG CL
SMALLER OF
2M M .7 N OR .7 L
b d
ITD 2N ( 1 + 2ITD
IDD
)
IDD
IDD WHERE N = SPECIFIED
DOME SHELL THICKNESS
(MAY BE ONE PIECE).
Fig. E.20.10 Reinforcement with external ring for dome opening greater than 30 in. (762 mm)
.7 N
N
L
.7 M
.7 N
K c
M a
2M
2N M
D 2M
b
.7 M d
D D
Fig. E.20.11 Flued reinforcement for dome opening 30 in. or less
C-III [M-1002] 312 11/2014
M-1002 APPENDIX E
N
D
c
FULL a
PENETRATION 2 M 2N
WELD M
2M 2N
d
SMALLER OF b
" (6.35) OR .7N D D
Fig. E.20.12 Built-up nozzle with full penetration weld
11/2014 C-III [M-1002] 313

APPENDIX E M-1002
" DIA. EIGHT HOLES
" DIA. FOUR HOLES

10 " BOLT CIRCLE 6'' SQ. MIN.
6 " BOLT CIRCLE
12'' DIA.
7 " DIA. MIN.
7.1875'' .005'' DIA.
2 8 " DIA. MIN.
7
6 " " LINED OR UNLINED

1
32
LINED OR UNLINED
"
FLANGE MAY BE SQUARE OR ROUND

A B
THREE HOLES DIA. TO SUIT
7.652'' MAJOR DIA. EQUALLY SPACED
5 " BOLT CIRCLE
1 " MIN.
7'' DIA. MIN.

7'' TAPER PIPE THREAD
8 THREADS PER INCH 1 " DIA. MIN.
2'' N.P.T. AFTER LINING
C
D FOR RUBBER LINED TANKS ONLY

E
Fig. E.21 Pressure relief device connections for nonpressure cars
C-III [M-1002] 314 11/2014

M-1002 APPENDIX E
" DIA. EIGHT HOLES
" DIA. FOUR HOLES

260 BOLT CIRCLE 152 SQ. MIN.
159 BOLT CIRCLE
305 DIA.
190 DIA. MIN
182.44 TO 182.68
73.0 DIA. MIN.
164.31 TO 165.89 LINED OR UNLINED
LINED OR UNLINED
6.35
FLANGE MAY BE SQUARE OR ROUND

A B
194.36 MAJOR DIA. THREE HOLES DIA. TO SUIT

EQUALLY SPACED
140 BOLT CIRCLE
38.1 MIN.
178 DIA. MIN.

7'' TAPER PIPE THREAD
8 THREADS PER INCH 44.4 DIA. MIN.
AFTER LINING
C 2'' N.P.T.
D FOR RUBBER LINED TANKS ONLY

E
Fig. E.21.1 Pressure relief device connections for nonpressure carsSI units
11/2014 C-III [M-1002] 315

APPENDIX E M-1002
A A
5
EDGE OF
DISCONTINUITY 1 NOTE:
1) All strain gauges located on external tank surfaces
2) Rosettes 1 and 2 located on tank shell as shown
2'' (50.8) 2
3) Rosette 3 located in center of reinforcement
4) Rosette 4 located in center of flat portion of nozzle
5) Rosette 5 located in center of curved portion of nozzle
2'' (50.8) EDGE OF DISCONTINUITY

3
SECTION A-A
Fig. E.22 Strain gauge rosette location
C-III [M-1002] 316 11/2014

M-1002 APPENDIX E
2.2'' 0.1'' DIA.
3.13'' 0.03'' DIA.
16" TO 8 "
1 1
CHAMFER OR
3.25'' 0.03'' DIA. RADIUS
2.2'' 0.1'' DIA.
Note: The outside diameter of a rupture disc for use in the nominal 2 in. rupture disc device should be in the range of 3.07 to
3.20 in.
Fig. E.23 Detail of nominal 2 in.-diameter rupture disc device
11/2014 C-III [M-1002] 317

APPENDIX E M-1002
55.6 TO 56.1 DIA.

78.7 TO 80.2 DIA.
1.59 TO 3.18
CHAMFER OR
81.7 TO 83.3 DIA. RADIUS
53.3 TO 58.4 DIA.
Notes:
The outside diameter of a rupture disc for use in the nominal 2 in. rupture disc device should be in the range of 3.07 to 3.20 in.
All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.23.1 Detail of nominal 2 in.-diameter rupture disc deviceSI units
Fig. E.24 <This caption must become white text; there is no Fig. E24, but there must be a holder for it.>
C-III [M-1002] 318 11/2014

M-1002 APPENDIX E
2 3
4
6
4
Fig. E.24.1 Bolted flange closure
1 Fig. E.24.4 Quick-coupling device with external

threaded cap closure
1
7
4
6
Fig. E.24.2 Threaded cap closure
4
1
Fig. E.24.5 Quick-coupling device with internal
threaded cap closure
1
5
5
7
6
8
Fig. E.24.3 Quick-coupling device with threaded plug
closure
4
Fig. E.24.6 Quick-coupling device with auxiliary test

valve and internal threaded cap closure
Bottom outlet closure arrangements
11/2014 C-III [M-1002] 319
APPENDIX E M-1002
1 1
4*
4
8
5
Fig. E.24.7 Quick-coupling device with internal

threaded cap closure and alternative test valve
1
10
4*
* Either Location Acceptable
Fig. E.24.9 Two-piece quick-coupling device with
auxiliary valve
OUTLET CONNECTION PARTS LEGEND
1 Outlet Nozzle
2 Outlet Flange-bolted
3 Cap-Threaded
10
4 Plug 1" NPT Minimum
4 Quick Coupling Adapter
5
6 Gasket
Fig. E.24.8 Two-piece quick-coupling device with
integral auxiliary valve 7 Plug with Dust Protector Threaded
8 Auxiliary Valve
9 Quick Coupling Adaptor with Integral Valve
10 Quick Coupling Dust Cap
Bottom outlet closure arrangements

Fig. E.25 <This caption must become white text; there is no Fig. E25, but there must be a holder for it.>
C-III [M-1002] 320 11/2014
M-1002 APPENDIX E
HIGHEST POINT ON COVER
15 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.1 Top fittings profile nonpressure carshinged manway
DIMENSION
A
OUTSIDE DIAMETER
TANK SHELL
Valve Size 2 in. 3 in.

Dimension A 19 " 22 "
NOTE:
DIMENSION A IS APPLICABLE FOR EITHER
THREADED OR FLANGED VALVES AND PLUGS
Fig. E.25.2 Top fittings profile nonpressure carsmultihousing (welded cover plate)
11/2014 C-III [M-1002] 321

APPENDIX E M-1002
Dimension
A
OUTSIDE DIAMETER
TANK SHELL
Valve Size 2 in. 3 in.

Dimension A 20 " 24"
NOTE:
DIMENSION A IS APPLICABLE FOR EITHER
THREADED OR FLANGED VALVES AND PLUGS
Fig. E.25.3 Top fittings profile nonpressure carsmultihousing (bolted cover plate)
20"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.4 Top fittings profile nonpressure cars6 in. pressure relief valve
C-III [M-1002] 322 11/2014

M-1002 APPENDIX E
22 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.5 Top fittings profile nonpressure cars3 in. top style pressure relief valve
15 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.6 Top fittings profile nonpressure cars3 in. pressure relief valve
11/2014 C-III [M-1002] 323
APPENDIX E M-1002
15 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.7 Top fittings profile nonpressure cars2 in. rupture disc device
THREADED FLANGED 28 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.8 Top fittings profile nonpressure carsrupture disc device or vacuum relief valve applied on hinged
manway cover
27 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.9 Top fittings profile nonpressure carspressure relief valve applied on hinged manway cover
C-III [M-1002] 324 11/2014
M-1002 APPENDIX E
25 "
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E.25.10 Top fittings profile nonpressure carsmanway with nozzlehydrochloric acid car
34"
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E.25.11 Top fittings profile nonpressure carsmanway with nozzles and valvehydrochloric acid car
11/2014 C-III [M-1002] 325

APPENDIX E M-1002
26 "
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.12 Top fittings profile nonpressure carsmanway with nozzlessulfuric acid car
NOMINAL NOMINAL
1
" OVERLAP
16
OVERLAP 1
"
16
(A) SHOWN WITH HARD GASKET RETAINED ON I.D. (B) SHOWN WITH HARD GASKET RETAINED ON O.D.
NOMINAL
1
"
32
1
" OVERLAP
16
(C) SHOWN WITH ELASTOMERIC GASKET RETAINED ON I.D. AND O.D.
Note: Other gasket groove configurations or combinations of the grooves shown are allowed as long as the conditions of
paragraph 3.3.1 in this appendix are met. The gaskets shown in this figure are to illustrate retention methods and overlaps
required. Any of the gaskets could be used in any of the grooves.
Fig. E.26 Gasket grooves for AAR-1 manway style
C-III [M-1002] 326 11/2014
M-1002 APPENDIX E
*
QTY (*)
ON * B.C.
* * * * B
*
Blind Flange for
DIM
Blind Flange for Blind Flange for
Gauging Device A
1-in. Angle Valve Gauging Device for VCM Tank Cars
A .75 in. (19 mm) 1 in. (25 mm) .75 in. (19 mm)
B 5 in. (127 mm) 5.75 in. (146 mm) 4.5 in. (114 mm)
* Remaining dimensions to be per applicable Fig. E.19 through Fig. E.19.25.
Fig. E.27 Detail of pressure car blind flange for 1 in. angle valve or gauging device
6.00" (152 mm) * Dimensions to be per applicable Fig. E.19 through Fig. E.19.25.
*
QTY (*)
ON * B.C.
* * * *
6.00" (152 mm)
*
R.81" (R21 mm) TYP
1" (25 mm)
Fig. E.28 Detail of pressure car blind flange for 2 in. or 3 in. angle valve
11/2014 C-III [M-1002] 327
APPENDIX E M-1002
8 "
R1 16"
9
TRANSVERSE
CENTERLINE A A 11
"
D 8 16
SAMPLING VALVE "
6 TYP
THERMOMETER WELL
C
GAUGING DEVICE
ANGLE VALVE 9 "

3 PLACES R1 "
B
PROTECTIVE LONGITUDINAL 9 "
"
HOUSING CENTERLINE
MOUNTING 6 TYP
(SEE NOTE)
A A
C
6
DRAIN HOLES 8"
R1 8 "
3
3
8 "
LARGE SAFETY VALVE B
8" D
"
3
11
"
16
NOTE:
6 TYP
PROTECTIVE HOUSING MUST HAVE FOUR 3 1/2 IN. MINIMUM DIAMETER
5
"
16
PORTS LOCATED ON LONGITUDINAL AND TRANSVERSE CENTERLINES. SMALL SAFETY

ADDITIONALLY, A 3 IN. WIDE 2 1/2 IN. HIGH CLEARANCE IS REQUIRED VALVE
ABOVE ANY FITTING EXTENDING THROUGH A PORT.
Fig. E.29 Clearance requirements for capping kits (except chlorine cars)
1" CHLORINE ANGLE VALVE

(4) PLACES NOTES:
1. THE 6BMV GASKET FITS AROUND ANY OF THE FOUR 1 IN.
CHLORINE ANGLE VALVES.
2. THE 24BMV GASKET FITS AROUND THE PRESSURE RELIEF
DEVICE IN THE CENTER OF VALVE ARRANGEMENT.
3. THE VALVE OUTLET PLUG MUST BE REMOVED PRIOR TO
THE INSTALLATION OF THE 6BMV GASKET AND HOOD.
4. PROTECTIVE HOUSING MUST HAVE FOUR 3 1/2 IN.
MINIMUM DIAMETER PORT OPENINGS ON LONGITUDINAL
1 AND TRANSVERSE CENTERLINES. THE CENTERLINE OF
THE PORT OPENINGS MUST BE LOCATED 4 IN. FROM THE
BOTTOM OF THE 12 3/4 IN.-HIGH PROTECTIVE HOUSING
WALL.
7 8 " SQUARE
7
6 8 " SQUARE
5
7" OD
5 32" ID
23
1 2
6BMV 24BMV
MOLDED VITON GASKET MOLDED VITON GASKET
2
PRESSURE RELIEF DEVICE
Fig. E.30 Capping clearances for standard chlorine cars with 18 in. manways
C-III [M-1002] 328 11/2014
M-1002 APPENDIX H
APPENDIX H
BASIC PHILOSOPHY AND PRINCIPLES FOR THE METRICATION OF THE
AAR SPECIFICATIONS FOR TANK CARS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
2.0 Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
2.1 Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.0 Items Not Converted to SI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.2 Obsolete Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.3 Appendix M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.4 Appendix W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.5 Bolt and Pipe Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III330
3.6 Accepted Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III331
4.0 Stage 1 Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III331
4.1 Standard Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III331
4.2 Conversion Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III331
4.3 Significant Figures in Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III331
5.0 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
5.1 Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
5.2 Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
5.3 Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
5.4 Tolerances for Production Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
6.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
6.1 Applications for Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
6.2 Standard Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III334
6.3 Rounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III335
6.4 Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III335
6.5 Stamping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III335
6.6 Plate Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III335
6.7 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III335
11/2014 C-III [M-1002] 329

APPENDIX H M-1002
APPENDIX H
BASIC PHILOSOPHY AND PRINCIPLES FOR THE METRICATION OF THE
AAR SPECIFICATIONS FOR TANK CARS
1.0 INTRODUCTION
1.1 Scope
1.1.1 Appendix H outlines the basic philosophy and principles for the metrication of the AAR
Specifications for Tank Cars. These are the guidelines for converting the specifications from
conventional units to SI units. For conversions not specifically covered herein, see IEEE/ASTM
SI10.
1.1.2 Changes to the basic philosophy contained herein are to be made by approval of the Tank
Car Committee.
2.0 SEQUENCE
The conversion of the tank car specifications from conventional units to SI units will be
accomplished in three stages. At some later date it may be decided to omit stage 2. If stage 2 is
utilized at the time the decision is made to implement it, a decision will also be made whether or
not the SI-dimensioned tank cars and components are to be interchangeable with existing
equipment. If not, the SI-dimensioned tank cars will be the beginning of a new and independent
set of specifications.
2.1 Stages
2.1.1 Conversion of the Specifications for Tank Cars will be addressed in three stages:
Stage 1 Measurement units are expressed in conventional units followed by the

equivalent SI units in parentheses.
Stage 2 Measurement units are expressed in SI units followed by the equivalent
conventional units in parentheses.
Stage 3 Measurement units are expressed in SI units only.
2.1.2 For production drawings, the placement of conventional and SI equivalents is optional,
within ANSI Y14.5 guidelines, if covered by an explanatory note on the drawings.
3.0 ITEMS NOT CONVERTED TO SI UNITS
3.1 Specification Numbers
Specification numbers (such as 112J340W) are to remain unchanged and are to be considered as
specification designators that only incidentally reflect test pressures.
3.2 Obsolete Specifications
Obsolete specifications will not be converted to reflect SI equivalents, because the obsolete
specifications authorize no new construction, but only maintenance, repair, and retest of existing
equipment.
3.3 Appendix M
Established ASTM conversions will be adopted for ASTM materials in Appendix M. Rounding
used by ASTM will be applied to non-ASTM materials in Appendix M (e.g., TC128).
3.4 Appendix W
Established ASME conversions will be adopted for parallel material in Appendix W.
3.5 Bolt and Pipe Threads
Bolt threads and pipe threads are to be left in conventional units. Metric threads are to be used
only with Tank Car Committee approval.
C-III [M-1002] 330 11/2014
M-1002 APPENDIX H
3.6 Accepted Conventions

Do not convert
truck sizes
journal sizes
valve nominal sizes
pipe sizes
4.0 STAGE 1 PHILOSOPHY
4.1 Standard Conditions
Standard conditions will be 14.696 psia (101.325 kPa abs) at 60 F (15.56 C).
4.2 Conversion Method
4.2.1 Conversions to SI units will be soft, as specified herein, with no deviations without
approval.
4.2.2 SI units will be established using the entire conventional-to-metric conversion factor and
then rounding to a designated number of significant figures as specified herein. Do not round
either the conversion factor or the quantity before the multiplication, since accuracy would be
reduced.
4.3 Significant Figures in Conversion
The number of significant figures to be used will follow the general guide that the last unit is equal
to or smaller than the implied accuracy of the conventional unit or its intended precision. This
philosophy cannot be the sole criteria, because engineering judgments might introduce
inconsistencies and because portions of the tank car specification requirements are interrelated
and prescribed by law to be certain percentages of one another. Within this general philosophy, the
following conversion factors and significant figures will be used:
4.3.1 Mass
Pounds (lb) should be converted to kilograms (kg).
pound (lb) 4.535 924 E 01 = kg

Up to 2200 lbuse three significant figures in kilograms (kg)
From 2200 through 21,361 lbuse four significant figures in kilograms (kg)
Over 21,361 lbuse five significant SI figures in kilograms (kg)
4.3.2 Pressure and Stress
Pounds per square inch (psi) should be converted to kilopascals (kPa).
psi 6.894 757 E + 00 = kPa

Round to nearest 1 kPa, but do not violate set percentage requirements of test pressure to burst
pressure, start-to-discharge to test pressure, etc. For example, convert burst pressures accurately
to three decimal places; apply percentages and round the answer to the nearest 1 kPa for
everything but burst pressure. Typical figures for a Class 105A200W tank car will be as follows:
Pressure Factors Conventional SI Soft SI Equivalent

Burst 500 psi 3447.378 kPa 3447.378 kPa
Test 40% Burst 200 psi 1378.95 kPa 1379 kPa
Start-to-Discharge 33% Burst 165 psi 1137.63 kPa 1138 kPa
Vapor Tight 80% STD 132 psi 910.11 kPa 910 kPa
Flow Rating 110% STD 181.5 psi 1251.40 kPa 1251 kPa
11/2014 C-III [M-1002] 331

APPENDIX H M-1002
For conversions not involving set percentages, the following guidelines will be used:
For pressures below 14.696 psiuse two significant SI figures in kilopascals (kPa)
For pressures from 14.696 to 145 psiuse three significant SI figures in kilopascals (kPa)
For pressures or stresses from 145 psi to 1459 psiuse four significant SI figures in
kilopascals (kPa)
When kilopascals (kPa) exceed five figuresuse megapascals (MPa) to three significant
figures
Pressures in kilopascals (kPa) are gauge pressures, unless otherwise noted. Stresses are to
be expressed in kilopascals (kPa) or megapascals (MPa), not bars.
4.3.3 Volume
Cubic feet (ft3) should be converted to cubic meters (m3) with three significant figures.
ft3 2.831 685 E 02 = m3
Cubic inches (in.3) should be converted to cubic centimeters (cm3) up to five figures
Over five figures of cubic centimeters (cm3)use cubic meters (m3)to three significant
figures
in.3 1.638 706 E + 01 = cm3

Gallons (gal) should be converted to liters (L) with three significant figures.
gal (U.S.) 3.785 412 E + 00 = L

4.3.4 Area
Square inches (in.2) should be converted to square millimeters (mm2).
Up to 1 1/2 in.2convert to three significant SI figures of square millimeters (mm2)
From 1 1/2 in.2 through 15.5 in.2convert to four significant SI figures of square
millimeters (mm2)
in.2 6.451 600 E + 02 = mm2

From 15.6 in.2 through 1728 in.2convert to four significant SI figures of square meters
(m2)
in.2 6.451 600 E 04 = m2

Over 12 ft2convert to three significant SI figures of square meters (m2)
ft2 9.290 304 E 02 = m2

4.3.5 Linear Measurement
Inches (in.) should be converted to millimeters (mm).
in. 25.4 E + 00 = mm
Up to 36 in.convert to three significant SI figures of millimeters (mm)
For 36 in. and aboveround to the appropriate number of SI figures of millimeters (mm)
to arrive at the desired accuracy for the stage of conversion covered in paragraph 2.1 of
this appendix
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M-1002 APPENDIX H
4.3.6 Temperature
Convert Fahrenheit temperatures to three significant figures of degrees Celsius.
(F 32)/1.8 = C
4.3.7 Work
Foot pounds-force (ft lbf) should be converted to joules (J).
ft lbf 1.355 818 E + 00 = J

Up to 75 ft lbfconvert to three significant SI figures of joules (J)
For 75 ft lbf and overconvert to four significant SI figures of joules (J)
4.3.8 Force
Pounds force (lbf) should be converted to newtons (N).
lbf 4.448 222 E + 00 = N

Up to 1000 lbfconvert to three significant SI figures of newtons (N). For 1000 lbf and
over, convert to four significant SI figures of kilonewtons (kN).
Continue to use acceleration of X g gravitational force (see Appendix A, paragraph 3.3.4) for
stage 1. In stage 3, gravitational force of 1 kg will be equivalent to 9.806 650 kg m/s2
(9.806 650 N).
4.3.9 Speed
Convert speed in miles per hour (mph) to three significant SI units of kilometers per hour (km/h).
mph 1.609 344 E + 00 = km/h

4.3.10 Thermal Conductance
Convert British thermal units per hour per square foot per degree Fahrenheit (Btu/(h ft2 F) to
kilojoules per hour per meter squared per degree Celsius (kJ/(h m2 C) using four significant
figures.
Btu/(hr ft2 F) 2.044 176 E + 01 = kJ/(h m2 C)

4.3.11 Thermal Conductivity
Convert British thermal units per day per pound (Btu/da/lb) to three significant SI figures in
kilojoules per day per kilogram[ kJ/(d kg)].
Btu/da/lb 2.326 000 E + 00 = kJ/(d kg)

Convert Btu-in./hr-ft2-F to kJ mm/(h m2 C) using four significant figures.
Btu-in./hr-ft2-F 5.192 207 E + 02 = kJ mm/(h m2 C)

4.3.12 Flow
Convert flow in cubic feet per minute (ft3/min) to three significant figures of cubic meters per
second (m3/s).
ft3/min 4.719 474 E 04 = m3/s
11/2014 C-III [M-1002] 333

APPENDIX H M-1002
4.3.13 Torque
Convert torque or moment in foot pounds force (lbf ft) to three significant SI figures of newton
meters (Nm).
lbf ft 1.355 818 E + 00 = Nm

4.3.14 Flow Rating
Convert the gas factors for noninsulated containers (Gu) using the multiplier 3.3121 E 03 to four
decimal places.
Convert the gas factors for insulated containers (Gi) using the multiplier 1.6198 E 04 to four
decimal places.
5.0 TOLERANCES
The conventional system of units describes tolerances in terms of a desired value, plus or minus
stated incremental limits (or limiting values), whereas the SI system provides a range of values.
5.1 Stage 1
The following are examples for stage 1 tolerances:
On Fig. E.6, the dimension 19.238 in. 0.010 would read 19.238 in. 0.010 in. (448.40 mm
to 448.89 mm). Rounding is to be done toward the interior of the tolerance so as not to cause
possible misfits.
Chapter 3, paragraph 3.2.10.4, would read, ...to a start-to-discharge pressure no higher
than 35 psi 3 psi (221 kPa to 262 kPa).
5.2 Stage 2
The following is an example for stage 2 tolerances:
than 221 kPa to 262 kPa (35 psi 3 psi).
5.3 Stage 3
The following is an example for stage 3 tolerances:
than 221 kPa to 262 kPa.
5.4 Tolerances for Production Drawings
Although range tolerances are preferred and will be used in the specifications, unilateral and
bilateral tolerances may be used for production drawings during stage 1 if the rounding principles
of paragraph 6.3 below are followed.
6.0 GENERAL
6.1 Applications for Approval
Stage 1 provides for metric equivalents in parentheses. Tank car applications may be submitted in
conventional units or conventional units followed by SI units in parentheses, but not in SI units
alone.
References to millimeters (mm) will be omitted in SI drawings.
6.2 Standard Conditions
For stage 1, standard conditions will be 14.696 psia (101.325 kPa abs) at 60 F (15.56 C). For
stages 2 and 3, standard conditions will be 101.325 kPa abs at 15 C.
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M-1002 APPENDIX H
6.3 Rounding
Rounding will be done to arrive at specified significant figures after the conversion.
XXX51 will always round upward.
XXX49 will always round down.
XXX50 will always round to an even number, e.g., XX450 to XX4; XX350 to XX4.
When tolerance affects fits and rounding is used, the rounding will only be inward to the spread so
that the rounding will result in a tighter tolerance rather than a more permissive one.
6.4 Formulas
6.4.1 Formulas in the appendices (such as found in Appendix E paragraphs 3.1, 5.2, 7.0, and
11.0) will be revised per guidelines and a separate metric formula provided. A derivation and
example must be kept on file.
6.4.2 The derivation of the formulas in Appendix A will have a separate listing of metric
dimensions for clarity.
6.5 Stamping
Stamping specified in Chapter 3, paragraph 3.5.14, will show water capacity as 0000 GAL, or
0000 GAL and 00 000 L. Stamping specified in Chapter 3, paragraph 3.4.19, will show volumetric
capacity as 0000 CU FT, or 0000 CU FT and 000 CU M.
6.6 Plate Sizes
For showing SI equivalents, minimum required design thicknesses must be maintained (except
7/16 in., which will be equivalent to 11.0 mm).
6.7 Miscellaneous
6.7.1 Do not mix symbols and words (e.g., do not use square m). Use m2 or square meters.
6.7.2 As industrial standards are converted to metric, their effect on the Tank Car Specifications
will be evaluated.
6.7.3 Instead of converting references to letter-size sheets 8 1/2 11 in. to metric, approximately
8 1/2 11 in. will be specified.
6.7.4 Only the tables in the DOT regulations, as published in the AAR Specifications for Tank
Cars, will be converted. This is for the convenience of those using the AAR specifications and is a
prelude to the proposed metrication of the DOT regulations.
6.7.5 The conventional terms (dimensions) will be retained on the drawings and titles found in
Appendix E, such as Figs. E.6, E.7, E.8, E.19, and E.19.2. They incorporate conventional
dimensions such as Detail of Cover and Nozzle Joint for 20 in. Manway. In such cases, there will
be only conventional units in the titles, without dualizing.
6.7.6 Conversion factors are presented for ready adaptation to computer readout and electronic
data transmission. The factors are written as a number, greater than one and less than ten, with
six or fewer decimal places. The number is followed by the letter E (for exponent), a plus or minus
sign, and two digits that indicate the power of 10 by which the number must be multiplied to
obtain the correct value. For example:
3.523 907 E 02 is 3.523 907 10-2 or 0.035 239 07

similarly,
3.386 389 E + 03 is 3.386 389 103 or 3 386.389
11/2014 C-III [M-1002] 335

APPENDIX H M-1002
6.7.7 The number of significant figures specified are minimum. More significant figures will be
used when greater accuracy is required.
C-III [M-1002] 336 11/2014

M-1002 APPENDIX J
APPENDIX J
THREADED AND BOLTED FLANGE JOINT ASSEMBLY
CONTENTS

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III338
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III338
2.0 Threaded Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III338
2.1 Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III338
2.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III339
2.5 Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III339
3.0 Bolted Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III339
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III339
3.2 Gasket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.3 Removal of Asbestos-Containing Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.6 Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.7 Inspect Fasteners, Nuts, and Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III340
3.8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III341
3.9 Alignment of Mating Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III341
3.10 Installation of Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III341
3.11 Thread Engagement (Not Applicable to Manway Eye Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
3.12 Blind-Tapped Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
3.13 Existing Fasteners (Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
3.14 Tightening of Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
4.0 Joint Leak Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
5.0 Function-Specific Training of Assembly Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III342
11/2014 C-III [M-1002] 337

APPENDIX J M-1002
APPENDIX J
THREADED AND BOLTED FLANGE JOINT ASSEMBLY
1.0 GENERAL
1.1 Introduction
Appendix J describes the recommended practice for the correct assembly of threaded and bolted
connections of service equipment to tank cars.
1.2 Scope
This document presents general guidelines for the assembly of threaded and bolted connections
and recommended procedures. It is not a complete and comprehensive set of methods, instructions,
or procedures applicable for all situations. Each user company is encouraged to develop specific
procedures using this document as a general guide where it applies. The guidelines outlined in
this document cover the assembly elements essential for a high level of joint integrity of otherwise
correctly designed and constructed threaded and bolted flanged connections.
1.3 Before performing any work, follow plant safety procedures to relieve the pressure safely
from the tank.
Observe current conditions.
Utilize checklists to ensure thorough documentation of as received conditions.
In particular, look for apparent leaks, loose fasteners, and gasket condition.
Assembly personnel should report visible leaks through their proper channels/appropriate
supervisor.
1.4 Recognizing the array of areas that could lead to equipment connection failures, this
appendix uses a best practices approach to evaluate and work with equipment connections. In
simplified terms, this is an inspect-to-pass process where the equipment connection is evaluated,
and if the connection fails, additional examination and possibly rework will be required. Tank car
leaks not only endanger employees, but also result in expensive fines and remediation along with
poor visibility in the public domain.
1.5 Each tank car facility performing work in accordance with this appendix must obtain an
Association of American Railroads, Manual of Standards and Recommended Practices, Section C,
Part III, Specifications for Tank Cars, Appendix B, certification or registration, as appropriate.
2.0 THREADED CONNECTIONS
2.1 Disassembly and Inspection
2.1.1 Disassemble with an appropriate wrench to avoid damaging valve, fitting body, or flats.
2.1.2 With a wire brush, clean threads of foreign material, such as PTFE tape, joint compound,
paint, and commodity.
2.1.3 Using a clean cloth or paper towel, wipe the thread surface to remove any residual material
or solution.
2.1.4 Inspect the threads to confirm that there are no cuts, gouges, or other defect that may affect
sealing integrity.
2.1.5 Inspect the threads with an appropriate ring or plug gauge.
2.1.6 Repair damaged or out-of-tolerance threads when practical or replace in-kind.
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M-1002 APPENDIX J
2.2 Assembly
2.2.1 Ensure that the threads (male and female) are clean prior to assembly.
2.2.2 Apply a PTFE tape or paste to the male threads. If using tape, wrap the tape in the
direction of the thread spiral, beginning with first thread. Do not wrap outside of the threads, or
exceed three wraps of tape. Thread sealants are acceptable when used to secure the joint but not to
mask defects in the joint makeup.
2.2.3 Thread the joint slowly to avoid producing excess friction. Heat produced by friction can
cause the metal to expand before properly making the joint.
2.3 Table J.1 identifies the typical length of total thread engagement, including the first three
hand-tight lead threads, required to make a tight joint.
Table J.1 Thread engagement

Size of Pipe (diameter; in.) Length of Thread (in.)
1/4 3/8
3/8 3/8
1/2 1/2
3/4 9/16
1 11/16
1 1/4 11/16
1 1/2 11/16
2 3/4
2 1/2 15/16
3 1
3 1/2 1 1/16
4 1 1/8
2.4 All joint connections must pass a leak test after assembly.
2.5 Tool Usage
2.5.1 When replacing a valve or fitting, use two wrenches to prevent rotation of other joints.
2.5.2 Use a suitably sized wrench for the size of pipe or fitting removed or installed.
3.0 BOLTED CONNECTIONS
3.1 Disassembly
3.1.1 When orientation is relevant (e.g., siphon pipes and valve handles) and prior to
disassembly, draw a reference mark from the component to the car to ensure proper orientation
when reassembling.
3.1.2 Loosen fasteners or nuts using a suitable type of wrench, avoiding damage to fasteners
where possible.
3.1.3 On badly corroded fasteners, penetrating oil may be used to ease removal.
3.1.4 Separate fitting flanges using soft metal tools, taking care not to score or scrape mating
surfaces.
11/2014 C-III [M-1002] 339

APPENDIX J M-1002
3.2 Gasket Removal

3.2.1 Removal of Non-Asbestos Gaskets and Other Debris
3.2.1.1 Use steel, plastic, or brass tools to remove all parts of the old gasket material and debris
from the flange sealing surface.
3.2.1.2 Avoid scoring or scraping the sealing surface.
3.3 Removal of Asbestos-Containing Gaskets
Follow your facilitys asbestos removal procedures.
3.4 Cleaning
3.4.1 Clean the gasket-sealing surface.
3.4.2 Use a wire brush made of material compatible with the flange material to prevent cross-
contamination to clean the flange-sealing surface.
3.4.3 If needed, use fine sand or a light abrasive blast to avoid damaging the gasket surface
profile, or utilize a gasket-removal compound, or a suitable general-purpose degreaser.
3.4.4 Clean sealing surfaces that are clad, plated, or lined only with a clean cloth.
3.5 Inspection
3.5.1 Examination of Sealing Surfaces
3.5.1.1 Sealing surface should be clean, with no corrosion, gasket residue, dirt particles, or
commodity residue.
3.5.1.2 Sealing surface should have no damage, such as tool marks, chatter, cracks, gouges, or
pits, that will affect sealing.
3.5.1.3 Defects that are deeper than 1/32 in. and are continuous across the gasket-sealing surface
should be addressed.
3.6 Coated Surfaces
A coated flange or rubber-lined surface is subject to special design consideration. Use best
practices when dealing with this type of joint.
3.7 Inspect Fasteners, Nuts, and Washers
3.7.1 Before performing an inspection, clean fasteners, nuts, and washers as necessary.
3.7.2 Visibly check to ensure that there is adequate thread engagement.
3.7.3 Visibly check to ensure that there are no missing or unreadable grade markings (may not
apply to all fasteners, e.g., eye bolts and nuts).
3.7.4 Visibly check to ensure that there is no damage to the fastener working surface.
3.7.5 Inspect for thread damage.
3.7.6 Fasteners must not be bent or deformed.
3.7.7 Gouges, dents, or nicks from tool marks (e.g., hammer marks) in non-functional areas do
not constitute renewal.
3.7.8 Visibly check to ensure that the washers are dimensionally suitable and are not damaged,
cupped, scored, or cracked.
3.7.9 Check that the nut can be run up and down along the usable portion of the threads.
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M-1002 APPENDIX J
3.7.10 Inspect hinged and bolted manway cover, fill port cover, and eye bolts in accordance with
Appendix D.
3.7.11 If components are defective, replace in kind or according to owner instructions.
3.8 Assembly
3.8.1 Installation of Gasket
3.8.1.1 Ensure that the gasket meets the following criteria:
Chemically compatible with the lading
Thermally compatible with the highest and lowest temperature range (e.g.,
loading/unloading hot products)
Mechanically suitable for the respective flange
Dimensionally suitable
3.8.1.2 When installing the gasket, the gasket should not bind or interfere with the fasteners.
3.8.1.3 When installing the gasket, the gasket should not interfere with product flow or the
function of the pressure relief device, and the gasket should be concentric within the flange.
3.8.1.4 The size of the gasket must be sufficient to ensure gasket compression for sealing.
3.8.1.5 The gasket must have no damage after installation.
3.8.1.6 Other than in tongue and groove joints, the gasket, in general, should not be less than
1/2 in. wide.
3.9 Alignment of Mating Surfaces
3.9.1 When so marked, component must be installed in the same orientation as when removed
from the tank car using the reference mark drawn during disassembly.
3.9.2 During installation, and as the component flanges come together, the flanges should remain
parallel to prevent pinching the gasket.
3.9.3 The weight of some components can create handling challenges; and therefore, consider
supporting the weight of the component during installation with the use of a lifting device.
3.10 Installation of Fasteners
3.10.1 New Fasteners
3.10.1.1 Fasteners securing a pressure-retaining fitting must be approved in accordance with
Appendix M, or meet the design specification as annotated on the tank car drawing.
3.10.1.2 In accordance with Appendix M, paragraph 1.2.3, fasteners must have grade and
manufacturers identification (manway eye bolts and socket-head cap screws are excluded unless
required by the car owner).
3.10.1.3 Fastener grade markings must be oriented to allow for visible inspection.
3.10.1.4 Fasteners must be of the same grade and specification, unless specified otherwise by the
car owner.
3.10.2 If required by design, apply specified lubrication (e.g., anti-seize) to the working surfaces
of the fastener and nut (i.e., fastener threads, nut bearing surface, and if applicable, underside of
bolt head).
3.10.2.1 Some commodities may require a specialized thread lubricant (e.g., chlorine) or no
thread lubricant.
11/2014 C-III [M-1002] 341

APPENDIX J M-1002
3.11 Thread Engagement (Not Applicable to Manway Eye Bolts)

As a minimum, and in accordance with Appendix D, nuts must be fully engaged. That is, no nut
thread may be showing.
3.12 Blind-Tapped Hole
3.12.1 Thread the entire stud into the mounting flange. No more than one or two run-out threads
should be visible.
3.12.2 The chamfered end of the stud should be fully engaged in the blind-tapped holes of the
mounting flange.
3.13 Existing Fasteners (Used)
3.13.1 Follow the requirements in paragraph 3.10.1 of this appendix for new fasteners.
3.13.2 Fasteners may be reapplied if they are functional and not damaged. Clean by wire brush
and compressed air when required. Do not clean fasteners by sandblasting.
3.13.3 After cleaning the fastener, the nut should turn freely for the entire threaded portion (not
applicable to nuts with anti-vibration technology [i.e., nylon insert nuts or security locknuts]).
3.13.4 When replacing one-half or more fasteners on the same fitting, the remaining fasteners on
the same fitting also should be replaced.
3.14 Tightening of Fasteners
3.14.1 Refer to car owner or other approved assembly procedures for proper joint tightening and
fastener torque recommendations. The assembly procedures should take into consideration gasket
size, gasket material, lubricant, bolt type, and regulatory requirements.
3.14.2 In the absence of a tightening sequence from the car owner or other approved assembly
procedure, refer to the following:
Appendix D, paragraph 3.2.1, Fig. D.1 for manway cover plates, valves, fittings, and
flanges
Appendix D, paragraph 6.6, Fig. D.3 for hinged and bolted manways
3.14.3 When tightening fasteners, use a calibrated manual or pneumatic torque wrench.
3.14.4 After assembly, perform a leak test, if required, in accordance with the applicable
procedure.
4.0 JOINT LEAK TIGHTNESS
Acceptable methods of nondestructive testing (NDT) are shown in Appendix T, Table T.1. The
NDT Level III must determine the applicability of any particular NDT method for a given
inspection.
5.0 FUNCTION-SPECIFIC TRAINING OF ASSEMBLY PERSONNEL
Federal regulations require tank car facilities to train their employees on the AAR-approved
quality assurance program, including work instructions the employees use as a means to monitor
and control processes and product characteristics during production (e.g., assemble, manufacture,
inspect, test, and repair). Joint assembly personnel perform job functions that have an effect on
the continuing qualification of the tank; and therefore, each employer is responsible for properly
training and certifying their employees on the job functions the employees perform. Employers
may use this appendix as a guide in developing a systematic training program.
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M-1002 APPENDIX L
APPENDIX L
INTERIOR CLEANING, LINING, AND COATING
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III344
2.0 Application and Cleaning or Stripping of Linings and Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III344
2.1 Lining/Coating Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III344
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III344
2.3 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III345
3.0 Personnel, Training, and Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III346
4.0 Valves and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III346
5.0 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III347
6.0 Application/Removal Reporting and Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III347
6.1 Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III347
6.2 Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III347
7.0 Coatings and Linings Applied for Corrosive Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III348
8.0 Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III348
9.0 Certification of Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III348
10.0 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III348
11/2014 C-III [M-1002] 343

APPENDIX L M-1002
APPENDIX L
INTERIOR CLEANING, LINING, AND COATING
1.0 INTRODUCTION
1.1 Scope
Appendix L describes the AAR requirements for interior cleaning for, and the application and
stripping of, interior linings and coatings for tank car tanks, valves, and fittings.
2.0 APPLICATION AND CLEANING OR STRIPPING OF LININGS AND COATINGS
2.1 Lining/Coating Materials
Table L.1 Lining/coating materials
Clad metal Bonding of dissimilar metal sheets or plates to form a composite
metal. The more corrosion-resistant metal acts as the interior
protective covering after the tank is fabricated.
Dispersion coating A coating where relatively large resin particles are distributed in
a solvent system as opposed to being dissolved.
Electroless plating Deposition of a metal on a base metal by chemically reducing
metal ions to metal.
Electroplating Deposition of a metal on a base metal by the passing of an electric
current through an electrolyte.
Glass Transparent or translucent inorganic material fused on base
metal.
Laminated-type A plastic substance with basic rubber-like elastic characteristics,
material applied in two or more spray-coat operations (e.g., polyvinyl
chloride and polyurethane). See DOT 179.201-3.
Lead lining Deposition of a homogeneous layer of lead to the interior of the
tank.
Metallizing Formation of a fused metallic coating by atomized spray of a
(metal spray) molten metal such as tin, aluminum, zinc, nickel, or stainless steel
on base metal.
Rubber A natural polymer (latex) coagulated into an elastic solid, applied
in sheet form.
Rubber compound A synthetic polymer with rubber-like elastic characteristics,
applied in sheet form.
2.2 Procedure
Application of interior linings and coatings must be performed using methods and materials that
will not change the designed physical or mechanical properties or function of the tank or the
function of the valves, fittings, seals, gaskets, insulation, cradle blocks, or other critical parts of the
tank car.
2.2.1 For lined tank car tanks, see additional requirements of DOT 179.201-3.
2.2.2 When stripping or applying an interior lining or protective coating, all valves and fittings
must be removed unless the contracting authority approves, in writing, other handling. If left in
place, all valves and fittings must be effectively protected.
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M-1002 APPENDIX L
2.3 Methods
2.3.1 Chemical Methods
2.3.1.1 When chemicals are used for the cleaning, application, or stripping of linings or coatings,
it is the responsibility of the contracting authority to determine whether the chemicals to be used
can have a damaging effect upon the tank interior, valves, fittings, seals, or gaskets.
2.3.1.2 If subject to damage, all valves and fittings must be removed; however, if the bottom
outlet valve is too difficult to remove, it must be effectively protected, and the contracting
authority must be notified.
2.3.1.3 Seals or gaskets may be retained for containment of cleaning or stripping solutions during
a chemical procedure. If the chemical procedure has a damaging effect, the seals or gaskets
exposed to the chemical procedure must be replaced. Gaskets must be replaced in kind, unless
otherwise specified by the contracting authority.
2.3.2 Thermal Methods
2.3.2.1 When thermal methods are used for cleaning, application, or stripping of linings or
coatings, it is responsibility of the contracting authority to determine whether the temperatures to
be used can have a damaging effect upon the tank car tank, valves, fittings, seals, gaskets,
insulation, exterior coatings, or cradle blocks.
2.3.2.2 Valves, fittings, seals, or gaskets can be damaged when the temperature exceeds 150 F
(65.6 C). If subject to such damage, all valves and fittings must be removed; however, if the
bottom outlet valve is too difficult to remove, it must be effectively protected, and the contracting
authority must be notified.
2.3.2.3 Consideration must be given to all other car components if any procedure is to be used
that exposes such components to elevated temperatures.
2.3.2.4 Certain types of insulation can be damaged by temperatures above 250 F (121 C). Wood
and composition cradle blocking materials can be damaged above 425 F (218 C). Tank car tank
material can be damaged if the temperature exceeds 350 F (177 C) for aluminum or 800 F
(427 C) for steel tanks. If subject to damage, such areas must be effectively protected, and the
contracting authority must be notified.
2.3.3 Mechanical Methods
2.3.3.1 Cleaning, application, and stripping techniques that entail the use of scrapers or other
mechanical tools, sand, shot, grit, or other abrasive blasting can cause damage to the tank car
tank, valves, fittings, seals, and gaskets.
When mechanical tools are used, the valves, fittings, seals, and gaskets must be effectively
protected from damage. When sand, shot, grit, or other abrasive blasting is used, all valves,
fittings, seals, and gaskets must be removed; however, if the bottom outlet valve is too difficult to
remove, it must be effectively protected, and the contracting authority must be notified.
2.3.3.2 Tank shell thickness is critical. If a weld bead is blended by grinding, air hammer
scraping, or contouring, care must be taken not to cause sharp notches or gouges and to avoid
reduction in tank shell plate thickness.
11/2014 C-III [M-1002] 345

APPENDIX L M-1002
3.0 PERSONNEL, TRAINING, AND QUALIFICATION

3.1 Facilities that perform stripping, cleaning, and repair and/or apply interior protective
coatings and/or linings activities regulated by 49 CFR 180 must have available a coatings
inspector capable of establishing techniques and procedures and interpreting codes, standards,
and specifications who has been qualified in-house on the basis of demonstrated ability,
achievement, experience, and training, in accordance with a written company practice.
3.2 Interior surfaces of tank cars subject to activities covered in paragraph 3.1 above shall be
prepared by personnel trained and qualified in accordance with a written company practice.
3.3 Protective interior coatings and/or linings shall be applied in accordance with the material
manufacturers application procedure and/or the contracting authoritys requirements by
personnel qualified in accordance with a written company practice.
4.0 VALVES AND FITTINGS
4.1 Any pressure relief device, valve, or fitting removed from the tank and not disassembled may
be reapplied without retest of the valve or fitting.
4.2 In the reapplication of any valve or fitting, the valve or fitting must be replaced in the same
orientation as before removal. The nuts, bolts, or other fastening devices utilized in the application
of the valve or fitting to the tank car tank must be uniformly and properly tightened. Gaskets,
when replaced, must be replaced in kind, unless otherwise specified by the contracting authority.
4.3 Except as provided for in paragraph 4.7 below, pressure relief devices must not be lined but
may be coated for product purity purposes, provided the coating thickness does not exceed
0.005 in. (0.127 mm) in the orifice area. After a pressure relief device is coated, and before the tank
car is tendered to a carrier for transportation of a lading, the pressure relief device must be
retested in accordance with the provisions of Appendix D, and a certificate of test must be
submitted to the car owner. The reassembled tank must be tested for leakage in accord with
49 CFR 180.509(j) and must meet 180.509(f). If the facility does not make this test, the car must be
tagged and the contracting authority notified.
4.4 The proper operation of all other valves or fittings that have been disassembled for cleaning,
or application or stripping of a lining or coating, must be verified when they are reapplied to the
tank car tank. The reassembled tank must be tested for leakage in accord with 49 CFR 180.509(j)
and must meet 180.509(f). If the facility does not make this test, the car must be tagged and the
contracting authority notified.
4.5 Dimensions or fits of pressure relief devices, if coated, must not be reduced by the coating
below the minimums specified for the assembled components. See Appendix E, Fig. E.21A or
Fig. E.21B for the specified inside diameters of pressure relief device nozzles after coating. The car
owner or pressure relief valve manufacturer must be consulted if minimum specified dimensions
or fits are not known to the facility applying the coating.
4.6 When linings or coatings are to be applied to or stripped from valves or fittings, the
removable parts must be disassembled from the valves or fittings and each metallic part handled
separately, unless the contracting authority approves other handling. All gaskets, O rings, or
other plastic or elastomeric sealing components in valves or fittings must be removed and must
not be lined or coated.
4.7 Seats of product valves must not be lined or coated unless specified by the car owner or the
coating/lining owner.
4.8 Threaded areas of operating parts must not be lined or coated.
C-III [M-1002] 346 11/2014

M-1002 APPENDIX L
5.0 COMPLIANCE
5.1 All interior cleaning, lining, or coating applications or stripping must be performed in accord
with the provisions of this specification.
5.2 Facilities that apply, inspect, strip, or repair interior protective coatings and/or linings for
protection of tank car tanks against corrosion must maintain applicable standards, guidelines, and
procedures covering application, testing, and removal of interior protective coatings and/or linings.
5.3 Facilities that apply, inspect, qualify, or repair interior protective coatings and/or linings for
the purpose of tank protection shall develop and implement a quality assurance program in
compliance with all requirements of 49 CFR 179.7, this appendix, AAR specifications or rules, and
DOT/TC regulations.
5.4 The interior surface, prime coat, or adhesive layer and all subsequent coats of interior
protective coatings and linings shall meet conditions of acceptance as agreed upon by the
contracting authority and the applicator, with consideration of the material manufacturers
recommendations.
5.5 The contracting authority shall prepare an inspection and test plan per 49 CFR 180.509.
6.0 APPLICATION/REMOVAL REPORTING AND RECORD RETENTION
6.1 Reporting
6.1.1 A report, including copies of final inspection report forms, must be furnished by the
applicator to the contracting authority and car owner stating, at a minimum, the following:
That the application/removal of the coating or lining has been accomplished in accord with
the provisions of Appendix L (reporting for application of a rubber lining is covered in DOT
179.201-3.);
The date (month and year) that the interior coating or lining was applied or stripped;
The type of interior coating or lining applied or stripped; and
The car stenciling, including capacity and lightweight changes, if applicable
6.1.2 No report is required for cleaning of tank cars.
6.2 Record Retention
6.2.1 The applicator shall retain inspection reports for each car for not less than 5 years.
6.2.2 The contracting authority shall retain inspection records for each lining/coating for not less
than 10 years, until the next application or when ownership of the lining/coating is relinquished.
6.3 See paragraph 7.0 below for record retention requirements for car in-service/inspection repair
records.
11/2014 C-III [M-1002] 347

APPENDIX L M-1002
7.0 COATINGS AND LININGS APPLIED FOR CORROSIVE SERVICE

7.1 When an interior coating or lining is applied to a car used in corrosive service as defined
below, the coating or lining shall be considered to be employed for the purpose of tank protection,
versus one installed for product purity.
7.2 The lining/coating owner, unless otherwise agreed to, bears primary responsibility for
compliance with the requirements of this section.
7.3 Commodities that have a corrosion rate, as determined from test or field measurements or
from a reliable compendium of corrosion rate data, greater than 2.5 mil per year on the tank
material shall be considered corrosive.
7.4 The installed coating or lining shall have a frequency of inspection and repair as devised by
rational or empirical means based upon specific product, coating or lining properties, or service
experience. This interval must not exceed 8 years, unless the coating or lining owner can establish,
document, and show that the service history or scientific analysis of the coating or lining and
commodity pairing supports a longer inspection interval.
7.5 In any given period, the most corrosive product transported shall dictate the inspection
interval, but in no case shall the inspection interval exceed 10 years.
7.6 New rubber linings must be spark-tested in accordance with a qualified procedure.
7.7 For linings and coatings in corrosive service, the tank shell beneath degraded or defective
areas must be inspected and repaired, as necessary, and the coating or lining retested if repaired.
See Appendix R, paragraph 10.0, for tank repairs to pits and corrosion.
7.8 Records of in-service inspection/repair per this section must be kept by the contracting
authority for the life of the coating/lining.
7.9 Cars receiving coatings or linings per this section shall be marked in accord with Appendix C,
paragraph 2.3.3.
8.0 STENCILING
See Appendix C, Appendix D, and 49 CFR 180.509(i).
9.0 CERTIFICATION OF FACILITIES
9.1 See Appendix B, paragraph 2.0, regarding the activity codes requiring certification regarding
the installation, qualification, removal, inspection, and/or repair of interior linings and coatings.
9.2 Certified facilities that repair and/or apply coatings and linings for product purity only do not
need to be certified; however, certification to activity code C6 is required to remove and replace
tank car service equipment and gaskets.
10.0 REFERENCE DOCUMENTS
The following reference documents are listed here as a guide for removing and applying interior
coatings and linings and are not mandated by AAR rules.
NACE RP0188 Discontinuity (holiday) testing of protective coatings

NACE RP0295 Application of a coating system to interior surfaces of new and used rail tank cars
NACE RP0495 Guidelines for qualifying personnel as abrasive blasters and coating and lining applicators in
the rail industries
NACE 6Q187 Current practices in quality assurance during application of protective coating materials
NACE RP0592 Application of a coating system to interior surfaces of new and used rail tank cars in
concentrated (90% to 98%) sulfuric acid service
NACE 37519 Corrosion Data SurveyMetals Section, sixth edition
C-III [M-1002] 348 11/2014
M-1002 APPENDIX M
APPENDIX M
SPECIFICATIONS FOR MATERIALS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
1.2 Approved Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
1.3 Welded Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
2.0 Procedure for Securing Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
2.1 Application for Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
3.0 Approved Plate Materials for Tank Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
3.1 Carbon Steel Plate (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
3.2 Aluminum Alloy Plate (Material Group 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III351
3.3 High Alloy Steel Plate (Material Group 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III352
3.4 Nickel Plate (Material Group 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III352
3.5 Nickel Alloy Steel Plate (Material Group 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III352
3.6 Manganese-Molybdenum Steel Plate (Material Group 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III352
3.7 Manganese-Silicon Steel Plate (Material Group 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III352
4.0 Approved Materials for Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III353
4.1 Manway Covers for Nonpressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III353
4.2 Threaded Fasteners for Pressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III353
4.2.3 Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III353
4.4 Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III354
4.5 Castings for Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III355
4.6 Miscellaneous Tank Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III357
4.7 Exterior and Interior Coil Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III359
4.8 Tank Bottom Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III359
4.9 Quality of Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III360
5.0 Specification for High-Strength Carbon Manganese Steel Plates for Tank CarsAAR TC128 . . . . C-III360
5.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III360
5.2 General Condition for Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III360
5.3 Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III360
5.4 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III361
5.5 Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III361
5.6 Test Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III362
5.7 Number of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III362
5.8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III362
5.9 Rejection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III362
5.10 Rehearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III362
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APPENDIX M M-1002
6.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Double Normalized and
TemperedAAR TC133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III363
6.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III363
6.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III363
6.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III364
7.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Water Quenched and
TemperedAAR TC134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III364
7.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III364
7.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III365
7.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III366
8.0 Supplementary Specification for ASTM A516, Grade 70 Pressure Vessel Plates for Tank Car
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III368
8.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III368
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M-1002 APPENDIX M
APPENDIX M
SPECIFICATIONS FOR MATERIALS
1.0 INTRODUCTION
1.1 Scope
Appendix M describes the procedures to be followed to obtain approval of proposed material
specifications for tank car tank fabrication, and it lists the material specifications that are
approved.
1.2 Approved Materials
1.2.1 Approved plate materials complying with ASTM specifications are listed in Table M.10.
Other approved plate materials are listed in Tables M.10.1 through M.10.6 and appear complete in
the following sections. Approved castings for fittings are listed in paragraph 4.0 below. Unless a
specific year is recorded after the specification number wherever AAR, ACI, ASTM, AWS, or other
specifications are noted, the latest editions are approved.
1.2.2 ASME materials, when identical to the approved ASTM materials listed in this appendix,
may be used.
1.2.3 Threaded fasteners, excluding eyebolts, securing pressure-retaining parts and tank anchors
installed after January, 2012, shall be of a specification that requires grade identification marks
and manufacturers identification marks, unless excluded by specification or standard due to size
or configuration. Grade marks are to be stamped on the nut end of studs.
1.3 Welded Condition
For the purpose of this specification, welded condition must be considered as-welded and after
postweld heat treatment, when required.
2.0 PROCEDURE FOR SECURING APPROVAL
2.1 Application for Approval
A proposed material specification must be submitted to the AAR Executive DirectorTank Car
Safety with 20 copies for consideration by the appropriate committee.
3.0 APPROVED PLATE MATERIALS FOR TANK FABRICATION
3.1 Carbon Steel Plate (Material Group 1)
Carbon steel plate must comply with one of the specifications shown in Table M.10.1 and with its
indicated minimum tensile strength in the welded condition. The plates may be clad with other
approved materials.
3.2 Aluminum Alloy Plate (Material Group 2)
Aluminum alloy plate must be suitable for fusion welding and comply with one of the
specifications shown in Table M.10.2 and with its indicated minimum tensile strength and
elongation in the welded condition.
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APPENDIX M M-1002
3.3 High Alloy Steel Plate (Material Group 3)

3.3.1 High alloy steel plate must comply with one of the specifications shown in Table M.10.3 and
with its indicated minimum tensile strength and elongation in the welded condition.
3.3.2 High alloy steel materials used to fabricate tank, and expansion dome when used, must be
tested in accord with ASTM A262 Practice A. If the specimen does not pass Practice A, Practice B
or C must be used and the corrosion rate must not exceed the following:
Table M.1 Corrosion test procedures

Corrosion Rate
Test Procedurea/ Materialb/ in./month mm/month
Practice B Types 304, 304L, 316, and 0.004 0.102
316L
Practice C Type 304L 0.002 0.051
a/ The test specimen may be finished on all surfaces by machining or grinding prior
to testing.
b/ Type 304L and Type 316L test specimens must be given a sensitizing treatment
prior to testing. A typical sensitizing treatment is 1 hour at 1250 F (677 C).
3.4 Nickel Plate (Material Group 4)
3.4.1 Nickel plate must comply with the specification shown in Table M.10.4 and with its
indicated minimum tensile strength and elongation in the welded condition.
3.4.2 When used as cladding for carbon steel plate, specify low-carbon nickel.
3.5 Nickel Alloy Steel Plate (Material Group 7)
Nickel alloy steel plate must comply with one of the specifications shown in Table M.10.5 and with
the indicated minimum tensile strength and elongation in the welded condition.
3.6 Manganese-Molybdenum Steel Plate (Material Group 1)
Manganese-molybdenum steel plate must be suitable for fusion welding and comply with the
specification shown in Table M.10.6 and with the indicated minimum tensile strength and
3.7 Manganese-Silicon Steel Plate (Material Group 1)
Manganese-silicon steel plate must be suitable for fusion welding and comply with the
specification shown in Table M.10.7 and with the indicated minimum tensile strength and
C-III [M-1002] 352 11/2014

M-1002 APPENDIX M
4.0 APPROVED MATERIALS FOR APPURTENANCES

4.1 Manway Covers for Nonpressure Tank Car Tanks
Manway covers must be of approved cast, forged, or fabricated metals. Cast iron manway covers
must not be used.
4.2 Threaded Fasteners for Pressure Tank Car Tanks
4.2.1 This section lists approved materials for threaded fasteners used to fasten any valve or
fitting to the manway cover plate or the manway cover plate to the manway nozzle. Other
materials may be used with specific approval of the Tank Car Committee. For all materials,
mechanical properties must be considered in the design.
4.2.2 Unless otherwise required in Chapter 2, paragraph 2.1.2 for hydrogen sulfide, or
paragraph 2.1.4 for hydrogen fluoride (anhydrous) or by a Tank Car Committee approval,
fasteners must meet one of the following specifications:
4.2.2.1 Studs and Bolts
Alloy steel ASTM A193 Grades B5, B7, B7M, or B16, Supplement S2. Charpy impact
tests are required for these grades. Impact values must be as specified in
Table W.1 at 50 F (45.6 C). Material must be marked 50 to signify that
it meets these supplemental requirements.
ASTM A320 Grades L7, L7A, or L7M.
High alloy ASTM A193 Grades B8 Class 2; B8M Class 2; B8T Class 2; B8C Class 2; B8S;
steel or B8SA.
ASTM F593 Group 2 Condition SH; ASTM F593 Group 3 Condition SH
ASTM A320 Grades B8 Class 2; B8M Class 2; B8T Class 2; or B8C Class 2.
4.2.2.2 Nuts
ASTM A194; ASTM F594
4.2.3 Washers
When used, washers shall be ASTM F436.
4.3 Threaded Fasteners for Pressure-Retaining Parts on Nonpressure Tank Car Tanks
4.3.1 Any threaded fastener used, except eyebolts, must be an ASME, ASTM, or SAE
specification or standard with markings per paragraph 1.2.3 of this appendix.
4.3.2 All threads are to be Unified Coarse as specified in ANSI B1.1.
4.3.3 Externally Threaded Fasteners
Type Minimum Tensile Minimum Yield Minimum Thread

Strength (ksi) Strength (ksi) Tolerances
Carbon/alloy steel 60 UNC 2A
High alloy 75 30 UNC 2A
11/2014 C-III [M-1002] 353

APPENDIX M M-1002
4.3.4 Eyebolts
Eyebolts manufactured after January 2012 must be marked with the material and grade. Eyebolts
shall be
forged, machined from bar stock or plate;
fabricated by welding from means other than using castings.; any welding must be
performed in accordance with a procedure qualified by testing for proof loads for each
material combination.
4.3.5 Washers
It is recommended that a washer compatible with the fastener material be applied under the
turned element (i.e., head of bolt or nut).
4.4 Rivets
4.4.1 Rivets must comply with the current issue of ASTM A31 or ASTM A502, Grade 1.
4.4.2 Two-piece rivets for anchor attachments must be of a medium carbon steel, processed to
either a 50,000 psi to 60,000 psi (345 MPa to 414 MPa) shear strength level or to a 126,000 psi to
157,000 psi (869 MPa to 1082 MPa) ultimate shear strength. See Chapter 5, paragraph 5.2.1.6.7.
C-III [M-1002] 354 11/2014

M-1002 APPENDIX M
4.5 Castings for Valves and Fittings

4.5.1 Fittings includes pressure relief devices; bottom outlet and washout nozzles; caps;
reducers; plugs; valves and stuffing boxes; and top unloading devices and their nozzles, caps, and
plugs.
4.5.2 Castings for fittings that are normally in contact with the lading must comply with one of
the specifications listed below. Castings to other specifications may be used, if approved by the Tank
Car Committee.
Ductile Welding, brazing, or repair plugging is not permitted on ductile iron castings.
iron
The purchaser of ductile iron castings to these specifications is responsible for
quality control and inspection procedures to ensure that castings are ductile
and that the supplier conforms to all conditions of the specifications,
including microstructure examinations and certification for all lots of
castings. Records of tests, microstructure examinations, and certification
must be maintained for 5 years and must be available for review by a
representative of the Tank Car Committee.
ASTM A395, except repair plugging prohibited
Test requirements of ASTM A395, including the microstructure, are to be
followed. A minimum of one test coupon or casting, separately cast
immediately after the production castings are poured, is to be tested. These
shall represent the last of each quantity or ladle of metal treated with the
nodularizing agent and must be certified by both the foundry and the fittings
manufacturer as meeting the microstructure and, after heat treatment, the
hardness requirements of ASTM A395. A minimum of one tension test shall
be made from each days melt and for each heat treatment. Failure of any
coupon to meet the specifications shall be cause for rejection of the entire lot
of castings from that ladle. The castings may be reannealed and two retests
made. If either retest fails to conform to ASTM A395 specifications, the
castings they represent shall be rejected.
ASTM A439, Type D2C
Test requirements of ASTM A439 are to be followed. A minimum of one
sample casting from the last metal poured from each ladle treated with the
nodularizing agent must be certified by the fittings manufacturer as meeting
the microstructure requirements of A395 (a minimum of 90% types I and II
graphite). Hardness and chemistry of this sample must meet the
requirements for the D2C grade of A439. Failure of any one sample to meet
these requirements shall be cause for rejection of the entire lot of castings
from that ladle. If the rejection is due to mechanical properties, the castings
and sample castings may be annealed or stress relieved, and new tests made.
If the retest fails to conform to the requirements, the castings they represent
shall be rejected.
Malleable Welding not permitted on malleable iron castings.
iron
ASTM A47, Grade 32510
Grade 32510 limited to caps, plugs, reducers, and excess flow valve floats.
Cast steel ASTM A27, Grades U-60-30, 60-30, 65-35
ASTM A216, Grades WCA, WCB
ASTM A352, Grade LCB
AAR M201, Grades A, B, C
11/2014 C-III [M-1002] 355

APPENDIX M M-1002
Alloy steel ASTM A351, Grades CF8M, CN7M, CF8, CD4MCu, CF3, CF3M
ASTM A743, Grades CA-15, CF-8, CF-3, CF-3M, CF-8M, CN-7M, CF10SMnN
ASTM A744, Grades CF-8, CF-3, CF-8M, CF-3M
ASTM A747, Alloy CB7Cu-1, CB7Cu-2
Alloy steel castings, when required by DOT 179.201-4 for corrosive service,
must be tested in accord with ASTM A262 Practice A. If the specimen does
not pass Practice A, Practice B or C must be used, and the corrosion rate must
not exceed the following:
Corrosion rate
Test Procedurea/ Material in/mo mm/mo
Practice B CF-3, CF-8, CF-3M 0.004 0.102
and CF-8M
Practice C CF-3 and CF-8 0.002 0.051
a/ The test specimen may be finished on all surfaces by machining or
grinding prior to testing.
Copper base ASTM B61

alloy
ASTM B62
Nickel and ASTM A494, Grades CZ-100, M-35-1, M-35-2, M-30H, M-30C, CW-12MW,
Nickel Alloys CW-2M, CW-6M, and N-12MV
Grade M-30C or M-35-1 should be used when weldability is desired.
Grades M-30C, M-35-1, and M-35-2 have equal corrosion resistance and can
be used interchangeably.
Aluminum ASTM B26
ASTM B108
Aluminum castings must not be used, except where required by the nature of
the lading.
4.5.3 Gray cast iron is not authorized for fittings in contact with the lading on all classes of
tank cars. When specified for AAR 207W pressure-differential covered hopper cars, gray iron must
comply with the following:
ASTM A126, Class B

ASTM A278, Class 30
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M-1002 APPENDIX M
4.6 Miscellaneous Tank Materials

4.6.1 The following list is intended to be used as a guide in the selection of materials for manway
covers, flanges, pads, reinforcing plates, structural shapes, nozzles, pipe, and tubes. These
materials are approved for general use, provided they are compatible with the tank plate
materials of paragraph 3.0, Table M.10, and castings of paragraph 4.5 (all in this appendix), where
applicable. They are not intended to exclude the use of suitable materials described by other
specifications. Other materials may be used on specific approval of the Tank Car Committee.
4.6.2 For stainless steel appurtenances on carbon steel tanks, low carbon grades of stainless steel
(304L, 316L) are recommended.
4.6.3 The materials listed hereafter are supplemental to the plate materials of paragraph 3.0,
Table M.10, and castings of paragraph 4.5 (all in this appendix) and may be used for the same
purpose, except that they may not be substituted for or used in place of required plate materials
specified in DOT 179 for tank shells and heads, manway nozzles, or expansion domes.
4.6.4 All steels defined by the specifications hereafter must be manufactured by the open hearth,
electric furnace, or basic oxygen process. Bessemer steel is prohibited.
Steel plates, ASTM A36 Structural Steela/

shapes, bars,
sheet, and strip ASTM A242 Structural Steel
ASTM A283 Structural Plates, Grades A, B, C, Db/
ASTM A455 Plates, Pressure Vessel (0.31 carbon max.)
ASTM A529 Bars and Shapes
ASTM A1011 Sheet and Strip
ASTM A572 Structural Steel, all grades, Type 2
ASTM A575 Bars, Merchant Quality, AISI and M Grades 10081025,
inclusivec/
ASTM A576 Bars, Special Quality, AISI Grades 10081026, inclusivec/
ASTM A612 Plates, Pressure Vessel
CSA G40.21, Types W, WT, A, and AT
Forgings ASTM A105 Steel
ASTM A181 Steel, Classes 60 and 70
ASTM A182 Alloy Steel
ASTM A350 Low Temperature Steel
Aluminum bars, ASTM B211 Rolled Bars, Rods
rods, and shapes
ASTM B221 Extruded Bars, Rod Shapes
ASTM B308 Structural Shapes, Rolled or Extruded Alloy 6061-T6
Nickel ASTM B160 Rod and Bar
11/2014 C-III [M-1002] 357

APPENDIX M M-1002
Steel pipe and ASTM A53 Welded and Seamless Pipe

tubes
ASTM A106 Seamless Pipe
ASTM A161 Seamless Tubes
ASTM A178 Welded Tubes
ASTM A512 Welded Mechanical Tubing, AISI and MT Grades
10101025, inclusive
ASTM A513 Welded Mechanical Tubing, AISI and MT Grades
10081026, inclusived/
ASTM A519 Seamless Mechanical Tubing, AISI and MT Grades
10081026, inclusive
Stainless steel ASTM A269 Seamless and Welded Tubinge/
pipe and tubes
ASTM A312 Seamless and Welded Pipe
ASTM A511 Seamless Steel Mechanical Tubingf/
Aluminum tubing ASTM B210 Drawn Seamless Tubes
ASTM B221 Extruded Tubes
ASTM B241 Extruded Seamless Pipe and Tubes
Nickel pipe and ASTM B161 Seamless Pipe and Tubes
tubes
Notes:
a/ Not for pressure car or DOT-111A100W4 parts subject to tank internal pressure.
b/ Not for parts subject to tank internal pressure.
c/ Not for tank nozzles or nozzle reinforcement.
d/ Option for hydrostatic test may be specified.
e/ Not for tank nozzles or reinforcements unless tensile properties are determined equal to
ASTM A312.
f/ Annealed austenitic grades only and supplementary requirement S2, tensile test, must be
included.
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M-1002 APPENDIX M
4.7 Exterior and Interior Coil Materials

4.7.1 In addition to the plate materials specified in Table M.10, the following plate, shape, and
strip materials are approved for exterior heater coils:
Carbon steel ASTM A36 Structural Steel

ASTM A414 Sheets, Grade C
ASTM A1011 Sheet and Strip
ASTM A659 Sheet and Strip, Grade 1015
SAE 1015 Sheet or Strip, Silicon Killed
Stainless steel ASTM A240 Types 304, 304L, 316, 316L
Aluminum ASTM B221 Extruded Shapes, Alloy 6061-T4, -T6
4.7.2 The following are approved materials for interior heater coils:
Carbon steel ASTM A53 Welded and Seamless Pipe

ASTM A178 Welded Tubes
Stainless steel ASTM A312 Seamless and Welded Pipe
ASTM A269 Seamless and Welded Tubing
Aluminum ASTM B241 Extruded Seamless Pipe and Tubes
ASTM B210 Drawn Seamless Tubes
ASTM B221 Extruded Tubes
Nickel ASTM B161 Seamless Pipe and Tubes
4.7.3 The following are approved thicknessesa/ for interior heater coils:
Carbon steel Thickness must be 0.175 in. for 2 in. nominal pipe size and Schedule 40
for nominal pipe size over 2 in.
Stainless steel Thickness must be Schedule 40.
Aluminum Thickness must be Schedule 80.
Nickel Thickness must be Schedule 40S.
a/ For all materials, the minimum thickness must be increased 25% or to the next higher
schedule, whichever is less, when threaded joints are used.
4.8 Tank Bottom Reinforcing Pads

Tank bottom reinforcing pads for attaching sills and head braces shall be made from one of the
following materials:
Carbon steel ASTM A516

ASTM A572
ASTM A612
TC128 Grade B
11/2014 C-III [M-1002] 359

APPENDIX M M-1002
4.9 Quality of Castings

4.9.1 Castings that are used to retain pressure in tank cars must be qualified in accordance with
the following procedures:
4.9.1.1 The design and foundry process must be qualified for the pressure-retaining portions of
the castings through inspection of one or more sample castings from each impression on the
pattern. Qualification may be accomplished through use of radiography, sectioning and etching, or
other comparable examination technique. In addition, qualification must include a pressure test
after machining.
4.9.1.2 Castings that are radiographed for qualification must meet the following quality levels of
ASTM E446: A-2, B-3, CA-2, CB-3, CD-3 and no indications for categories D, E, and F. Other
qualification techniques must demonstrate casting soundness comparable to the requirements
used for radiography.
4.9.1.3 Changes to patterns or rigging (except minor changes such as labeling), changes to
foundry processes, a new casting location, or material changes that affect castability will require
that castings be requalified.
4.9.2 Every pressure-retaining casting used in production, except manway cover castings, must
pass a pressure test after machining. The test pressure must be no less than the maximum service
pressure. Manway cover castings are pressure-tested at the time of the tank pressure test.
4.9.3 This section applies to all pressure-retaining castings manufactured after July 1, 1996.
5.0 SPECIFICATION FOR HIGH-STRENGTH CARBON MANGANESE STEEL PLATES
FOR TANK CARSAAR TC128
5.1 Scope
5.1.1 This specification covers one grade of high-strength carbon manganese steel plate for use in
fusion-welded tank car tanks. The maximum thickness must be 1 in. (25.4 mm). The steel must be
made to fine grain practice.
5.1.2 The material shall be furnished in the as-rolled or normalized condition. When specified for
low-temperature service, the material must be furnished normalized to meet the Charpy V-notch
energy absorption requirements of 15 ftlb (20.3 J) minimum average for three specimens, and
10 ftlb (13.6 J) minimum for one specimen, at 50 F (45.6 C) in the longitudinal direction of
rolling, in accord with ASTM A370.
5.2 General Condition for Delivery
Material furnished under this specification must conform to the applicable requirements of ASTM
A20, entitled General Requirements for Steel Plates for Pressure Vessels, except when specified
for low-temperature service, refer to paragraph 5.1.2 for the energy absorption requirement only.
5.3 Process
The steel must be made by the open hearth, electric furnace, or basic oxygen process.
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M-1002 APPENDIX M
5.4 Chemical Composition

The steel must conform to the chemical composition requirements prescribed in Table M.2. All of
these elements, and any others intentionally added, must be reported on the Material Test
Certificate. No intentional additions of boron or nitrogen are permitted.
Table M.2 Chemical requirements for AAR TC128 Grade B steel
Element Heat Analysis Product Analysis
Carbon (max %) 0.24 0.26
Manganese (%) (3/4 in. thick) 1.001.65 1.001.70
(> 3/4" to 1 in. thick)
Phosphorus (max %) 0.025 0.025
Sulfur (max %) a/ 0.009 0.009
Silicon (%) (3/4 in. thick) 0.150.40 0.130.45
(> 3/4 in. thick) 0.150.50 0.150.50
Vanadium (max %) 0.080 0.084
Copper (max %) 0.35 0.35
Nickel (max %) No limit No limit
Chromium (max %) No limit No limit
Molybdenum (max %) No limit No limit
Aluminum (%)b/ 0.0150.060 0.0150.060
Niobium (max %) Per ASTM A20 Per ASTM A20
Titanium (max %) 0.020 0.020
Boron (max %) 0.0005 0.0005
Nitrogen (max %) 0.010 0.012
Tin (max %) 0.020 0.020
CEq (max %) 0.53 0.55
Cu + Ni + Cr + Mo (max %) 0.65 0.65
Nb + V + Ti (max %) 0.11 0.11
Ti /N (max ratio) 4.0 4.0
a/ 0.015 maximum is allowed for cars ordered before July 1, 2015
b/ A minimum of 0.015% must be acid-soluble.
5.5 Tensile Properties
The material as represented by the test specimens must conform to the tensile properties
prescribed in Table M.3.
Table M.3 Tensile requirements for AAR TC128 steel

Property Grade B
Tensile strength, psi (MPa) 81,000 to 101,000 (560 to 695)
Yield strength, psi (MPa) Min. 50,000 (345)
Elongation in 8 in. (200 mm) % Min. 16.0a/
Elongation in 2 in. (50 mm) % Min. 22.0
a/ For material under 5/16 in. (7.94 mm) thick, a reduction of 1.25% must be made from the
specified percentage elongation for each decrease of 1/32 in. (0.794 mm) of thickness below
5/16 in. (7.94 mm). For material over 3/4 in. (19.0 mm) thick, a reduction of 0.5% must be
made from the specified percentage elongation for each increase of 1/8 in. (3.18 mm) of the
thickness above 3/4 in. (19.0 mm). This reduction must not exceed 3%.
11/2014 C-III [M-1002] 361

APPENDIX M M-1002
5.6 Test Specimens

Test specimens furnished by the steel manufacturer must be prepared from the material in the
condition specified for the plate use, such as normalized, as-rolled, or postweld heat treated.
5.7 Number of Tests
One tension test must be made from each plate as rolled.
Note: The term plate as rolled used here refers to the unit plate rolled from a slab, or directly
from an ingot, in its relation to the location and number of specimens, not to its condition.
5.8 Inspection
5.8.1 The inspector representing the purchaser shall have free entry, while the work on the
contract of the purchaser is being performed, to all parts of the manufacturers works that concern
the manufacture of the material. The manufacturer shall afford the inspector, free of charge, all
reasonable facilities and necessary assistance to satisfy him that the material is being furnished in
accord with these specifications. Tests and inspection must be made at the place of manufacture,
prior to shipment, unless otherwise specified.
5.8.2 The purchaser may make tests to cover the acceptance or rejection of the material in the
purchasers own laboratory or elsewhere. Such tests must be made at the expense of the purchaser.
5.9 Rejection
5.9.1 Material represented by samples that fail to conform to the requirements of these
specifications will be rejected.
5.9.2 Material that shows injurious defects, subsequent to its original inspection and acceptance
at the manufacturers works, or elsewhere, will be rejected, and the manufacturer must be
notified.
5.10 Rehearing
Samples, tested in accord with these specifications, that represent rejected material must be held
for a period of 14 days from date of the test report. In case of dissatisfaction with the results of the
tests, the manufacturer may make claim for a rehearing within that time.
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M-1002 APPENDIX M
6.0 SPECIFICATION FOR HIGH-STRENGTH NINE PERCENT NICKEL ALLOY STEEL

PLATES, DOUBLE NORMALIZED AND TEMPEREDAAR TC133
6.1 Scope
6.1.1 This specification covers high-strength 9% nickel alloy steel plates, double normalized and
tempered, for use in fusion-welded tank car tanks.
6.1.2 Material furnished under this specification must conform to the requirements of ASTM
A353, with modifications to chemical composition and impact requirements as follows:
The steel must conform to the additional requirements for chemical composition that are
prescribed in Table M.4.
Table M.4 Chemical composition for AAR TC133 steel

Element Percent
Sulphur Max.a/ 0.025
Phosphorus Max.a/ 0.025
Aluminum (soluble) Min., heat 0.015
Silicon heatb/ 0.150.30
productb/ 0.0130.32
a/ Heat and product analysis.
b/ Minimum of range not applicable when vacuum carbon deoxidation practice is used.
6.3 Impact Properties
The transverse Charpy V-notch impact properties of the material must be not less than the values
prescribed in Table M.5 when the test is conducted at a temperature of 320 F (196 C) or
175 F (115 C), whichever is specified.
Table M.5 Impact properties for AAR TC133 steelconventional units

Minimum Impact Value Minimum Impact Value
Required for Average of Permitted on One Specimen Only of
Each Set of Three Specimens Each Set of Three Specimens
Size of Specimen (ftlb) for Both 175 F and 320 F
(mm) 175 F 320 F (ftlb)
10 10 35 25 20
10 7.5 30 21 17
10 6.6 28 19 15
10 5 24 17 14
10 2.5 12 8 6
See note after Table M.6.
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APPENDIX M M-1002
Table M.6 Impact properties for AAR TC133 steelSI units

Size of Specimen (J) for Both 115 C and 196 C
(mm) 115 C 196 C (J)
10 10 47.4 33.9 27.1
10 7.5 40.7 28.5 23.0
10 6.6 38.0 25.8 20.3
10 5 32.5 23.0 19.0
10 2.5 16.3 10.8 8.13
Note: For all specimen sizes, the lateral expansion opposite the notch must be at least 0.015 in.
(0.381 mm). If the value of lateral expansion for one specimen is below 0.015 in. (0.381 mm),
but not below 0.010 in. (0.254 mm), and if the average value for the three specimens is not less
than 0.015 in. (0.381 mm), a retest of three additional specimens may be made, each of which
must equal or exceed the specified minimum value of 0.015 in. (0.381 mm). If the required
values are not obtained upon retest, or if the values on the initial test are below the minimum
required for retest, the plate may be reheat treated. After reheat treatment, a set of three
specimens must be made, each of which must equal or exceed the specified minimum value of
0.015 in. (0.381 mm).
6.4 Reports
Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
7.0 SPECIFICATION FOR HIGH-STRENGTH NINE PERCENT NICKEL ALLOY STEEL
PLATES, WATER QUENCHED AND TEMPEREDAAR TC134
7.1 Scope
7.1.1 This specification covers high-strength 9% nickel alloy steel plates, water quenched and
tempered, for use in fusion-welded tank car tanks.
7.1.2 Material furnished under this specification must conform to the requirements of ASTM
A553, Type I, with modifications to chemical composition and impact requirements as follows:
The steel must conform to the additional chemical composition requirements prescribed in Table
M.7.
Table M.7 Chemical composition for AAR TC134 steel

Element Percent
Sulphur Max.a/ 0.025
Phosphorus Max.a/ 0.025
Aluminum (soluble) Min., heat 0.015
Silicon heatb/ 0.150.30
productb/ 0.130.32
a/ Heat and product analysis.
b/ Minimum of range not applicable when vacuum carbon deoxidation practice is used.
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M-1002 APPENDIX M
7.3 Impact Properties

The transverse Charpy V-notch impact properties of the material must be not less than the values
prescribed in Table M.8 when the test is conducted at a temperature of 320 F (196 C) or 175 F
(115 C), whichever is specified.
Table M.8 Impact properties for AAR TC134 steelconventional units

Size of Specimen (ftlb) for Both 175 F and 320 F
(mm) 175 F 320 F (ftlb)
10 10 35 25 20
10 7.5 30 21 17
10 6.6 28 19 15
10 5 24 17 14
10 2.5 12 8 6
See note after Table M.9.
Table M.9 Impact properties for AAR TC134 steelSI units

Size of Specimen (J) for Both 115 C and 196 C
(mm) 115 C 196 C (J)
10 10 47.4 33.9 27.1
10 7.5 40.7 28.5 23.0
10 6.6 38.0 25.8 20.3
10 5 32.5 23.0 19.0
10 2.5 16.3 10.8 8.13
Note: For all specimen sizes, the lateral expansion opposite the notch must be at least 0.015 in.
(0.381 mm). If the value of lateral expansion for one specimen is below 0.015 in. (0.381 mm),
but not below 0.010 in. (0.254 mm), and if the average value for the three specimens is not less
than 0.015 in. (0.381 mm), a retest of three additional specimens may be made, each of which
must equal or exceed the specified minimum value of 0.015 in. (0.381 mm). If the required
values are not obtained upon retest, or if the values on the initial test are below the minimum
required for retest, the plate may be reheat treated. After reheat treatment, a set of three
specimens must be made, each of which must equal or exceed the specified minimum value of
0.015 in. (0.381 mm).
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APPENDIX M M-1002
7.4 Reports
Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
Table M.10 Approved materials for tanks fabricated by welding

The grouping of materials by P-number in this table does not imply that base materials of
different analyses within a group may be indiscriminately substituted for a material that was
used in a welding procedure qualification test without consideration of the compatibility of the
base materials and filler metals from the standpoint of metallurgical properties, postweld heat
treatment, design and service requirements, and mechanical properties.
Table M.10.1 Carbon steel platea/

Minimum Tensile Strength, Minimum Elongation in
Welded Conditionc/ 2 in. (50 mm) Weld Metal
Group (Longitudinal)
Material Specification P- Numberb/ Number psi MPa %
Material Group 1d/
ASTM A516, Gr. 70 1 2 70,000 485 20
ASTM A537 1 2 70,000 485 22
AAR TC128, Gr. B e/ e/ 81,000 560 19
Table M.10.2 Aluminum alloy platef/

O Temper, Welded 2 in. (50 mm) O Temper,
Conditionc/ Welded Condition
(Longitudinal)
Material Specificationf/ P- numberb/ psi MPa %
Material Group 2
ASTM B209, Alloy 5052g/ 22 25,000 172 18
ASTM B209, Alloy 5083h/ 25 38,000 262 16
ASTM B209, Alloy 5086g/ 25 35,000 241 14
ASTM B209, Alloy 5154g/ 22 30,000 207 18
ASTM B209, Alloy 5254g/ 22 30,000 207 18
ASTM B209, Alloy 5454g/ 22 31,000 214 18
ASTM B209, Alloy 5652g/ 22 25,000 172 18
Table M.10.3 High alloy steel plate

Group (Longitudinal)
Material Specification P- numberb/ Number psi MPa %
Material Group 3i/
ASTM A240, Type 304 8 1 75,000 515 30
ASTM A240, Type 304L 8 1 70,000 485 30
ASTM A240, Type 316 8 1 75,000 515 30
ASTM A240, Type 316L 8 1 70,000 485 30
C-III [M-1002] 366 11/2014

M-1002 APPENDIX M
Table M.10.4 Nickel plate

(Longitudinal)
Material Specification P- numberb/ psi MPa %
Material Group 4
ASTM B162 41 40,000 276 20
Table M.10.5 Nickel alloy steel plate

(Longitudinal)
Material Group 7
AAR TC133j/k/ 11A SG-1 95,000 655 22
AAR TC134j/k/ 11A SG-1 95,000 655 22
Table M.10.6 Manganese-molybdenum steel platea/

(Longitudinal)
Material Group 1
ASTM A302, Gr. B 3 80,000 550 20
Table M.10.7 Manganese-silicon steel platea/

(Longitudinal)
Material Group 1
ASTM A537, Cl. 1 1 70,000 485 23
Notes:
a/ These plates may be clad with other approved metals.
b/ The assigned P-numbers are the same as those used in ASME Boiler and Pressure Vessel Code.
c/ Maximum stresses to be used in calculations.
d/ This material group is for Appendix B certification purposes and not welding procedure
qualification purposes.
e/ For the purpose of this specification, TC128 Grade B is to be considered a P10C, Group1 material.
f/ Weld filler metal 5556 must not be used.
g/ For fabrication, the parent plate material may be O, H112, or H32 temper, but design
calculations must be based on minimum tensile strength shown.
h/ O temper only.
i/ This material group is for Appendix B certification purposes and not welding procedure
qualification purposes.
j/ Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
k/ See paragraph 6.0 or paragraph 7.0 of this appendix, as applicable.
11/2014 C-III [M-1002] 367

APPENDIX M M-1002
8.0 SUPPLEMENTARY SPECIFICATION FOR ASTM A516, GRADE 70 PRESSURE

VESSEL PLATES FOR TANK CAR TANKS
8.1 Scope
When used to fabricate tank car heads, shells, and sumps, ASTM A516, Grade 70 steel must meet
this specification in addition to the requirements of ASTM A516 and ASTM A20.
The steel must conform to the chemical requirements shown in Table M.11. All of these elements,
and any others intentionally added, must be reported on the Material Test Certificate. No
intentional additions of boron or nitrogen are permitted.
Table M.11 Supplementary chemical requirements for ASTM A516 Grade 70

Element Heat Analysis Product Analysis
Carbon (max %)a/ b/ 0.23 0.25
Manganese (%)b/ 0.851.20 0.791.26
Phosphorus (max %) 0.025 0.025
Sulfur (max %) 0.015 0.015
Silicon (%) 0.150.40 0.150.45
Vanadium (max %) Per ASTM A20 Per ASTM A20
Copper (max %) 0.35 0.35
Nickel (max %) Per ASTM A20 Per ASTM A20
Chromium (max %) Per ASTM A20 Per ASTM A20
Molybdenum (max %) Per ASTM A20 Per ASTM A20
Aluminum (%)c/ 0.0150.060 0.0150.060
Niobium (max %) Per ASTM A20 Per ASTM A20
Titanium (max %) 0.020 0.020
Boron (max %) 0.0005 0.0005
Nitrogen (max %) 0.010 0.012
Tin (max %) 0.020 0.020
CEq (max %) 0.45 0.45
Cu + Ni + Cr + Mo (max %) 0.65 0.65
Nb + V + Ti (max %) 0.11 0.11
Ti /N (max ratio) 4.0 4.0
a/ Limits apply only for thicknesses up to 3/4 in.
b/ For each reduction of 0.01 percentage point below the
specified maximum for carbon, an increase of 0.06
percentage point above the specified maximum for
manganese is permitted, up to a maximum of 1.50% by heat
analysis and 1.60% by product analysis.
c/ A minimum of 0.015% must be acid-soluble.
C-III [M-1002] 368 11/2014

M-1002 APPENDIX R
APPENDIX R
REPAIR, ALTERATION, AND CONVERSION TO TANK CAR TANKS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III372
1.2 Certified Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III372
1.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III372
1.4 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III372
2.0 Qualification of Personnel and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
2.1 Welders and Welding Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
2.2 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
2.3 Nondestructive Testing (NDT) Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
2.4 Nondestructive Testing (NDT) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
3.0 Approvals and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
3.1 New Procedures or Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
3.2 Currently Approved Procedures and Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III373
3.3 Exhibit R-1 Report of Tank Repairs, Alterations, or Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . C-III374
3.4 Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs . . . . . . . . . . . C-III378
3.5 Availability of Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III384
4.0 Special Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III385
4.1 Hydrogen Fluoride, Anhydrous (AHF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III385
5.0 Damaged Stub Sills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.2 Cleaning for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.4 Inspection Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.5 Inspection Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
5.6 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III386
6.0 Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
7.0 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
7.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
7.2 Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
7.3 Low Hydrogen Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
8.0 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
11/2014 C-III [M-1002] 369

APPENDIX R M-1002

9.0 Repair of Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
9.1 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III387
9.2 Welding of Cracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III388
9.3 Reinforcements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III388
9.4 Cracks in Dome Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III388
9.5 Repair of Surface Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III388
10.0 Repair of Pits and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
10.1 Patch Plate RepairAAR Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
10.2 Repair of Pressure Car Manway Gasket Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.0 Repair of Deformation and Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.1 Dents or Buckles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.2 Pressing or Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.3 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.4 Scores and Gouges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III389
11.5 Wheel Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
12.0 Welded Inserts and Tank Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
12.1 When Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
12.3 Inspection of Nonpressure Tanks Inserted in Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
12.4 Welded Inserts in Void Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III390
13.0 Riveted Repairs and Seal Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
13.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
13.2 Riveted Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
13.3 Seal Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.0 Connections Added or Relocated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.1 When Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.3 Removal of Rivet Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.4 Welding of Rivet Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.5 Nozzles and Domes on Welded Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III391
14.6 Permanent Closure of Bottom Outlet or Washout Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
14.7 Closures for Tongue-and-Groove Fittings Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.0 Attachments Added or Relocated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.1 Welded Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.2 Anchor Rivet Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.3 Welded Bolster Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.4 Welding Stud Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III392
15.5 Repairs in Kind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
16.0 Attachment of Stub Draft Sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
16.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
C-III [M-1002] 370 11/2014

M-1002 APPENDIX R

17.0 Insertion of Interior Tank Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
17.1 Head Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
17.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
17.3 Voids Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
18.0 Nondestructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
18.1 Radiographic Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
18.2 Liquid Penetrant Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
18.3 Magnetic Particle Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
18.4 Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III393
19.0 Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III394
19.1 When Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III394
19.2 Unit Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III394
19.3 Local Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III394
20.0 Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III397
21.0 Repairs to Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III397
22.0 Repairs to Fire-Damaged Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III397
23.0 Repairs to Tapped Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III398
24.0 Welding to Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III399
24.1 Welding to Carbon Steel Tank Car Tanks after Unit PWHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III399
Fig. R.12 Form SS-1 Report of Tank Car Stub Sill Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III406
11/2014 C-III [M-1002] 371

APPENDIX R M-1002
APPENDIX R
REPAIR, ALTERATION, AND CONVERSION TO TANK CAR TANKS
1.0 INTRODUCTION
1.1 Scope
1.1.1 Appendix R describes repairs, alterations, or conversions that affect tank heads, shells,
sumps, and welds attaching connections thereto and defines required documentation for reporting.
Repairs to connections shall be in accord with the American Welding Society (AWS) Railroad
Welding Specification D15.1, except for welds attaching connections to the tank shell or heads.
1.1.2 Forms (Exhibit R-1, Exhibit R-2, and Form SS-3), at the owners discretion, may be
transmitted electronically for any car that has received an inbound inspection and estimate prior
to January 1, 2015, at which time electronic submittal via the Web-based Tank Car Inspection
Database (TCID) becomes mandatory. To obtain access to the TCID system, use the following URL:
http://www.rsiaarproject.com.
1.2 Certified Facilities
Repairs, alterations, or conversions to tank car tanks requiring welding, riveting, or removal of
deformations must be performed only by facilities certified by the AAR for fabrication, alterations,
conversions, or repairs. See Appendix B.
1.3 General
1.3.1 When special materials, procedures, or dimensional requirements must be maintained, the
car owner must provide such data and drawings to the facility performing repair, alteration, or
conversion.
1.3.2 Unacceptable imperfections shall be removed and reexamination made to ensure complete
removal. Whenever an imperfection is removed by chipping or grinding and subsequent repair by
welding is not required, the excavated area shall be blended into the surrounding surface so as to
avoid sharp notches, crevices, or corners. Where welding is required after removal of an
imperfection, the area shall be cleaned and welding performed in accord with Appendix W for tank
heads, shell, sumps, and welds attaching connections thereto. Repairs to connections shall be in
accord with the American Welding Society (AWS) Railroad Welding Specification D15.1, except for
welds attaching connections to the tank shell or heads.
1.3.3 After an imperfection has been removed, and prior to making weld repairs, the area shall be
examined by suitable methods to ensure that the imperfection has been eliminated.
1.3.4 After repairs have been made, the repaired area shall be blended into the surrounding
surface so as to avoid sharp notches, crevices, or corners, and reexamined using the same NDT
method that failed the initial repair, and by all other methods of examination that were originally
required for the affected area.
1.4 Personnel
Repairs, alterations, and conversions shall be examined by NDT examiners, qualified per
Appendix T for methods employed.
C-III [M-1002] 372 11/2014

M-1002 APPENDIX R
2.0 QUALIFICATION OF PERSONNEL AND PROCEDURES

2.1 Welders and Welding Operators
Qualification of welders and welding operators must comply with Appendix W for tank heads,
shell, sumps, and welds attaching connections thereto. For other repairs, qualification welders and
welding operators shall be in accord with AWS D15.1.
2.2 Welding Procedures
Qualification of welding procedures must comply with Appendix W for tank heads, shell, sumps,
and welds attaching connections thereto. For other repairs, qualification welding procedures shall
be in accord with AWS D15.1.
2.3 Nondestructive Testing (NDT) Personnel
Qualification of NDT personnel must comply with Appendix T.
2.4 Nondestructive Testing (NDT) Procedures
Qualification of NDT procedures must comply with Appendix T.
3.0 APPROVALS AND REPORTS
3.1 New Procedures or Materials
When repairs, alterations, or conversions to tank car tanks are to be made using procedures or
materials that have not been previously approved, an application for approval must be submitted
as prescribed in Chapter 1, paragraph 1.4. Tank cars must not be returned to service until
approval has been granted and repairs have been made.
3.2 Currently Approved Procedures and Materials
3.2.1 Alterations, conversions or accident-related repairs to tank car tanks must be made using
current AAR approved procedures and materials as well as car owners instructions. An
Exhibit R-1 report, in compliance with this appendix, must be submitted by the certified or
registered facility performing the work to the car owner and to the AAR Executive Director-Tank
Car Safety (Director).
The purpose of Exhibit R-1 is to
Amend the approved Certificate of Construction for each tank car and certify that all
alterations, conversions, and accident-related repairs were made in accordance with AAR-
approved procedures, materials, and owners instructions.
Provide traceability to the original and subsequent 3.2 or Appendix R procedures.
Provide a historical record of changes to the tank car.
3.2.2 Tank cars must not be returned to service until submission of Exhibit R-1. Failure to submit
the required Exhibit R-1 may be cause for action by the AAR.
3.2.3 By signing Exhibit R-1, the certified or registered facilitys management representative
shall be understood to certify that the work was performed in accordance with AAR-approved
procedures and materials as well as with car owners instructions.
3.2.4 If drawings depicting the previously approved procedures and materials have not been
submitted for approval within the last 10 years, then such drawings must be resubmitted for
approval on Form AAR 4-2, 4-3, 4-5, or 4-7.
11/2014 C-III [M-1002] 373

APPENDIX R M-1002
3.3 Exhibit R-1 Report of Tank Repairs, Alterations, or Conversions

Exhibit R-1 is required for reporting the following:
Accident damage repairs to tank shell, heads, sumps, nozzles, and pads welded directly to
the tank
Alterations that affect the Certificate of Construction, such as changes to valves or fittings
Conversions (changes in tank or fittings that change the specification)
Changes in reporting mark and/or car number
Changes in authorized commodities (listed on the original Certificate of Construction or
subsequent Exhibit R-1)
3.3.1 Until September 1, 2014, the owner or, by agreement, the facilitys management
representative is responsible for providing all requested information, via hard copy or e-mail, in a
format approved by the AAR, to the AAR Executive DirectorTank Car Safety, Association of
American Railroads, 425 Third Street SW, Suite 1000, Washington, DC 20024. Other methods of
transmission are acceptable if agreed to by the AAR. Exhibit R-1 reports must be typed or hand-
written legibly or, if transmitted electronically, in a format that the AAR can view. A copy also
must be sent to the car owner.
3.3.2 A separate Exhibit R-1 must be prepared for each tank car, except that with the car owners
permission, multiple identical cars receiving identical work may be reported on a single
Exhibit R-1. When multiple cars are reported on a single Exhibit R-1, a separate copy must be
retained by the car owner for each car listed.
3.3.3 The information from the completed Exhibit R-1 must be retained in such a way that a
printable electronic copy or paper copy can be obtained and that changes to the original
information can be detected by the car owner or owners representative1/ as back-up
documentation of the work performed. The form used by the repair facility to provide information
as to the work performed should be as agreed upon by the two parties and need not be the
Exhibit R-1 provided in this manual.
1/ The term representative does not automatically mean the shop performing the work. It is
intended to mean an entity legally contracted to represent the owner, which may or may not
be the shop performing the work.
C-III [M-1002] 374 11/2014
M-1002 APPENDIX R
3.3.4 The following instructions corresponding to the line numbers and field name in the
database must be followed in filling out the report:
Instructions for Completing Exhibit R-1
Line Instruction
1. The report is the responsibility of the certified or registered facility performing the work.
2. Car reporting mark(s) and number(s).a/
3. The name of the management representative of the facility performing the work.
4. Date that the work was performed (MM/DD/YYYY).
5. Name and location of the company or station symbol of where the work was performed.
6. Enter X in boxes as applicable for all types of work performed on the car.
7. Enter original date built of the tank car (MM/YYYY). If there is a different date built
between the tank and the underframe, indicate the underframe date.
8. Enter the name of the car manufacturer.
9. Enter the original AAR certificate number under which the tank car was built.
10. Identify the commodity to be transported after the work is completed. If unknown, indicate
last contents. When listing a regulated commodity, use the DOT/TC proper shipping name.
11. Enter the as-built car specification.b/ If the car was converted by Form AAR 4-2, or if
Exhibit R-1 (for a conversion) was issued prior to the work, enter the conversion
specification.b/
12. Indicate the car specification following the work.b/
13. Indicate the stenciled car specification following the workb/
14. For repairs:
a. Describe the damage using Appendix R terminology (crack, fracture, dent, gouge, etc.)
and indicate the affected area (reference Fig. R.2, Tank location chart) and dimensions
(e.g., 10 in. crack at ABS). When repairs are required due to an accident, list the
railroad involved, the date of the accident, and the location of the accident, if the
information is available.
b. Describe the repair performed. List appropriate Appendix R references or previously ap-
proved procedures. List material specification (e.g., A516 gr. 70 plate, E7018 rod, etc.).
15. For alteration, conversion, pressure relief device change, or other work, describe the work
performed. List appropriate Appendix R references or previously approved procedures.
List material specification (e.g., A516 gr. 70 plate, E7018 rod, CS valve body, SS valve trim,
Neoprene gasket, etc.). If material is shown on the drawings listed on line 16, indicate
Materials: See 16.a/
16. List Tank Car Committee-approved drawings only. Drawings must relate to the work
performed. For instance, a drawing representing a crack repair for a DOT-103AW tank
cannot be used for a DOT-103CW or DOT-103DW tank that uses different steel. Indicate
the approved AAR certificate number (current within 10 years) for each drawing listed. If
reference drawings are not in the name of the applicant, the applying facility must state
at line 17 Permission has been granted for use of drawings, by the certificate holder, for
this specific car.
17. If it is necessary to revise a report, a new completed copy must be submitted. Indicate the
revision level, the previous date approved by car owner, and the items that were changed.
18. Print the company name and location of the facility performing the work.
19. Print the name and title of the facilitys management representative.
20. Management representatives signature and date signed.
a/ When changing the reporting mark and/or number, show the new reporting mark and
number at line 2. Record the previous mark and number at line 15.
b/ Enter a specification without dashes or spaces (e.g. DOT111A100W1).
11/2014 C-III [M-1002] 375

APPENDIX R M-1002
Exhibit R-1
EXHIBIT R1 REPORT OF TANK REPAIRS, ALTERATION, OR CONVERSION
1. To AAR Executive DirectorTank Car Safety 2. Reporting mark and number:_____________________

3. Reported by: _________________________________ 4. Date work performed: __________________________
5. Work performed at: ______________________________________________________________________________
6. Report of: Tank repairs Alterations Conversions Relief device sizing Other
7. Built date: ___________________________________ 8. Built by: _____________________________________
9. Original AAR Certificate No.:_____________________ 10. Commodity: __________________________________
11. Constructed car spec: __________________________ 12. Car spec (after this work): _______________________
13. Stenciled spec (after this work): __________________
14. Tank repairs (Reference M-1002 Appendix R, Fig. R2)
A) Nature and location of defect:
B) Procedure and materials:
15. For alterations, conversions, pressure relief devices, or other, list procedure and materials:
16. Pertinent approved drawings:
DRAWING TITLE DRAWING NUMBER AAR CERTIFICATE NUMBER

A.
B.
C.
D.
E.
F.
17. Revisions and notes:
The cars listed above conform to all approvals mentioned and to all applicable DOT and AAR requirements, including
specifications, regulations, rules of interchange, and the DOT safety appliance standards.
FACILITY
Company name: __________________________________ Location (City/State): _______________________________
Management Representative (Name): __________________________________________ Title: __________________
Management Representative Signature: ________________________________________ Date: __________________
Rev. 04/2010
Fig. R.1 Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
C-III [M-1002] 376 11/2014

M-1002 APPENDIX R
ATS CTS BTS
A-END ALS CLS BLS B-END
ABS CBS BBS
LEFT SIDE VIEW
BTS CTS ATS
B-END BRS CRS ARS A-END
BBS CBS ABS
RIGHT SIDE VIEW
ATH BTH
ABH BBH
A-END B-END
Legend
ATS = A-end top shell BTS = B-end top shell
CTS = Center top shell CBS = Center bottom shell
ABS = A-end bottom shell BBS = B-end bottom shell
ARS = A-end right shell BRS = B-end right shell
ALS = A-end left shell BLS = B-end left shell
CRS = Center right shell CLS = Center left shell
ATH = A-end top head BTH = B-end top head
ABH = A-end bottom head BBH = B-end bottom head
Note: By convention, Right and Left sides are relative to a vantage point facing
the B-end of the car.
Fig. R.2 Tank location chart
11/2014 C-III [M-1002] 377

APPENDIX R M-1002
3.4 Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
3.4.1 Exhibit R-2 (shown in Fig. R.3) is a means for collecting information pertaining to the
following:
tank buckle repairs
tank corrosion repairs
tank crack repairs
center sill repairs
repairs to stub sill, bolster, and cradle pad connections to tank
3.4.2 Information supplied will be entered into a database and analyzed in an effort to establish
failure trends. The AAR will maintain the database and provide periodic reports.
3.4.2.1 The owner, or owners designee, is responsible for providing all requested information per
paragraph 1.1.1 of this appendix. The AAR is not to receive a hard copy of Exhibit R-2.
3.4.2.2 A separate Exhibit R-2 must be prepared for each car each time nonaccident buckles,
cracks, or corrosion repairs are made to it. Up to six repairs per car may be reported on one
Exhibit R-2 by inserting information for each in the proper blank, a., b., c., d., e. or f., for each item
of information. The Exhibit R-2 software allows entry of up to 26 different repairs per car.
3.4.2.3 The information from completed Exhibit R-2 must be retained, for back-up documentation
of the work performed, by the car owner or the car owners representative in such a way that a
printable electronic copy or paper copy can be obtained and that changes can be detected. The
Exhibit R-2 at the back of this publication may be used as the hard copy, but is not mandatory. The
software is capable of generating a printed record of repairs, which may also serve as the hard
copy. The form used by the repair facility to provide repair information to the owner should be as
agreed upon by the two parties, and need not be the Exhibit R-2 provided in this manual.
3.4.2.4 Exhibit R-2 data in the software is entered by line number. These line numbers
correspond to the entries on the Exhibit R-2 provided in this manual. Each item of the form is to be
filled in as described below. Consult the R-2 Program Users Guide before attempting to complete
Exhibit R-2.
Instructions for Completing Exhibit R-2
Line Instruction
1. Enter the name of the car owner.
2. Enter the car reporting mark and number.
3. Enter the name of the company having performed work on the car.
4. Enter the location of the repair shop or company at which work was performed.
5. Enter the month, day, and year of repair.
6. Enter the month and year car was built.
7. Enter the builders code as listed in Table R.1.
8. Enter the original AAR Certificate of Construction number under which the tank car was
approved.
9. Enter the commodity to be transported after the work is completed.
10. Enter the tank specification, as built.
11. Enter the tank specification after work is completed.
12. Enter the specification to be stenciled on the tank car after work is completed.
13. Enter the manufacturers stub sill design style designation and corresponding builder code
as shown in Table R.1.
14. Indicate whether or not the car is jacketed.
C-III [M-1002] 378 11/2014

M-1002 APPENDIX R
Line Instruction
15. Indicate whether or not the car is equipped with head braces.
16. Enter the code for the component on which failure occurred. For cracks in stub sill-related
welds, refer to Fig. R3.1 through Fig. R3.6 on page C-III381. If (O)-Other is indicated,
explain in line 24Comments.
17. Enter the code for the type of failure repaired. If (H)-Other is indicated, explain in
line 24Comments.
18. Enter the code for the suspected cause of failure. Avoid indicating (D)-Unknown if at all
possible.
19. Select the code for the method of repair, as listed below. The following repair procedures
are listed in the corresponding paragraphs of Appendix R or in the Field Manual of the
AAR Interchange Rules:
9.2 Welding of Cracks 11.1 Dents/Buckles

9.5 Repair of Surface Cracks 12.2 Inserts
10.1 Patch Plate Repair Field Manual of the AAR Interchange Rules, Rule 82 (Weld Sill)
If repair is made by a method other than one of the above, show the number of the approved
Certificate of Construction for the procedure used or explain in line 24Comments.
20. For cracks (reported on line 17 as failure type B or C), enter crack length to the nearest inch,
with a minimum of 1 in. for cracks less than 1 in. long.
21. For corrosion (reported on line 17 as failure type D, E, F, or G), indicate the approximate
location. See Fig. R.3 on page C-III380. Dimensions are not required.
22. Enter the code and dimensions for the location of repair. See page C-III380 for guidance.
23. Enter the code for the method of inspection utilized to detect the defect. If Other is indicated,
explain in line 24Comments.
24. Provide additional information that may be relevant, including observations that may
preclude similar failures in the future. Information must be furnished here if Other was
selected in lines 16, 17, 19, or 23.
25. Sign and date the form and print your name and title.
11/2014 C-III [M-1002] 379

APPENDIX R M-1002
Exhibit R-2
EXHIBIT R2 (PAGE 1 OF 3)
REPORT OF NONACCIDENT-RELATED BUCKLES, CORROSION, AND CRACK REPAIRS
1. Car Owner __________________________________ 2. Reporting Mark and Number ________________________
3. Reported by ___________________________________ 4. Performed at _____________________________________
5. Date ______________ 6. Tank Built Date ______________ 7. Built by ____________________________________
8. Original AAR Cert. of Const. No. _____________________ 9. Commodity (after this work)___________________
Tank spec.: 10. (as const.) ______________ 11. (after this work) _______________ 12. Stenciled ______________
13. Stub Sill Design Style _______________________ 14. Car Jacketed? (Y/N) ______ 15. Head Brace? (Y/N) ______
16. Component Where Failure Occurred:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Tank Shell-Interior (B)-Tank ShellExterior (C)-Tank HeadInterior (D)-Tank HeadExterior (E)-Cen-
ter SillWeb (F)-Center SillFlange (G)-Center SillBoth (H)-Bolster Pad (Tank Cradle) (J)-Tank Reinforc-
ing Pad (Inboard of Bolster) (M)-Brake Support (N)-Tank Bolster (O)-Other (Explain in Item 24. Comments)
(P)-WeldBolster Pad to Tank (Q)-Stub Sill Web (R)-Stub Sill Top Flange (S)-Stub Sill Bottom Flange
(T)-Head Brace (U)-Head Pad (V)-Top Longitudinal Centerline (W)-Bottom Longitudinal Centerline.
Cracks in Stub Sill Related Welds (See Figs. R3.1 through R3.6):
Transverse Welds: (A1)-Pad to Tank, (B1)-Pad to Sill, (C1)-Brace to Sill, (D1)-Brace to Pad, (E1)-Other. Longi-
tudinal Welds: (A2)-Pad to Tank, (B2)-Pad to Sill, (C2)-Brace to Sill, (D2)-Brace to Pad, (E2)-Other (BF)-Bot-
tom Outlet Flange (MW)-Manway Nozzle (SN)-Safety Device Nozzle.
17. Type of Failure: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Buckle (B)-Crack in Parent Metal (C)-Crack in Weld (D)-CorrosionRandom Pits (E)-CorrosionGrouped
Pits (F)-CorrosionAdjacent to Weld (G)-CorrosionGeneral (H)-Other (Explain in Item 24. Comments)
(I)-CorrosionBathtub Ring (BL)-Blister.
18. Cause of Failure: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Fatigue (B)-Workmanship (C)-Missing Weld (D)-Unknown (E)-Overstressed (F)-Abused (G)-Corrosion
(BL)-Blister.
19. How Repaired: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-10.2 (B)-10.5 (C)-25.0 (D)-11.1 (E)-13.2 (F)-Replaced in Kind (G)-Precedent Certificate of Construction,
Number: a. ________; b. ________; c. ________; d. ________; e. ________; f. ________
(H)-12.2 Buckles (I)-Rule 82 Weld Sill (J)-Rule 57 (K)-Other (Explain in Item 24. Comments).
20. Length of Crack: If Item 17 is (B) or (C) [crack], enter length in inches:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
21. Location of Corrosion: If Item 17 is (D), (E), or (F) [corrosion], indicate approximate location on sketches on
reverse side of form. Dimensions are not required.
22. Location of Repair on Car:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-A End (B)-B End (C)-BR Side (D)-BL Side (E)-AR Side (F)-AL Side (P)-Top or Bottom of Transverse Cen-
terline (Q)-Transverse Centerline Left (R)-Transverse Centerline Right (S)-Top Long. Centerline (T)-Bottom
Long. Centerline a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(G)-Circumferential Distance on Tank Shell from Bottom Longitudinal Centerline, (xxx) inches
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(H)-Longitudinal Distance on Tank Shell from Head/Shell Seam Along Longitudinal Axis, (xxx) inches
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(J)-Horizontal Curved Distance on Head Shell from Vertical Centerline of Head, (xxx inches)
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(M)-Vertical Curved Distance on Head from Top of Sill, (xxx inches)
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(N)-Horizontal Distance from Striker, (xxx inches)
23. Inspection Method Used to Detect Defect: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(AE)-Acoustic (RVT)-Fiber Optic (LP)-Liquid Penetrant (MT)-Magnetic Particle (UT)-Ultrasonics (VT)-Visual
(RT)-X-RAY (OT)-Other (Explain in Item 24. Comments)
24. Comments: ________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
25. Completed by:_____________ Date:____________ Title:________________ Signature: ________________________
Distribution: OriginalCar owner; Electronic copyAAR
Fig. R.3 Exhibit R2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
C-III [M-1002] 380 11/2014
M-1002 APPENDIX R
Fig. R.3 Exhibit R2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (continued)
11/2014 C-III [M-1002] 381
APPENDIX R M-1002
A1
A2
D2 A1 A2
A1 A2
C2 D1 B1
A1 C1
A2
D1 C2
C1 B1
B2 B2 B2
CL LONG CL LONG
Fig. R3.1
Fig. R3.1 Fig. R3.2 Fig. R3.2
Fig. R3.3
Fig. R3.4
NON-STRUCTURAL
A2 Fig. R3.5 A2 SEAL WELD.
NOT REPORTABLE
Fig. R3.6
A1
A2
A2
A2
B2 B2 B2
CL LONG C
A1 L LONG
Fig. R3.3 Fig. R3.4
SEAL WELD
A2
A1 A1
B1
A1
B1
B2
A2 CL LONG
CL LONG
Fig. R3.5 Fig. R3.6
Fig. R.3 Exhibit R2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (concluded)
C-III [M-1002] 382 11/2014
M-1002 APPENDIX R
Table R.1 Builder and design style identification (page 1 of 2)

Exhibit R2 Designation for:
Builder Name Builder Stub Sill Design Style
ACF Industries, Inc. ACF 100 (Fig. R3.3)
American Railcar Industries ARI 200 (Fig. R3.4)
230 (Fig. R3.4)
270 (Fig. R3.4)
300 (Fig. R3.1)
AMF- Beaird design AMF
(Built by NACCO, Davie, Hawker Siddeley) DSL
HST ABC (Fig. R3.5)
NAC JKL (Fig. R3.5 w/Hd. Brace)a/
Constructora CNC 001 (Fig. R3.2)
002 (Fig. R3.1)a/
Davie Shipbuilding Ltd. (See AMF-Beaird)
Evans Railcar EVA EVA (Fig. R3.2)
WBR (Fig. R3.1)a/
General American Transportation Corporation GAT 018 (Fig. R3.1)
18A (Fig. R3.1)
18B (Fig. R3.1)
020 (Fig. R3.1)
090 (Fig. R3.6)
095 (Fig. R3.1)
097 (Fig. R3.2)
098 (Fig. R3.1)
102 (Fig. R3.2) as built
102 (Fig. R3.1)a/b/
Gulf Railcar GUL GUL (Fig. R3.4)
WBR (Fig. R3.1)a/
Hargis Railcar HAR HAR (Fig. R3.1)
270 (Fig. R3.4)
Hawker Siddeley HST 080 (Fig. R3.4)
081 (Fig. R3.1)a/
098 (Fig. R3.1)
Lox Equipment LOX LOX
National Steel Car NSC 001 (Fig. R3.1)
North American Car Corp. (NACCO) NAC AB1(Fig. R3.5)
DEF (Fig. R3.2)
GHI (Fig. R3.1)a/
JK3 (Fig. R3.5)a/
ZBN (Fig. R3.1)
200 (Fig. R3.1)a/
Process Engineering PEN PEN
Procor Limited (See Union Tank Car Co.)
Richmond Tank Car Company RIC RIC (Fig. R3.2)
WBR (Fig. R3.1)a/
Riley-Beaird RIL RIL (Fig. R3.2)
WBR (Fig. R3.1)a/
11/2014 C-III [M-1002] 383

APPENDIX R M-1002
Table R.1 Builder and design style identification (page 2 of 2)

Exhibit R2 Designation for:
Builder Name Builder Stub Sill Design Style
Texana Tank Car & Mfg. TEX TEX (Fig. R3.1)
Trenton Works Lavalin TWL TWL (Fig. R3.1)
Trinity Industries TRN TYA (Fig. R3.1)
TY1 (Fig. R3.2)
TY2 (Fig. R3.1)
TY3 (Fig. R3.1)
021 (Fig. R3.1)
022 (Fig. R3.1)
023 (Fig. R3.1)
024 (Fig. R3.1)
Union Tank Car Company UTL 00F
Procor Limited PRO CBO (Fig. R3.1)
CBR (Fig. R3.1)a/
CWO (Fig. R3.5)
FBR (Fig. R3.1)a/
ZBA (Fig. R3.1)
ZBB (Fig. R3.1)
ZBC (Fig. R3.1)
ZBD (Fig. R3.1)
ZBE (Fig. R3.1)
ZBF (Fig. R3.1)
ZBG (Fig. R3.1)
ZBH (Fig. R3.1)
ZBI (Fig. R3.1)
ZBN (Fig. R3.1)
ZBR (Fig. R3.1)a/
a/ Original design modified to include head braces
b/ Builder code to be GAX for modified sills for this style only
3.5 Availability of Forms

Reproducible copies of Exhibit R-1 and Exhibit R-2 are located at the back of this publication.
C-III [M-1002] 384 11/2014

M-1002 APPENDIX R
4.0 SPECIAL REQUIREMENTS

For special commodity requirements, see Tariff No. BOE-6000. Also refer to the special commodity
requirements in Chapter 2.
4.1 Hydrogen Fluoride, Anhydrous (AHF)
4.1.1 Existing tank cars placed into anhydrous hydrogen fluoride service must conform to
Chapter 2, paragraph 2.1.4.
4.1.2 Weld repair of blisters in AHF tank cars shall be repaired by insert in accordance with
paragraph 12.0 of this appendix. Insert material shall conform to the requirements of Chapter 2,
paragraph 2.1.4. Low-hydrogen electrodes must be used. Radiography and postweld heat
treatment is required for any weld repair made to an AHF tank. Radiography must be performed
after postweld heat treatment. The tensile strength of the deposited weld material must not
exceed 85 ksi and must have a carbon equivalent (C.E.) of less than 0.42. Preheat and interpass
temperature of 300 F shall be maintained during welding. The postweld heat treatment
temperature must be between 1125 F and 1225 F for 1 hour per inch of thickness of material
with a 1 hour minimum holding time and must be controlled to prevent a harmful temperature
gradient in the welds and the adjacent base metal. The maximum hardness of the weld and heat-
affected zone shall not exceed 248 DPH (Diamond Pyramid HardnessVickers) or 20 HRC.
Brinell hardness testers are not permitted on repair welds due to the large size of the indenter
relative to the features being measured; however, it is common practice to convert hardness
measurements to Brinell hardness values using published conversion tables.
4.1.2.1 Portable hardness test methodology and procedures shall conform to the following:
This procedure provides the techniques to use portable hardness testers to screen the
hardness of welds, base metal, and heat-affected zones in tank car construction and repair.
A microhardness measurement device with a Vickers diamond indenter must be used (e.g.,
a Krautkramer MIC 10).
Use a power tool to remove any rust, fine corrosion pits, or other roughness from the
surface to be tested. Finish the test surface with a high-speed medium sandpaper disc or a
wire wheel to create a suitably smooth surface. The surface finish is satisfactory when the
majority readings are consistently within 1 or 2 units of Rockwell C hardness (or 5 units of
Brinell hardness).
At each test location, the hardness of the base metal on each side of the weld, the heat-
affected zones immediately adjacent to the toes of the weld, and three readings across the
face of the weld deposit itself must be tested and recorded separately on both sides of the
plate. Each hardness test location must be spaced 3 in. apart for a repair insert up to 12 ft
in circumference. For a repair insert larger than 12 ft in circumference, hardness test
locations must be spaced 6 in. apart.
Take five readings at each test location and average them together. If an extremely large or
small reading occurs, delete it. Continue taking readings until the average stabilizes by
changing less than 1 Rockwell C unit (or less than 5 units of Brinell hardness) with each
new reading.
4.1.2.2 Weld repair to cracks and other defects requiring welding on the tank heads or manway
nozzle in AHF tank cars shall conform to the requirements of paragraph 4.1.2.1 above.
11/2014 C-III [M-1002] 385

APPENDIX R M-1002
5.0 DAMAGED STUB SILLS

5.1 Scope
Stub sill tank cars must be home-shopped for stub sill inspection, and the owner must be notified if
the car has been damaged to the extent outlined below:
Stub sill bent, twisted, or bulged in excess of 3/4 in. per 30 in. of sill length
Bottom tank or stub sill reinforcing plate buckled 1/2 in. in depth or more
Broken rear draft lug assemblies or attachment welds
Any cracks in the draft sill inboard of the face of the rear lug assembly
Any cracks in the area of the head brace
5.2 Cleaning for Inspection
Welds must be cleaned and made accessible consistent with the inspection technique.
5.3 Inspection
5.3.1 The following areas must be inspected at a minimum:
The inboard end of the stub sill reinforcement pad and its welds, for a 12 in. length from
the inboard end.
All welds between sill and head brace (if used), between head brace and head
reinforcement pad, and between the tank and reinforcement pad to at least 1 in. inboard of
the sill-to-head reinforcement pad connection.
All parent metal of the stub sill assembly outboard of the bolster.
5.3.2 The draft gear pocket must be inspected.
5.4 Inspection Methods
Inspection methods, such as acoustic emission (twist test), fiber optics, or visual techniques may be
used. Magnifiers, mirrors, or liquid penetrant may be used to aid in the inspection.
5.5 Inspection Reporting
When required by car owner, documentation of inspection results should be submitted to the
owner using Form SS-1, Report of Tank Car Stub Sill Inspection (see Fig. R.12).
5.6 Repairs
5.6.1 Repair per owners instructions or in kind to restore original design.
5.6.2 Straighten bent sills.
5.6.3 Reinspect all repairs.
5.6.4 Repair all cracks, including seal welds.
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M-1002 APPENDIX R
6.0 ACCEPTANCE CRITERIA

6.1 Welding
6.1.1 All welded repairs to tank car tanks must conform to the applicable sections of Appendix W,
paragraphs 2.0, 13.0, and 14.0.
6.1.2 All welded repairs to related components or assemblies must conform to the applicable
sections of AWS D15.1 (latest revision).
6.2 NDT
All nondestructive testing results shall meet the requirements of Appendix W, paragraph 10.0.
7.0 MATERIALS
7.1 Specifications
Materials for repairs, alterations, or conversions must comply with the material specification for
the original tank, or must have comparable physical and chemical properties and be listed in
Appendix M.
7.2 Corrosion Resistance
Procedures and materials used in repairs to high alloy steel tanks must maintain the corrosion
resistance capability required for the tanks, as originally built.
7.3 Low Hydrogen Electrodes
When repair welding procedures involve the use of low hydrogen electrodes, they must be handled
in accord with the requirements of Appendix W, paragraph 14.12.
8.0 HARDNESS TESTS
Butt-welded repairs in pressure car tanks that are constructed of Table M.10.1 materials must be
tested for hardness. Each weld must be checked at one point inside and one point outside the tank
at the center line of the weld. Weld hardness must not exceed Brinell 225 (Rc 20) after postweld
heat treatment.
9.0 REPAIR OF CRACKS
9.1 Methods
Tank cracks may be repaired by one of the following methods:
9.1.1 By preparation and welding of the crack in compliance with Fig. R.5. An interior or exterior
reinforcement patch may be applied over the repaired area, if deemed necessary.
9.1.2 By removal of the defective area and application of a welded insert, except as noted in
paragraph 13.2.2 below.
9.1.3 On riveted tanks only, by removal of the defective area and application of a riveted patch.
11/2014 C-III [M-1002] 387

APPENDIX R M-1002
9.2 Welding of Cracks

9.2.1 When a crack of any size is repaired by welding, the entire discontinuity must be removed
by chipping, grinding, or by the air-carbon arc or plasma arc processes. The chipped, ground, air-
carbon arc gouged, or plasma arc gouged groove cut into the base metal must be tapered toward
the plate surface to provide sound metal for the weld.
9.2.2 On aluminum tanks, flame gouging or air-carbon arc gouging must not be used.
9.3 Reinforcements
Reinforcements may be applied to areas where cracks have occurred; however, cracks must first be
repaired in accordance with paragraph 24.0. The reinforcement may then be applied, by welding,
to the interior or exterior of the tank. Reinforcements must be of a thickness at least equal to the
original tank plate. The area must be postweld heat treated.
9.4 Cracks in Dome Apron
Cracks in the dome apron of riveted tanks may be repaired by fusion welding. A reinforcement
must be applied if the welded area requires postweld heat treating. If a crack extends into the
dome flange rivet holes, the joint must be separated to permit weld groove preparation as
prescribed in paragraph 9.2.1 above. See Fig. R.7. If it is necessary to remove the tank shell sheet,
see paragraph 12.0 or 13.0 below.
9.5 Repair of Surface Cracks
For areas on tank car tanks that are allowed reduced thickness in 49 CFR 180.509(g), surface
cracks 1/16 in. or less in depth may be removed by grinding to sound metal and blending the
ground area smooth with the surrounding plate and/or weld. If the area to be ground is at the toe
of a weld, the final surface must be free from undercut and slag. Grinding must be accomplished
transverse to crack length unless the crack is along a weld toe, in which case the grinding must be
along the length of the crack. Grinding marks and localized frictional heating from grinding must
be kept to a minimum. For hand-held disc grinding, the disc should be inclined between 30 and
45. After grinding repairs, the ground area must be examined by magnetic particle or liquid
penetrant method.
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M-1002 APPENDIX R
10.0 REPAIR OF PITS AND CORROSION

10.1 Patch Plate RepairAAR Tanks
10.1.1 Repair of corroded areas on AAR-class tank car tanks may be made by application of a
patch plate contoured to the shape of the tank and with 1 in. (25.4 mm) minimum corner radii. The
minimum patch plate thickness must be equal to the original tank thickness, and the plate
material properties must equal or exceed the tank material properties.
10.1.2 The patch plate must be limited to a 24 in. (609.6 mm) circumferential width dimension
between longitudinal fillet welds. If welds intermediate to the longitudinal fillet welds are also
applied, such as longitudinally spaced slot or plug welds, the maximum plate width is 48 in.
(1219.2 mm) between the longitudinal fillet welds.
10.2 Repair of Pressure Car Manway Gasket Grooves
Repair of a gasket groove on a pressure car manway nozzle is to be made by removing corroded or
damaged material, applying weld metal, machining the flange face, and recutting the groove. See
paragraph 24.0 in this appendix for welding and NDE requirements.
11.0 REPAIR OF DEFORMATION AND SCORING
11.1 Dents or Buckles
Dents or buckles may be repaired, provided the procedure by which the areas are restored to
contour does not damage the material or alter the physical properties of the material beyond
specification limits.
11.2 Pressing or Jacking
11.2.1 If the sharpest radius formed by dents is at least four times the plate thickness, such dents
or buckles may be removed by pressing or jacking to restore original contour to within the limits
specified in Appendix W, paragraph 13.5. Excessive heating of the metal shall be avoided. For
carbon steel, the maximum temperature is 1250 F (677 C).
11.2.2 After complete removal of a deformation, the interior and exterior surfaces of the affected
area must be examined for surface cracking, by either liquid penetrant or magnetic particle
method, in accord with Appendix W, paragraph 10.0. All weld seams in the deformed area and
adjacent within 2 in. (50.8 mm) of the deformed area must be radiographed or ultrasonically
examined for the entire weld seam length and 2 in. (50.8 mm) beyond the deformed area.
11.3 Replacement
If the sharpest radius formed by dents or buckles is less than four times the plate thickness, or if
material thickness has been reduced, the affected area must be removed and replaced.
11.4 Scores and Gouges
11.4.1 Scores or gouges associated with dents must be prepared first by restoring the dented area
to original contour, per paragraph 11.2 above. The score or gouge must then be prepared by
grinding or by air-carbon arc or plasma arc gouging, to sound metal, removing all upset metal and
injurious defects. The prepared area must have a smooth transition to the surrounding plate. After
preparing, the area must be examined by magnetic particle or dye penetrant method, in accord
with Appendix W, paragraph 10.0.
11.4.2 If the plate has been reduced below the limitations shown below, it must be restored or
replaced in accordance with the applicable reference and paragraph 24.0.
All DOT specification tanks49 CFR 180.509
AAR specification tanks transporting regulated hazardous commodities49 CFR 180.509
AAR specification tanks transporting nonregulated commoditiesM-1002 Appendix D
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APPENDIX R M-1002
11.5 Wheel Burn

11.5.1 A shell damaged as a result of wheel contact (burn) must be repaired by one of the
following methods:
11.5.2 Wheel burns that do not exceed 1/16 in. (1.58 mm) in depth and 6 in. (152 mm) in length,
width not limited, can be repaired by grinding, provided the shell thickness following grinding is
not less than the minimum allowable thickness. The general location must have all upset metal
and injurious defects removed, and the repaired area must be examined by magnetic particle or
liquid penetrant method, in accord with Appendix W, paragraph 10.0.
11.5.3 Wheel burns that exceed the limitations of paragraph 11.5.2 must be repaired per
paragraph 24.0.
12.0 WELDED INSERTS AND TANK SECTIONS
12.1 When Permitted
12.1.1 On riveted tanks, welded inserts and tank sections may be applied if the welding can be
locally postweld heat treated.
12.1.2 On fusion-welded tanks, welded inserts and sections may be applied to any part of the
tank shell and heads.
12.1.3 On forge-welded tanks, welded inserts and tank sections may be applied to any part of the
tank shell and heads, provided the welds of the insert are at no point closer than 12 in. (305 mm)
to any forge-welded seam.
12.2 Procedure
12.2.1 The insert or plate must have a double-welded butt joint (DOT-113, DOT-115A, AAR-
204W, and AAR-206W specification tanks can be welded from one side using backing strips) with
1 in. (25.4 mm) minimum corner radius. The insert must restore original contour.
12.2.2 The inserted material must be of a thickness equal to or not more than 1/8 in. (3.14 mm)
greater than the original material. See Appendix E when the inserted material is thicker than the
original material. Inserted material must comply with the material specification for the original
tank or must have comparable chemical composition and physical properties equal to or greater
than the original material. Materials used for insert material must be listed in Appendix M and in
the relevant table for that material type.
12.2.3 Heads repaired by welded inserts are considered to have the same welded joint efficiency
as the original head. Head insert welds in the knuckle area, or straight flange, must be ground
flush on both sides.
12.3 Inspection of Nonpressure Tanks Inserted in Groups
When uniform inserts, tank sheet sections, or tank heads are being installed in succession on a
series of tanks of the same material specification on a production basis, utilizing the same welding
procedures and practices employed in the construction of new tanks, the inspection requirements
shall comply with Appendix W, paragraph 18.0.
12.4 Welded Inserts in Void Areas
Indentations or cracks in void areas of compartmented tanks may be repaired by application of an
insert, per Fig. R.9. The backing strip must be made in one piece, securely clamped and tack-
welded before being utilized as a backing.
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M-1002 APPENDIX R
13.0 RIVETED REPAIRS AND SEAL WELDING

13.1 Requirements
Riveted repairs must be made in compliance with the specification covering original tank
construction.
13.2 Riveted Patches
13.2.1 When it is necessary to remove a section of a riveted tank shell because of extensive
cracks, reduction in plate thickness, or other defects too large to permit a welded insert from being
successfully applied and locally postweld heat treated, a riveted patch must be applied or the
defective area replaced in accord with original construction.
13.2.2 Riveted patches may be applied to rubber-lined or elastomeric-lined welded tanks when a
welded repair will destroy the lining. A riveted patch must be replaced with a welded repair when
the tank is relined.
13.3 Seal Welding
Seal welding inside caulking edges of tank seams and inside rivet heads, attachments, and outside
caulking edge of dome flange is permitted, provided the throat thickness does not exceed 3/16 in.
(4.76 mm).
14.0 CONNECTIONS ADDED OR RELOCATED
14.1 When Permitted
Additional and relocated connections, such as nozzles, may be added or relocated on dome heads
and tank shells, in compliance with Figs. E.20.1 through E.20.12.
14.2 Procedure
Miscellaneous connections through the tank shell or heads, when added, relocated, or eliminated,
and closures for openings may be fusion-welded by a double-welded butt joint, or a double full fillet
lap joint, or these closures may be riveted. Note that this permits riveted connections on welded
tanks. For computing rivet area, the effective diameter of a driven rivet is the diameter of its
reamed hole. In no case is the hole to exceed the nominal diameter of the rivet by more than
1/16 in. (1.59 mm). Use of rivets of less than 5/8 in. (15.9 mm) nominal diameter is prohibited.
14.3 Removal of Rivet Holes
When welded inserts are applied to cover riveted nozzle openings, the openings shall preferably be
increased in diameter so that the rivet circle is removed and an insert large enough to cover the
entire area applied.
14.4 Welding of Rivet Holes
When necessary to close rivet holes, the holes must be plug-welded. See Fig. R.6. The back-up
strip(s) must be removed after welding and prior to performing any nondestructive examination
(NDE). Plug welds must be ground smooth if tanks are to be lined.
14.5 Nozzles and Domes on Welded Tanks
14.5.1 Nozzles and domes attached to a tank shell must be designed to meet the reinforcement
requirements of Appendix E.
14.5.2 Approved nozzle and dome designs and welded attachments are shown in Appendix E,
Figs. E.20.1 through E.20.12.
14.5.3 Other designs of nozzles and domes and their attachments to tanks may be used,
providing reinforcement meets the requirements of Appendix E and welding is equivalent to that
shown for designs in Figs. E.20.1 through E.20.12.
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APPENDIX R M-1002
14.5.4 When nonpressure tank cars are altered or repaired, or when pressure tank cars are
converted to nonpressure status, insert-type nozzle applications may be made, utilizing partial
penetration welds per Fig. R.10, subject to the following limitations:
Applications apply to top fittings only
Joint gap must not exceed 3/32 in. (2.38 mm) with joint ground smooth or reamed
Nozzle size must not exceed 10 in. (254 mm) inside diameter
The welding joint must be preheated to 250 F (121 C)
14.5.5 When nonpressure cars are altered or repaired, or when pressure cars are converted to
nonpressure status, lap joint nozzle applications may be made, in accord with Fig. R.11.
14.6 Permanent Closure of Bottom Outlet or Washout Flange
A bottom outlet or bottom washout flange may be internally sealed by a plate of tank car tank
material of the minimum thickness for the car specification that is welded by continuous double
full fillet or a combination of full fillet and groove welds. Radiography or ultrasonic testing and
postweld heat treatment are not required for welding to the flange.
14.7 Closures for Tongue-and-Groove Fittings Interfaces
When fittings equipped with tongue-and-groove interfaces are removed from a pressure car
manway cover plate, they must be replaced using tongued blind flanges that are in accord with
Figs. E.27 or E.28. When 3 in. full-ported flanged ball valves equipped with ANSI B16.5 large
tongue design are removed from a nonpressure car top fittings cover plate, they must be replaced
using 3-in. ANSI Class 300 blind flanges equipped with ANSI B16.5 large tongue design.
15.0 ATTACHMENTS ADDED OR RELOCATED
15.1 Welded Attachments
15.1.1 Exterior or interior brackets, supports, and reinforcement bar pads may be fillet-welded to
a tank shell per the requirements of paragraph 24.0.
15.1.2 When adding or relocating reinforcing pads or appurtenances, such as skids, washouts,
and sumps, to the bottoms of stub sill tank cars, the requirements of Appendix E, paragraph 15.0,
must be met. The fillet welds must meet Appendix W, paragraph 14.10, and the circumferential
portions of the fillet welds must be examined by magnetic particle or liquid penetrant, including
the corner and at least 3 in. of the weld extending longitudinally beyond the corner.
15.2 Anchor Rivet Caps
One-piece anchor rivet caps may be attached to a tank shell per the requirements of
paragraph 24.0. A tapped hole must be provided through the tank shell under each cap to permit
making an air test. Each test hole must be tightly closed with an approved plug after completion of
the test. Caps must be tested by applying air pressure of 100 psi (689 kPa) and must be tight
against leakage.
15.3 Welded Bolster Supports
Welded steel tanks mounted on underframes may be modified by attaching welded bolster
supports to tank bottom reinforcement plates or directly to the tank, securely fastened to
underframe, with necessary provision for expansion and contraction. Welding must be done in
accordance with the requirements of paragraph 24.0.
15.4 Welding Stud Attachments
Stud welding on carbon steel tank car tanks shall be done in accord with Table R.2. Stud welding
on tank car tanks made from P-8 (types 304L, 316L), P-22, or P-25 materials shall be done in
accord with Table R.3. Welding Purpose Code F applies for both tables.
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M-1002 APPENDIX R
15.5 Repairs in Kind

Repairs in kind to tank car tanks that have developed service failures in bolster or anchor areas, at
the dome-shell interface, or in bottom discontinuity protective devices, must be submitted on Form
AAR 4-2 for a review of the adequacy of the original design.
16.0 ATTACHMENT OF STUB DRAFT SILL
16.1 Procedure
Stub draft sills may be fusion-welded to bottom reinforcement plates. Tanks mounted on
underframes also may be modified by attaching welded stub draft sills.
17.0 INSERTION OF INTERIOR TANK HEADS
17.1 Head Requirements
When AAR or DOT tanks are altered by dividing into compartments or by reducing capacity by the
insertion of interior heads, interior heads must comply with the requirements specified in DOT
179.200-6.
17.2 Welding
Welding of inserted heads must be performed in accord with Appendix E, paragraph 6.0. Welding
of the replaced head must be performed in accord with paragraph 12.0 above.
17.3 Voids Created
A void created by the addition of interior heads must be provided with at least one tapped drain
hole at the lowest point and a tapped hole at the top of the tank. The top hole must be closed, and
the bottom hole may be closed, with not less than 3/4 in. nor more than 1 1/2 in. solid pipe plugs
having NPT threads.
18.0 NONDESTRUCTIVE TESTING
All documents, films, tapes, etc., generated during the NDE process shall be retained for a period
as indicated in Appendix Y. All examinations are for the full length and extent of the repair unless
otherwise noted.
18.1 Radiographic Examination
Radiographic examination shall be performed in accord with Appendix T. Evaluation and
acceptance of indications shall be in accord with Appendix W, paragraph 10.2.2.
18.2 Liquid Penetrant Examination
Liquid penetrant examination shall be performed in accord with Appendix T. Evaluation and
acceptance of indications shall be in accord with Appendix W, paragraphs 10.3.2 and 10.3.3.
18.3 Magnetic Particle Examination
Magnetic particle inspection shall be performed in accord with Appendix T. Evaluation and
acceptance of indications shall be in accord with Appendix W, paragraphs 10.4.2 and 10.4.3.
18.4 Ultrasonic Examination
Ultrasonic examination shall be performed in accord with Appendix T. Evaluation and acceptance
of indications shall be in accord with Appendix W, paragraph 10.5.2.
18.5 Where Appendix R does not specify NDT for welding to the tank, the car owner shall specify
a suitable NDT method using personnel and procedures qualified to Appendix T.
11/2014 C-III [M-1002] 393

APPENDIX R M-1002
19.0 POSTWELD HEAT TREATMENT

19.1 When Required
19.1.1 Postweld heat treatment for tank car tanks steel-stamped to AAR specifications shall be
done in accordance with paragraph 24.0.
19.1.2 Any repair or alteration involving welding on a carbon steel pressure car tank must be
postweld heat treated.
19.2 Unit Postweld Heat Treatment
After all welding is complete, postweld heat treatment of the tank, as a unit or by the double-
ended method, is preferable for carbon steel tanks. Postweld heat treatment of the tank as a unit is
mandatory for high alloy steel tanks, except tanks fabricated from Types 304L or 316L materials.
Postweld heat treatment must be performed in accord with Appendix W, paragraph 16.0.
19.3 Local Postweld Heat Treatment
19.3.1 In lieu of unit postweld heat treatment for carbon steel tanks, local postweld heat
treatment (LPWHT) per requirements below may be employed by certified facilities or contracted
out to approved subcontractors. If subcontractors are used, an AAR Exhibit B1 Subcontractor
Evaluation Sheet is to be completed and retained by the certified facility. Approved stress-
relieving equipment must be used, such as controlled gas or electrical systems that will provide a
constant and uniform temperature to the welded area.
Local postweld heat treatment for cars in hydrogen sulfide service is not permitted. (Refer
to Chapter 2, paragraph 2.1.2.2.1.)
Local postweld heat treatment by a manually held gas torch is not permitted.
19.3.2 Requirements for Local Postweld Heat Treatment (LPWHT)
19.3.2.1 Minimum Equipment Requirements
Automatic temperature recorder
Heater control unit
Heaters and insulation
Control and monitor thermocouples and control cables
19.3.2.2 Heat Treating Procedure, Minimum Requirements
19.3.2.2.1 Heaters are to be positioned such that the LPWHT heating soak band extends past
each edge of the weld a distance of six times the shell thickness minimum. Heaters and the
opposite side of the heating area are to be covered with thermal insulation to reduce heat loss.
19.3.2.2.2 To avoid ignition and fire, sufficient insulation or lining should be removed from the
LPWHT area.
19.3.2.2.3 All thermocouples or insulation pins in the heating area are to be securely attached to
the tank shell by capacitance discharge welding. A written welding procedure is required. Neither
qualification of the procedure nor performance qualification of the welder is required.
19.3.2.2.4 Each heater circuit or control zone is to have a control thermocouple placed near the
geometric center of the heating zone. (See Fig. R.4.)
19.3.2.2.5 Monitor thermocouples are to be located a distance of six times the shell thickness
from the edge of the weld. Control and monitor thermocouples are to be located to ensure uniform
temperature within the heating zone. The number of thermocouples will depend on weld length
and material thickness.
19.3.2.2.6 Heat sinks, such as pads, brackets, flanges, etc., in the heating area are to be heavily
insulated to prevent false temperature readings in the control zone.
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M-1002 APPENDIX R
19.3.2.2.7 To prevent harmful temperature gradient in the tank shell or adjacent appurtenances,
heater control units are to be monitored frequently by the LPWHT technician during the entire
heat-treating cycle. A temperature gradient greater than 250 F throughout the portion of the
tank being heated is considered harmful.
19.3.2.2.8 LPWHT cycle temperatures and time are to be in accordance with Appendix W,
paragraphs 16.3 and 16.4.
19.3.2.3 Equipment Calibration
Temperature recorders are to be calibrated and heater controllers aligned annually, per written
procedure. Units are to be marked to indicate the date of calibration or alignment status (date of
calibration or alignment and due date for the next calibration or alignment), and a certificate is to
be available upon request.
19.3.2.4 Documentation
19.3.2.4.1 A written local postweld heat treatment procedure is required.
19.3.2.4.2 Temperature time record is to be recorded on a strip chart or record showing
thermocouple location, car number, and technician signature.
19.3.2.5 Heat Treating Technicians
19.3.2.5.1 LPWHT technicians shall be qualified through a written training program conducted
either in-house or by a recognized subcontractor.
19.3.2.5.2 The training program shall, as a minimum, cover the following areas: safe use of
equipment, equipment calibration, thermocouple/insulation placement, and AAR temperature
limits.
19.3.2.5.3 Technicians shall demonstrate competence in completing tasks outlined in the
companys written LPWHT procedure.
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APPENDIX R M-1002
XS
ONE PADONE CIRCUIT
XS
XS OS XS OS
XS
TWO PADSTWO CIRCUITS TWO PADSONE CIRCUIT FOUR PADSONE CIRCUIT
S
XS O
XS X
X = CONTROLLING THERMOCOUPLE
S O = MONITORING THERMOCOUPLE
XS O S = SPARE THERMOCOUPLE
THREE PADSTHREE THREE PADSONE

CIRCUITS CIRCUIT
NOTES:
1. TYPICAL HEATING ELEMENT AND THERMOCOUPLE PLACEMENT ARE SHOWN ON THE DIAGRAMS ABOVE. VARIATIONS TO THESE PLACEMENTS MAY BE
NECESSARY FOR SPECIAL HEATING ZONE REQUIREMENTS ON THE TANK.
2. TO AVOID PROBLEMS DURING THE HEATING CYCLE, THE PREFERRED APPLICATION IS TO USE ONE CONTROL THERMOCOUPLE PROPERLY PLACED DIRECTLY
UNDER EACH HEATING ELEMENT (PAD).
3. AT THE HEAT-TREATING TECHNICIANS DISCRETION, SPARE THERMOCOUPLES SHOULD BE USED IN THE HEATING ZONE IN CASE OF CONTROL
THERMOCOUPLE MALFUNCTION.
4. IF MORE THAN TWO PADS ARE USED WITH ONE CIRCUIT, AT LEAST TWO MONITOR THERMOCOUPLES ARE TO BE APPLIED FOR PROPER CONTROL.
5. THERMOCOUPLE LOCATION IS IMPORTANT. WHEN THE THERMOCOUPLE IS PLACED TOO FAR FROM THE HEATING ELEMENT OR NEXT TO A LARGE HEAT SINK,
THE HEATING ELEMENT CAN OVER-HEAT THE TANK WHILE THE THERMOCOUPLE RECORDS A SMALL TEMPERATURE INCREASE. ANY LARGE MASS OF STEEL
IN DIRECT CONTACT WITH THE TANK IN THE HEATING AREA WILL ABSORB LARGE AMOUNTS OF HEAT AWAY FROM THE THERMOCOUPLE. EXAMPLES OF HEAT
SINKS ARE REINFORCEMENT PADS, MOUNTING FLANGES, NOZZLES, BOLSTER AND DRAFT SILL WEBS, AND EXTERIOR COILS. HEAVILY INSULATING THESE
AREAS IS CRITICAL.
6. IT IS CRITICALLY IMPORTANT THAT THE HEATING ELEMENT BE PLACED DIRECTLY AGAINST THE TANK SHELL AND THE THERMOCOUPLE ATTACHMENT BE
Fig. R.4 Postweld heat treatment thermocouple placement and use
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M-1002 APPENDIX R
20.0 HYDROSTATIC TESTING

In addition to the nondestructive requirements, hydrostatic testing of pressure car tanks is
required for the following repairs or alterations:
Complete penetration welds of the tank, such as inserts, rings, heads, and through-wall
repairs
The application, replacement, or relocation of welded components that retain pressure,
such as nozzles, flanges, and sumps
21.0 REPAIRS TO ANCHORS
21.1 Requirements
21.1.1 When necessary to remove fasteners from tank anchors for any reason, the fasteners must
not be reused. Fasteners may be replaced in kind, except as otherwise noted in paragraph 15.5
above. Bolts used to replace rivets (or two-piece rivets) must be ASTM A325. Washers, if used,
must be hardened steel.
21.1.2 It is permissible to replace discarded fasteners with bolts or two-piece rivets specified by
the car owner. The car owner or owners authorized agent must comply with the following:
21.1.2.1 The ultimate shear strength of the bolts or two-piece rivets securing the anchor to the
underframe must not exceed 70% of the ultimate shear strength of the welds used for connecting
the anchor to the tank. In anchor designs that utilize more than one mechanically fastened
connection in each leg, the 70% requirement need only apply to the connection limited in the
original design to not exceed 70% of the shear strength of the welded connection between the tank
and the anchor.
21.1.2.2 The shear strength of the connection must be equal to the shear strength of the
connection it replaced. Refer to Chapter 5, paragraph 5.2, for design and installation criteria of
allowable fasteners. Do not recalculate Su.
21.1.2.3 If it is necessary to rework the fastener hole, the final diameter must be reamed. In any
case, the diameter of the resulting hole must not be greater than 1/16 in. (1.59 mm) larger than
the nominal diameter of the fastener.
21.1.2.4 If the resulting connection has unused fastener holes, they must be closed by welding or
with cover plates. When choosing holes to eliminate, do not eliminate consecutive holes or end
holes.
22.0 REPAIRS TO FIRE-DAMAGED TANK CAR TANKS
22.1 Requirements
22.1.1 Parts or portions of a tank car tank that have been exposed to fire or heat sufficient to
render their performance unsafe must be replaced.
22.1.2 Unsafe parts or portions must be identified by physical testing of removed material or by
evaluation of the physical condition of materials on the tank car tank, such as paint film,
insulation, gasket materials, surface oxidation film, etc.
22.1.3 Detailed evidence of the safe condition of any part or portion of the tank car tank that is to
be retained in service must be submitted for approval using Form AAR 4-2.
22.1.4 All valves and fittings must be removed, overhauled, and tested according to the valve
manufacturers instructions for suspected overheating.
11/2014 C-III [M-1002] 397

APPENDIX R M-1002
23.0 REPAIRS TO TAPPED HOLES

23.1 Requirements
Tapped holes in flanges or cover plates that are damaged mechanically or by corrosion may be
repaired using thread inserts, provided the following conditions are met:
23.1.1 Insert installation is to be in accord with manufacturers specifications.
23.1.2 Insert material is to be compatible with commodity service.
23.1.3 After drilling out damaged threads, the metal surface is to be free of defects before
retapping for the insert.
23.1.4 Nominal thread size of the insert is to match the original size of the existing tapped hole.
Oversized holes are not permitted.
23.1.5 Each modified hole must be tested by application of the carbon steel or strain-hardened
stainless steel stud, which is to be loaded to the lower of the following:
23.1.5.1 55% of the minimum tensile strength (lb) of the stud, which may be evaluated as either
the tensile strength of the stud (lb) from the specification for studs/bolts;
or
the tensile strength of the stud material (psi) from the specification for the stud/bolt
material, multiplied by the stress area (i.e., the area corresponding to the minor diameter)
of the stud/bolt.
23.1.5.2 The load that results in a shear stress equal to 40% of the yield strength (psi) in tension
of the flange/cover parent metal, evaluated at the outside diameter of the insert.
P = 0.4DtSy or
= 1.25 DtSy
where
P = load (lb)
D = outside diameter of insert (in.)
t = depth of original threads (in.)
Sy = yield strength of flange/cover material
Testing must be done using a direct tension indicator, following manufacturers specifications for
use, or using a calibrated torque wrench.
C-III [M-1002] 398 11/2014

M-1002 APPENDIX R
24.0 WELDING TO TANK CAR TANKS

24.1 Welding to Carbon Steel Tank Car Tanks after Unit PWHT
When additional welding is found necessary following unit postweld heat treatment, the following
applies for carbon steel tank car tanks as categorized in Table R.2. See paragraph 4.0 in this
appendix for additional AHF tank car tank repair requirements. (Note: hydrostatic testing may be
used in addition to NDT methods but not in place of NDT; see paragraph 20.0.)
Table R.2 Processing additional welding to carbon steel tank car tanks
Welding PT or MT after removal
Purpose of imperfection and PT or MT RT or UT
Car Category Code prior to welding after welding a/,b/ PWHT
Pressure cars A Yesc/ Yesc/ Yes Yes
B Yesc/ Yesc/ No Yes
C No No No No
D No No No Yes
E No No No Yes
F No No No Yes
H No No Yesd/ Yes
I No No Yes Yes
J Yes No No Yes
Nonpressure cars or the A Yesc/ Yesc/ Yese/ Yesf/

portions thereof built from B Yesc/ Yesc/ No Yesf/
carbon steel materials other
C No No No No
than TC-128
D No No No No
E No No No Yesf/
F No No No Yese/,f/,g/
H No No No Yesf/
I No No Yese/ Yesf/
J Yes No No Yesf/,g/
Nonpressure cars, or the A Yesc/ Yesc/ Yese/ Yesf/

portions thereof built from B Yesc/ Yesc/ No Yesf/
TC-128
C No No No No
D No No No Yesf/
E No No No Yesf/
F No No No Yesf/
H No No No Yesf/
I No No Yese/ Yesf/
J Yes No No Yesf/
a/ If tank material is type 430A, repair welds and intersections of all longitudinal and
circumferential double-welded butt joints in the tank must be radiographic or ultrasonic
tested after postweld heat treatment.
b/ When uniform inserts, tank sections, or heads are being welded on a series of tanks of the
same material using the same welding procedures and practices as in new construction, the
inspection must comply with Appendix W, paragraph 18.0.
11/2014 C-III [M-1002] 399

APPENDIX R M-1002
c/ If repair is within 4 ft (1219 mm) of bottom longitudinal centerline

d/ See Appendix W paragraph 18.0 for inspection requirements
e/ Not required for tank car tanks steel stamped to AAR specifications unless the steel-stamped
AAR tank material is TC-128, then Note f applies.
f/ A welding procedure with a minimum 300 F (149 C) preheat and interpass temperature may
be used in lieu of postweld heat treatment.
g/ If fillet weld size exceeds 5/16 in. (8 mm) or length exceeds 24 in. (610 mm)
24.1.1 Welding to Aluminum and Stainless Steel Tank Car Tanks after Hydrostatic
Testing
When additional welding is found necessary following hydrostatic testing, the following applies for
tank car tanks fabricated from materials listed in Tables M.10.2 and M.10.3.
Table R.3 Processing additional welding to aluminum and stainless steel tank car tanks
Welding PT after removal of
Purpose imperfection and prior PT RT or UT
Car Category Code to welding after welding a/
All cars A Yesb/ Yesb/ Yes

B Yesb/ Yesb/ No
C No No No
D No No No
E No No No
F No No No
H No No No
I No No Yes
J Yes No No
a/ When uniform inserts, tank sections, or heads are being welded on a series of
tanks of the same material using the same welding procedures and practices as
in new construction, the inspection must comply with Appendix W,
paragraph 18.0.
b/ If repair is within 4 ft (1219 mm) of bottom longitudinal centerline
C-III [M-1002] 400 11/2014

M-1002 APPENDIX R
24.1.2 Welding Purpose Code
Code Description
A Repair defective areas (after preparation for welding) greater than 3/16 in. (5 mm) deep,
of any width and length.
B Repair defective areas (after preparation for welding) equal to or less than 3/16 in.
(5 mm) deep, of any width and length.
C Weld to nozzles and flanges (when welding to the tank shell or head is involved, see
Welding Purpose Code F and/or H).
D Repair exterior coil fillet weld with weld length 6 in. (152 mm) or less.
E Repair exterior coil fillet weld with weld length over 6 in. (152 mm).
F Add or replace attachments to tank head or tank shell by fillet welding or stud welding
(including temporary welds).
H Add or replace attachments to tank head or tank shell by groove welding.
I Groove-welded inserts.
J Repair of attachment fillet welds.
24.1.3 Local Postweld Heat Treatment
Local postweld heat treatment may be used, provided that the heated area includes at least six
times the tank or head plate thickness on each side of the weld. The temperature distribution
must be controlled as follows:
24.1.3.1 Above 800 F (427 C), the rate of heating shall be no more than 400 F per hour divided
by the tank thickness in inches (5644 C divided by tank thickness in millimeters), but in no case
more than 400 F (222 C) per hour.
24.1.3.2 During the heating and cooling periods, there shall be no greater variation in
temperature than 250 F (139 C) throughout the heated area of the tank, nor shall any portion
exceed 1250 F (677 C).
24.1.3.3 During the holding period, there shall be no greater difference than 50 F (28 C)
throughout the heated area of the tank. During the holding period, the minimum temperature
throughout the heated area shall be not less than 1100 F (593 C) or greater than 1250 F
(677 C).
24.1.3.4 Above 800 F (427 C), cooling shall be done at a rate not greater than 500 F per hour
divided by the tank thickness in inches, but in no case more than 500 F (260 C) per hour. Below
800 F (427 C), the tank may be cooled in still air.
11/2014 C-III [M-1002] 401

APPENDIX R M-1002
60
Fig. R.5 Welding fractures
45
INSIDE OF TANK
Fig. R.6 Welding rivet holes
60
JOINT SEPARATION
Fig. R.7 Welding fracture that extends into riveted joint
60
JOINT SEPARATION
BACK-UP STRIP
Fig. R.8 Welding fracture that extends into riveted joint (with back-up strip)
C-III [M-1002] 402 11/2014
M-1002 APPENDIX R
Fig. R.9 Insert application in void area on compartment car
11/2014 C-III [M-1002] 403

APPENDIX R M-1002
t ACTUAL
3
" (2.38) MAX GAP
32
NOTE: MINIMUM FILLET OR GROOVE WELD SIZE " (6.35 mm)

Fig. R.10 Insert-type nozzle application (reference paragraph 14.5.4, this appendix)
C-III [M-1002] 404 11/2014

M-1002 APPENDIX R
NOTE: t MIN. TO COMPLY WITH MINIMUMS

SET BY TANK SPECIFICATION.
Fig. R.11 Lap joint nozzle application (reference paragraph 14.5.5, this appendix)
11/2014 C-III [M-1002] 405

APPENDIX R M-1002
FORM SS-1
REPORT OF TANK CAR STUB SILL INSPECTION
1. To: Car Owner 2. Reporting mark and

_____________________________________________________ Number _________________
_________________________
3. Reported by __________________________________________
4. Performed at _________________________________________ 5. Date______________________
6. Tank Car Builder _____________________________________ 7. Built Date________________
8. Current AAR Certificate ______________________________ 9. Commodity_______________
10. Constructed Tank Spec. _______________________________ __________________________
11. Stenciled Tank Spec. __________________________________ 12. Car Jacketed (Y/N)________
13. Top & Bottom Shelf Couplers (Y/N) ____________________ 14. Head Shields (Y/N)________
15. Priority Level for This Inspection: ______________________ 16. Head Braces (Y/N) ________
INSPECTION RESULTS A-END B-END
17. Any evidence of striker damage? (Y/N) _______ _______
AR AL BR BL
18. Is draft sill bent or warped? (Y/N) _____ _____ _____ _____
19. Any evidence of passed couplers?(Y/N) _____ _____ _____ _____
20. Any damage to front draft lugs? (Y/N) _____ _____ _____ _____
21. Any damage to rear draft lugs? (Y/N) _____ _____ _____ _____
22. Describe prior sill repairs ____________________________________________________________
23. Inspect for defects at welds. Note inspection method used . . . [AE = Acoustic, F = Fiber Optic,
LP = Liquid Penetrant, V=Visual, O=Other (Explain)]
METHOD A-END B-END
A1 - Pad to Tank (Transverse) ________ ________ ________
B1 - Pad to Sill (Transverse) ________ ________ ________
C1 - Brace to Sill (Transverse) ________ ________ ________
D1 - Brace to Pad (Transverse) ________ ________ ________
Other Transverse - (Describe)
_______________________________ ________ ________ ________
AR AL BR BL
A2 - Pad to Tank (Long.) _______ _______ _______ _______ _______
B2 - Pad to Sill (Long.) _______ _______ _______ _______ _______
C2 - Brace to Sill (Long.) _______ _______ _______ _______ _______
D2 - Brace to Pad (Long.) _______ _______ _______ _______ _______
Other Long. - (Describe)
_______________________________ _______ _______ _______ _______ _______
24. Describe location and nature of defects found (e.g., C23-in. crack in weld)
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
25. Disposition of Car: ____________________________________________________________________
Inspected by: ____________________________________ Title: __________________________________
/
Fig. R.12 Form SS-1 Report of Tank Car Stub Sill Inspection
C-III [M-1002] 406 11/2014
M-1002 APPENDIX R
INSTRUCTIONS FOR COMPLETING FORM SS-1

Form SS-1 reports must be typewritten or printed in a legible manner and must be submitted to
the car owner. The following instructions must be followed in filling out the report:
Line Instruction
1. Enter the company name of the car owner.
2. Enter the cars reporting mark and number.
3. List the company reporting the work that was performed.
4. List the facility and location that performed the work.
5. The date must be that on which the report was completed.
6. List manufacturer of tank car.
7. Enter the original built date of the tank car.
8. Show the most recent AAR certificate number under which the tank car is currently approved.
9. Identify the commodity to be transported in this tank car.
10. Show the tank specification, as built.
11. Show the stenciled tank specification for the tank car, as operated.
12. Enter Y (yes) or N (no) to indicate if car is jacketed.
13. Enter Y (yes) or N (no) to indicate if car is equipped with top and bottom shelf couplers.
14. Enter Y (yes) or N (no) to indicate whether car is equipped with head shields.
15. Indicate priority I for inspections required per paragraph 5.0, this appendix.
16. Enter Y (yes) or N (no) to indicate if car is equipped with head braces.
17. Enter Y (yes) or N (no) to indicate evidence of striker damage (two places).
18. Enter Y (yes) or N (no) to indicate if sill is bent or warped (four places).
19. Enter Y (yes) or N (no) to indicate evidence of sill damage due to passed couplers (four places).
20. Enter Y (yes) or N (no) to indicate evidence of damage to front lugs (four places).
21. Enter Y (yes) or N (no) to indicate evidence of damage to rear draft lugs (four places).
22. Describe prior sill repairs, if present.
23. Indicate the inspection method that was utilized to examine each weld. Refer to the
illustration. Enter Y (yes) or N (no) to indicate evidence of defects in or adjacent to the
welds A1, B1, C1, D1 (two places) or A2, B2, C2, D2 (four places). If the design incorporates
other welds, describe them and indicate the inspection method and results, as above.
A1
D2
C2 D2 D1
A1 C2
A2 A2
D1
C1
CL DRAFT B2 CL C1
B1
B2 B1
CL BOLSTER
24. Describe location and nature of defects found, reference lines 17 through 23.
25. Indicate disposition of car following the inspection (e.g., returned to service, repaired,
scrapped, etc.).
Inspector must sign the report.
11/2014 C-III [M-1002] 407

APPENDIX R M-1002
C-III [M-1002] 408 11/2014

M-1002 APPENDIX S
APPENDIX S
LOADING APPURTENANCES FOR TANK CAR
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III410
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III410
2.0 Operating Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III410
2.1 Side Operating Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III410
2.2 Top Operating Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III410
3.0 Ladders and Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III411
3.1 Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III411
3.2 Top Operating Platform Railing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III411
3.3 End Platform Safety Railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
4.0 Handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
4.1 Side Operating Platform Handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
4.2 Dome Handholds for Cars Having Side Operating Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
5.0 Pertinent Portions of AAR Interchange Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
5.1 Field Manual of the AAR Interchange Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III412
11/2014 C-III [M-1002] 409

APPENDIX S M-1002
APPENDIX S
LOADING APPURTENANCES FOR TANK CAR
1.0 INTRODUCTION
1.1 Scope
Appendix S describes AAR requirements for ladders, platforms, railings, and handholds for use by
personnel loading or unloading tank cars. Safety appliance matters, as such, are covered by DOT
under 49 CFR 231.
Effective January 1, 2015 all cars built after this date must comply with the Manual of Standards
and Recommended Practices, Section C, Standard S-2044, AAR Safety Appliance Requirements
for Freight Cars, adopted 2014.
1.2 General
All tank cars must be equipped with a suitable platform or other arrangement for loading and
unloading. There are four basic arrangements that may be applied on tank cars, as follows:
1.2.1 Any tank car may be equipped with a side operating platform located on the hand brake
side of the car as well as one dome handhold, one operating platform handhold, and one ladder.
1.2.2 Any tank car may be equipped with an operating platform surrounding the manway and
fittings used for loading and unloading, as well as one platform safety railing and two ladders, one
on each side of the car.
1.2.3 Tank cars having tanks or jackets of such diameter that the use of side ladders will exceed
the provisions of Plates B-1 and C-1 in MSRP Section C, S-2027 and S-2029, respectively, may be
equipped with a top operating platform having access by means of top running boards and two
ladders, one at each end.
1.2.4 Tank cars having two side running boards running the full length of the tank, one on each
side, above tank center line, require no operating platform.
2.0 OPERATING PLATFORMS
2.1 Side Operating Platform
Number One
Dimensions Minimum width, 7 in. (178 mm). Minimum thickness 1 3/4 in.
(44.4 mm). Length sufficient to provide access to all operating
fittings used for loading or unloading. Supporting brackets must be
steel bars, not less than 3/8 in. 2 in. (9.52 mm 50.8 mm), or
equivalent.
Location On hand brake side of car.
Application Supported to prevent sagging by brackets securely fastened to tank
or to suitable bands.
2.2 Top Operating Platform
Number One for each manway or one platform surrounding all manways.
Dimensions Not specified. Supporting brackets must be steel bars, not less than
3/8 in. 2 in. (9.52 mm 50.8 mm) or equivalent.
Location Surrounding the manway and fittings used in loading or unloading.
Access to platform may be by side ladders or by top running boards.
Application Supported to prevent sagging by brackets securely fastened to tank,
to suitable bands, or to jacket.
C-III [M-1002] 410 11/2014

M-1002 APPENDIX S
3.0 LADDERS AND RAILINGS

3.1 Ladders
Number and Location a. On car with continuous running board and side operating
platformone, on platform side.
b. On car with continuous running board and top operating
platformtwo, one on each side.
c. On car with top running boards and top operating platformtwo,
one at each end.
d. On car with side running boards above tank center linefour,
one at each end of each running board.
e. On car with top operating platform, but without running
boardstwo, one on each side.
Dimensions Stiles: steel bar, not less than 3/8 in. 2 in. (9.52 mm 50.8 mm), or
steel pipe 1 1/4 in. Sch. 80, or equivalent. Treads: steel rod,
minimum diameter, 5/8 in. (15.9 mm); minimum clear length, 14 in.
(356 mm mm); maximum spacing, 19 in. (483 mm). Minimum
clearance of treads and stiles: 2, preferably 2 1/2 in. (50.8, preferably
63.5 mm). Safety railing may be considered a ladder tread. Ladder
treads must be spaced uniformly within a limit of 2 in. (50.8 mm).
Application a. On tank cars with side running boards below tank center line
securely fastened at the bottom to the running boards.
b. On tank cars without side running boardsthe lower portion of
the ladder must be braced so as to prevent movement. Ladder at
the top must be securely fastened to the underside of operating
platform or to safety railing. If fastened to operating platform, the
ladder stiles must be securely fastened with not less than 1/2 in.
bolts, with nuts riveted over, or with not less than 1/2 in. rivets.
c. On cars with top running boards or side running boards above
tank center linesecurely fastened to running board or running
board safety railing at top and to end platform at bottom.
3.2 Top Operating Platform Railing
Location Enclosing platform. Railing must be open only at side ladders or at
top running board where it must extend vertically downward to and
be securely fastened to platform. If car is equipped with top running
board, platform railing also may be open at sides for access to
loading or unloading facilities provided opening is closed by a chain
when not in use.
Dimensions Steel pipe, 1 1/4 in. Sch. 40 pipe minimum. Maximum width of
opening, 24 in. (610 mm).
Application The safety railing must be securely attached to four stanchions, or
corner posts, which must each be securely fastened to the operating
platform with not less than two 1/2 in. bolts with nuts and riveted
over, or with not less than two 1/2 in. rivets. Arrangement must be
such that the entire safety railing assembly can be removed for
repairs.
11/2014 C-III [M-1002] 411

APPENDIX S M-1002
3.3 End Platform Safety Railing

Number Two
Dimensions Minimum 1 1/4 in. Schedule 40 steel pipe or 7/8 in. (22.2 mm)
diameter solid steel. Minimum clearance around horizontal and
vertical lengths, 2 1/2 in. (63.5 mm).
Location One safety rail at each end of car shall extend horizontally across not
less than 36 in. (914 mm) nor more than 54 in. (1372 mm) above end
platform and extend downward within 3 in. (76.2 mm) of the end
platform. The vertical leg of the safety railing must be located not
more than 6 in. (152 mm) from the inside edge of the end platform.
Application Safety railings shall be supported at center of car and at each end by
extending downward at the ends and attaching to the platform.
When safety railing is 1 1/4 in. pipe and securement involves
flattening, pipe must be reinforced with a steel pipe insert at least
11 in. (279 mm) long or twice the length of the flattened portion,
whichever is greater.
4.0 HANDHOLDS
4.1 Side Operating Platform Handholds
Number One
Dimensions Steel rod, minimum diameter, 5/8 in. (15.9 mm). Minimum clear
length, 14 in. (356 mm).
Location In line with the ladder, not more than 2 in. (50.8 mm) back from the
outside edge of platform, projecting downward and outward, with
horizontal portion of the handhold flush with or extending 1 in.
beyond edge of platform. [Top ladder tread may be considered as
operating platform handhold if located not less than 2 in. or more
than 3 in. (not less than 50.8 mm or more than 76.2 mm) from
bottom edge of platform.]
Application Securely fastened to platform with not less than 1/2 in. bolts with
nuts riveted over, or with not less than 1/2 in. rivets.
4.2 Dome Handholds for Cars Having Side Operating Platform
Number One (in lieu of safety railing specified in paragraph 3.2 above).
Dimensions Steel rod, minimum diameter, 5/8 in. (15.9 mm). Minimum clear
length, 14 in. (356 mm). Minimum clearance 2 in., preferably
2 1/2 in. (50.8 mm, preferably 63.5 mm).
Location On tanks equipped with expansion domes, handhold must be applied
on each dome body in line with the ladder. On tanks not equipped
with expansion domes, handhold must be applied on each manway
nozzle or protective housing or on the tank shell or jacket in line with
the ladder.
Application Securely fastened with not less than 1/2 in. bolts with nuts riveted
over, or with not less than 1/2 in. rivets.
5.0 PERTINENT PORTIONS OF AAR INTERCHANGE RULES
5.1 Field Manual of the AAR Interchange Rules
See Rules 53, 79, and 81 for welding requirements and restrictions applicable to tank car
appurtenances.
C-III [M-1002] 412 11/2014

M-1002 APPENDIX T
APPENDIX T
NONDESTRUCTIVE EXAMINATION
CONTENTS

1.0 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III416
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III416
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III416
1.4 Levels of Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III416
1.5 Written Practice for Qualifying and Certifying NDT Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III417
1.6 Education, Training, and Experience Requirements for Initial Certification . . . . . . . . . . . . . . . . . . C-III417
1.7 Training Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III418
1.8 Examination Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III419
1.9 Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III423
1.10 Technical Performance Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III423
1.11 Expiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III423
1.12 Interrupted Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III424
1.13 Recertification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III424
1.14 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III424
1.15 Revocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III424
1.16 Reinstatement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III424
1.17 Limited Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III425
1.18 NDT Procedure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III426
1.19 Qualification of NDT Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III426
1.20 NDT Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III427
1.21 NDT Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
1.22 Equipment Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.0 Acoustic Emissions Testing (AE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.3 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.4 Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
2.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III428
11/2014 C-III [M-1002] 413

APPENDIX T M-1002
3.0 Leak Testing (LT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III429

3.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III429
3.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III429
3.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III430
3.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III430
3.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III430
4.0 Liquid Penetrant Testing (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III431
4.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III431
4.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III431
4.4 Examinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III431
4.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
4.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
4.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
5.0 Magnetic Particle Testing (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
5.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
5.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III432
5.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III433
5.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III434
5.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III434
6.0 Radiographic Examination (RT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III434
6.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III434
6.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III435
6.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III438
6.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III440
6.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III440
7.0 Ultrasonic Testing (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III440
7.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III440
7.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III440
7.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442
7.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442
7.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442
C-III [M-1002] 414 11/2014

M-1002 APPENDIX T
8.0 Ultrasonic Thickness Testing (UTT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442

8.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442
8.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III442
8.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III443
8.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III443
8.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III443
9.0 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
9.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
9.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
9.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
9.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
9.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III444
10.0 Thermal/Infrared (IR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
10.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
10.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
10.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
10.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
10.7 Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III445
11.0 Radiographic Film Interpreter (RFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.3 Identification of Radiograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.4 Viewing Radiographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
11.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III446
12.0 Automated Ultrasonic Testing (AUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III447
12.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III447
12.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III447
12.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III448
12.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III448
12.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III448
11/2014 C-III [M-1002] 415

APPENDIX T M-1002
APPENDIX T
NONDESTRUCTIVE EXAMINATION
1.0 GENERAL REQUIREMENTS
1.1 Purpose
The purpose of this appendix is to outline the requirements of the nondestructive testing program
and the responsibilities for its administration.
1.2 Scope
This appendix contains requirements and methods for nondestructive testing and personnel
requirements when and to the extent they are specifically referenced and required by this
specification, in a tank specification, or by other referencing documents. The most commonly used
nondestructive testing methods are listed in Table T.1. Additional or alternative techniques or
methods shall be approved by the Tank Car Committee. For the purpose of this document, the
terms NDT (testing), NDE (examination or evaluation), or NDI (inspection) shall be considered
equivalent terms. When not directly covered by this specification, the ASTM Standards, Volume
03.03, Nondestructive Testing and/or ASME Section V may be used to develop nondestructive test
procedures.
1.3 Effectivity of Revisions
1.3.1 Procedures
All changes to the requirements for procedures shall be effective 6 months after publication.
1.3.2 Personnel Qualifications
All changes for the certification of personnel shall be complied with at the next certification or
6 months, whichever is later. This includes all current requirements.
1.4 Levels of Qualification
Levels of qualification are defined in terms of skills and knowledge required in a given method or
methods to perform specified NDT activities.
1.4.1 Level III: A Level III shall have the skills and knowledge to establish techniques; interpret
codes, standards, and specifications; designate the particular technique to be used; and verify the
adequacy of procedures. The Level III shall ensure that the procedures cover the particular type of
work to be performed to meet the end product requirements. The individual also shall have
general familiarity with the NDT methods. The Level III shall be capable of conducting or
directing the training and examining of NDT personnel in the methods for which the Level III is
qualified. An NDT Level III shall be responsible for the administration of the NDT program as
described in this paragraph. An AWS CWI, SCWI, or CSA 178.2 can function as a Level III for
visual weld inspection. An AWS CWI, SCWI, or CSA 178.2 can function as a Level III for remote
visual inspection if they have received documented training in the set-up, operation, and use of
remote visual equipment. The level of training shall be defined in the companys written practice.
The individual shall ensure that the visual procedures cover the particular type of work to be
performed to meet the end product requirements.
1.4.2 Level II: A Level II shall have the skills and knowledge to set up and calibrate equipment;
conduct tests; and interpret, evaluate, and document results in accordance with procedures
approved by an NDT Level III. The Level II shall be thoroughly familiar with the scope and
limitations of the method to which certified. The Level II shall be capable of directing the work of
trainees and Level I personnel and shall be able to organize and report nondestructive testing
results.
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M-1002 APPENDIX T
1.4.3 Level I: A Level I shall have the skills and knowledge to properly perform specific
calibrations and tests, and with a prior written approval of the NDT Level III, to perform specific
interpretations and evaluations for acceptance or rejection and document the results in accordance
with specific approved procedures. The Level I shall be able to follow approved nondestructive
testing procedures and shall receive the necessary guidance or supervision from a certified NDT
Level II or NDT Level III individual.
1.4.4 Trainee: A person who is not yet certified to any level shall be considered a trainee.
Trainees shall work with a certified person under the direction of an NDT Level II or NDT Level
III and shall not independently conduct any tests or complete a report of test results.
1.4.5 Qualification for visual weld inspection shall be in accord with the requirements set forth in
Appendix T, paragraph 9.0.
1.5 Written Practice for Qualifying and Certifying NDT Personnel
All nondestructive testing shall be performed by personnel qualified and certified in accord with a
written practice. The written practice shall describe the program for the control and
administration of NDT personnel training, examination, and certification modeled on this
appendix and on ASNT SNT-TC-1A. The written practice shall be reviewed and approved by the
NDT Level III and shall include, as a minimum, the following:
Levels of qualification
Duties and responsibilities of each level of certification for determining the acceptability of
materials or components in accord with applicable codes, standards, specifications, and
procedures
Initial and refresher training requirements
Personnel experience requirements
Education requirements
Personnel examination requirements
Record and documentation requirements, including control, responsibility, and retention
(training and initial experience will be documented)
Recertification requirements
Visual acuity requirements
1.6 Education, Training, and Experience Requirements for Initial Certification
1.6.1 Candidates for initial certification in NDT should have sufficient education, training, and
experience to ensure qualification in those NDT methods in which they are being considered for
certification. Documentation of prior certification may be used by an employer as evidence of
qualification for comparable levels of certification.
1.6.2 The minimum education, training, and experience requirements for NDT Level I and
Level II personnel shall be stated in the companys written practice.
1.6.3 To be considered for certification, the NDT Level III candidate must satisfy one of the
following criteria:
1.6.3.1 A graduate from a minimum 4-year college or university curriculum with a degree in
engineering or science, plus one additional year of experience beyond the Level II requirements in
the applicable NDT method(s); or
1.6.3.2 Have completed with passing grades at least 2 years of engineering or science study at a
university, college, or technical school, plus two additional years of experience beyond the Level II
requirements in the applicable method(s); or
1.6.3.3 Have 4 years of experience beyond the Level II requirements in the applicable NDT
method(s).
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APPENDIX T M-1002
1.7 Training Programs

1.7.1 An NDT instructor shall have the skills and knowledge to plan, organize, and present
classroom, laboratory, demonstration, and/or on-the-job training and/or education programs in
accordance with a course approved by an NDT Level III.
1.7.2 Personnel being considered for initial certification should complete sufficient organized
training to become thoroughly familiar with the principles and practices of the specified NDT
method related to the level of certification desired and applicable to the processes to be used and
products to be tested.
1.7.3 Presentation of Training
An NDT instructor or NDT Level III shall present all training. The NDT instructor may use
personnel with specialized expertise (for example, metallurgists, welding engineers, etc.) who are
not qualified in accordance with this standard to assist in presentation of specific information. The
NDT Level III shall approve and be responsible for the content of the completed course.
1.7.4 Previous Training and Experience
Level I and Level II: A candidates previous training and experience may be accepted by the
employer if verified and documented by the previous employer(s) or, for training, by the previous
training agency(ies). Any claimed training and experience that cannot be verified and documented
shall be considered invalid.
1.7.5 NDT Instructor
The NDT instructor shall be approved by an NDT Level III. The approval shall be documented.
1.7.6 Outside Services
At the option of the employer, an outside agency may be engaged to perform the duties of an NDT
Level III. In such instances, the employer shall be responsible for evaluating the outside agency to
ensure that the services are in accordance with the employers written practice and this standard,
and so documented.
1.7.7 Training
Training of NDT personnel shall be conducted in accord with a course outline approved by an NDT
Level III. The course should include topics deemed necessary by the NDT Level III for the
particular applications to be performed. The sequence, content, amount of time spent, and depth of
coverage for each topic shall be approved by the NDT Level III. Training programs shall include
examinations, as described in the written practice, to demonstrate that the necessary information
has been comprehended.
1.7.7.1 Additional topics may be presented as deemed necessary by the NDT Level III for the
particular applications to be performed. The sequence, content, amount of time spent, and depth of
coverage for each topic shall be approved by the NDT Level III. Training programs shall include
written and practical examinations to demonstrate that the necessary information has been
comprehended.
1.7.7.2 Portions of recommended training topics contained in CP-105 that address only the
individual techniques for which certification is being sought may be used at the discretion of the
NDT level III.
1.7.7.3 The minimum number of hours of training and experience required for NDT Level I and
NDT Level II candidates are described in Table T.3.
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M-1002 APPENDIX T
1.8 Examination Requirements

1.8.1 Written and Practical Examinations for Level I and Level II Certifications
A three-part examination shall be administered as outlined below.
1.8.1.1 General: A general written examination shall be approved by an NDT Level III.
Administration of the examination shall be in accordance with this standard and shall be closed
book. Reference material, such as charts, formulas, tables, and graphs, may be provided by the
NDT Level III. Questions shall be developed that represent a cross-section of the body of
knowledge applicable to each method and level. The minimum number of questions required for
each method and level is listed in Table T.1.
1.8.1.2 Specific: A specific written examination shall be approved by an NDT Level III.
Administration shall be in accordance with this standard. The NDT Level III shall determine
whether appropriate procedures, specifications, standards, or code sections will be provided. The
examination shall address various examples of equipment, procedures, and test techniques that
the candidate may use in the performance of assigned duties. The minimum number of questions
required for each method and level is listed in Table T.2.
1.8.1.3 Practical: A practical examination shall be approved by an NDT Level III.
Administration shall be in accordance with this standard. The test piece(s) used for the practical
exam, whether actual or samples, shall contain at least one flaw per piece. The practical
examination shall consist of the following:
1.8.1.3.1 Level I Practical Exam: The candidate shall demonstrate proficiency using the
applicable nondestructive test method to examine at least one test sample for each technique to be
used in the candidates job and by documenting the results of the examination. At least 10
different checkpoints requiring an understanding of the test variables and the employers
procedural requirements should be included in this practical examination.
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APPENDIX T M-1002
1.8.1.3.2 Level II Practical Exam: The candidate shall demonstrate proficiency by performing
the applicable nondestructive test method in examining at least one sample per technique and a
minimum of two samples per method and by interpreting, evaluating, and documenting the results
of the examination. At least 10 different checkpoints requiring an understanding of the test
variables and the employers procedural requirements should be included in this practical
examination.
Table T.1 General examination

Minimum Number of Questions
Method Level I Level II
1 Acoustic Emission 40 40
2 Leak Testing:
3 Bubble 10 10
4 Pressure Change 20 20
5 Halogen Diode 20 20
6 Mass Spectrometer 20 20
7 Chemical Reactivity 10 10
8 Liquid Penetrant 30 30
9 Magnetic Particle 30 30
10 Radiography 40 40
10A Radiographic Film Interpreter N/A 40
11 Ultrasonic 40 40
12 Ultrasonic Thickness 10 10
13 Visual Inspection:
14 Remote Visual 30 30
15 Weld Inspection 30 70
16 Thermal/Infrared 20 20
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M-1002 APPENDIX T
Table T.2 Specific examination

Minimum Number of Questions
Method Level I Level II
1 Acoustic Emission 20 20
2 Leak Testing:
3 Bubble 10 10
4 Pressure Change 15 15
5 Halogen Diode 15 15
6 Mass Spectrometer 20 15
7 Chemical Reactivity 10 10
8 Liquid Penetrant 20 15
9 Magnetic Particle 20 15
10 Radiography 20 20
10A Radiographic Film Interpreter N/A 40
11 Ultrasonic 20 20
12 Ultrasonic Thickness 10 10
13 Visual Inspection:
14 Remote Visual 20 20
15 Weld Inspection 20 20
16 Thermal/Infrared 20 20
1.8.2 Administration and Grading

1.8.2.1 An NDT Level III shall be responsible for the administration and grading of examinations
specified in the employers written practice for NDT Level I, II, or other Level III personnel. The
administration and grading of examinations may be delegated to a qualified representative of the
NDT Level III and documented. A qualified representative of the employer may perform the actual
administration and grading of Level III examinations.
1.8.2.2 For Level I and II personnel, a composite grade should be determined by simple averaging
of the results of the general, specific, and practical examinations described below. For Level III
personnel, the composite grade should be determined by simple averaging of the results of the
basic, method, and specific examinations described below.
1.8.2.3 Examinations administered for qualification should result in a passing composite grade of
at least 80%, with no individual examination having a passing grade less that 70%.
1.8.2.4 The employer who retains outside services is responsible for ensuring that the
examination services meet the requirements of the employers written practice.
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APPENDIX T M-1002
1.8.3 Vision Examinations

1.8.3.1 Near distance: NDT personnel shall be examined to ensure that they have natural or
corrected near-distance visual acuity in at least one eye such that each individual is capable of
reading a Jaeger Number 2 test chart or equivalent at a distance of not less than 12 in. The vision
examination shall be administered prior to certification and annually thereafter.
1.8.3.2 Color Contrast Differentiation: Color perception is desirable in some applications but
is not considered essential for all applications. It shall be the employers responsibility to establish
color perception requirements in the written practice.
1.8.3.3 Visual acuity examinations shall be administered in accord with a written procedure by
an oculist, optometrist, or other professionally recognized person or by personnel approved by the
NDT Level III.
1.8.4 Level III Examination
1.8.4.1 Basic Examination
NDT Basic Examination (required only once when more than one method examination is taken).
The minimum number of questions that should be given is as follows:
Fifteen questions relating to understanding of SNT-TC-1A or Appendix T
Twenty questions relating to applicable materials, fabrication, and product technology
Twenty questions that are similar to published Level II questions for other appropriate
NDT methods
1.8.4.2 Method Examination (for each method)
Thirty questions relating to fundamentals and principles that are similar to published
ASNT Level III questions for each method
Fifteen questions relating to application and establishment of techniques and procedures
that are similar to the published ASNT Level III questions for each method
Twenty questions relating to capability for interpreting codes standards and specifications
relating to the method
1.8.4.3 Specific Examination (for each method)
Twenty questions relating to specifications, equipment, techniques, and procedures
applicable to the employers product(s) and methods employed and to the administration of
the employers written practice.
The employer may delete the specific examination if the candidate has a valid ASNT Level III
certificate in the method and if documented evidence of experience exists, including the
preparation of procedures to codes, standards, or specifications and the evaluation of test results.
1.8.4.4 A valid endorsement on an ASNT Level III certificate fulfills the examination criteria
described in paragraphs 1.8.4.1 and 1.8.4.2 for each applicable method.
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M-1002 APPENDIX T
1.9 Certification
1.9.1 Certification of all levels of NDT personnel is the responsibility of the employer.
1.9.2 Certification of NDT personnel shall be based on demonstration of satisfactory qualification
in accordance with paragraphs 1.6 and 1.7 and stated written practice. Certifications that are
recognized by the employers written practice, including ASNT, ACCP, or CGSB certification, must
be qualified by examination as administered by the governing organizations.
1.9.3 A subcontract Level III (for the method) may be engaged by the employer to administer the
Level III examination requirements of paragraph 1.8.4. The employer shall certify the Level III
candidate for each applicable method based upon a valid endorsement by the subcontract Level III
in the method. The employers subcontractor who administers the Level III exam shall possess a
current ASNT, ACCP, or CGSB Level III certificate in the method for which the examination is
administered and shall be knowledgeable and familiar with the standards, specifications, and
products used or made by the employer.
1.9.4 Certification Records
Personnel certification records shall be documented by the employer for the duration specified in
the employers written practice and should include the following:
Name of certified individual
Level of certification and NDT method and any limitation or restriction
Educational background and experience of certified individuals
Statement indicating satisfactory completion of training in accordance with the employers
written practice
Results of vision examinations prescribed in paragraph 1.8.3
Current examination copy(ies) or evidence of successful completion of examinations
Other suitable evidence of satisfactory qualifications when such qualifications are used in
lieu of the specific examination as prescribed in the employers written practice
Composite grade(s) or suitable evidence of grades
Approval of the Level III that verified qualifications of candidate for certification
Date of certification and/or recertification
Certification expiration date
Approval of employers certifying authority
1.10 Technical Performance Evaluation
1.10.1 NDT personnel may be reexamined any time at the discretion of the employer and have
their certificates extended or revoked.
1.10.2 Periodically, as defined in the employers written practice, the technical performance of
Level I and II personnel shall be evaluated and documented by an NDT Level III or their designee.
The evaluation and documentation shall follow the format and guidelines described in the written
procedure.
1.11 Expiration
An individuals certifications shall expire
when employment with employer is terminated;
at the end of 3 years for NDT Level I and Level II individuals;
at the end of 5 years for NDT Level III individuals.
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APPENDIX T M-1002
1.12 Interrupted Service

1.12.1 The employers written practice should include rules covering the types and duration of
interrupted service.
1.12.2 The written practice should specify the requirements for reexamination and/or
recertification for the interrupted service.
1.13 Recertification
1.13.1 All levels of NDT personnel shall be recertified periodically in accordance with one of the
following criteria:
Evidence of continuing satisfactory technical performance
Reexamination of those portions of the examinations in paragraph 1.8 deemed necessary
by the employers Level III
Refresher training covering topics deemed necessary by the employers Level III
1.13.2 Maximum recertification intervals shall be as follows:
Levels I and II3 years
Level III5 years
1.14 Suspension
The employer shall suspend an individuals certification under any of the following situations:
The vision examination interval has been exceeded. Certification is reinstated
concurrently with passing the vision reexamination.
The individuals performance is determined to be deficient in the required method or
technique for specific documented reasons.
An individuals conduct is deemed by the employer to be or have been unethical or
incompetent.
1.15 Revocation
1.15.1 The employees certification shall be deemed revoked when employment is terminated.
1.15.2 A Level I, Level II, or Level III whose certification has been terminated may be certified to
the former NDT level by a new employer based on examination, as described in paragraph 1.8
provided all of the following conditions are met to the new employers satisfaction:
The employee has proof of prior certification.
The employee was working in the capacity to which certified within 6 months of
termination.
The employee is being recertified within 6 months of termination.
1.15.3 Prior to being examined for certification, employees not meeting the above requirements
should receive additional training as deemed appropriate by the Level III.
1.16 Reinstatement
A Level I, Level II, or Level III whose certification has been terminated may be reinstated to the
former NDT level without a new examination provided all of the following conditions are met:
The employer has maintained the personnel certification records required in
paragraph 1.9 above.
The employees certification did not expire during termination.
The employee is being reinstated within 6 months of termination.
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M-1002 APPENDIX T
1.17 Limited Certification

Limited certification of NDT personnel who do not perform all of the operations or techniques of an
NDT method that consists of more than one operation or technique, or who perform NDT of limited
scope, may be based on fewer hours of training and experience than recommended in Table T.3.
The minimum requirements for limited certification shall be described in the companys written
practice. Any limitations or restrictions placed upon a qualified person shall be described on the
certification.
Table T.3 Minimum initial training and experience requirements
Examination Training Hours Experience Required
Method Technique Level Requirements (Months / Hours)
I 40 4 / 280
Acoustic emission
II 16 8 / 560
I 2 2 hours
Leak testing BT
II 4 .5 / 35
I 8 1.5 / 105
Leak testing PCT
II 4 4 / 280
I 12 1.5 / 105
Leak testing HDLT
II 8 4 / 280
I 40 4 / 280
Leak testing MSLT
II 24 6 / 420
I 2 2 hours
Leak testing CRLT
II 4 .5 / 35
I 4 1 / 70
Liquid penetrant
II 8 2 / 140
I 12 1 / 70
Magnetic particle
II 8 3 / 210
I 39 3 / 210
Radiography
II 40 9 / 630
Radiographic Film Interpretera/ II 18 22 hours
I 40 3 / 210
Ultrasonic
II 40 9 / 630
I 4 40 hours
UltrasonicThickness UTT
II 8 80 hours
Welding I 16 1/70
Visual
Inspection II 16 2/140
I 8 1 / 70
Visual RVIb/
II 16 3 / 210
I 8 40 hours
Thermal/Infrared
II 8 80 hours
a/ A certified RT Level I require 2 hours of formal refresher training and
22 hours of interpretation of radiograph experience to become an RFI.
b/ Must be VT-certified as a prerequisite for RVI certification.
NOTES:
1. TECHNIQUES:
2. INITIAL EXPERIENCE MAY BE GAINED SIMULTANEOUSLY IN TWO OR MORE METHODS IF THE
BTBUBBLE TEST
CANDIDATES SPEND A MINIMUM OF 25% OF WORK TIME ON EACH METHOD FOR WHICH
PCTPRESSURE CHANGE TEST
CERTIFICATION IS SOUGHT. THE REMAINDER OF THE WORK TIME CLAIMED AS EXPERIENCE IS SPENT
HDLTHALOGEN DIODE LEAK TEST
IN NDT-RELATED ACTIVITIES AS DEFINED IN THE EMPLOYERS WRITTEN PRACTICE.
MSLTMASS SPECTROMETER LEAK TEST
3. FOR CERTIFICATION DIRECTLY TO LEVEL II WITH NO TIME AT LEVEL I, THE TRAINING AND EXPERIENCE
CRLTCHEMICAL REACTIVITY LEAK TEST
HOURS SHALL BE THE SUM OF TIME REQUIRED FOR LEVEL I AND LEVEL II.
RVIREMOTE VISUAL INSPECTION
UTTULTRASONIC THICKNESS TEST
VT VISUAL TESTING
IRTHERMAL INFRARED
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APPENDIX T M-1002
1.18 NDT Procedure Requirements

All nondestructive testing shall be performed in accord with a written procedure. NDT Procedures
shall be approved by an NDT Level III certified in the method and qualified in accordance with
paragraph 1.19. The procedure shall include, as a minimum, all of the requirements of this
appendix, including the requirements of this paragraph and the applicable method section. The
parameters for essential and nonessential variables shall be stated in the procedure.
Paragraph 1.19 describes the requirements for the qualification of NDT procedures. In addition to
the method section, the procedure shall, as a minimum, contain the following:
Requirements Essential Variable Nonessential Variable

Personnel requirements x
Responsibility requirements x
Techniques on how inspection is to be performed x
Surface preparation requirements x
Calibration requirements x
Specific equipment requirements (type or model, if applicable) x
Temperature constraints x
Acceptance criteria x
Report and data requirements, including forms x
Post-examination cleaning requirements x
Procedure qualification requirements, including sensitivity and reliability x
Method and technique limitations and special requirements x
1.19 Qualification of NDT Procedures

1.19.1 The NDT Level III shall be responsible for the qualification and the technical approval of
all NDT procedures, repairs, and service-related testing.
1.19.1.1 An individual certified to AWS CWI, SCWI, or CSA W178.2 can approve visual weld
inspection procedures.
1.19.2 Documentation of NDT Examinations
Figs. T.2 through T.7 or other equivalent forms that meet the requirement of paragraph 1.19 shall
be used for the purpose of documenting NDT examinations.
1.19.3 Qualification Specimen
The item to be examined during the qualification may be a component or a specimen not intended
for service. The specimen must contain either actual or simulated known discontinuities.
1.19.4 Demonstration
1.19.4.1 The demonstration requires a minimum of two individuals: a Level III witness and at
least one Level II or Level III demonstrator.
1.19.4.2 The demonstration examination of the selected specimen shall be conducted by a Level
II or Level III who is certified in the method of the procedure being qualified. The demonstration
shall be performed in accordance with the procedure being qualified.
1.19.4.3 An NDT Level III shall witness the demonstration of the procedure. This individual does
not perform the demonstration examination.
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M-1002 APPENDIX T
1.19.4.4 Results of the procedure demonstration shall be documented using an NDT Procedure
Qualification Record having spaces to record the procedure identification, signatures, and date. In
addition, the applicable NDT report form referenced in the procedure being qualified shall be
completed and shall describe the demonstration specimen and results.
1.19.4.5 The NDT procedure is considered qualified when the results of the demonstration
indicate the ability to detect discontinuities to the satisfaction of the NDT Level III. An NDT Level
III witness and the individual(s) who performed the demonstration examination shall sign the
Procedure Qualification Record form.
1.19.4.6 All records of the demonstration shall be documented.
1.19.4.7 If a documented probability of detection study (POD) has been performed for the NDT
method, the results will satisfy the procedure demonstration requirements of paragraph 1.19. A
procedure qualification record (PQR) must still be completed (see Fig. T.1 on page C-III449).
1.19.5 Essential Variables
1.19.5.1 A change in those NDT parameters considered essential requires a new qualification
and demonstration of the NDT procedure.
1.19.5.2 A change of a requirement identified as a nonessential variable does not require
requalification of the NDT procedure.
1.19.5.3 All changes of essential or nonessential variables from the parameters specified by the
NDT procedure shall require revision of, or addendum to, the procedure.
1.20 NDT Reports
1.20.1 All nondestructive testing performed as required by the referencing specification shall be
documented. In addition to the requirements of the method section, the report shall contain the
following information:
Procedure used
Examiner identification
Date examination was performed
Facility responsible for test
NDT method
NDT equipment identification number traceable to a calibration record, where applicable.
Test specimen identification
Examination results
1.20.2 The following shall be either contained on the report or specifically identified in the
procedure:
Technique
Specific equipment and materials used
Equipment test settings, where applicable
Surface preparation, if required
Post-examination cleaning, if required
1.20.3 NDT reports shown in the figures in the back of this appendix, or other forms that meet
the requirement of paragraph 1.20, shall be used for the purpose of documenting NDT
examinations.
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APPENDIX T M-1002
1.21 NDT Inspection Records

All records shall be maintained as required by the referencing specification.
1.22 Equipment Calibration
All NDT equipment calibration required by this specification shall be in accord with the AAR
Manual of Standards and Recommended Practices, Section J, Specification M-1003; and with the
companys QA calibration requirements.
2.0 ACOUSTIC EMISSIONS TESTING (AE)
2.1 Procedures
AE testing shall be in accord with an Association of American Railroads (AAR) written procedure.
2.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
2.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration).
2.4 Examination
Acoustic emission examinations shall be performed in accord with the provisions of the approved
procedure.
2.5 Evaluation
All examinations shall be evaluated to the acceptance standards of the approved procedure.
2.6 Reports
At a minimum, acoustic emission test reports shall meet the requirements of paragraph 1.20.
2.7 Records
Calibration and examination records shall be maintained by the owner per the latest edition of the
approved AE testing procedure.
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M-1002 APPENDIX T
3.0 LEAK TESTING (LT)

3.1 Procedures
Written procedures for leak testing shall include as a minimum the following:

All the provisions of paragraph 1.18 above (NDT Procedure
Requirements)
Type of equipment to be used for detecting leaks or measuring leakage x
rates
Acceptable test sensitivity or leakage rate x
Pressure, pressurizing medium, and percentage concentrations to be x
used
Hold/soak and dwell time x
Leak detector fluid and percentage concentrations, if applicable x
Pressure gauge and temperature measuring device range PCT BT, HDLT
MSLT, CRLT
Tracer gas(es) and percentage concentrations, if applicable x
Report and data requirements, including forms x
3.2 Personnel
3.3 Calibration
3.4 Examination
3.4.1 Bubble Leak Testing (BT) (Liquid Film Solution Technique)
3.4.1.1 The bubble-forming solution shall produce a film that does not break away from the area
to be tested, and the bubbles formed shall not break rapidly as a result of to air drying or low
surface tension. Household soap or detergents are not permitted as substitutes for bubble-testing
solutions.
3.4.1.2 The leak-test solution must be suitable for the ambient temperature of the test. Local
heating or cooling is permitted, provided that the examination area and the solution remain in the
correct temperature range throughout the examination.
3.4.1.3 Application of bubble-forming solution can be any suitable method; however, bubbles
produced by the application of the solution should be minimized.
3.4.1.4 A sufficient hold/soak and dwell time shall pass prior to evaluation.
3.4.1.5 Continuous bubble growth on the surface of the object being tested indicates leakage in
the region of examination.
3.4.2 Bubble Leak Testing (BT) (Immersion Technique)
3.4.2.1 Immersion bath fluid may be water or any other suitable solution.
3.4.2.2 Immersion of the inspection area should be performed so as to minimize formation of
bubbles on the surface.
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APPENDIX T M-1002
3.4.3 Pressure Change Test (PCT)

3.4.3.1 Gauges used to monitor pressure change are to be compatible to the sensitivity
requirements of the method.
3.4.3.2 The test is to be performed in an area that will minimize changing thermal effects.
3.4.3.3 The pressurizing medium shall be introduced and allowed to reach thermal equilibrium
prior to the examination.
3.4.4 Halogen Diode Detector Leak Test (HDLT)
3.4.4.1 When using this technique, precautions should be taken to prevent release of halogen
tracer gases to the atmosphere.
3.4.4.2 The provisions of ASME Section V, Article 10, Mandatory Appendix III shall be observed.
3.4.4.3 Due to similarity in method of test, thermal conductivity leak-detection probes may be
used with non-halogen gases. The test method shall comply with paragraph 3.4.4.2 above.
3.4.5 Helium Mass Spectrometer Leak Test (MSLT)
The provisions of ASME Section V, Article 10, Mandatory Appendix IV or V shall be observed.
3.4.6 Chemical Reactivity Leak Test (CRLT)
3.4.6.1 This leak indicator technique depends on a chemical reaction between a tracer gas and
chemical reagent or developer to produce visible leak indications, such as a white fog or mist.
3.4.6.1.1 The tracer can be either gaseous or liquid, such as chlorine, ammonia, or hydrogen
sulfide. The addition of a tracer gas is not required if it is inherent, in sufficient concentration, in
the commodity being tested.
3.4.6.1.2 The chemical reagent or developer shall have the ability to react with the tracer and
indicate visibly. The reaction shall be of sufficient color contrast between reacted and unreacted
areas.
3.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
3.6 Reports
3.6.1 Leak test reports shall meet the requirements of paragraph 1.20. In addition, the following
shall be either contained on the report or specifically identified in the test procedure:
Test conditions and test pressure
Gas, liquid, or medium type and concentration
Temperature range requirements
Gauge(s) identification
Surface temperature of component being tested
Temperature measuring device(s) identification number(s)
3.7 Records
Records shall be maintained as required by the referencing specification.
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M-1002 APPENDIX T
4.0 LIQUID PENETRANT TESTING (PT)

4.1 Procedures
Written procedures shall include at least the following:

Requirements)
Cleaning dry-time per paragraph 4.4.3. x
Type of penetrant material x
Penetrant dwell time and developer time x
Post-examination cleaning requirements x
4.2 Personnel
4.3 Calibration
4.3.1 Equipment calibration shall be in accord with paragraph 1.22 above (Equipment
Calibration).
4.3.2 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 W/cm2 shall be required on the surface of the part being examined. The
intensity of the ultraviolet light shall be measured prior to the start of the inspection and at least
once every 8 hours during the inspection.
4.4 Examinations
4.4.1 Surface preparation may be necessary where contamination or irregularities could mask
indications. Any suitable mechanical process may be used to prepare the surface. The mechanical
integrity of the object of examination shall not be reduced by this process, and all requirements of
the referencing specification must be satisfied after the process is complete.
4.4.2 The surface to be examined and all adjacent areas within 1 in. of the area to be examined
shall be dry and free of dirt, grease, lint, scale, welding flux, spatter, oil, or other matter that could
cause interference with the examination. Cleaning methods shall not impair the chemical or
mechanical integrity of the object of examination.
4.4.3 After cleaning, drying of the surfaces to be examined shall be accomplished by normal
evaporation or with forced hot or cold air. Procedures shall establish a minimum period of time in
order to ensure that the cleaning solution has evaporated prior to application of the penetrant.
4.4.4 Special care is warranted when penetrant-testing nickel base alloys, austenitic stainless
steels, and titanium. When these materials are to be tested, the provisions of ASME Section V,
Article 6 shall be strictly observed for the control of contaminants.
4.4.5 Either a color contrast (visible) penetrant or a fluorescent penetrant shall be used with one
of the following penetrant processes:
Water washable
Post-emulsifying
Solvent removable
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APPENDIX T M-1002
4.4.6 Fluorescent penetrant examinations shall be performed using an ultraviolet light.

Fluorescent penetrant examination shall be performed in a darkened area. Personnel performing
the fluorescent penetrant examinations shall enter the darkened area at least 5 minutes prior to
proceeding with the examination in order to enable the eyes to adjust to dark viewing.
Photosensitive glasses shall not be worn during the test by examiners using these penetrants
(Note: direct viewing of ultraviolet light should not take place).
4.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing codes.
4.6 Reports
4.6.1 Liquid penetrant reports shall meet the requirements of paragraph 1.20. In addition, the
following shall be either contained on the report or specifically identified in the test procedure:
The type of liquid penetrant material (water-washable; post-emulsifying or solvent-
removable; visible or fluorescent)
Manufacturer and designation of penetrant, remover, emulsifier, and developer
Temperature range requirements
4.7 Records
5.0 MAGNETIC PARTICLE TESTING (MT)
5.1 Procedures
As a minimum, written procedures shall include the following:

Requirements)
Magnetization techniques to be used x
Equipment to be used for magnetization x
Type of ferromagnetic particles to be used; wet or dry and size x
Manufacturer and color of magnetic particles x
Magnetization currents (type and amperage) x
Demagnetization x
Directions, extent, and method of examination x
Method of applying examination media x
Contrast paint x
5.2 Personnel
5.3 Calibration
Calibration).
5.3.2 Each alternating current electromagnetic yoke shall have a lifting power of 10 lb minimum
at the maximum pole spacing allowed by the written procedure(s) to be used.
5.3.3 Each direct current or permanent magnetic yoke shall have a lifting power of 40 lb
minimum at the maximum pole spacing allowed by the written procedure(s) to be used.
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5.3.4 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 W/cm2 shall be required on the surface of the part being examined. The
intensity of the ultraviolet light shall be measured prior to the start of the inspection and at least
once every 8 hours during the inspection.
5.3.5 When required by the referencing specification, the adequacy or direction of the
magnetizing field shall be verified using a magnetic field indicator as described and shown in
ASME Section V, Article 7.
5.4 Examination
5.4.1 Examination shall be performed with the magnetizing current on during application of
examination medium and removal of excess medium.
5.4.2 The ferromagnetic particles used may be either wet or dry and may be either fluorescent or
non-fluorescent.
5.4.3 The surface to be examined and all adjacent areas within 1 in. of the area to be examined
shall be dry and free of dirt, grease, lint, scale, welding flux, spatter, oil, or other matter that could
cause interference with the examination. Cleaning methods shall not impair the chemical or
mechanical integrity of the object of examination.
5.4.4 If coatings are to be undisturbed on the part in the area of examination, it must be
demonstrated that indications can be detected through the maximum coating thickness. If
indications cannot be detected through the maximum coating thickness, either the coating shall be
removed or the requirements of ASME Section V, Article 7, Mandatory Appendix I shall be met.
5.4.5 When temporary coatings are applied in order to enhance particle contrast, it must be
demonstrated that indications can be detected through the enhancement coating.
5.4.6 The color of dry particles shall provide sufficient contrast against the surface being
examined. Dry particles shall not be used if the surface temperature of the object of examination
exceeds 600 F.
5.4.7 The color of wet particles shall provide sufficient contrast against the surface being
examined. The particles shall be suspended in a suitable medium in the concentration
recommended by the manufacturer of the medium. Wet particle suspensions and the surface of the
part shall not exceed 135 F.
5.4.8 Fluorescent particle examinations shall be performed using an ultraviolet light.
Fluorescent particle examination shall be performed in a darkened area. Personnel performing the
fluorescent particle examination shall enter the darkened area at least 5 minutes prior to
proceeding with the examination in order to enable eyes to adjust to dark viewing. Photosensitive
glasses shall not be worn during the test by examiners using this medium (Note: direct viewing of
ultraviolet light should not take place).
5.4.9 Rectified current may be used when direct current is specified. The rectified magnetization
current shall be either three-phase (full-wave rectified) or single-phase (half-wave rectified). The
required amperage shall be verified by measuring the average current for three-phase rectified
current, and by measuring the average current output during the conducting half-cycle only for
single-phase rectified current.
5.4.10 Demagnetization of the object under examination shall be performed when required by the
referencing specification.
5.5 Evaluation
specification.
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APPENDIX T M-1002
5.6 Reports
5.6.1 Magnetic particle test reports shall meet the requirements of paragraph 1.20. In addition,
the following shall be either contained on the report or specifically identified in the test procedure:
The types of magnetic particle material (dry or wet; visible or fluorescent)
Magnetizing process
Magnetizing current
Direction of magnetic field
Demagnetizing techniques, when required
A technique sketch in accord with ASME Section V; Article 7, when multidirectional
magnetization is used
5.7 Records
6.0 RADIOGRAPHIC EXAMINATION (RT)
6.1 Procedures
6.1.1 As a minimum, written procedures shall include the following:

Requirements)
Material types and thickness ranges x
Type of isotope x
X-ray voltage and mA x
Minimum source-to-film distance x
Source strength x
Screens used x
Surface condition and preparation x
Detection of backscatter radiation x
System of identification of radiographs x
Density limitations and method(s) for monitoring density limitations and x
variations of radiographs
Image quality indicator (IQI) selection and placement x
Radiographic techniques (single-wall or double-wall) x
Minimum radiograph quality level x
Minimum IQI size and sensitivity requirements x
Film classification x
6.1.2 Radiography
6.1.2.1 Satisfactory evidence of compliance with the written procedure may be demonstrated
when the density and image quality indicator (IQI) requirements of the written procedure on
production or technique radiographs are satisfied.
6.1.2.2 X-rays or gamma rays shall be used. All requirements for resulting radiographs shall
apply equally to X-rays or gamma rays.
6.1.2.3 Only X-rays shall be used for aluminum and its alloys.
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6.1.2.4 Radiographic film shall be of industrial classification I, II, or III, as recommended in

ASTM E1815.
6.1.3 Fluoroscopy
6.1.3.1 A detailed procedure for the fluoroscopic examination of welded joints shall be established
to ensure that both live fluoroscopic images and fluorotapes have sufficient clarity and contrast.
Defects in the welds shall be clearly discernible, as demonstrated by the images of properly
selected and located IQIs.
6.1.3.2 X-rays shall be used solely as a radiation source for fluoroscopy.
6.1.4 Paper Radiography
Paper radiography is not allowed.
6.1.5 Computed Radiology (Digital Radiography)
6.1.5.1 Computed radiology (digital radiography) shall be in accord with the provisions of ASTM
E2033-99.
6.1.5.2 The requirements of paragraphs 6.4 and 6.5 apply, except where radiology process
differences prohibit it.
6.2 Personnel
6.3 Calibration
Calibration) and the following:
6.3.2 Acceptable source size verification may be made by documentation of the equipment
manufacturers or suppliers publications or by written statements documenting the actual or
maximum source size or focal spot.
6.3.3 Step-wedge comparison films and densitometer calibration shall be verified by comparison
with a calibrated step-wedge film. Densitometers shall be calibrated in accord with ASTM E1079,
latest revision.
6.4 Examination
6.4.1 Technique for Radiographic Examination
A lead symbol B with minimum dimensions of 1/2 in. in height and 1/16 in. in thickness shall be
attached to the back of each film holder during each exposure to determine if backscatter radiation
is exposing the film.
6.4.2 Any inside or outside weld surface irregularities, including weld toes, that may interfere
with the radioscopic image by masking or being confused with the image of any objectionable
defect shall be removed, or sufficiently reduced in extent, to prevent such interference. Any
suitable mechanical process may be used for this purpose.
6.4.3 For radiographic examination, a minimum of one IQI shall be used for each radiograph.
When a radiation source is placed on the axis of a circumferential joint and the complete joint is
radiographed with a single exposure, at least three uniformly spaced IQIs shall be used.
6.4.4 For fluoroscopic examination, IQIs shall be placed near each end of a longitudinal joint and
at the start-finish point of a circumferential weld scan.
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APPENDIX T M-1002
6.4.5 Hole-Type IQIs

6.4.5.1 Each hole-type IQI shall be placed adjacent to the weld, its length parallel to the weld, its
plane normal to the radiation beam, and on the side of the plate nearest the radiation source.
When inaccessibility prevents hand placing the IQI on the source side, the IQI used shall be one
designation level down from the corresponding one used on the source side. A lead letter F at
least as high as the IQI identification number shall be placed adjacent to or on the IQI, but shall
not mask the essential hole. If the weld reinforcement, and/or backing strip, is not removed, a
3/4 in. 1 3/4 in. (19.0 mm 44.4 mm) shim, of a material radioscopically similar to the filler
metal, shall be placed (centered) under the IQI. The shim thickness shall be selected so that the
total thickness being examined under the IQI is the same as the total weld thickness, including
backing strip up to and including 1/4 in. (5 mm) thickness. The IQI thickness shall be based on the
nominal metal thickness.
6.4.5.2 Hole-type IQI thickness shall be as shown in Table T.4. It is recommended that IQIs be
protected by embedment in plastic.
6.4.5.3 There shall be three holes in each IQI. They shall be equal to one (1T), two (2T), and four
times (4T) the IQI thickness. The essential hole size and designated IQIs shall be as specified in
Table T.6. A smaller hole or a thinner IQI than listed for each range may be used, provided all
other requirements for radiography are met.
6.4.6 Wire-Type IQIs
6.4.6.1 Each wire-type IQI shall conform to the requirements of ASTM E747.
6.4.6.2 The quality level required using wire IQIs shall be equivalent to the hole-type
requirements. Wire sizes equivalent to corresponding 1T, 2T, and 4T holes for hole-type IQIs are
listed in Tables T.4 and T.5.
6.4.6.3 The essential wire size for wire IQIs shall be as specified in Table T.6 A smaller or a
thinner wire IQI than listed for each range may be used, provided all other requirements for
radiography are met.
6.4.6.4 The material of the IQI shall have X-ray absorption similar to that of the weld metal
being examined. For example, any steel (preferably stainless) may be used for steel; aluminum for
aluminum; etc.
Table T.4 Hole IQI designation, thickness, hole diameters, and corresponding wire IQI size (in.)
IQI 1T Hole Wire Size 2T Hole Wire Size 4T Hole Wire Size
Hole IQI Thickness Diameter 1T Diameter 2T Diameter 4T
Designation (in.) (in.) Equivalent (in.) Equivalent (in.) Equivalent
7 0.007 0.010 0.020 0.040
10 0.010 0.010 0.004 0.020 0.006 0.040 .0.010
12 0.012 0.012 0.005 0.025 0.008 0.050 0.012
15 0.015 0.015 0.0065 0.030 0.010 0.060 0.016
17 0.017 0.017 0.0076 0.035 0.012 0.070 0.020
20 0.020 0.020 0.010 0.040 0.015 0.080 0.025
25 0.025 0.025 0.013 0.050 0.020 0.100 0.032
30 0.030 0.030 0.016 0.060 0.025 0.120 0.040
35 0.035 0.035 0.020 0.070 0.032 0.140 0.050
40 0.040 0.040 0.025 0.080 0.040 0.160 0.063
45 0.045 0.045 0.030 0.090 0.045 0.180 0.071
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M-1002 APPENDIX T
Table T.5 Hole IQI Designation, Thickness, Hole Diameters and Corresponding Wire IQI Size (SI Units)
IQI 1T Hole Wire Size 2T Hole Wire Size 4T Hole Wire Size
Hole IQI Thickness Diameter 1T Diameter 2T Diameter 4T
Designation (mm) (mm) Equivalent (mm) Equivalent (mm) Equivalent
7 0.190 0.254 - 0.508 - 1.016 -
10 0.254 0.254 0.10 0.508 0.15 1.016 0.25
12 0.318 0.318 0.13 0.636 0.20 1.272 0.28
15 0.381 0.381 0.16 0.762 0.25 1.524 0.41
17 0.444 0.444 0.19 0.888 0.28 1.776 0.51
20 0.508 0.508 0.25 1.016 0.38 2.032 0.63
25 0.635 0.635 0.33 1.270 0.51 2.540 0.81
30 0.762 0.762 0.41 1.524 0.63 3.048 1.02
35 0.889 0.889 0.51 1.778 0.81 3.556 1.27
40 1.016 1.016 0.63 2.032 1.02 4.064 1.57
45 1.143 1.143 0.717 2.286 1.25 4.572 1.90
Table T.6 IQI selection (in.)

Nominal Material Thickness of IQI Essential Essential
Thickness Range (in.) IQI (in.) Designation Hole Size Wire Size (in.)
Up to 1/4 inclusive 0.010 10 4T 0.010
Over 1/4 through 3/8 0.012 12 4T 0.012
Over 3/8 through 1/2 0.015 15 4T 0.016
Over 1/2 through 5/8 0.015 15 4T 0.016
Over 5/8 through 3/4 0.017 17 4T 0.020
Over 3/4 through 7/8 0.020 20 4T 0.025
Over 7/8 through 1 0.020 20 4T 0.025
Over 1 through 1 1/4 0.025 25 4T 0.032
Over 1 1/4 through 1 1/2 0.030 30 2T 0.025
Over 1 1/2 through 2 0.035 35 2T 0.032
Over 2 through 2 1/2 0.040 40 2T 0.040
Over 2 1/2 through 3 0.045 45 2T 0.045
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APPENDIX T M-1002
Table T.7 IQI Selection (SI Units)

Nominal Material Essential
Thickness Range Thickness of IQI Essential Wire Size
(mm) IQI (mm) Designation Hole Size (mm)
Up to 6.35 inclusive 0.254 10 4T 0.25
Over 6.35 through 9.52 0.318 12 4T 0.28
Over 9.52 through 12.7 0.381 15 4T 0.41
Over 12.7 through 15.9 0.381 15 4T 0.41
Over 15.9 through 19.0 0.444 17 4T 0.51
Over 19.0 through 22.2 0.508 20 4T 0.63
Over 22.2 through 25.4 0.508 20 4T 0.63
Over 25.4 through 31.8 0.635 25 4T 0.81
Over 31.8 through 38.1 0.762 30 2T 0.63
Over 38.1 through 50.8 0.889 35 2T 0.81
Over 50.8 through 63.5 1.016 40 2T 1.02
Over 63.5 through 76.2 1.143 45 2T 1.42
6.4.7 Identification of Radiographs

6.4.7.1 The images of the identification marks shall be placed on the part adjacent to the weld.
Location markers shall be identified on the surface near the weld so that a defect appearing on a
radiograph can be accurately located; and in such a manner that it is evident on the radiograph
that complete coverage of the weld has been obtained.
6.4.7.2 The job number, tank number, joint number, and fabricators symbol or name shall be
plainly indicated on each radiograph.
6.5 Evaluation
6.5.1 All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
6.5.2 All radiographs shall be free from mechanical, chemical, or other blemishes that could
interfere with proper interpretation of the image of any discontinuity in the area of interest of the
object being examined. Such blemishes include, but are not limited to, the following:
Fogging
Processing defects such as streaks, watermarks, or chemical stains
Scratches, fingerprints, crimps, dirt, static marks, or tears
False indications resulting from defective screens
6.5.3 All fluorotape recordings shall be free of artifacts that could interfere with proper
interpretation of the resultant images.
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M-1002 APPENDIX T
6.5.4 The images of the identification numbers, the IQI outline, and the essential hole or wire are
all essential indexes of image quality. They shall appear clearly on the radiograph. For fluorotapes,
the IQI shall appear clearly, both statically and at the normal scanning speed. The density
difference between the images of the holes and the IQI shall be the same as that between the edge
of the IQI and the adjacent area. Every IQI shall represent an area of uniform density. The
transmitted film density through the radiographic image of the body of the appropriate hole IQI or
adjacent to the designated wire of a wire IQI and the area of interest shall be 1.8 minimum for
single-film viewing for radiographs made with an X-ray source and 2.0 minimum for radiographs
made with a gamma ray source. For composite viewing of multiple film exposures, each film of the
composite set shall have a 1.3 minimum density. The maximum density shall not exceed 4.0 for
either single or composite viewing. A tolerance of 0.05 in density is allowed for variation between
densitometer readings.
6.5.5 If the density of the radiograph varies anywhere in the area of interest by more than 15%
or +30% from the density through the body of the hole IQI or adjacent to the designated wire of a
wire IQI, within the minimum/maximum allowable density ranges specified in paragraph 6.5.4,
then an additional IQI shall be used for each exceptional area or areas and a new radiograph
taken. When calculating the allowable variation in density, the calculation may be rounded to the
nearest 0.1 within the range specified in paragraph 6.5.4. When shims are used, the plus 30%
density restriction may be exceeded, provided that the required IQI sensitivity is displayed and
the density limitations of paragraph 6.5.4 are satisfied.
6.5.6 The images of the identification numbers, of the IQI outline, and of the essential hole or
designated wire of the IQI are all essential indexes of image quality. These images shall appear
clearly on the radiograph. If the required hole IQI image and specified hole, or designated wire, do
not show on any film in a multiple film technique but do show in composite film viewing,
interpretation shall be permitted only by composite film viewing.
6.5.7 For fluoroscopy, the readout system variables shall be adjusted so that the resolution of the
IQI at the start of the weld seam is at maximum and shall be maintained between IQI sightings.
6.5.8 If a light image of the B as described in paragraph 6.4.1 appears on a darker background,
protection from backscatter is insufficient and the radiograph shall be considered unacceptable. A
dark image of the B on a lighter background is not cause for rejection.
6.5.9 Viewing Radiographs
6.5.9.1 When viewing radiographs, the illuminator must provide light of an intensity that will
illuminate the average density areas of the radiographs without glare. The light must be evenly
diffused over the viewing area of the film.
6.5.9.2 When necessary, masks shall be used to exclude any extraneous light from the eyes of the
viewer when viewing radiographs smaller than the viewing port of the illuminator or to cover low-
density areas of the radiograph.
6.5.9.3 High-intensity light illuminators shall be used for viewing areas of the radiographs
between 3.0 and 4.0 density.
6.5.9.4 Subdued lighting shall be available in the viewing room. Subdued lighting is preferable to
total darkness. The brightness of the surroundings should be nearly the same as the area of
interest in the radiograph. Room illumination must be arranged such that there are no reflections
from the surface of the film under examination.
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APPENDIX T M-1002
6.6 Reports
Radiographic examination reports shall meet the requirements of paragraph 1.20. In addition, the
following shall be either contained on the report or technique sheet or specifically identified in the
test procedure:
Lead number/marker locations or increments
Material type and thickness
X-ray voltage and mA or isotope type
X-ray machine focal spot size or isotope physical source size
Source-to-object distance
Object-to-film or detector distance
Film manufacturer and manufacturers type/designation
A listing of each radiograph location
6.7 Records
A complete set of radiographs for each tank shall be retained for not less than 5 years by the tank
fabricator or by the car owner.
7.0 ULTRASONIC TESTING (UT)
7.1 Procedures

Requirements)
Weld and/or material types and configurations to be examined, including x
dimensions and product form (casting, forging, plate, etc.)
The surface or surfaces from which the examination shall be performed x
Angles and mode(s) of wave propagation in the material x
Search unit type, frequency(ies), and transducer size(s) x
Special search units, wedges, shoes, or saddles x
Directions, extent, and method of scanning x
Recording of scan evaluation data and method of recording x
Recording equipment, as applicable x
Rotating, revolving, or scanning mechanisms x
Calibration procedure x
7.2 Personnel
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M-1002 APPENDIX T
7.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration) and
the following:
7.3.1 The proper functioning of the examination equipment shall be checked and the equipment
shall be calibrated by the use of the calibration standards (calibration blocks) at the beginning and
end of each examination; when examination personnel are changed; or at any time that
malfunctioning equipment is suspected. If, during any check, it is determined that the testing
equipment is not functioning properly, all of the material that has been tested since the last valid
equipment calibration shall be reexamined.
7.3.2 Screen height linearity and amplitude control linearity shall be evaluated in accord with
ASME Section V, Article 4.
7.4 Examination
7.4.1 Ultrasonic examination other than thickness testing shall be performed in accord with the
provisions of ASME Section V, Article 4, for the applicable material product form and the
provisions of this paragraph.
7.4.2 The technique used will depend on the thickness, surface geometry, and condition of the
workpiece. The measurement technique used and the extent of examination shall comply with the
referencing specification.
7.4.3 When continuous scanning techniques are utilized, the rate of search unit movement for
examination shall not exceed 6 in./second unless calibration is verified and documented at
scanning speed.
7.4.4 Examinations shall be conducted with a pulse-echo ultrasonic instrument capable of
generating frequencies between 1 MHz and 5 MHz. Instruments operating at other frequencies
may be used if equal or better sensitivity is demonstrated and documented.
7.4.5 Examination surfaces shall be uniform and free of loose scale and paint, discontinuities
such as pits or gouges, weld spatter, dirt, or other foreign matter that could affect the examination
results. Tightly adhering paint, scale, or coatings do not necessarily need to be removed for
examination purposes if they present uniform attenuation characteristics. The examination
surface must be adequate to permit ultrasonic examination at the sensitivity specified. If needed,
surfaces may be ground, sanded, wire brushed, scraped, or otherwise prepared for examining
purposes, if this surface preparation is not detrimental to the functioning of the item under
inspection.
7.4.6 Curved surfaces, either concave or convex, may be examined; however, the calibration
system should compensate for the effective change in search unit transmitting area between the
reference standard and the item under inspection. When practical, the reference standard should
have the same geometry as the item being examined.
7.4.7 The material shall be examined by moving the search unit over the surface such that the
scan encompasses the entire volume to be examined. Each pass of the search unit shall overlap a
minimum of 10% of the transducer element dimension perpendicular to the direction of transducer
movement.
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APPENDIX T M-1002
7.5 Evaluation
specification.
7.5.2 For all examinations, recording of indications shall be made with respect to the reference
level.
7.5.3 For examinations using a distance amplitude correction (DAC) curve, any reflector that
causes an indication greater than 20% of DAC shall be investigated to the extent that it can be
evaluated in terms of the acceptance standards of the referencing specification.
7.6 Reports
Ultrasonic test reports shall meet the requirements of paragraph 1.20. In addition, the following
shall be either contained on the report or specifically identified in the test procedure:
Transducer size and frequency used
Special equipment used, if applicable
Map or description of scan locations
Couplant manufacturer and type
Calibration block identification
Condition of the surfaces of the material
7.7 Records
8.0 ULTRASONIC THICKNESS TESTING (UTT)
8.1 Procedures

Requirements)
Weld and/or material types and configurations to be examined, including x
dimensions and product form (casting, forging, plate, etc.)
The surface or surfaces from which the examination shall be performed x
Calibration procedure x
Search unit type, frequency(ies), and transducer size(s) x
Special transducer attachments x
Directions, extent, and method of scanning x
Recording of scan evaluation data and method of recording x
Recording equipment, as applicable x
8.2 Personnel
8.2.1 NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel)
and the following:
8.2.2 Recommended training topics contained in ASNT SNT-TC-1A for UT may be used at the
determination of the NDT Level III.
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M-1002 APPENDIX T
8.3 Calibration
Calibration) and the following:
shall be calibrated by the use of the calibration standards (calibration blocks) at the beginning and
end of each examination; when examination personnel are changed; or at any time that
malfunctioning equipment is suspected. If, during any check, it is determined that the testing
equipment is not functioning properly, all of the material that has been tested since the last valid
equipment calibration shall be reexamined.
8.3.3 The examination system shall be calibrated on at least three calibration thicknesses
covering the thickness range to be measured. Calibration blocks are required having the same
acoustic velocity and attenuation of the material to be tested, and having thicknesses accurately
measured and in the range of the thicknesses to be measured. Calibration blocks shall have
thickness value within 0.300 in. of the maximum of the range of interest, within 0.300 in. of the
minimum thickness, and within 0.200 in. of the median of the maximum and minimum
thicknesses to be tested. Calibration block temperature shall be within 50 F of the object being
examined.
8.4 Examination
Examination shall include all of the provisions in paragraphs 7.4.2 through 7.4.6 above and the
following:
8.4.1 Where reflecting surfaces are rough, pitted, or corroded, equipment with waveform display
capabilities shall be required.
8.4.2 Time-based linearity is required on instruments used in ultrasonic thickness testing, so
that a change in the thickness of the material will produce a corresponding change in indicated
thickness.
8.5 Evaluation
specification.
8.6 Reports
Ultrasonic thickness test reports shall meet the requirements of paragraph 1.20. In addition, the
Transducer size and frequency used
Special equipment used, if applicable
Map or description of scan locations
Couplant manufacturer and type
Calibration block identification
Condition of the surfaces of the material
8.7 Records
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APPENDIX T M-1002
9.0 VISUAL INSPECTION

9.1 Procedures

Requirements)
Illumination requirements and special illumination instruments or x
equipment to be used
Minimum resolution requirements for remote x
9.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above.
9.3 Calibration
9.4 Examination
9.4.1 Weld Inspection
Weld inspection should be made when access is sufficient to place the eye within 24 in. of the
surface to be examined at an angle of not less than 30 to the surface to be examined. Mirrors may
be used to improve the angle of vision, and aids such as a magnifying lens may be used to assist
examinations. The specific part, component, tank, or section thereof, under immediate
examination shall be illuminated with sufficient lighting as defined by the procedure.
9.4.2 Remote Visual Inspection
9.4.2.1 Remote visual inspection shall be performed with suitable remote equipment.
9.4.2.2 If remote inspection will include weld inspection, the remote technician shall be weld
inspection certified.
9.5 Evaluation
specification.
9.6 Reports
Visual test reports shall meet the requirements of paragraph 1.20. In addition, the following shall
be either contained on the report or specifically identified in the test procedure:
Any special equipment or techniques
9.7 Records
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M-1002 APPENDIX T
10.0 THERMAL/INFRARED (IR)

10.1 Procedures

Requirements)
Emissivity requirements of the test surface x
Method of obtaining temperature differential (inside of tank to outside of x
jacket)
Amount of temperature differential required x
Scanning technique x
Acceptable environmental conditions (weather, solar radiation, shop x
lighting, etc.)
10.2 Personnel
10.3 Calibration
10.4 Examination
10.4.1 Examination shall take place after the temperature differential has been achieved and
within a timeframe that the temperature differential is maintained.
10.4.2 The test surface shall be scanned as close as possible to a normal incident angle.
10.5 Evaluation
specification.
10.6 Reports
10.6.1 Reports shall be made for each examination.
10.6.2 As a minimum, the report shall contain the following information:
All the requirements of paragraph 1.20 above (NDT Reports)
Environmental conditions (if test performed outdoors)
Scanning distance from test object
Emissivity setting of test equipment
Emissivity of test object
10.7 Record Retention
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APPENDIX T M-1002
11.0 RADIOGRAPHIC FILM INTERPRETER (RFI)

11.1 Procedures
As a minimum, written procedures shall include verification of the following:
Radiographic quality
Density limitations and methods for monitoring density limitation and variations of
radiographs
Image quality indicator (IQI) selection and placement
System of identification of radiographs
11.2 Personnel
11.2.1 NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT
personnel) and the following:
11.2.2 Recommended training topics contained in ASNT CP-105 or other publications for RFI
may be used at the determination of the NDT Level III.
11.2.3 An AWS Certified Radiographic Interpreter (CRI) meets the qualification requirements of
this section.
11.3 Identification of Radiograph
Radiographs shall be identified in accordance with paragraph 6.4.7.
11.4 Viewing Radiographs
Radiographs shall be viewed in accordance with paragraph 6.5.9.
11.5 Evaluation
All examinations shall be evaluated per paragraph 6.5.
11.6 Reports
A radiographic interpretation review form shall accompany the radiographs.
11.7 Records
Radiographs and interpretation review form shall be maintained as required by Appendix Y.
C-III [M-1002] 446 11/2014

M-1002 APPENDIX T
12.0 AUTOMATED ULTRASONIC TESTING (AUT)

12.1 Procedures
12.1.1 As a minimum, written procedures shall include the following:
All the provisions of paragraph 1.18, NDT Procedure Requirements
Weld and/or material types and configurations to be examined, including dimensions and
product form
The surface or surfaces from which the examination shall be performed
Ultrasonic techniques [pulsed-echo, phased array, or time of flight diffraction (TOFD)]
Angles and mode(s) of wave propagation in the material
Search unit type, frequency(ies), and transducer size(s)
Special search units, wedges, shoes, or saddles
Type of couplant and application
Directions, extent, and method of scanning
Data to be recorded and method of recording
Recording equipment, as applicable
Rotating, revolving, or scanning mechanisms
Detailed scan plan
Calibration procedure
Evaluation of screen height linearity and amplitude control linearity, as in accord with
ASME Section V, Article 4
12.2 Personnel
NDT personnel shall be in accord with paragraphs 1.3 through 1.16 (NDT Personnel).
12.3 Calibration
12.3.1 Equipment calibration shall be in accord with paragraph 1.22, Equipment Calibration,
and the following:
shall be calibrated by the use of the reference standards at the beginning and end of each
examination, when examination personnel are changed, or at any time that malfunctioning
equipment is suspected. If, during any check, it is determined that the testing equipment is not
functioning properly, all of the material that has been tested since the last valid equipment
calibration shall be reexamined.
12.3.3 Reference standards of the same configuration of the test material shall be scanned
dynamically at the same speed at which the examination will be performed.
12.3.4 Overall dimensions and shape of the reference standard shall be determined by the size of
the search unit array and scanning device.
12.3.5 Reference standards shall be of the same product form, P-number grouping, nominal
thickness, and radius (10%).
12.4 Examination
12.4.1 Automated ultrasonic examination may use ASME Section V, Article 4, as a guideline
concerning implementation and use of AUT technology.
11/2014 C-III [M-1002] 447

APPENDIX T M-1002
12.4.2 Examination surfaces shall be uniform and free of loose scale and paint, discontinuities
such as pits or gouges, weld spatter, dirt, or other foreign matter that affect the examination
results. Tightly adhering paint, scale, or coatings do not necessarily need to be removed for
examination purposes if they present uniform attenuation characteristics. The examination
surface must be adequate to permit ultrasonic examination at the sensitivity specified. If needed,
surfaces may be ground, sanded, wire brushed, scraped, or otherwise prepared for examining
purposes, if this surface preparation is not detrimental to the functioning of the item under
inspection.
12.4.3 Phased array or multi-channel pulsed-echo focused search units utilizing zone
discrimination shall be utilized. Time of flight diffraction (TOFD) may be used in addition to the
above.
12.4.4 Couplant shall be applied utilizing an irrigated system or other suitable method that will
provide a thin consistent layer.
12.4.5 Mechanical indexing and raster scanning shall be encoded and included in the saved
examination data.
12.4.6 Data collection systems shall have the ability to electronically save collected examination
data in unchanged raw data format. The saved examination data shall clearly indicate the location
of discontinuities.
12.4.7 Data analysis may be performed utilizing A, B, or C scan presentations.
12.4.8 The material shall be examined by moving the search unit(s) over the surface such that
the scan encompasses the entire volume to be examined. Each pass of the search unit shall overlap
a minimum of 10% of the transducer element dimension perpendicular to the direction of
transducer movement.
12.5 Evaluation
specification.
12.5.2 Time or distance amplitude corrections shall be used during calibration and examination.
Any reflector that causes an indication greater than 20%, minimum, of primary reference level
shall be investigated to the extent that it can be evaluated in terms of the acceptance standards of
the referencing specification. Evaluation of indications shall be performed at primary reference
level, at minimum.
12.6 Reports
12.6.1 Ultrasonic reports shall meet the requirements of paragraph 1.20. In addition, the
Transducer size, frequency, angles, and modes of ultrasound used
Scan plan of test locations and probe configuration
Type of couplant and method of application
Calibration block and reference standard identification
Condition of the surfaces of the test material
Method of scanning and scan speed
Active elements used (phased array)
Probe separation (TOFD)
12.7 Records
Electronically stored scan data for each tank shall be retained for not less than 5 years by the tank
fabricator or by the car owner.
C-III [M-1002] 448 11/2014

M-1002 APPENDIX T
Sample
NDT PROCEDURE QUALIFICATION RECORD
The NDT Level III shall be responsible for the qualification and technical approval of all NDT
procedures.
1. Qualification Specimen: The item to be examined during the qualification may be a compo-
nent or a specimen not intended for service. The specimen must contain known (actual or sim-
ulated) discontinuities.
2. Demonstration: The demonstration examination of the selected specimen shall be conducted
by a Level II or Level III who is certified in the method of the procedure being qualified. The
demonstration shall be performed in accordance with the procedure being qualified.
A minimum of one qualified individual shall perform the demonstration of the procedure. The
NDT Level III shall witness the demonstration.
Results of the procedure demonstration shall be documented using an NDT Procedure
Qualification Record having spaces to record the procedure identification, signatures, and date.
In addition, the applicable NDT report form referenced in the procedure being qualified shall be
completed and shall describe the demonstration specimen and results.
The NDT procedure is considered qualified when the results of the demonstration indicate the
ability to detect discontinuities to the satisfaction of the NDT Level III. The NDT Level III and
the witness(es) shall sign the NDT Procedure Qualification Record form.
COMPANY NAME DATE
PROCEDURE NO. REVISION TEST PIECE
METHOD TECHNIQUE
NDT EQUIPMENT USED

______________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________
RESULTS
______________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________
TECHNICIAN NAME (PRINT)
TECHNICIAN SIGNATURE LEVEL
I ATTEST TO WITNESSING THE ABOVE PROCEDURE QUALIFICATION:
LEVEL III NAME (PRINT)
NDT LEVEL III SIGNATURE
Fig. T.1 NDT Procedure Qualification Record (PQR)
11/2014 C-III [M-1002] 449

APPENDIX T M-1002
Fig. T.2 Ultrasonic Flaw Examination Report
C-III [M-1002] 450 11/2014

M-1002 APPENDIX T
Radiography Examination Report

Car Reporting Mark and Number: R e porting F a c ility: I ns pe c tor ( print na me ) :
Inspection Date: Facility Location: Inspector Signature / Certification level:
Material Thickness: Material Type / Grade: Surface Preparation Acceptable:
Isotope Type: I s otope S tre ngth: I s otope S iz e :
X-ray Machine Mfg. / Model: X -ra y Ma c hine F oc a l S pot S iz e : V olta ge / mA :
F ilm Mfg. / T ype : F ilm T e c hnique ( c irc le one ) : Exposure Time:

Single / Multiple
Exposure Technique (circle one) S ourc e to O bje c t D is ta nc e : S ourc e to F ilm D is ta nc e :
Single Wall / Double Wall
P a s s / F a il: C omme nts :
tification of intervals, on the diagram below.

Indicate a map of the x-ray area including iden
A-end B-end
Fig. T.3 Radiography Examination Report
11/2014 C-III [M-1002] 451

APPENDIX T M-1002
Fig. T.4 Ultrasonic Thickness Measurement Examination Report
C-III [M-1002] 452 11/2014

M-1002 APPENDIX T
Fig. T.5 Leak Test Examination Report
11/2014 C-III [M-1002] 453

APPENDIX T M-1002
Fig. T.6 Magnetic Particle Examination Report
C-III [M-1002] 454 11/2014

M-1002 APPENDIX T
Fig. T.7 Liquid Penetrant Examination Report
11/2014 C-III [M-1002] 455

APPENDIX T M-1002
C-III [M-1002] 456 11/2014

M-1002 APPENDIX U
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
CONTENTS

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III458
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III458
2.0 Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III459
2.1 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III459
2.2 Sample Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III460
2.3 Supplemental Maintenance or Modification Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III460
3.0 Reports and Service Reliability Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III461
3.1 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III461
3.2 Service Reliability Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III461
3.3 Program and Interval Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III462
11/2014 C-III [M-1002] 457

APPENDIX U M-1002
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
1.0 GENERAL
1.1 Introduction
The content of this Appendix U was originally designated as Recommended Practice RP-263 when
it was adopted in 2003. It has been incorporated herein and is no longer a standalone document.
Federal regulations require the maintenance of tank cars to ensure that there will be no
substantial reduction in the effectiveness of the car and that there will be no identifiable release of
material to the environment. It should be emphasized that federal rules require the car owner to
manage the maintenance of its fleet of cars, to develop plans, and to set inspection intervals
consistent with the failure mode and failure rate for each component on the car. This appendix is
simply one tool to meet that end. This implies that the shipper and car owner must understand the
relationship between what might fail, how it might fail, and when it might fail for the tank and
associated equipment (e.g., understanding failure modes, failure effects, and failure rates). This is
consistent with the goal of assessing, quantitatively, the reliability of the tank and associated
equipment against lading loss during all periods of operation (i.e., reliability-centered
maintenance programs). For further information, see 49 CFR 171.2(c); 173.24(b); 173.31(a)(1) and
(3); 179.7(b)(5), (b)(10), (d), and (f); 180.2; 180.3; 180.501; 180.507(a); and 180.511.
1.2 Scope
1.2.1 Appendix U describes the recommended practice for the development of a maintenance
program for tank cars. This appendix covers the application and coordination of regulatory and
industry test and inspection programs in the development of a maintenance program. To maintain
the fitness-for-service of a tank car, the maintenance program must be effective in preventing
failures.
1.2.2 This appendix requires cooperation and communication between the parties involved with a
tank car. Reliability will be greatly improved with appropriate communications. Each owner
should develop, in conjunction with each manufacturer and operator/user of a tank car, a
maintenance program and schedule.
1.2.3 The following are objectives of an efficient maintenance program:
Maintain the fitness-for-service of the tank car.
Obtain and analyze the data to determine appropriate action to minimize probabilities of
failures, damage, or deterioration.
Accomplish these objectives at a minimum net cost, including maintenance costs and the
savings of avoiding failures.
Validate inspection intervals.
1.2.4 Car owners may exceed the minimum criteria contained herein.
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M-1002 APPENDIX U
2.0 MAINTENANCE PLAN

2.1 Maintenance Manual
2.1.1 The maintenance manual provides maintenance instructions and consists of at least the
following four sections:
2.1.1.1 Introduction. This section sets forth general information about the maintenance
instructions.
2.1.1.2 Maintenance Plan. This section identifies the recommended maintenance plan based on
regulatory requirements and industry standards with references to the necessary instructions. For
each area identified for maintenance, the plan must establish a maintenance frequency and the
applicable maintenance instruction. See paragraph 2.2 for a sample maintenance plan.
2.1.1.3 Maintenance Instructions.
This section includes work forms, with detailed task instructions or specific references, for
interpreting and evaluating the results of test and inspection.
2.1.1.3.1 The maintenance task descriptions must provide the following:
A description and/or drawing of the part under observation
Likely sites of damage
Minimum size of damage considered significant
Examination methods for performing maintenance
Step-by-step instructions
Acceptance criteria. For example:
Wear limits
Replacement interval of life-limited components
2.1.1.3.2 In addition, this section must include forms and instructions for recording the results of
all tests and inspections.
2.1.1.4 Component Supplier Manuals. This section identifies the manufacturers inspection,
maintenance, and operating instructions for the various components on the tank car identified in
the categories in the Sample Maintenance Plan.
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APPENDIX U M-1002
2.2 Sample Maintenance Plan
Table U.1 Sample maintenance plan

Item Frequency (Years) Task/Procedure
Tank Qualification: 49 CFR 180.509
Visual inspection 10 MI-001
Structural integrity 10 MI-001
Thickness 10 MI-001
Safety systems 10 MI-001
Linings and coatings 8 MI-001
Leakage pressure test After assembly MI-001
Service equipment 10 MI-001
Pressure relief device(s)
Stub Sill Inspection (SS3, CPC-1094, CPC-1114)
Stub sill At tank qualification or mileage MI-002
or time limit
Sill pads At tank qualification or mileage MI-002
or time limit
Field Manual, Rule 88.B.2
Trucks 10 MI-003
Draft components 10 MI-003
Body bolster 10 MI-003
Appendix D, 3.0
Stub draft sills (inboard of bolsters) With 180.509(e) MI-004
Sill pads (inboard of bolsters) With 180.509(e) MI-004
Sill attachment welds (inboard of bolsters) With 180.509(e) MI-004
Tank anchors 5 2030-01
Turnbuckles 5 2030-02
Center plate 5 2030-03
Side sills and end sills 5 2030-04
Side bearings 5 2030-05
2.3 Supplemental Maintenance or Modification Programs

2.3.1 When the results of a service reliability assessment show unacceptable performance
(deviation from the maintenance plan) of the tank car, the owner, as appropriate, in conjunction
with the manufacturer and/or operator, as appropriate, shall initiate development of a
supplemental maintenance program or modification or redesign procedure on a timely basis to
reestablish acceptable performance.
2.3.2 When a service reliability assessment indicates that a safety concern exists that may be
common to other car owners, the owner shall forward information to the AARs Executive
DirectorTank Car Safety for consideration under the Maintenance Advisory system.
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M-1002 APPENDIX U
3.0 REPORTS AND SERVICE RELIABILITY ASSESSMENT

3.1 Reports
Operational and performance improvements depend on the submission of reports of defects and
damage to the car owner. Therefore, the following apply:
3.1.1 An initiator is responsible for identifying and reporting the failure of a material (e.g., a
component or item) or service (e.g., an inspection, repair, reclamation, reconditioning,
qualification, etc.) using the AAR Manual of Standards and Recommended Practices, Section J,
Specification M-1003, Chapter 7, Form 7.1. The initiator shall forward a copy of the report to the
car owner.
3.1.2 An initiator shall report all non-accident-related damage discovered on a tank, to the car
owner using Exhibit R-2. The car owner shall forward this report to the manufacturer if the
damage is design or manufacturing related.
3.1.3 An initiator shall report defects discovered during test and inspection to the car owner. The
car owner shall forward these reports to the manufacturer if the damage is design or
manufacturing related.
3.1.4 An initiator shall report damage to the car owner, as described in the Field Manual of the
AAR Interchange Rules, Rule 95 or Rule 96.
3.1.5 The car owner shall maintain the service-reliability assessment data on file for 10 years
after a car is scrapped. Upon a change in ownership, the selling organization shall provide these
data to the new owner of the tank car.
3.1.6 An initiator shall report defects requiring submittal of an Exhibit R-1 (See MSRP
Specification M-1002, Appendix R, paragraph 3.3) to the car owner.
3.2 Service Reliability Assessment
This section provides information on the application and development of a service reliability
assessment as an integral part of an owners maintenance program. The following paragraphs
explain the recommended general concepts of each system.
3.2.1 Collection of maintenance data: Collection of maintenance data, obtained from
sampling, surveys, maintenance, manufacturers, and operators identifying each system,
component, or item.
3.2.2 Data analysis: A systematic evaluation of an item based on a statistically valid sample
and an analysis of collected information. The analysis should compare the data to a standard
representing acceptable performance. The standard may be a running average, tabulation of
defects or removal rates for past periods, graphs, charts, or any other method depicting a norm.
3.2.3 Performance standards: A performance measurement expressed quantitatively in terms
of system, component, or item failures.
3.2.4 Data display and report: The development of a periodic report, with appropriate
displays, summarizing the periods activities in sufficient depth to evaluate the effectiveness of the
maintenance program. The report should highlight systems, components, or items that exceed the
established performance standards and those that do not. The report should also detail the
changes that were made to systems, components, or items that were operating below an acceptable
level of performance.
3.2.5 Maintenance interval or content change: A system or process for adjusting the
maintenance interval or content if the systematic evaluation shows that an owners cars are
operating above or below the performance standard.
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APPENDIX U M-1002
3.2.6 Program change: A system for changing the maintenance program, such as the methods
used to collect data or process change, or the procedures relating to reliability measurement or
performance standards.
3.3 Program and Interval Change
This section provides information on establishing maintenance policies to improve safety,
reliability, and operating performance; reduce maintenance costs; and extend the useful life of the
asset. A maintenance program consists of a continuing analysis of maintenance data to produce
documentary evidence that the program has defensible foundations that support not only
maintenance policies but also changes in the intervals of maintenance.
3.3.1 Operations: The maintenance program shall consider the operational effects on the tank
car that may lead to damage. For example, the program should consider the effects of fatigue and
incorporate a maintenance interval that allows for two opportunities for maintenance before the
car reaches its critical cycle time of failure.
3.3.2 Fleet sampling: The maintenance program may include sampling of the fleet leaders with
respect to mileage for fatigue and age for corrosion. An owner should consider the effects of the
material of construction and design to support a maintenance program based on fleet sampling.
3.3.3 Interval or content changes: To support an extended maintenance interval beyond
federal or industry requirements, or to change the mandatory content in the maintenance
program, an owner must obtain supporting evidence and approval by the governing bodies. This
can include the owners engineering analysis, maintenance data, pooled industry data, historical
data, benefit/cost data, and testing.
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M-1002 APPENDIX U
PRESSURE RELIEF VALVE INSPECTION REPORT

(REQUESTED BY AAAR TASK FORCE ON PRESSURE RELIEF DEVICES)
1. Reporting marks and car number |__|__|__|__| |__|__|__|__|__|__|

2. Last lading (UN or NA number) |__|__| |__|__|__|__| CAR
3. Last valve qualification date (stenciled) |__|__| |__|__|__|__| INFO
Month Year
4. Last valve qualification location (if stenciled) ______________________________________________
5. Valve manufacturer__________________________________________________________________
PRV
6. Valve model number_________________________________________________________________ INFO
7. Serial number ____________________________ Mfg. Date |__|__| |__|__|
Month Year
8. Gauge pressure on car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig
9. Passed leak test on car (circle one) A. Yes B. No C. Not combo TESTING
10. Is flow passage way fully open? (circle one) A. Yes B. No ON CAR
11. Was the tank car cleaned before removing the PRV? A. Yes B. No
12. On a combination valve, leak test disc at 1/2 start-to-discharge
pressure and open telltale indicator (circle one). . . . . . . . . . . . A. No leak B. Leaks C. Not combo
13. Start to leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig
14. Start to discharge test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig
15. Vapor tight pressure test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig
BENCH
TESTING
20. Test remarks _______________________________________________________________________
_________________________________________________________________________________
Physical condition on teardown (circle all that apply)
21. Spring A. Good conditionB. Some corrosionC. All corrosion D. Cracked
22. Spring free height
23. Stem A. Good B. Dirty C. Cracked D. Bent
24. Body seat A. Bright/clean B. Dirty C. Corroded D. Gouged
25. Seat O-ring A. Like new B. Dirty C. Cracked D. Swelled E. Metal-to-metal
TEAR-
26. PLug/Stem O-ring A. Like new B. Dirty C. Cracked D. Swelled E. Metal-to-metal DOWN
27. Seal Retainer A. Bright/clean B. Dirty C. Corroded D. Gouged
28. Disc/Diaphragm markings & conditions: _______________________________________________
29. Comments ______________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
30. Reporting Facility a. ___________________________________ b. _________________________________
(Station Stencil) (Phone Number)
Date (Tester Name (print) ID#
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APPENDIX U M-1002
INSTRUCTIONS FOR COMPLETING THE

PRESSURE RELIEF VALVE INSPECTION REPORT
ON THE CAR:
1. Record the reporting marks and car number.
2. Record the last lading in the car (UN or NA number).
3. Record the pressure relief valve (PRV) qualification date stenciled on the car as received.
4. Record the facility of the PRV qualification as (if) stenciled on the car.
5. Record the PRV manufacturer.
6. Record the PRV model number.
7. Record the PRV serial number and date of manufacture. For the date of manufacture, record
the month and year (example: March 198803 88).
Note: Before proceeding, contact your safety department for safe handling procedures for a specific
commodity.
8. Install a gauge on the tank car fittings to determine if there is any pressure in the tank. If so,
record the pressure.
9. If there is pressure in the car, bubble leak-test the PRV. The purpose of this test is to determine
if the seat seals are functional. Record the result. If there is no pressure in the tank car, or the
test cannot be performed, circle C. No Test. If the PRV is a combination device, check the
needle valve, trycock, or tell-tale indicator for any signs of leakage.
Note: Contact your safety department to determine if the PRV can be removed from the car before
cleaning the tank. The purpose is to remove the PRV before the seals can be damaged by the tank
cleaning process.
10. Before covering the nozzle, note if the flow passageway is fully open (not blocked with
commodity). Record the result.
11. Note if the tank car was cleaned before removing the PRV.
Remove the PRV from the car. Cover the nozzle opening to avoid introducing contaminants to the
car.
BENCH TESTING:
12. If the PRV is not a combination valve, circle C. Not combo. If the PRV is a combination
pressure relief valve with a needle valve, trycock, or tell-tale indicator, perform the following
test before removing the disc/diaphragm. Install the complete assembly with disc on the test
stand. Slowly raise the pressure in the test stand to one half of the valves labeled start-to-
discharge pressure. Check the needle valve or trycock outlet for disc leakage or the tell-tale
indicator for pressure rise. If the PRV is a combination pressure relief valve, remove the disc or
diaphragm before proceeding. The disc or diaphragm condition is recorded on line 27.
13. Put water in the outlet of the PRV. Slowly increase the pressure in the test stand and record the
pressure at the first bubble. The start-to-leak pressure is defined as The pressure, measured
at the valve inlet of a PRV, at which the relieved fluid is first detected at the downstream side
of the seat.
14. Continue raising the pressure in the test stand until the start-to-discharge pressure has been
observed. Record the pressure. The start-to-discharge pressure is defined as The pressure,
measured at the valve inlet of a PRV, at which there is a measurable lift of the closure device
on a PRV or at which discharge becomes continuous as determined by seeing, feeling, or
hearing.
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M-1002 APPENDIX U
15. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed by
no bubbles for a minimum of 30 seconds. Record the pressure. The vapor-tight pressure is
defined as The pressure, measured at the valve inlet after closing, at which no further flow is
detected at the downstream side of the seat of a PRV. Discharge the pressure in the test stand
to one half the start-to-discharge pressure or below the vapor-tight pressure, whichever is
lower.
16. Raise the pressure in the test stand until the start-to-discharge pressure has been observed a
second time. Record the pressure.
17. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed a
second time. Record the pressure. Discharge the pressure in the test stand to one half the start-
to-discharge pressure or below the vapor-tight pressure, whichever is lower.
18. Raise the pressure in the test stand until the start-to-discharge pressure has been observed a
third time. Record the pressure.
19. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed a
third time. Record the pressure. Discharge the pressure in the test stand.
20. Record any remarks out of the ordinary during bench testing of the PRV.
TEARDOWN:
Each facility should have a procedure to verify that the parts of a valve are kept together during
disassembly and assembly. Carefully inspect the PRV. Inspect the different PRV parts for cracking,
corrosion, damage, etc. Follow the PRV manufacturers instructions for disassembling the PRV.
21. If the spring is steel, note the condition of the plating and circle the choices that best describe
the condition of the spring. If other conditions exist, note the condition and line number in
line 29.
A. Good conditionThe plating is intact and in good condition (less than 1 in.2 gone).
B. Some corrosionThe plating is no longer intact and some corrosion exists.
C. All corrosionThe plating no longer exists and the entire spring is covered with corrosion.
D. CrackedThe spring is cracked or has visible cracks or is broken.
If the spring is stainless steel, note the condition of the spring and circle the choices that best
describe the condition of the spring. If other conditions exist, note the condition and line
number in line 29.
A. Good conditionThe spring has no corrosion or pitting and is in good condition.
B. Some corrosionSome corrosion or pitting exists.
C. All corrosionThe entire spring is covered with corrosion or pitting.
D. CrackedThe spring is cracked or has visible cracks.
22. Stand the spring up on a flat surface. With a straight edge across the top of the spring, put a
ruler in the middle of the spring and measure the free height. Record the result to the nearest
1/8 in.
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APPENDIX U M-1002
23. Inspect the stem seat seal area, threads, the shaft of the stem, and the transition area between
the shaft and the disc. Circle the choices that best describe the condition of the stem. If other
conditions exist, note the condition and line number in line 29.
A. GoodThe stem is straight. The threads and the seat area are in good condition.
B. DirtyThe seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. CrackedThe stem has visible cracks.
D. BentThe stem is bowed or bent when rolled on a flat surface.
24. Inspect the seat seal area of the valve body and circle the choice that best describes the condition
of it. If other conditions exist, note the condition and line number in line 29.
A. Bright/cleanThe seat seal area is bright and clean (like new).
B. DirtyThe seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean up.
C. CorrodedThe seat seal area has pitting that would not allow the PRV to be rebuilt.
D. GougedThe valve body has mechanical damage (scratches, dents, galled, etc.) that would
not allow the valve to be rebuilt.
If the PRV has two O-rings, record the condition of both O-rings in lines 25 and 26. The seat
O-ring is the O-ring that seals between the stem, the cap, and the seat on the PRV body.
The plug or stem O-ring is the O-ring with the smaller outer diameter and seals between
the cap and plug or stem.
If the PRV has one O-ring, record the condition of the O-ring in line 25.
25. Inspect the seat O-ring and circle the choice that best describes the condition of it. If other
A. Like newThe O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. DirtyThe O-ring has contamination on it, which may not allow it to function properly.
C. CrackedThe O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. SwelledThe O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-MetalThe valve design does not have an O-ring, but a metal-to-metal seat.
26. Inspect the plug or stem O-ring and circle the choice that best describes the condition of it. If
other conditions exist, note the condition and line number in line 29.
A. Like newThe O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. DirtyThe O-ring has contamination on it, which may not allow it to function properly.
C. CrackedThe O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. SwelledThe O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-MetalThe valve design does not have an O-ring, but a metal-to-metal seat.
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M-1002 APPENDIX U
27. Inspect the seal retainer and circle the choice that best describes the condition of it. If other
A. Bright/cleanThe seal retainer is bright and clean (like new).
B. DirtyThe seal retainer has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. CorrodedThe seal retainer has pitting that would not allow the PRV to be rebuilt.
D. GougedThe seal retainer has mechanical damage (scratches, dents, galled, etc.) that
would not allow the valve to be rebuilt.
28. If the PRV is a combination device, inspect the disc or diaphragm for any manufacturers
markings and record them and the condition (such as like-new, burst, corroded, etc.).
29. Record any comments out of the ordinary of the physical condition of the parts during the
teardown of the PRV.
30. Record the following information for the facility that removed the valve from the car and
performed the testing and teardown:
A. Station stencil
B. Phone number
Record the date and print the name and ID# of the person performing the test.
11/2014 C-III [M-1002] 467

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C-III [M-1002] 468 11/2014

M-1002 APPENDIX W
APPENDIX W
WELDING OF TANK CAR TANKS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
1.2 Certified Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
1.3 Repairs, Alterations and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
1.4 Welding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
2.0 Requirements for Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
2.2 Tank Shell Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III472
2.3 Welds Other than Tank Shell JointsAttachments Welded Directly to the Tank Shell. . . . . . . . . . C-III472
3.0 Test Plate Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III473
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III473
3.2 Longitudinal Joint Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III473
3.3 Circumferential Joint Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
3.4 Straightening of Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
3.5 Heat Treatment of Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
3.6 Radiography of Test Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
3.7 Test Specimens Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
4.0 Types and Purposes of Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
4.1 Tension, Bend, and Fillet Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III474
4.2 Impact Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
4.3 Radiographic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
4.4 Corrosion Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
4.5 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
5.0 Tension Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
5.1 Joint Tension Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III475
5.2 Joint-Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III476
5.3 All-Weld-Metal Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III476
6.0 Bend Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III476
6.1 Guided-Bend Test Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III476
6.2 Guided-Bend Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III476
7.0 Fillet Weld Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III477
7.1 Fillet Weld (Tee-Joint) Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III477
7.2 Fillet Weld Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III477
8.0 Impact, Corrosion and Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III477
8.1 Impact Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III477
8.2 Corrosion Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III479
8.3 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III479
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9.0 Procedure and Performance Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III480
9.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III480
9.2 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III480
9.3 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III480
9.4 Identification of Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III480
9.5 Qualification Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III481
9.6 Weld Orientation and Test Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III481
10.0 Nondestructive Examinations and Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III483
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III483
10.2 Radioscopic Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III483
10.3 Liquid Penetrant Examination Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III485
10.4 Magnetic Particle Examination Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III485
10.5 Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III486
11.0 Performance Qualification of Welders and Welding Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III487
11.1 Qualification of Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III487
11.2 Qualification of Welding Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III488
11.3 Weldments Involving Combination of Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III488
11.4 Essential Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III489
11.5 Test Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III489
11.7 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III491
11.8 Renewal of Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III492
12.0 Procedure Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III492
12.1 Qualification of Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III492
12.3 Test Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III495
12.5 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
12.6 Renewal of Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
13.0 Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
13.1 Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
13.2 Cutting to Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
13.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III497
13.4 Welding Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
13.5 Out-of-Roundness of Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
13.6 Tolerance for Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
13.7 Arc Strikes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
14.0 Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
14.1 Welder Visual Acuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
14.2 Visual Acuity Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
14.3 Cleaning During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III498
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14.4 Alignment Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III499
14.5 Weld Reinforcement (Butt Welds). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III499
14.6 Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III499
14.7 Interrupted Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III499
14.8 Identification of Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III500
14.9 Repair of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III500
14.10 Surface Quality of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III500
14.11 Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III500
14.12 Low Hydrogen Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III501
15.0 Welding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III502
15.1 Welding Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III502
16.0 Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III506
16.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III506
16.2 Procedures for Postweld Heat Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III506
16.3 Requirements for Postweld Heat Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III506
16.4 Carbon Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III507
16.5 Manganese-Molybdenum Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III507
16.6 Manganese-Silicon Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III507
16.7 Nonferrous Metal Tanks (Material Groups 2, 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III507
16.8 Nickel Alloy Steel Tanks (Material Group 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
16.9 High Alloy Steel Tanks (Material Group 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
17.0 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
17.1 Quality Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
18.0 Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III508
18.2 Welded Joints to be Inspected (Radiograph or Ultrasonic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III509
18.3 Inspection of Nonpressure Tanks Constructed in Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III509
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APPENDIX W M-1002
APPENDIX W
WELDING OF TANK CAR TANKS
1.0 INTRODUCTION
1.1 Scope
Appendix W describes AAR requirements for fusion welding on tank heads, shells, sumps, and
welds attaching connections thereto. Other welding, including repairs, shall be in accord with the
American Welding Society (AWS) Railroad Welding Specification D15.1, latest revision.
1.2 Certified Facilities
Fusion welding on tank car tanks shall be performed only by facilities certified by the AAR for
fabrication or for alterations, conversions, or welded repairs. See Appendix B.
1.3 Repairs, Alterations and Conversions
For repairs, alterations, and conversions to tank car tanks, see Appendix R.
1.4 Welding Symbols
Welding symbols used shall conform to AWS Standard A2.4 (see Fig. W.21).
2.0 REQUIREMENTS FOR NONDESTRUCTIVE EXAMINATION
2.1 General
Tank car tanks, and any attachments welded directly to the tank, must be inspected by NDT
examiners qualified per Appendix T for the method employed, in accord with the following
paragraphs. For welder visual acuity requirements to check multi-pass welds, see paragraphs 14.1
and 14.2.
2.2 Tank Shell Joints
2.2.1 For manual and semiautomatic welding procedures, the weld root pass and each layer of
multi-pass weld shall be visually checked to make sure they are free from cracks, overlap,
incomplete fusion, and inclusions prior to deposition of subsequent passes. The welder making the
weld is responsible for this, which shall be monitored by the welding inspector.
2.2.2 All completed welded butt joints shall be visually inspected in accord with paragraph 14.10
below and radiographed in accord with paragraph 18.0, also below.
2.3 Welds Other than Tank Shell JointsAttachments Welded Directly to the Tank
Shell
2.3.1 The root pass and each layer of multi-pass weld shall be visually checked to make sure they
are free from cracks, overlap, lack of fusion, and slag inclusions prior to deposition of subsequent
weld passes. The welder making the weld is responsible for this, which shall be monitored by the
welding inspector.
2.3.2 All completed welds shall be visually inspected in accord with paragraph 14.10 below.
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M-1002 APPENDIX W
2.3.3 In addition to the requirements in paragraphs 2.3.1 and 2.3.2, pressure car tank and
aluminum tank (pressure and nonpressure) completed fillet welds listed below shall be examined
in accord with paragraph 10.0 below. For carbon steel tanks, the completed welds shall be
examined by magnetic particle or liquid penetrant, and for aluminum tanks by liquid penetrant.
Where practical, the completed welds shall be examined after postweld heat treatment or no
sooner than 24 hours after welding.
Tank anchor pad-to-tank, around the ends of the pad, including at least 3 in. of the
longitudinal welds
Draft sill pad-to-tank, around the outboard end of the pad, including at least 3 in. of the
longitudinal welds
Draft sill pad-to-tank, around the inboard end of the pad, including at least 3 in. of the
longitudinal welds, except where pads extend the full length of the tank
For aluminum tanks only, bolster pad to tank, around the upper end of the pad, including
at least 3 in. of the circumferential welds
2.3.4 Ultrasonic testing of welds may be employed in lieu of magnetic particle or liquid
penetrant inspections. Ultrasonic testing of welds shall be performed in accord with the
requirements of paragraph 10.0 below.
3.0 TEST PLATE REQUIREMENTS
3.1 General
3.1.1 When required by DOT specifications, test plates shall be prepared, tested, and evaluated
in accordance with applicable portions of paragraphs 4.0, 5.0, 6.0, and 8.0 below.
3.1.2 A test plate shall be prepared during fabrication for each WPS used in fabrication of the
tank shell.
3.1.3 When more than one welder and/or welding operator welds on a tank, the test plates shall
be made by the welder and/or welding operator designated by the fabricators inspector.
3.1.4 A test plate shall be prepared as a part of the qualification requirements for each welding
procedure. See paragraph 12.1.2 below.
3.1.5 When impact tests are required, the test plate groove details shall be the same as used for
the tank fabrication.
3.2 Longitudinal Joint Test Plates
3.2.1 For each tank having a longitudinal welded joint, a test plate shall be prepared from
material of the same specification and thickness as the shell plates of the tank. Test plate material
may be taken from any part of one or more plates of the same lot of material that is used in the
fabrication of the tank without reference to the direction of mill rolling, except when impact tests
are required. When impacts are required, test plates shall be oriented the same as the shell plates
with respect to mill rolling and weld directions.
3.2.2 The test plates may be attached to a shell plate being welded, reference Fig. W.1A, so that
the weld metal shall be deposited in the test plate continuously with the weld metal deposited in
the longitudinal joint.
3.2.3 As an alternative, detached test plates may be prepared, but weld metal shall be deposited
using the same WPS used for the longitudinal joints.
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APPENDIX W M-1002
3.3 Circumferential Joint Test Plates

3.3.1 When a test plate is welded for the longitudinal joints of a tank, none need be prepared for
the circumferential joints in the same tank, provided the same WPS is used for both types of joints.
3.3.2 When the WPS for circumferential joints is different from the one used for longitudinal
joints, a detached test plate shall be prepared using the same WPS used for the circumferential
joints.
3.4 Straightening of Test Plates
The test plate shall be supported so that distortion resulting from welding shall not throw the
finished test plate out of line by an angle over 5. Where the welding has distorted the test plate, it
shall be straightened before being stress-relieved or heat-treated. Where stress relieving or heat
treatment are not specified (aluminum and stainless steel, for example), test plates out of line by
an angle over 5 cannot be mechanically flattened. They must be scrapped and the test repeated.
3.5 Heat Treatment of Test Plates
3.5.1 The test plate shall be subjected to the same postweld heat treatment procedure required in
paragraph 16.0 below for the related tank. At no time shall the test plate be heated to a
temperature higher than that used for postweld heat treating the related tank.
3.5.2 When production test plate impact test specimens are required by DOT or AAR special
commodity requirements, the test plate shall be postweld heat treated with its related tank.
3.6 Radiography of Test Plates
Test plate welds shall be radiographed full length using technique and acceptance standards of
paragraph 10.2 below. If results do not comply with acceptance standards, a new test plate shall be
prepared.
3.7 Test Specimens Required
3.7.1 For tanks built of materials listed in Tables M.10.1, M.10.2, M.10.3, M.10.4, M.10.5, M.10.6,
and M.10.7, the test plate dimensions shall be sufficient to provide one reduced-section tension
specimen conforming to Fig. W.2, Sketch A, plus two guided-bend specimens, either two side-
bends, or one face-bend and one root-bend, or one longitudinal face-bend and one longitudinal root-
bend.
3.7.2 For tanks built of materials listed in Tables M.10.1, M.10.5, and M.10.7, include sufficient
material to provide three impact specimens each of weld metal and heat-affected zone, when
required.
4.0 TYPES AND PURPOSES OF TESTS
4.1 Tension, Bend, and Fillet Tests
Three types of tests are used to evaluate welding procedure, welder performance, and production
welding.
4.1.1 Tension Tests
Direct-tension tests are used in welding procedure qualification and production-weld tests.
Joint-tension specimens are used to measure strength of butt-welded joints.
All-weld-metal-tension specimens are used to measure strength and ductility of weld
metal.
4.1.2 Bend Tests
Bend tests are used in welding procedure and welder performance qualification and
production-weld tests.
Guided-bend tests are used to measure soundness and ductility of butt-welded joints.
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M-1002 APPENDIX W
4.1.3 Fillet Weld Tests

Fillet weld tests are sometimes used in welding procedure and welder performance tests to
check the size, contour, and penetration of fillet welds and degree of soundness of fillet-
welded joints.
4.2 Impact Tests
4.2.1 Impact tests are used to evaluate welding procedures and production welding when the
tank service involves the transportation of a low-temperature product.
4.2.2 Charpy impact tests are used to measure notch toughness, at low temperatures, of weld
metal and weld heat-affected zone of butt welded joints.
4.3 Radiographic Tests
4.3.1 Radiographic examination of a length of weld is used to evaluate the ability of a welding
operator to make an acceptable butt-welded joint. Under certain conditions, radiographic
examination may be used as an alternative to mechanical tests for welder performance
qualification.
4.3.2 Radiographic examination is recommended for welding procedure and production-welded
test plates to measure acceptance for preparation of test specimens.
4.4 Corrosion Tests
Corrosion tests are used to determine that weld, heat-affected zone, and plate specimens, from test
plates made from materials listed in Table M.10.3, are not susceptible to intergranular attack
associated with precipitated chromium carbides and meet the acceptable corrosion rates listed in
Appendix M, paragraph 3.3.2.
4.5 Hardness Tests
Hardness tests are used to evaluate production welding and to control maximum hardness
requirements.
5.0 TENSION SPECIMENS AND TESTS
5.1 Joint Tension Specimens
Flat, reduced-section tension specimens conforming to requirements of Fig. W.2, Sketch A, or
turned reduced-section tension specimens conforming to requirements of Fig. W.2, Sketch B, may
be used for test of welding procedure and production-welded impact test plates. If turned reduced-
section tension specimens are used, one complete test set shall be made for each required tension
test as given below.
5.1.1 For thicknesses to and including 1 1/4 in. (31.8 mm), a single specimen shall be used.
5.1.2 For thickness over 1 1/4 in. (31.8 mm), multiple specimens shall be cut through the full
thickness of the weld with their centers parallel to the material surface and not over 1 in.
(25.4 mm) apart. The centers of the specimens adjacent to material surfaces shall not exceed
5/8 in. (15.9 mm) from the surface.
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APPENDIX W M-1002
5.2 Joint-Tension Tests

5.2.1 Tension test specimens shall be ruptured under tensile load. The tensile strength shall be
computed by dividing the maximum load at failure by the least cross-sectional area of the
specimen, as measured before load is applied.
5.2.2 The tensile strength of the specimen shall be not less than
the specified tensile strength of the base material as given in Table M.10;
the specified tensile strength of the weaker of the two, if base materials of different
minimum tensile strengths, as given in Table M.10, are used.
5.2.3 If the joint specimen breaks in the base material outside the weld, the test shall be accepted
as meeting the requirements, provided the strength is not more than 5% below the specified
tensile strength of the base material as specified in Table M.10.
5.3 All-Weld-Metal Tension Tests
5.3.1 For the all-weld-metal specimen (the all-weld-metal turned reduced-section test specimen is
acceptable), fit the ends of the fractured specimen together carefully and measure the distance
between the gauge marks to the nearest 0.01 in. (0.254 mm). The elongation is the increase in
length of the gauge length, expressed as a percentage of the original gauge length.
5.3.1.1 The elongation shall be not less than the value specified for base material in Table M.10.
5.3.1.2 If any part of the fracture takes place outside of the middle half of the gauge length or in
a punched gauge mark, the elongation value obtained may not be representative of the material. If
the elongation so measured meets the minimum requirements, no further testing is required; but
if the elongation is less than the minimum requirements, discard the test and make a retest.
5.3.2 The tensile strength shall be not less than
the specified tensile strength of the base material as given in Table M.10;
the specified tensile strength of the weaker of the two, if base materials of different
minimum tensile strengths, as given in Table M.10, are used.
6.0 BEND SPECIMENS AND TESTS
6.1 Guided-Bend Test Specimens
6.1.1 Guided-bend test specimens conforming to requirements of Fig. W.3, Sketch B, and Fig. W.4
shall be used for qualification tests of welding procedures and welder performance and for
production-welded impact test plates.
6.1.2 Rectangular specimens cut from the test plates are of five types: side-bend, face-bend, root-
bend, longitudinal face-bend, and longitudinal root-bend. The cut surfaces shall be designated the
sides of the specimens. The other two surfaces shall be called face and root, the face having
the greater width of weld metal.
6.2 Guided-Bend Tests
6.2.1 Guided-bend specimens shall be bent in test jigs that are substantially in accord with
Fig. W.5. The surface of the specimen on the convex (outer) surface of the bent specimen shall be
the face for face-bend and longitudinal face-bend specimens; the root for root-bend and
longitudinal root-bend specimens; and the side (with greater defects, if any) for side-bend
specimens. The specimen at the time of bending shall be between the temperature of 50 F (10 C)
and 140 F (60 C). Apply the bending force smoothly without shock, and bend the specimen into
the die at a duration no faster than 15 seconds but no slower than 120 seconds by applying a load
on the plunger until a 1/8 in. (3.18 mm) diameter wire cannot be inserted between the specimen
and any point on the plunger.
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M-1002 APPENDIX W
6.2.2 Specimens shall pass the test if they have no cracks or other open defects exceeding 1/8 in.
(3.18 mm), measured in any direction on the convex surface of the specimen after bending, except
that cracks occurring on the corners of the specimen during testing shall not be considered, unless
there is definite evidence that they result from inclusions or other internal defects.
7.0 FILLET WELD SPECIMENS AND TESTS
7.1 Fillet Weld (Tee-Joint) Specimens
T-joint specimens, when required, shall conform to requirements of Fig. W.6.
7.1.1 The fillet weld specimen may be used for qualification test of welder performance and shall
be cut to provide a T-joint section for lateral loading and to provide a cross-section of the weldment,
to be smoothed and etched with a suitable etchant, to give a clear definition of the structure of the
weld metal and heat-affected zone. See Fig. W.6, Sketch A.
7.1.2 The fillet weld specimen shall be used for qualification test of welding procedures for ferritic
steels with their mechanical properties enhanced by quenching and tempering. It shall be cut to
provide five cross-sections of the weldment, each approximately 2 in. (50.8 mm) long. One face of
each section is to be smoothed and etched with suitable etchant to give a clear definition of
structure of the weld metal and heat-affected zone. See Fig. W.6, Sketch B.
7.2 Fillet Weld Tests
7.2.1 The T-joint specimens prepared in accord with Fig. W.6, Sketch A shall contain no visible
cracks.
7.2.2 The vertical member of the performance qualification T-joint shall be loaded laterally and
the load steadily increased until the specimen fractures or bends flat upon itself. To pass, the
specimen shall not fracture; or, if it fractures, the fractured surfaces shall show no evidence of
cracks or incomplete root fusion, and the sum of the lengths of open discontinuities visible on the
fractured surfaces shall not exceed 2 in. (50.8 mm) for ferrous materials and 3/4 in. (19.0 mm) for
nonferrous materials.
7.2.3 The performance qualification T-joint weld shall have no concavity or convexity greater
than 1/16 in. (1.59 mm) and shall have not more than 1/16 in. (1.59 mm) difference in the lengths
of the legs of the fillet weld.
7.2.4 The procedure qualification T-joint weld shall have not more than 1/8 in. (3.18 mm)
difference in the lengths of the legs of the fillet weld.
7.2.5 Visual examination of the etched cross sections of weld metal and heat-affected zones of
performance and procedure qualification T-joint welds shall show freedom from cracks and
complete fusion at the joint root, but not necessarily beyond the root.
8.0 IMPACT, CORROSION AND HARDNESS TESTS
8.1 Impact Specimens and Tests
Impact tests are required only when specified in the tank specification.
8.1.1 Material and Number Required
Test plates used to prepare specimens shall be provided for each tank and shall be from one of the
heats that provided plates for the tank. Where welding is involved, the plates shall be welded
using the same joint detail, WPS and electrodes as required for the tank. Unless otherwise
specified, at least one set of three specimens shall be taken across the weld with notch in the heat-
affected zone and one set of three with notch in the weld metal. See Fig. W.9. When two plates of
different materials are involved, an additional set of three specimens shall be taken so that there
is one set with the notch in each heat-affected zone.
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APPENDIX W M-1002
8.1.2 Type, Location and Orientation of Specimens

Unless otherwise specified, specimens shall be Type A (10 mm 10 mm Charpy V-notch),
prepared in accord with Fig. W.10. Where the thickness of the plate is not sufficient to permit full-
size specimens, the largest subsize possible shall be prepared, maintaining the 10 mm depth of the
specimens. The location and orientation of the specimens and their notches shall be as shown in
Fig. W.9. The heat-affected zone notch shall be located in an area of maximum grain size, as
determined by etching the specimen.
8.1.3 Test Procedure
Specimens shall be tested in accord with ASTM E23 at a temperature specified in the tank
specification. The following precautions are to be observed:
Test specimens, as well as the handling tongs, shall be cooled for a sufficient length of time
(usually 15 minutes) to reach the test temperature.
Test temperature shall be maintained within a range of 3 F (1.67 C).
Test specimens shall be transferred from cooling medium to the anvil of the test machine
and broken within a time lapse of not more than 5 seconds.
8.1.4 Test Results and Retests
8.1.4.1 Unless otherwise specified in the tank specification, the minimum impact test values of
full-size and subsize specimens shall be as shown in Table W.1.
Table W.1 Minimum impact test values

Minimum Value Minimum Value
Each of Two of Three Specimens and
Average of the Three Specimens One of the Three Specimens
Size of Specimen (mm) ft lb J ft lb J
10 by 10 15 20.3 10 13.6
10 by 7.5 12.5 16.9 8.5 11.5
10 by 5 10 13.6 7 9.49
10 by 2.5 5 6.78 3.5 4.74
8.1.4.2 If the value for more than one specimen is below the minimum value specified for the
average of three specimens, or if the value for one specimen is below the minimum value specified
for one of the three specimens (the other two being not less than the minimum value specified for
the average of three specimens), a retest of three additional specimens shall be made, each of
which must be equal or exceed the specified minimum value for the average of three specimens.
Such a retest shall be permitted only when the average value of the three specimens equals or
exceeds the minimum value specified for one of the three specimens.
8.1.4.3 If the required values are not obtained upon retest, or if the values on the initial test are
below the minimum required for retest, the welding procedure and/or the weld metal as the case
may be shall be rejected.
8.1.4.4 When an erratic result is caused by a defective specimen, or there is uncertainty in test
procedure, a retest shall be allowed.
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M-1002 APPENDIX W
8.1.5 Reports
8.1.5.1 A report of impact test results shall include identity of plate material (specification,
grade, and heat number), PQR, and welding electrodes; type and size of impact test specimens;
location and orientation of specimens and notches with respect to plate surface and rolling
direction; and weld metal and weld heat-affected zone impact value for each specimen tested.
8.1.5.2 The complete report of all impact tests shall be retained for not less than 5 years by the
tank fabricator, or by the car owner if the owner so requests.
8.2 Corrosion Specimens and Tests
Corrosion tests are required on tanks fabricated from materials listed in Table M.10.3 when
required by the tank specification.
8.2.1 Material and number required
Test plates used to prepare specimens shall be provided from each heat of material used to
fabricate tanks and each heat of filler metal that is used to weld tanks. Where welding is involved,
the plates shall be welded using the same WPS as used on the tank. At least one set of three
specimens shall be taken from the test plate, located as shown in Fig. W.1 Sketch B. Corrosion
testing of the base metal is not a requirement if the corrosion test has been conducted and certified
by the material supplier. Specimens shall be tested in accord with ASTM A262-85 Practice A. If
the results of Practice A are unacceptable, further testing with Practice B or C is required.
8.2.2 Test criteria
8.2.2.1 Corrosion test specimens shall be considered to be acceptable when each exhibits
corrosion rates not in excess of those listed in Appendix M, paragraph 3.3.2.
8.2.2.2 Weld corrosion test specimens need not be sensitized.
8.2.3 Reports
8.2.3.1 A report of corrosion test specimens shall include identity of plate material (specification,
grade, and heat number), welding procedure, welding electrodes, and corrosion rate for each
specimen tested.
8.2.3.2 The complete report of all corrosion tests shall be retained for not less than 5 years by the
tank fabricator, or by the car owner if the owner so requests.
8.3 Hardness Tests
Hardness tests of production butt welds are required for pressure tank car tanks fabricated from
materials listed in Table M.10.1.
8.3.1 On each tank, at least three points inside and three points outside shall be checked at the
centerline of the welds. Two of the inside points and two of the outside points shall be at
intersections of longitudinal and circumferential butt welds. Grind the weld metal to produce a
flat surface for hardness testing at these check points. Do not grind weld reinforcement below
joining plate surface.
8.3.2 Hardness of weld shall not exceed Brinell 225 (Rockwell C20) after postweld heat
treatment.
8.3.3 Hardness tests of butt welds on multi-unit tank car tanks shall be performed on exterior
weld seams only. One test per weld procedure is required on each tank.
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APPENDIX W M-1002
9.0 PROCEDURE AND PERFORMANCE QUALIFICATION

9.1 Scope
The rules of paragraphs 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0, 11.0, and 12.0 in this appendix apply to
qualification of welding procedures, welders, and welding operators for all types of manual and
machine welding processes permitted by the AAR Tank Car Committee.
9.2 Responsibility
9.2.1 Each facility shall be responsible for its welding and shall have on hand documentation
required by paragraph 9.3.
9.2.2 Each facility shall ensure that welders are trained and qualified in the areas of welding
symbols, welding procedures, acceptance criteria, and other sections of this specification applicable
to their work. The training shall be documented.
9.2.3 Welders not in the employ of the certified facility may be used to fabricate, alter, repair or
convert tank car tanks in accordance with this specification, provided all the following conditions
are met.
9.2.3.1 The certified facility shall be responsible for all welding.
9.2.3.2 All welding shall be performed in accordance with the certified facilitys welding
procedure specifications.
9.2.3.3 All welders shall be qualified by the certified facility in accordance with this specification.
9.2.3.4 The certified facilitys quality control program shall include as a minimum the following:
The designated authority for the administration of the welding quality control program.
A description of the administration and technical supervision for all welders.
A description of the exclusive authority to assign and remove welders without involvement
of any other organization.
A requirement for assigning welder identification symbols.
9.3 Records
Each facility shall maintain a WPS of each of its qualified welding procedures and shall maintain
records (PQR) obtained in qualification of welding procedures and performance qualification of
welders and welding operators. These records shall be certified by a responsible official of the
company and shall be accessible to the AAR representative. Companies may centralize record
storage. Recommended forms for these records are shown in Figs. W.11, W.12, and W.13.
9.4 Identification of Welds
Each qualified welder and welding operator shall be assigned a unique identifying number, letter,
or symbol by the facility. The assigned identification shall be used to identify the work of that
welder or welding operator.
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M-1002 APPENDIX W
9.5 Qualification Restrictions

9.5.1 Facilities shall use AAR-qualified welders and welding operators. ASME performance
qualification for plate materials listed in Appendix M, paragraph 3.0, may be accepted as meeting
this requirement. Radiography used for ASME performance qualification must be in accord with
Appendix W. Completed test plate assemblies must be visually inspected in accord with
paragraph 14.10 below and with paragraph 14.5 or paragraph 14.6, also below, as applicable.
9.5.2 Welders and welding operators shall be tested under the full supervision and control of the
company. Each facility shall qualify the welding procedures, welders, and welding operators used
to produce welds meeting this appendix. The test results from one facility or company shall not be
used to qualify a welding procedure, welder, or welding operator for another company, except that
companies with multiple facilities may share welding procedure specifications when the essential
variables are the same. It is permissible, however, to subcontract preparation of test materials for
welding, preparation of test specimens from completed weldments, nondestructive examination,
and mechanical testing, provided the company accepts full responsibility for any such work.
9.6 Weld Orientation and Test Positions
9.6.1 The orientation of butt and fillet welds with respect to horizontal and vertical planes of
reference are classified as shown in paragraphs 9.6.2 through 9.6.6 below and in Fig. W.7.
9.6.2 Butt welds (shown in Fig. W.14.)
Flat position 1Gplate in a horizontal plane with the weld metal deposited from above
Horizontal position 2Gplate in a vertical plane with the axis of the weld horizontal
Vertical position 3Gplate in a vertical plane with the axis of the weld vertical
Overhead position 4Gplate in a horizontal plane with the weld metal deposited from
underneath
9.6.3 Fillet welds (shown in Fig. W.15).
Flat position 1Fplates so placed that the weld is deposited with its axis horizontal and
its throat vertical
Horizontal position 2Fplate so placed that the weld is deposited with its axis horizontal
on the upper side of the horizontal surface and against the vertical surface
Vertical position 3Fplates so placed that the weld is deposited with its axis vertical
Overhead position 4Fplates so placed that the weld is deposited with its axis horizontal
on the under side of the horizontal surface and against the vertical surface
9.6.4 Performance qualification in one of the above positions shall permit welding within the
range of orientation specified for that position in the table in the tables in Figs. W.7 and W.8.
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APPENDIX W M-1002
9.6.5 Welders who pass the required groove or fillet weld tests listed in paragraphs 9.6.2 or 9.6.3
shall be qualified for the positions of groove welds and fillet welds shown in Table W.2. Welding
vertical down requires separate qualification.
Table W.2 Performance qualificationposition limitations

Qualification Test Position and Type of Weld Qualifieda/
Weld Position Groove Fillet
PlateGroove 1G F F
2G F, H F, H
3G F, V F, H, V
4G F, O F, H, O
3G and 4G F, V, O All
2G, 3G, and 4G All All
PlateFillet 1F F
2F F, H
3F F,H,V
4F F,H,O
3F and 4F All
a/ Welding positions (F=flat, H=horizontal, V=vertical, and O=overhead) are
defined in Figs. W.7 and W.8. Standard Test Positions (1G, 2G, 3G, 4G, 1F,
2F, 3F, and 4F) are defined in paragraphs 9.6.2 and 9.6.3 and Figs. W.14
and W.15.
9.6.6 A facility that does fabrication, repair, alteration, or conversion in a particular position may
make the tests in that position, but such a performance qualification is valid only for the flat
position and for the position actually tested, except that an angular deviation of 15 is permitted
in the inclination of the weld axis and the rotation of the weld face as defined in Figs. W.7 and W.8.
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M-1002 APPENDIX W
10.0 NONDESTRUCTIVE EXAMINATIONS AND ACCEPTANCE STANDARDS

10.1 Scope
These paragraphs define the acceptance criteria and personnel qualifications that shall be used
whenever nondestructive test methods are required by this specification or in a tank specification.
Acceptance criteria for nondestructive testing are described in the following paragraphs:
Radioscopy, paragraph 10.2
Liquid penetrant, paragraph 10.3
Magnetic particle, paragraph 10.4
Ultrasonic examination, paragraph 10.5
10.2 Radioscopic Acceptance Criteria
10.2.1 General
10.2.1.1 A detailed procedure for the radiographic examination of welded joints shall be
established in accord with Appendix T by each facility.
10.2.1.2 A Level II NDT technician, qualified in accord with Appendix T, shall review and
approve all required radiographic examinations.
10.2.2 Acceptance Standards for Radiographed Welds
10.2.2.1 Reference radiographs of ASTM E390, Reference Radiographs for Steel Fusion Welds,
are accepted as a guide to types and degrees of discontinuities detectable by radiographs of steel
welds.
10.2.2.2 Welds whose radiotapes show any of the following types of imperfections shall be
unacceptable:
An elongated slag inclusion that has a length greater than 1/4 in. (6.35 mm) for T up to
3/4 in. (19.0 mm), or 1/3 T for T from 3/4 in. to 2 1/4 in. (19.0 mm to 57.2 mm) (T is
thickness of the thinner plate of the joint)
A group of slag inclusions in line that have an aggregate length greater than T in a weld
length of 12T, except when the distance between successive inclusions exceeds 6L, where L
is the length of the longest inclusion in the group
Any type of crack or zone of incomplete fusion or incomplete penetration
Rounded indications in excess of that specified as acceptable in paragraphs 10.2.3 and
10.2.4 below
10.2.3 Rounded Indications
10.2.3.1 Images of a general circular or oval shape shall be interpreted as rounded indications for
the purpose of this standard. For radiography, the image will appear dark. For fluoroscopy, the
image will appear light.
10.2.3.2 Permissible rounded indications for weld thicknesses intermediate to those illustrated
shall be evaluated by comparison with rounded indications chart for the next thinner material or
by calculation as shown in Table W.3.
10.2.3.3 The total area of the rounded indications as determined from the radiograph shall not
exceed 0.060T in.2 (38.7T mm2) in any 6 in. (152 mm) length of weld, where T is the thickness of
the weld. If the weld is less than 6 in. (152 mm) long, the total area of rounded indications will be
reduced in proportion.
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10.2.3.4 In any 1 in. (25.4 mm) length of weld or 2T, whichever is smaller, rounded indications
may be clustered to a concentration four times that permitted by 0.060T in.2 (38.7T mm2). Such
clustered rounded indications shall be included in the rounded indications in any 6 in. (152 mm)
length of weld that includes the cluster.
10.2.3.5 Aligned rounded indications shall be acceptable provided the summation of the
diameters of the indications is no more than T in a length 12T or 6 in. (152 mm), whichever is less,
provided each indication is separated by a distance at least six times the diameter of the largest
adjacent indication. Aligned rounded indications shall be counted in the total area of permissible
indications in any 6 in. (152 mm) length of weld.
10.2.3.6 The maximum indication dimension shall be 0.2T or 1/8 in. (3.18 mm), whichever is
smaller, except that an isolated indication separated from an adjacent indication by 1 in.
(25.4 mm) or more may be 0.3T or 1/4 in. (6.35 mm), whichever is less.
Table W.3 Maximum permissible rounded indications in radiotapes per 6 in. length of weldconventional units
Total Area Large Indication Size Medium Indication Size Fine Indication Size
Weld of Permitted Approx. Decimal Approx. Decimal Approx. Decimal
Thickness, Indications, Fraction, Value, Fraction, Value, Fraction, Value,
in. in.2 in. in. a/ No. in. in. a/ No. in. in. a/ No.
1/4 0.015 3/128 0.025 31 1/64 0.0138 100
1/2 0.030 3/32 0.10 4 1/32 0.031 40 3/128 0.0195 101
3/4 0.045 1/8 0.125 4 1/32 0.034 50 3/128 0.024 99
1 0.060 1/8 0.125 5 5/128 0.039 50 1/32 0.0275 101
1 1/2 0.090 1/8 0.125 7 3/64 0.048 50 1/32 0.034 99
2 0.120 1/8 0.125 10 7/128 0.055 51 5/128 0.039 100
a/ These values used for calculating total area of permitted rounded indications.
Table W.4 Maximum permissible rounded indications in radiographs per 15.2 mm length of weldSI units
Total Area of Large Indication Size Medium Indication Size Fine Indication Size
Weld Permitted
Thickness, Indications, Decimal Value, Decimal Value, Decimal Value,
mm mm2 mma/ No. mma/ No. mma/ No.
6.35 9.68 0.64 31 0.351 100
12.7 19.4 2.54 4 0.79 40 0.495 101
19.0 29.0 3.18 4 0.86 50 0.610 99
25.4 38.7 3.18 5 0.99 50 0.699 101
38.1 58.1 3.18 7 1.22 50 0.864 99
50.8 77.4 3.18 10 1.40 51 0.991 101
a/ These values used for calculating total area of permitted rounded indications.
10.2.4 Rounded Indication Charts
The rounded indication charts, Figs. W.16 through W.19, illustrate various types of assorted and
uniform, randomly dispersed rounded indications. The chart for each thickness represents the
maximum acceptable rounded indication. The charts represent full-scale 6 in. radiographs and
shall not be enlarged or reduced. The rounded indication distributions shown are not necessarily
the patterns that may appear on the radiograph, but are typical of the number and size of
indications permitted. When rounded indications differ significantly from the charts, the actual
numbers and sizes of the rounded indications may be measured and the total area of rounded
indications calculated.
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10.3 Liquid Penetrant Examination Acceptance Criteria

10.3.1 General
10.3.1.1 This section describes methods that shall be employed whenever liquid penetrant
examination is specified in this specification or in a tank specification. A Level II NDT technician,
qualified in accord with Appendix T, shall review and approve all required liquid penetrant
examinations.
10.3.1.2 Liquid penetrant examination shall be performed in accord with a written procedure
qualified by the facility to be in accord with the requirements of Appendix T.
10.3.2 Evaluation of Indications
An indication is the evidence of a mechanical imperfection. Only indications with major
dimensions greater than 1/16 in. shall be considered relevant.
10.3.2.1 A linear indication is one having a length greater than three times the width.
10.3.2.2 A rounded indication is one of circular or elliptical shape with the length equal to or less
than three times the width.
10.3.2.3 Any questionable or doubtful indications shall be reexamined to determine whether or
not they are relevant.
10.3.3 Acceptance Standards
10.3.3.1 These acceptance standards shall apply, unless other more restrictive standards are
specified for specific materials or applications within this specification. Any indication that is
believed to be nonrelevant shall be regarded as an imperfection, unless it is shown by
reexamination, by the same method or by the use of other nondestructive methods and/or by surface
conditioning, that no unacceptable imperfection is present.
10.3.3.2 All surfaces to be examined shall be free of
relevant linear indications.
relevant rounded indications greater than 3/16 in.
four or more relevant rounded indications, in a line, separated by 1/16 in. or less, edge to
edge.
10.4 Magnetic Particle Examination Acceptance Criteria
10.4.1 General
10.4.1.1 A Level II NDT technician, qualified in accord with Appendix T, shall review and
approve all required magnetic particle examinations.
10.4.1.2 Magnetic particle examination shall be performed in accord with a written procedure
qualified by the facility to be in accord with the requirements of Appendix T.
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10.4.2 Evaluation of Indications

Indications will be revealed by retention of magnetic particles. All such indications are not
necessarily imperfections, however, because excessive surface roughness, magnetic permeability
variations (such as at the edge of heat-affected zones), etc., may produce similar indications. These
are considered nonrelevant indications.
Only indications that are the result of mechanical imperfection and have any dimension greater
than 1/16 in. shall be considered relevant.
10.4.2.1 A linear indication is one having a length greater than three times the width.
10.4.2.2 A rounded indication is one of circular or elliptical shape with a length equal to or less
than three times its width.
10.4.2.3 Any questionable or doubtful indications shall be reexamined to determine whether or
not they are relevant.
10.4.3 Acceptance Standards
10.4.3.1 These acceptance standards shall apply, unless other more restrictive standards are
specified for specific materials or applications within this specification. Any indication that is
believed to be nonrelevant shall be regarded as an imperfection, unless it is shown by
reexamination, by the same method or by the use of other nondestructive methods and/or by
surface conditioning, that no unacceptable imperfection is present.
10.4.3.2 All surfaces to be examined shall be free of
relevant linear indications.
relevant rounded indications greater than 3/16 in.
four or more relevant rounded indications, in a line, separated by 1/16 in. or less, edge to
edge.
10.5 Ultrasonic Examination
10.5.1 General
10.5.1.1 Ultrasonic examination may be employed in accord with Appendix T for groove welds in
butt joints on tank car tanks. A detailed procedure shall be established in accord with Appendix T
by each facility.
10.5.1.2 A Level II or Level III NDT technician, qualified in accord with Appendix T for
ultrasonic testing, shall review and approve all required ultrasonic examinations.
10.5.2 Ultrasonic Acceptance Criteria
Discontinuities that produce a response greater than 20% of the reference level shall be
investigated to the extent that the operator can determine the shape, identity, and location of all
such discontinuities and evaluate them in terms of the acceptance standards given below:
10.5.2.1 Indications characterized as cracks, lack of fusion, or incomplete penetration are
unacceptable regardless of length.
10.5.2.2 Any relevant indication that intersects the surface of the component or weld shall be
rejectable, unless the indication is determined to be caused by a visually (VT) acceptable condition.
10.5.2.3 Other discontinuities are unacceptable if the indications exceed the reference level and
have lengths that exceed the following:
10.5.2.3.1 1/4 in. (6.35 mm) for T up to 3/4 in. (19.0 mm), or 1/3 T for T from 3/4 in. to 2 1/4 in.
(19.0 mm to 57.2 mm) (T is thickness of the thinner plate of the joint)
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10.5.2.3.2 A group of indications that have an aggregate length greater than Ta/ in a weld length
of 12T or 6 in., whichever is less, except when the distance between successive indications exceeds
6L, where L is the length of the longest indication in the group.
10.5.3 Any indication that is believed to be non-relevant shall be regarded as an imperfection
unless it is shown by reexamination that no unacceptable imperfections are present.
Reexamination shall be performed by the same method or by the use of other nondestructive
methods and/or by surface conditioning.
11.0 PERFORMANCE QUALIFICATION OF WELDERS AND WELDING OPERATORS
11.1 Qualification of Welders
Each welder shall pass the mechanical tests prescribed in paragraph 11.6 below for performance
qualification, except that welders making a groove weld with shielded metal-arc welding, flux-
cored arc welding, gas metal arc welding (except short circuiting), or gas-shielded tungsten arc
welding may alternatively be qualified by radiographic or ultrasonic examination as prescribed in
paragraph 11.6 below. The welder who welds the welding procedure qualification test plate that
results in a qualified WPS shall be performance qualified, but only within the limits of essential
variables given in paragraph 11.4 below.
11.1.1 Performance qualification tests for butt, fillet, and buildup welds, including nozzles and
other circular attachments to the shell, shall be made using butt-welded test plates (see Figs. W.3,
Sketch A, W.14, W.20, Sketch C, and W.20, Sketch D). Satisfactory qualification test results on
specimens prepared from the butt-welded test plates, or alternatively by radiographic
examinations, shall qualify a welder to make butt welds in thicknesses determined by test plate
thickness and fillet welds in all thicknesses, both within the range of essential variables as
recorded in the welders Record of Welder Performance Qualification Test (see Fig. W.13).
11.1.2 Performance qualification tests for fillet welds, only, may be made using fillet-welded test
plates (see Figs. W.6, Sketch A and W.15. Satisfactory qualification test results on specimens
prepared from the fillet-welded test plate shall qualify a welder to make fillet welds in all
thicknesses within the range of essential variables as recorded in the welders Record of Welder
Performance Qualification Test (see Fig. W.13).
a/ "T" is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thicknesses at the weld, "T" is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in "T."
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11.2 Qualification of Welding Operators

Each welding operator who welds on tanks being fabricated, repaired, altered, or converted shall
be performance-qualified for each welding process under which the welder does welding with
automatic welding equipment, in which both the rate of travel and position of welding head with
respect to the work are controlled mechanically, except for minor adjustments for such factors as
plate unevenness, out-of-roundness, and lead angle of the welding head. The welding operator who
welds the welding procedure qualification test plate that results in a qualified WPS shall be
performance-qualified.
11.2.1 A 3 ft (914 mm) length of weld made by the operator shall be radiographed using the
technique of paragraph 10.0 above. To qualify the operators performance, the radiograph shall
comply with the acceptance standards of the same section. The length of weld radiographed may
be that of a test plate or of production welding.
11.2.2 If the weld does not comply with the acceptance standards, second and subsequent 3 ft
(914 mm) lengths welded by the operator using the machine-welding procedure shall be
radiographed, until the operator demonstrates that he or she is capable of producing welds that
comply with the acceptance standards. Production welds so examined shall be unacceptable if they
do not comply with the minimum requirements for the tank being fabricated.
11.2.3 The results of the radiographic examination shall be recorded and retained by the facility.
The radiographs may be retained or be discarded.
11.2.4 Performance qualification tests for fillet welds only may be made using fillet-welded test
plates (see Figs. W.6.1 and W.15. Satisfactory qualification test results on specimens prepared
from the fillet-welded test plate shall qualify a welder to make fillet welds in all thicknesses
within the range of essential variables as recorded in the welders Record of Welder Performance
Qualification Test (see Fig. W.13).
11.3 Weldments Involving Combination of Processes
11.3.1 Welds requiring a combination of processes may be performed by one or more welding
operators or welders, each welding only that portion of the weldment for which he or she is
performance-qualified.
11.3.2 Where a combination of processes are used, the welder or welding operator who is to make
the root pass shall be tested only by means of a minimum of two root-bend specimens instead of
the face-bend and side-bend specimens required in Table W.6.
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11.4 Essential Variables

When any of the applicable changes in the essential variables as described in paragraph 15.2
below and in Table W.5 are made, the welder must be requalified.
Table W.5 Essential variablesperformance qualification

Welding Process (references are to paragraph numbers in this appendix)
SMAW GTAW GMAW, FCAW SAW
Jointsparagraph 15.2.1 15.2.1.1 15.2.1.1 15.2.1.1 15.2.1.1
Base Metalsparagraph 15.2.2 15.2.2.2, 15.2.2.3 15.2.2.2, 15.2.2.3 15.2.2.2, 15.2.2.3 15.2.2.2, 15.2.2.3
Filler Metalsparagraph 15.2.3 15.2.3.17 15.2.3.9, 15.2.3.11, 15.2.3.9, 15.2.3.11, 15.2.3.17
15.2.3.17 15.2.3.17
Positionsparagraph 15.2.4 15.2.4.1, 15.2.4.3 15.2.4.1, 15.2.4.3 15.2.4.1, 15.2.4.3 15.2.4.1
Electrical Characteristics 15.2.7.2 15.2.7.1
paragraph 15.2.7
Shielding Gas or Flux 15.2.8.2 15.2.8.2
paragraph 15.2.8
Techniqueparagraph 15.2.9 15.2.9.4 15.2.9.4 15.2.9.4 15.2.9.4
11.5 Test Joints

11.5.1 Information regarding the essential variables in paragraph 11.4 above (base material,
filler metal, welding position, etc.) shall be recorded in the facilitys Record of Welder Performance
Qualification Test prepared for each welder qualified (see Fig. W.13.) Other details that are
essential variables of the WPS being used shall be followed in making the performance
qualification, except as otherwise allowed below. Postweld heat treatment of welder performance
test coupons may be omitted. The dimensions of the test plates and the length of the weld shall be
sufficient to provide the required test specimens. If the alternative qualification by radiographic or
ultrasonic examination is used for groove welds as permitted in paragraph 11.1, the minimum
length of weld radiographed or ultrasonically inspected and evaluated in plate shall be 6 in.
(153 mm) and shall include a stop-start in each pass along the length of weld.
11.5.2 The dimensions of the welding groove for the test joint for double-welded butt joints and
for single-welded butt joints with or without backing strip shall be the same as those for any WPS
the facility has qualified. The dimensions of the fillet weld shall be as shown in Fig. W.6, Sketch A.
11.5.3 Carbon and alloy steel. When a welder is to be qualified to weld on carbon or alloy steel,
except austenitic stainless steels of P-8, the test plates shall be base metal of the P-number or P-
numbers to be joined in production welding, except that carbon steel P-1 base metals may be used
for the qualification tests, with the following limitations:
11.5.3.1 The total alloy content of the base metal, for which carbon steel base metal is
substituted, shall not exceed a nominal 6%. The total alloy content of the weld metal used shall not
exceed this nominal 6%.
11.5.3.2 When a welder is to be qualified to weld on alloy steel base metal that has a total alloy
content exceeding a nominal 6%, carbon steel plates may be used in the performance qualification
tests when using F-41 filler metal of Table W.11. No preheating or postheating is required.
11.5.3.3 When alloy steel filler metals as permitted in paragraph 11.5.3.1 above are used on
carbon steel plate, the test specimens are to be preheated and postheated in accord with the WPS.
11.5.4 Austenitic stainless steel and nickel-base alloys. When a welder is to be qualified to
weld on austenitic stainless steel P-8 metal or nickel alloy P-41 metal, carbon steel plates of P-1
may be used for the performance test.
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11.5.5 When a welder is to be qualified for the use of F-5 filler metal of weld metal analysis A-7 or
A-8 to join P-1 or P-8 base metals to themselves or to each other, carbon steel plate may be used for
the performance qualification test. A performance qualification test made using A-8 or A-9 (F-5
filler metals) with one or a combination of P-1 or P-8 base metal will qualify for all combinations of
these base metals.
11.6 Test Specimens
11.6.1 The qualification test weld shall be visually inspected in the as-welded condition (no
grinding after completing the weld) in accordance with paragraphs 14.5 and 14.10 below, except
that reinforcement may be up to 1/8 in. For welder performance qualification by mechanical
testing, the type and number of test specimens required, together with the range of thickness of
materials for which a welder is qualified by use of a given thickness of test plate, are shown in
Table W.6. When alternative qualification by radiographic or ultrasonic examination of groove
welds is used as permitted in paragraph 11.1, the range of thickness of materials for which a
welder is qualified shall be the same as for mechanical testing in Table W.6.
11.6.2 Test specimens may be removed from the welded test plates in any order, but in a manner
similar to that shown in Figs. W.20, Sketch C, and W.20, Sketch D.
11.6.3 All test specimens shall be prepared, tested and meet the requirements as prescribed in
applicable portions of paragraphs 6.0, 7.0, and 9.0 of this appendix. When alternative qualification
by radiographic or ultrasonic examination of groove welds is used as permitted in paragraph 11.1,
the radiographic or ultrasonic acceptance standards of the applicable portions of paragraph 10.0
above shall be used.
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11.6.4 The number of test plates (and sets of test specimens) required by Table W.6 shall be
prepared and tested to provide performance qualification of each welder for the test positions
that will be used in the fabrication, repair, alteration, or conversion of tank car tanks.
Table W.6 Performance qualification tests required
Range of Thickness of Type and Number of Tests Required
Material Qualified by
Test Plate, in. (mm) Guided-Bend Test
Side- Face- Root-
Type Bend Bend Bend
of Thickness (t) of Test Plate Fig. W.4, Fig. W.4, Fig. W.4, Fillet Tee-
Joint As-Welded, in. (mm) Min. Max. Sketch Cb/c/d/ Sketch Ac/ Sketch Bc/ Jointa/
Butt 1/16 (1.59) to 3/8 (9.5 incl.) 1/16e/
(1.59e/) 2t 1 1
Butt Over 3/8 (9.5) but less than
1/2 (12.7) 3/16 (4.76) 2t 1 1
or
Over 3/8 (9.5) but less than
1/2 (12.7) 3/16 (4.76) 2t 2
Butt 1/2 (12.7) and over Max. to be
3/16 (4.76) weldedf/ g/ 2
Fillet Fig. W.6, Sketch A Unlimited 1
a/ Required only when qualification is desired to make fillet welds only.
b/ For aluminum alloy 6061, use Fig. W.4, Sketch D.
c/ Longitudinal face-bend and longitudinal root-bend tests (Fig. W.3, Sketch B) may be used in
lieu of side-, face-, and root-bend tests only for material combinations differing markedly in
physical bending properties between the two base materials or between the weld metal and
the base materials.
d/ For groove welds made by manual shielded metal-arc welding process, flux-cored arc process,
gas-shielded tungsten arc process, or gas metal arc welding (except short circuiting),
radiography may be used in lieu of guided-bend tests. See paragraph 11.6.3 above.
e/ 0.5t for nonferrous materials, but not less than 1/16 in. (1.59 mm).
f/ When longitudinal face-bend and longitudinal root-bend tests are used in lieu of side-bend
tests, the maximum thickness of material qualified is 2t.
g/ A welder who qualified with 1/2 in. material prior to the reduction in this table may have his
WPQR changed from 2T to thickness to be welded.
11.7 Retests
A welder who fails the performance qualification tests may be retested under the following
conditions:
11.7.1 If one or more of the test specimens prescribed in Table W.6 fails to meet the requirements,
or if the qualification failed has been that of the alternative qualification by radiographic
examination of paragraph 11.6 above.
11.7.1.1 When a retest is made without further training or practice, the welder shall make two
test welds of each type for each test position on which the welder failed, all of which shall meet
the requirements.
11.7.1.2 When the welder has had further training or practice, a complete retest shall be made
for each test position on which the welder failed to meet the requirements.
11.7.2 If the performance qualification test failed was by radiographic or ultrasonic examination,
the retest shall be by the radiographic or ultrasonic examination method, respectively.
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11.8 Renewal of Qualification

Renewal of qualification of welders and welding operators used to fabricate, repair, alter, or
convert AAR-approved tanks is required under the following circumstances:
11.8.1 When the welder or welding operator has not used the specific process for which he or she
was qualified by the employer for a period exceeding six months. Renewal of qualifications under
this paragraph shall be made in all positions in which welding is to be performed in accordance
with Table W.2.
11.8.2 When there is specific reason to question the welders ability to make welds that meet this
specification. Renewal of qualifications under this subparagraph shall be made in all positions in
which welding is to be performed in accordance with Table W.2.
12.0 PROCEDURE QUALIFICATION
12.1 Qualification of Procedures
12.1.1 All welding shall be done in accord with a WPS. Each manufacturer or contractor shall
qualify each WPS used by the welding of test coupons and the testing of specimens as required by
this appendix, recording the welding conditions and test results in a PQR. The essential variables
of the WPS must be within the limits that are qualified by the PQR.
Each facility must have and document a clearly defined system to ensure that the welding
parameters being used are within the limits of a qualified WPS. For gas shielded processes, the gas
flow rate range will be specified on the WPS.
12.1.2 Except for steels having their mechanical properties enhanced by quenching and
tempering, procedure qualification tests for butt and fillet welds shall be made using butt-welded
test plates (see Figs. W.3, Sketch A, W.14, W.20, Sketch A, and W.20, Sketch B). Procedures used
for deposits of metal applied to the surface of any thickness shall be qualified by using butt-welded
test plates of at least 7/16 in. thick. Satisfactory qualification test results on specimens prepared
from the butt-welded test plates shall qualify a welding procedure for use with both butt and fillet
welds, including nozzles and other circular attachments to the shell, within the range of essential
variables of its WPS. (See Fig. W.11.)
12.1.3 For steels having their mechanical properties enhanced by quenching and tempering,
procedure qualification tests for butt welds shall be made using butt-welded test plates (see
Figures Figs. W.3, Sketch A, W.14, W.20, Sketch A, and W.20, Sketch B), and tests for fillet welds
shall be made using fillet-welded test plates (see Figs. W.6, Sketch B and W.15). Satisfactory
qualification test results on specimens prepared from the butt-welded test plates shall qualify a
welding procedure for use with butt welds, including nozzles and other circular attachments to the
shell, within the range of essential variables of its WPS. Satisfactory qualification test results on
specimens prepared from the fillet-welded test plate shall qualify a welding procedure for use with
fillet welds, including nozzles and other circular attachments to the shell, within the range of
essential variables of its WPS. (See Fig. W.11.)
12.1.4 Unless otherwise specified for special commodities (see 49 CFR 179.102), WPS used in
welding pressure car head and shell joints (including nozzle-to-shell welds) shall be qualified with
PQRs that have been Charpy impact tested at or below 30 F (34 C) to meet the requirements
of Table W.1. In addition to the requirements specified in Table W.7, Essential Variables,
Table W.8, Supplementary Essential Variables, applies to procedure development. Production tests
do not require impact testing, unless otherwise specified. Austenitic stainless steel tanks made in
accord with paragraph 16.9.2 below without postweld heat treatment, using type 304L or 316L
filler metals meeting AWS specifications, are exempt from the requirements of this paragraph.
Weld procedures for special commodities shall match the base metal requirements listed in
49 CFR 179.102.
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When any of the applicable changes in the essential variables, as described in paragraph 15.2
below and in Tables W.7 and W.8, are made in a WPS, a new procedure qualification test will be
performed and documented on a PQR. Changes other than or within limits of those listed may be
made in the WPS and not require requalification, provided the WPS is revised to show the
changes. When notch toughness is required by the tank car specification, the supplementary
essential variables apply.
Table W.7 Essential variableswelding procedures
Welding Process
Base Metalsparagraph 15.2.2 15.2.2.1, 15.2.2.4, 15.2.2.1, 15.2.2.1, 15.2.2.4, 15.2.2.1, 15.2.2.4,
15.2.2.8 15.2.2.4, 15.2.2.8 15.2.2.8, 15.2.2.9 15.2.2.8
Filler Metalsparagraph 15.2.3 15.2.3.1, 15.2.3.2, 15.2.3.1, 15.2.3.1, 15.2.3.2, 15.2.3.1, 15.2.3.2,
15.2.3.16, 15.2.3.17 15.2.3.2, 15.2.3.3, 15.2.3.5, 15.2.3.6, 15.2.3.7,
15.2.3.3, 15.2.3.6, 15.2.3.7, 15.2.3.8, 15.2.3.10,
15.2.3.4, 15.2.3.8, 15.2.3.10, 15.2.3.15, 15.2.3.16,
15.2.3.10, 15.2.3.16, 15.2.3.17 15.2.3.17
15.2.3.16,
15.2.3.17
Positionsparagraph 15.2.4 15.2.4.3 15.2.4.3 15.2.4.3
Preheatparagraph 15.2.5 15.2.5.1, 15.2.5.3 15.2.5.1, 15.2.5.3 15.2.5.1, 15.2.5.3 15.2.5.1, 15.2.5.3
Postweld Heat Treatment 15.2.6 15.2.6 15.2.6 15.2.6
paragraph 15.2.6
Electrical Characteristics 15.2.7.2 15.2.7.1, 15.2.7.2
paragraph 15.2.7
Shielding Gas or Flux 15.2.8.1, 15.2.8.2 15.2.8.1, 15.2.8.2 15.2.8.4, 15.2.8.5
paragraph 15.2.8
Techniqueparagraph 15.2.9 15.2.9.4 15.2.9.2, 15.2.9.4 15.2.9.2, 15.2.9.4 15.2.9.4
Table W.8 Supplementary essential variableswelding procedures
when notch toughness required by tank car specification a/
Welding Process
Base Metalsparagraph 15.2.2 15.2.2.5, 15.2.2.7 15.2.2.5, 15.2.2.7 15.2.2.5, 15.2.2.7 15.2.2.5, 15.2.2.7
Filler Metalsparagraph 15.2.3 15.2.3.12, 15.2.3.13 15.2.3.13 15.2.3.13, 15.2.3.14
Positionsparagraph 15.2.4 15.2.4.2 15.2.4.2 15.2.4.2
Preheatparagraph 15.2.5 15.2.5.2 15.2.5.2 15.2.5.2 15.2.5.2
Electrical Characteristics 15.2.7.3 15.2.7.3 15.2.7.3 15.2.7.3
paragraph 15.2.7
Shielding Gas or Flux 15.2.8.3
paragraph 15.2.8
Techniqueparagraph 15.2.9 15.2.9.1, 15.2.9.3 15.2.9.1, 15.2.9.3 15.2.9.1, 15.2.9.3
a/ Applies to welds of tank heads, shells, and sumps and to welds attaching connections
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APPENDIX W M-1002
Table W.9 F-Numbers for steel filler metalsgrouping of electrodes and welding rods for qualification
F-No. AWS Specification No. AWS Classification No.
1 A-5.1 and 5.5 EXX20, EXX24, EXX27, EXX28
2 A-5.1 and 5.5 EXX12, EXX13, EXX14
3 A-5.1 and 5.5 EXX10, EXX11
4 A-5.1 and 5.5 EXX15, EXX16, EXX18, EXX48
4 A-5.4 other than austenitic EXX15, EXX16
5 A-5.4 (austenitic) EXX15, EXX16
6 A-5.17 FXX-EXX
6 A-5.9 ERXX
6 A-5.18 ERXXS-X
6 A-5.20 EXXT-X
6 A-5.22 EXXXT-X
6 A-5.23 FXX-EXXX-X, FXX-ECXXX-X, and FXX-EXXX-XN,
FXX-ECXXX-XN
6 A-5.28 ER-XXX-X and E-XXX-X
6 A-5.29 EXXTX-X
Table W.10 A-Numbersclassification of ferrous weld metal analysis for procedure qualification
Analysis, Percentagea/
A-No. Type of Weld Deposit C Cr Mo Ni Mn Si
1 Mild Steel 0.15 1.60 1.00
2 Carbon-Molybdenum 0.15 0.50 0.400.65 1.60 1.00
3 Chrome (0.4% to 2%)- 0.15 0.402.00 0.400.65 1.60 1.00
Molybdenum
4 Chrome (2% to 6%)-Molybdenum 0.15 2.006.00 0.401.50 1.60 2.00
5 Chrome (6% to 10.5%)- 0.15 6.0010.50 0.401.50 1.20 2.00
Molybdenum
6 Chrome-Martensitic 0.15 11.0015.00 0.70 2.00 1.00
7 Chrome-Ferritic 0.15 11.0030.00 1.00 1.00 3.00
8 Chromium-Nickel 0.15 14.5030.00 4.00 7.5015.00 2.50 1.00
9 Chromium-Nickel 0.30 25.0030.00 4.00 15.0037.00 2.50 1.00
10 Nickel to 4% 0.15 0.55 0.804.00 1.70 1.00
11 Manganese-Molybdenum 0.17 0.250.75 0.85 1.252.25 1.00
12 Nickel-Chrome-Molybdenum 0.15 1.50 0.250.80 1.252.80 0.752.25 1.00
a/ Single values shown above are maximum.
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M-1002 APPENDIX W
Table W.11 F-Numbers for nonferrous filler metalsgrouping of electrodes and welding rods for qualification
F-No. AWS Specification No. AWS Classification No.
Aluminum and Aluminum-Base Alloys
21 A-5.10 ER 1100
22 A-5.10 ER 5554, ER 5356, ER 5556, ER 5183, ER 5654
23 A-5.10 ER 4043, ER 4047, ER 4145
24 A-5.10 R-SC 51A, R356.0
Nickel and Nickel-Base Alloys,
41 A-5.11 E Ni-1
41 A-5.14 ER Ni-1
12.3 Test Joints
12.3.1 The base material, the filler metal, and the welding procedure shall comply with the
applicable WPS. Information regarding the essential variables in paragraph 12.2 above shall be
recorded in the facilitys PQRs prepared for each procedure qualified (See Fig. W.11). The
dimensions of the test plates and the length of the welds shall be sufficient to provide the required
test specimens.
12.3.2 The dimension for plates used for fillet welds shall be as noted in Fig. W.6, Sketch B.
12.3.3 When making procedure tests for butt welds, it is recommended that consideration be
given to the effect of angular, lateral, and end restraint on the weldment. This applies particularly
to material and weld metal of 80,000 psi (552 MPa) tensile strength or higher and heavy sections
of both low- and high-tensile-strength material. The addition of restraint during welding may
result in cracking that otherwise may not occur.
12.3.4 Weld grooves for thicknesses less than 5/8 in. (15.9 mm) shall be prepared by thermal
processes when such processes are to be employed during fabrication of quenched and tempered
materials. This groove preparation shall also include back gouging, back grooving, or removal of
unsound weld metal by thermal processes when this procedure is employed during fabrication.
12.4 Test Specimens
12.4.1 For procedure qualifications, the type and number of test specimens required, together
with the range of thickness qualified by a given thickness of test plate, are shown in Table W.12.
12.4.2 Test specimens shall be removed in the order shown in Figs. W.3, Sketch B, W.6, Sketch B,
W.20, Sketch A, and W.20, Sketch B.
12.4.3 All test specimens shall be prepared and tested and meet the requirements as prescribed
in applicable portions of paragraphs 5.0, 6.0, 7.0, 9.0, and 10.2 of this appendix.
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APPENDIX W M-1002
12.4.4 The number of test plates (and sets of test specimens) required by Table W.12 shall be
prepared and tested to provide procedure qualification that will be used in the fabrication, repair,
alteration, or conversion of AAR-approved tanks.
Table W.12 Procedure qualification tests required

Range of Type and Number of Test Requiredb/
Thickness of
Material
Qualified by
Test Plate,a/
in. (mm) Tension Guided Bend Tests
Fillet
Side-Bend Face-Bend Root-Bend Tee-Joint
Thickness (t) of Test Plate Fig. W.4, Fig. W.4, Fig. W.4, Fig. W.6,
As-Welded, in. (mm) Min.c/ Max. Fig. W.2 Sketch Cd/e/ Sketch Ae/ Sketch Be/ Sketch Bf/
1/16 (1.59) to 3/8 (9.5) incl. 1/16g/ 2t 2 2 2
(1.59g/)
Over 3/8 (9.5) but less than 3/4 (19.0) 3/16 2th/ 2 2 2
(4.76)
or 3/16
Over 3/8 (9.5) but less than 3/4 (19.0) (4.76) 2th/ 2 4
3/4 (19.0) and over 3/16 2th/ 2 4
(4.76)
Fillet (Fig. W.6, Sketch B) Unlimited 5
a/ All groove welds qualify fillet welds on any thickness of base metal.
b/ When impact or corrosion tests are required by the tank specification, they shall be included
as a requirement of the procedure qualification and taken at test plate locations as shown in
Figs. W.20, Sketch A and W.2.1.
c/ Unless restricted by Table W.8 and paragraph 15.2.2.7
d/ For aluminum alloy 6061, use Fig. W.4, Sketch D.
e/ Longitudinal face-bend and longitudinal root-bend tests (Fig. W.3.1) may be used in lieu of
side-, face-, and root-bend tests only for testing material combinations differing markedly in
physical bending properties between the two base materials or between the weld metal and
the base materials.
f/ Required only for ferritic steels having their mechanical properties enhanced by quenching
and tempering.
g/ 0.5t for nonferrous materials, but not less than 1/16 in. (1.59 mm).
h/ For gas metal-arc welding, submerged arc welding, and gas tungsten arc welding, the
thickness limitations for production welding based on a test plate thickness, t, shall be as
follows:
1. For single-pass welding, with no backing strip or against a metal or ceramic backing, the maxi-
mum thickness welded in production shall not exceed the thickness of the test plate.
2. If the test plate is welded by a procedure involving one pass from each side, the maximum thick-
ness that may be welded in production shall be 2t, where 2t shall not exceed 2 in. (50.8 mm). If
sections heavier than 2 in. (50.8 mm) are to be welded in production, a separate test plate shall be
prepared, of a thickness not less than the thickness to be used in production.
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12.5 Retests
When one or more of the test specimens in Table W.12 fail to meet the requirements, a retest may
be made under the following conditions:
12.5.1 When failure of specimens can be attributed to welder performance, an immediate retest
may be made.
12.5.2 When failure of specimens can be attributed to essential variables of the WPS, make
necessary changes and make a new qualification test.
12.6 Renewal of Qualification
Once a welding procedure is qualified, it shall continue in effect indefinitely, within the range of its
essential variables.
13.0 FABRICATION
13.1 Forming
Forming of plates shall be done by pressure and not by impact. This includes the edges of the
plates forming longitudinal joints.
13.2 Cutting to Size
13.2.1 Ferrous and nonferrous plates, edges of heads, and other parts may be cut to size and
shape by mechanical means such as machining, shearing, or grinding or by applicable thermal
cutting.
13.2.2 Oxygen- or arc-cut edges shall be uniform and smooth and shall be free of fins, tears,
cracks, loose or thick scale, slag, surface oxides, moisture, grease, and other foreign material that
would prevent proper welding. Detrimental oxidation of material that was molten shall also be
removed. Discoloration that may remain on oxygen-cut carbon and low-alloy-steel surfaces is not
considered detrimental to welding.
13.3 Alignment
13.3.1 Plates and heads that are being welded shall be fitted, aligned, and retained in position
during the welding operation.
13.3.2 Bars, jacks, clamps, or other appropriate devices, including tack welds, may be used to
hold in alignment the edges to be welded. Temporary tack welds shall be removed. Tack welds
shall be incorporated during final welding or removed. Temporary and/or tack welds shall be
deposited in accordance with a qualified welding procedure. Temporary tack welds shall be
removed and the surface restored to original contour. When temporary welds are deposited after
unit PWHT, the affected area shall be examined (after removal of the temporary weld) by PT or
MT to ensure soundness. Repairs shall be made in accordance with Appendix R.
13.3.3 The parts to be joined by fillet welds shall be brought into as close contact as practicable.
The root opening shall not exceed 3/16 in. (4.8 mm). If the separation is 1/16 in. (1.6 mm) or
greater, the leg of the fillet weld shall be increased by the amount of the separation, or the
manufacturer shall demonstrate that the required effective weld size has been obtained.
13.3.4 For butt welding of plates of unequal thickness, see Appendix E.
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APPENDIX W M-1002
13.4 Welding Conditions

13.4.1 Welding shall not be done when the ambient temperature is lower than 0 F (17.8 C). At
temperatures between 32 F (0 C) and 0 F (17.8 C), the surface of all areas, within 3 in.
(76.2 mm) of the point where a weld is to be started, shall be heated to a minimum of 50 F (10 C)
before welding is started. If the ambient environmental temperature is below 0 F (17.8 C), a
heated structure or shelter around the area being welded may maintain the temperature adjacent
to the weldment at 0 F (17.8 C) or higher.
13.4.2 Welding shall not be done when the surfaces of the parts to be welded are wet. Welding
shall not be done when rain or snow is falling or during periods of high winds, unless the welder
and work are properly shielded.
13.5 Out-of-Roundness of Shells
The shell of a completed tank of circular cross-section shall be circular within 1% of the inside
diameter of the tank at the location of measurement.
13.6 Tolerance for Heads
See Appendix E, paragraph 1.3, for permissible deviation of a head from the specified shape.
13.7 Arc Strikes
Cracks or blemishes (visible marks) caused by arc strikes shall be removed and the surface
restored to original contour. When arc strikes are discovered after unit PWHT, the affected area
shall be examined (after removal of the arc strike) by PT or MT to ensure soundness. Repairs shall
be made in accordance with Appendix R.
13.8 Preheat and Interpass Temperature
Base metal shall be preheated, if required, to a temperature not less than the minimum value
listed on the WPS (see Table W.7 for WPS essential variable limitations). The preheat and all
subsequent minimum interpass temperatures shall be maintained during the welding operation
for a distance at least equal to the thickness of the thickest welded part, but not less than 3 in. in
all directions from the point of welding. Minimum interpass temperature requirements shall be
considered equal to the preheat requirements, unless otherwise indicated on the WPS. The
preheat and interpass temperature shall be checked just prior to initiating the arc for each pass.
14.0 WELD JOINTS
14.1 Welder Visual Acuity
Welders are not subject to the requirements of Appendix T unless also certified to perform
nondestructive examination in accordance with Appendix T.
14.2 Visual Acuity Requirements
14.2.1 Welders must have a documented visual acuity examination administered prior to
production welding and at a minimum once every 3 years. Welders shall be examined to ensure
that they have natural or corrected near-distance visual acuity in at least one eye such that each
individual is capable of reading a Jaeger Number 2 test chart or equivalent at a distance of not less
than 12 in.
14.2.2 Welders examined in accordance with the vision requirements of AWS QC-1, CSA 178.2, or
Appendix T meet Appendix W visual acuity requirements for welders.
14.3 Cleaning During Welding
When weld metal is to be deposited over a previously welded surface, all visible slag shall be
removed to prevent inclusion of impurities in the weld metal.
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M-1002 APPENDIX W
14.4 Alignment Tolerances

Alignment of sections at edges that have been butt-welded shall be such that the maximum offset
is not greater than the applicable amount listed in Table W.13. Joints within tank heads and dome
heads shall meet the requirements in Table W.13 for longitudinal joints.
Table W.13 Alignment tolerances

Direction of Joints in Cylindrical Shells
Section Thickness, in. (mm) Longitudinala/ Circumferentiala/
Up to 1/2 (12.7) inclusive 1/4 t 1/4 t
Over 1/2 (12.7) to 3/4 (19.0) inclusive 1/8 in. (3.18 mm) 1/4 t
Over 3/4 (19.0) to 1 1/2 (38.1) inclusive 1/8 in. (3.18 mm) 3/16 in. (4.76 mm)
Over 1 1/2 (38.1) to 2 (50.8) inclusive 1/8 in. (3.18 mm) 1/8 t
Over 2 (50.8) Lesser of 1/16 t or 3/8 in. Lesser of 1/8 t or 3/4 in.
(9.52 mm) (19.0 mm)
a/ t is nominal thickness of the thinner section of the joint.
14.5 Weld Reinforcement (Butt Welds)
The surface of any weld metal shall be at least flush with the adjoining plate surface and may be
built up as reinforcement, which shall not exceed 3/32 in. (2.38 mm) for plates 5/8 in. (15.9 mm)
and thinner, nor 1/8 in. (3.18 mm) for thicker plates. The weld bead reinforcement shall have a
gradual transition from its maximum allowable crown to the plane of the base metal surface.
14.5.1 The reinforcement need not be removed, except to the extent that it exceeds the allowable
buildup above or does not conform with requirements of paragraphs 10.2.1 and 14.10 of this
appendix.
14.5.2 For a single-welded butt joint with backing strip, the requirements for reinforcement
apply only to the side opposite the backing strip.
14.6 Fillet Welds
14.6.1 Concavity and convexity shall fall within the ranges shown in Table W.14. Weld size of
fillet welds shall not be below the specified size by more than 1/32 in., except that fillet welds over
3/16 in. may be 1/16 in. undersize for up to 10% of the length of the weld.
14.6.2 Weld metal shall be deposited in such a way that adequate penetration into the base metal
at the root of the weld is secured.
14.6.3 Toes of fillet welds shall blend smoothly into base metal.
Table W.14 Concavity and convexity of fillet welds

Maximum, in. (mm)
Fillet Leg Size, in. (mm) Concavity Convexity
Up to 3/16 (4.76) inclusive 1/32 (0.794) 1/32 (0.794)
Over 3/16 (4.76) to 5/16 (7.94) inclusive 1/32 (0.794) 1/16 (1.59)
Over 5/16 (7.94) to 1/2 (12.7) inclusive 1/16 (1.59) 3/32 (2.38)
Over 1/2 (12.7) 3/32 (2.38) 1/8 (3.18)
14.7 Interrupted Welding
If the welding is stopped for any reason, care shall be taken in restarting to ensure full penetration
to the bottom of the joint and thorough fusion between the weld metal and the base material and
to the weld metal previously deposited. All craters shall be filled.
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APPENDIX W M-1002
14.8 Identification of Welds

14.8.1 Each welder and welding operator shall stamp his or her identifying number, letter, or
symbol, assigned by the manufacturer, adjacent to their welds made in ferrous plates 1/4 in.
(6.35 mm) and over in thickness and in nonferrous plates 1/2 in. (12.7 mm) and over in thickness.
14.8.2 For identifying welds in ferrous plates less than 1/4 in. (6.35 mm) thick and nonferrous
plates less than 1/2 in. (12.7 mm) thick, suitable stencil or other surface markings shall be used.
14.8.3 An acceptable alternative for all plate thicknesses, both ferrous and nonferrous, is for the
fabricator to keep a record of welders and welding operators employed on each joint. These records
shall be available.
14.9 Repair of Defects
Defects in welded joints shall be repaired by removing the defect and rewelding. The defect may be
removed by mechanical means, by air-carbon arc, or by plasma arc gouging.
14.10 Surface Quality of Welds
14.10.1 The surface of the weld shall be free of cracks, incomplete fusion, and slag. Weld surfaces
shall be free from surface porosity. Undercut shall not be in excess of 0.010 in. and shall not reduce
the thickness below the minimum required value in the tank. Tank car tank groove welds shall be
filled to their specified cross section.
14.10.2 Welded joints in draft sills and underframes and other components attached to the tank
car tank shall be constructed in such a manner as to limit undercut and porosity to values
permitted by AWS D15.1 (current edition). All welds shall be classified as Class 1 unless otherwise
specified by the tank manufacturer or car owner. Undercut in tank car tanks shall be limited per
paragraph 14.10.1 of this appendix.
14.10.3 Weld spatter shall not be permitted in areas where it would interfere with the function or
corrosion protection of the tank car tank (e.g., interior coating, linings). Weld spatter that resists
normal cleaning methods (e.g., de-slagging, blasting, etc.) may be permitted.
14.11 Flux
14.11.1 Handling equipment shall be of a design, location, and support that will minimize any
tendency toward separation or segregation of flux particle size or density.
14.11.2 All containers and reservoirs used for flux shall be so designed that they will empty in
normal usage with no residue remaining.
14.11.3 Normal vacuum pickup recycling of unfused flux shall screen all particles of previously
fused flux or slag for a screen size not exceeding 10 per 1 in. (4 per 10 mm).
14.11.4 Recycling of used flux as a separate operation shall remove harmful dusts and foreign
materials.
14.11.5 Where fused flux (slag) is recrushed, net recovered (including crushed) material shall be
blended with not less than 25% by weight new flux.
14.11.6 No reprocessed flux shall contain more than 10% by weight of any material of a screen
size finer than 200 mesh (79 per 10 mm).
14.11.7 Recrushed slag residue from alloying type fluxes shall not be used.
14.11.8 Flux from damaged packages shall be discarded or shall be dried at a minimum
temperature of 500 F (260 C) for one hour before use. Flux that has been wet shall not be used.
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14.12 Low Hydrogen Electrodes

When welding procedures involve the use of low hydrogen electrodes, they must be handled in
accord with the following requirements:
14.12.1 Low hydrogen electrodes shall be purchased in hermetically sealed containers. After
opening of hermetically sealed containers or removal from baking ovens, electrodes shall be used
or stored in an oven held at a temperature of at least 250 F (121 C).
14.12.2 Bake electrodes at the temperature and time shown in Table W.15 if
the seal on a hermetically sealed container is damaged;
allowable exposure time to atmosphere per Table W.15 is exceeded.
14.12.3 Electrodes must not be baked more than once.
14.12.4 Discard electrodes that have been wet.
Table W.15 Low hydrogen electrodes
Maximum Dry and Redry

Atmosphere Minimum Time at
Classification Exposure Time Temperature of Temperature
AWS/CSA Specification Numbera/ (hours)b/ Electrodes (hours)
AWS A5.1/CSA W48.1 Mild Steel E70** 4 450 F500 F 2
E70**R 9 (232 C260 C)
E70**HZR 9
E7018M 9
AWS A5.5/CSA W48.3 Low Alloy Steel E70##-X 4 700 F800 F 1
(371 C427 C)
E80##-X 2 700 F800 F 1
E90##-X 1 700 F800 F 1
E100##-X 1/2 700 F800 F 1
E110##-X 1/2 700 F800 F 1
a/ **=15, 16, 18, 28, 48
##=15, 16, 18
X=A1, B1, B2, etc., and designates composition of the deposited weld metal.
b/ Alternative atmosphere exposure time may be used as established by testing per AWS D15.1,
Railroad Welding Specification.
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15.0 WELDING DATA

15.1 Welding Variables
Each welding variable described in this section is applicable as an essential variable when
specified in paragraph 11.0 or paragraph 12.0 above.
15.2.1 Joints
15.2.1.1 The deletion of the backing in single-welded butt joint welds. Double-welded groove
welds are considered welding with backing.
15.2.1.2 A change in the edge preparation that would make a groove angle smaller, make groove
root radius smaller, make root face (land) larger, or decrease the joint root opening.
15.2.2 Base Metals
15.2.2.1 A change from a base material having one P-number to a material having another P-
number. Welding procedures must be qualified using approved tank shell material as listed in
Appendix M for each material group to be welded. See Appendix M, Table M.10, for tank plate
base metals and ASME Section IX for other base metals. ASTM A612 can be used to qualify TC128
Grade B if chemical and mechanical properties of TC128 Grade B are met. Qualifications with
AAR TC128 Grade B or ASTM A612 base metals qualify for P-1 materials, but not vice versa.
When joints are made between two base materials that have different P-numbers, whether
nonferrous or ferrous, a welding procedure qualification shall be made for the applicable
combination of P-numbers, even though procedure qualification tests have been made for each of
the materials welded to itself. Welding procedure qualification with a base metal in one P-number,
or P-number plus Group-number, qualifies for all other base metals in the same M-number
grouping (M-numbers as defined by AWS D15.1). Qualifications for M-number materials do not
qualify corresponding P-number materials.
15.2.2.2 A change in either or both base materials from a nonferrous material shown with one
P-number in Appendix M, Table M.10, to a nonferrous material shown with another P-number, or
to a nonferrous material not shown, except that a change involving only aluminum and its alloys
shown in Table M.10.2 will not require requalification.
15.2.2.3 A change in base material thickness beyond the range qualified in accord with
Table W.6.
15.2.2.4 A change in base material thickness beyond the range qualified in accord with
Table W.12.
15.2.2.5 Welding procedure qualifications shall be made using one of the following:
the same base metal (including type and grade) to be used in production welding
for ferrous materials, a base metal listed in the same P-Number Group Number as the
base metal to be used in production welding. See Table M.10 for tank plate base metals
and ASME Section IX for other base metals.
for nonferrous materials, a base metal listed with the same P-Number UNS Number in
ASME IX, Table QW/QB-422, as the base metal to be used in production welding
15.2.2.6 In all cases, joint tension test specimens of the PQRs must meet the requirements of
paragraph 6.3.2 of this appendix.
15.2.2.7 The minimum thickness qualified is the thickness of the test coupon T or 5/8 in.
(15.9 mm), whichever is less. However, where T is less than 1/4 in. (6.35 mm), the minimum
thickness qualified is 1/2T.
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15.2.2.8 For single-pass or multipass welding in which any pass is greater than 1/2 in. (12.7 mm)
thick, an increase in base metal thickness beyond 1.1 times that of the qualification test coupon.
15.2.2.9 For the short-circuiting transfer mode of the gas metal-arc process, when the
qualification test coupon thickness is less than 1/2 in. (12.7 mm), an increase in thickness beyond
1.1 times that of the qualification test coupon.
15.2.3 Filler Metals
15.2.3.1 A change from one F-number in Tables W.9 and W.11 to any other F-number, or to any
other filler metal not listed in Tables W.9 and W.11, except qualification under any F-number up to
and including F-No. 5, shall qualify a welder for all lower F-numbers.
15.2.3.2 For the ferrous metals in Table W.10, a change in the chemical composition of the weld
deposit from one A-number to any other A-number in Table W.10. Qualification with A-No. 1 shall
qualify for A-No. 2 and vice versa. In lieu of an A-number designation, the nominal chemical
composition of the weld deposit shall be indicated on the PQR and WPS. Designation of nominal
chemical composition may also be by reference to the AWS classification (where such exists), the
manufacturers trade designation, or other established procurement documents.
15.2.3.3 A change from a nonferrous filler metal listed with one AWS classification number in
Table W.11 to a filler metal listed with another classification number, or to any other filler metal.
15.2.3.4 The deletion or addition of filler metal.
15.2.3.5 A change from one of the following filler metal product forms to another:
flux cored
bare (solid) or metal cored
powder
15.2.3.6 The addition or deletion or change of more than 10% in volume of supplemental filler
metal as qualified.
15.2.3.7 In submerged arc welding where the alloy content of the weld metal is largely dependent
upon the composition of the flux used, any change in any part of the welding procedure that would
result in the important alloying elements in the weld metal being outside of the specification range
of chemistry given in the applicable WPS. If there is evidence that production welds are not being
made in accord with the applicable WPS, the inspector may require that a check be made on the
chemical composition of the weld metal. The check preferably shall be made on a production weld.
15.2.3.8 Where the alloy content of the weld metal is largely dependent upon the composition of
the supplemental powdered filler metal, any change in any part of the welding procedure that
would result in the important alloying elements in the weld metal being outside of the
specification range of chemistry given in the procedure specification.
15.2.3.9 Qualification with an F-No. 2X aluminum filler metal shall qualify to weld with any
other F-No. 2X filler metal.
15.2.3.10 If filler metal does not have an AWS classification that defines chemical limits, a
change in weld wire brand name or grade.
11/2014 C-III [M-1002] 503

APPENDIX W M-1002
15.2.3.11 A change from one F-number in Table W.9 to any other F-number, or to any other filler
metal not listed in Table W.9, except that deposited weld metal using a bare rod not covered by an
AWS specification that conforms to an analysis listed in Table W.10, shall be considered to be
classified as F-No. 6.
15.2.3.12 A change in the nominal diameter of the electrode to over 1/4 in. (6.35 mm).
15.2.3.13 A change in the AWS specification filler metal classification, or to a weld metal or filler
metal composition not covered by these specifications.
Exception: For carbon steel, low alloy steel, and stainless steel, a change in low hydrogen coating
type having the same minimum tensile strength and chemical analysis.
15.2.3.14 A change in FCAW filler metal brand name or grade, unless the AWS specification
requires Charpy properties equal to the required values in the relevant postweld heat treated
condition.
15.2.3.15 A change in
the indicator for minimum tensile strength (e.g., the 7 in F7A2-EM12K) when the
flux/wire combination is classified by AWS specifications.
either the flux trade name or wire trade name when neither the flux nor the wire is
classified by AWS specifications.
the flux trade name for A-No. 8 deposits.
15.2.3.16 When a filler metal with a minimum required tensile strength less than the base metal
is used, the filler metal brand and grade must be essential variables.
15.2.3.17 The omission or addition of consumable inserts.
15.2.4 Positions
15.2.4.1 The addition of welding positions other than those already qualified. See paragraph 9.6
above.
15.2.4.2 A change from any position to the vertical position, uphill progression. Vertical-uphill
progression qualifies for all positions. In uphill progression, a change from stringer bead to weave
bead.
15.2.4.3 A change from uphill to downhill, or from downhill to uphill, in the progression specified
for any pass of a vertical weld.
15.2.5 Preheat
15.2.5.1 A decrease of 100 F (37.8 C) or more in the minimum specified preheating temperature
of the qualification test. The minimum temperature for welding shall be specified in the WPS. See
paragraph 13.4.1 in this appendix.
15.2.5.2 An increase of more than 100 F (37.8 C) in the maximum interpass temperature
recorded on the PQR.
15.2.5.3 For a preheat temperature of 32 F (0 C) or lower, the PQR test temperature is the
minimum.
15.2.6 Postweld Heat Treatment
A separate procedure qualification is required for each of the following:
No PWHT (Note: Alternate PWHT times and temperatures listed in Table W.16 may be
used without welding procedure requalification.)
PWHT within a specified temperature range
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M-1002 APPENDIX W
15.2.7 Electrical Characteristics

15.2.7.1 A change from spray arc, globular arc, or pulsed arc to short-circuiting arc, or vice versa.
15.2.7.2 A change from AC to DC, or vice versa. In DC welding, a change from direct current
electrode negative (straight polarity) to direct current electrode positive (reverse polarity), or vice
versa.
15.2.7.3 A change in the type of current or polarity, an increase in heat input, or an increase in
volume of weld metal deposited per unit length of weld, over that qualified. The increase may be
measured by either of the following:
15.2.7.3.1 Heat input
Heat input (J/in.) = Voltage Amperage 60 Heat input (J/cm) = Voltage Amperage 60
-------------------------------------------------------------- --------------------------------------------------------------
Travel Speed (in./min) Travel Speed (cm/min)
15.2.7.3.2 A change in volume of weld metal means an increase in bead size, or a decrease in
length of weld bead, per unit length of electrode.
The requirement for measuring the heat input or volume of deposited weld metal does not apply
when the procedure specification is qualified with a grain refining austenitizing heat treatment
after welding.
15.2.8 Shielding Gas or Flux
15.2.8.1 A change from a single gas to any other single gas or to a mixture of gases, or a change in
specified percentage composition of gas mixture.
15.2.8.2 In gas-shielded arc welding processes, the omission of gas backing.
15.2.8.3 A change in flux brand name or designation.
15.2.8.4 A change in flux involving either addition or deletion of any material of screen size finer
than 200 mesh (79 per 10 mm).
15.2.8.5 A change in flux involving the use of recrushed flux.
15.2.9 Technique
15.2.9.1 A change in width, frequency, or dwell time of oscillation for machine or automatic
welding only.
15.2.9.2 In machine welding, a change from single arc to multiple arc, or vice versa.
15.2.9.3 A change from single electrode to multiple electrode, or vice versa, for machine or
automatic welding only.
15.2.9.4 A change from one welding process to any other welding process or combination of
welding processes.
11/2014 C-III [M-1002] 505

APPENDIX W M-1002
16.0 POSTWELD HEAT TREATMENT

16.1 General
16.1.1 Postweld heat treatment, when required, shall be done before the final hydrostatic test,
after any repairs to welding, and after all attachments to be welded to the tank shell or heads have
been welded in place.
16.1.2 Minimum temperatures required by this section shall be temperatures of plate material of
shell and heads of the tank.
16.1.3 Thickness referred to as controlling the heating rate and holding time shall be the metal
thickness of the thickest shell or head plate in the tank.
16.1.4 Tank shell and head material shall determine postweld heat treatment requirements. See
Appendix R, paragraph 24.0.
16.2 Procedures for Postweld Heat Treatment
16.2.1 The tank shall preferably be postweld heat treated as a unit in an enclosed furnace.
16.2.2 A tank may be postweld heat treated in more than one heat in a furnace, provided the
overlap of the heated sections of the tank is at least 5 ft (1520 mm).
Any portion of the tank outside the furnace shall be shielded so that the temperature gradient is
not harmful to the tank.
16.3 Requirements for Postweld Heat Treatment
16.3.1 The furnace shall be designed to prevent direct flame impingement on the tank being
heated.
16.3.2 During the heating, holding, and cooling periods, the furnace atmosphere shall be
controlled to avoid excessive oxidation of the tank surface.
16.3.3 The temperature of the furnace shall not exceed 800 F (427 C) at the time the tank or
part is placed in it.
16.3.4 Above 800 F (427 C), the rate of heating shall be not more than 400 F per hour divided
by the tank thickness in inches, but in no case more than 400 F (204 C) per hour.
16.3.5 During the heating period, there shall be no greater variation in temperature throughout
the portion of the tank being heated than 250 F (139 C) within any 15 ft (4570 mm) interval of
length.
16.3.6 During the holding period, there shall be no greater difference than 150 F (83.3 C)
throughout the portion of the tank being heated, except when a smaller difference is specified for a
specific material.
16.3.7 Above 800 F (427 C), cooling shall be done in a closed furnace or cooling chamber, or in
still air, at a rate not greater than 500 F per hour divided by the tank thickness in inches, but in
no case more than 500 F (260 C) per hour. Below 800 F (427 C), the tank may be cooled in still
air or in a cooling chamber.
16.3.8 Holding temperatures and/or holding times in excess of the minimum values specified in
this section for specific types of materials may be used, except when otherwise specified, for a
specific material.
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M-1002 APPENDIX W
16.4 Carbon Steel Tanks (Material Group 1)

Unless otherwise provided in the specifications for a tank, all tanks fabricated from materials in
Appendix M, Table M.10.1, shall be postweld heat treated at a minimum temperature of 1100 F
(593 C) for a minimum holding time of one hour per 1 in. (25.4 mm) of tank thickness, with a
minimum of one hour for thickness less than 1 in. (25.4 mm). The maximum temperature during
postweld heat treatment shall not exceed 1250 F (677 C).
16.4.1 When it is impractical to postweld heat treat at the minimum temperature of 1100 F
(593 C), any of the lower temperatures and corresponding longer times shown in Table W.16 may
be used.
Table W.16 Permissible postweld heat treatment time-temperature combinations

Metal Temperaturea/ Holding Time
F C Hours per 1 in. (25.4 mm) of Thicknessb/
1050 566 2
1000 538 3
950 510 5
900 482 10
a/ For intermediate temperature, the holding time shall be determined by straight-line
interpolation.
b/ The holding times shown are minimum for thickness less than 1 in. (25.4 mm).
16.4.2 Nickel-clad tanks shall not be heated to a temperature exceeding 1200 F (649 C) and
shall be heated in an atmosphere essentially free of sulfur.
16.4.3 Type 304L- or 316L-clad tanks shall not be heated to a temperature exceeding 1050 F
(566 C).
16.5 Manganese-Molybdenum Steel Tanks (Material Group 1)
Unless otherwise provided in the specifications for a tank, all tanks fabricated from materials in
Appendix M, Table M.10.6, shall be postweld heat treated as required for carbon steel tanks in
paragraph 16.4 above.
16.6 Manganese-Silicon Steel Tanks (Material Group 1)
16.6.1 Unless otherwise provided in the specifications for a tank, and except as required in
paragraph 16.6.2 below, all tanks fabricated from materials in Appendix M, Table M.10.7, shall be
postweld heat treated as required for carbon steel tanks in paragraph 16.4 above.
16.6.2 When the base material has been heat treated by tempering, the maximum postweld heat
treatment shall be at least 50 F (27.8 C) below the tempering temperature.
16.7 Nonferrous Metal Tanks (Material Groups 2, 4)
16.7.1 Tanks fabricated from aluminum and its alloys shall not be postweld heat treated.
16.7.2 Tanks fabricated from nickel are not required to be postweld heat treated. Nickel tanks, if
heat treated, shall not be heated to a temperature exceeding 1200 F (640 C) and shall be heated
in an atmosphere essentially free of sulfur.
11/2014 C-III [M-1002] 507

APPENDIX W M-1002
16.8 Nickel Alloy Steel Tanks (Material Group 7)

16.8.1 Unless otherwise provided in the specifications for a tank, all tanks fabricated from
materials in Appendix M, Table M.10.5, shall be postweld heat treated in the temperature range
1025 F to 1085 F (552 C to 585 C) for a period of two hours, plus one hour for each 1 in.
(25.4 mm) of tank thickness over 1 in. (25.4 mm).
16.8.2 In lieu of the requirements of paragraph 16.3.7 above, the cooling rate from 1025 F
(552 C) to 600 F (316 C) shall be a minimum of 300 F (167 C) per hour in air or water.
16.9 High Alloy Steel Tanks (Material Group 3)
Unless otherwise provided in the tank specifications, the following postweld heat treatment
requirements apply to tanks fabricated from materials in Appendix M, Table M.10.3:
16.9.1 Types 304 and 316. Tanks fabricated from these materials shall be postweld heat treated
(solution annealed) and shall be capable of meeting the corrosion rates listed in Appendix M,
paragraph 3.3.2, and the mechanical properties listed in Table M.10.3. Solution annealing shall
consist of heating the material to a temperature of 1900 F (1038 C) minimum, followed by water
quenching or rapid cooling by other means.
16.9.2 Types 304L and Type 316L. Tanks fabricated from these materials are not required to
be postweld heat treated.
17.0 QUALITY ASSURANCE
17.1 Quality Control Program
See the AAR Manual of Standards and Recommended Practices, Section J, Specification M-1003,
for quality assurance requirements.
18.0 INSPECTION REQUIREMENTS
18.1 General
18.1.1 Unless otherwise provided in a tank specification, the requirements of this section shall
apply. For the purposes of this section, "inspection" refers to either radiography (RT) or ultrasonic
testing (UT).
18.1.2 All rewelded or repaired areas shall be re-examined by the original nondestructive test
method that discovered the defect.
18.1.3 All radiographic examinations shall be made using the technique and acceptance
standards of paragraph 10.2 above.
18.1.4 All ultrasonic examinations shall be made using the technique and acceptance standards
of paragraph paragraph 10.5 above, provided the process is automated. Automated scanning is the
relative displacement of the ultrasonic beam and the material being tested by other than manual
means. Manual ultrasonic inspection methods are prohibited for initial inspection of tanks
constructed in groups per paragraph 18.3.
C-III [M-1002] 508 11/2014

M-1002 APPENDIX W
18.2 Welded Joints to be Inspected (Radiograph or Ultrasonic)

18.2.1 The entire length of the following double-welded butt joints shall be inspected:
18.2.1.1 All longitudinal and circumferential joints of a tank, except circumferential joints in a
multi-unit tank car tank need not be radiographed or ultrasonically inspected.
18.2.1.2 The joint between the shell and certain types of fittings used to provide a reinforced
opening. See Appendix E, Fig. E.20.2.
18.2.2 The entire length of a single-welded butt joint with backup shall be inspected when it is
used, in combination with less than a full fillet weld, to attach the interior heads of compartment
tanks. See Appendix E.
18.2.3 Exceptions
The following double-welded groove welds do not require radiographic inspection or ultrasonic
inspection:
Nozzle seam welds
Nozzle-to-flange welds
Nozzle-to-shell welds of non-pressure tanks (other than reinforced openings per
Fig. E.20.2)
18.2.4 Nozzle-to-Shell Welds of Pressure Tanks (Other Than Reinforced Openings per
Fig. E.20.2)
A 6 in. minimum length of each nozzle-to-shell weld shall be inspected using radiography or
ultrasonic examination. If the inspected length of weld meets the specified acceptance criteria of
paragraph 10.0 (for the NDT method used), no further volumetric examination is required. If the
6 in. area fails to meet the specified acceptance criteria of paragraph 10.0, then 100% of the weld
shall be volumetrically examined by the same NDT method used in the initial examination and
repaired as required.
18.3 Inspection of Nonpressure Tanks Constructed in Groups
18.3.1 When a series of carbon steel or high alloy steel tanks made in accord with DOT 179.200
or DOT 179.220, using the same material specifications grouping and welding procedures, are
being welded in succession, all double-welded butt joints in each weld joint category must be
inspected in accord with paragraph 18.2.1 above, except as follows:
18.3.2 Weld Joint Category
18.3.2.1 The double-welded butt joints in the tanks may be categorized with respect to WPS,
welding operator, and welding machine. Accordingly, the double-welded butt joints in a tank may
be placed in one or more categories.
18.3.2.2 Welds in each category shall be treated independently of welds in other categories, and
acceptance or rejection and requirements for complete radiography of welds in one category shall
have no effect on welds in other categories.
18.3.3 If, in the first 3 tanks in the initial series of 20 tanks, there are no more than two
unacceptable defects in any circumferential joint, nor more than one unacceptable defect in any
15 ft (4570 mm) longitudinal joint, then for the next 17 tanks, only the intersections of the
longitudinal and circumferential double-welded butt joints need be inspected. The two
unacceptable defects in a circumferential joint must be separated by no less than 10 times the
shell thickness of the thinner member to qualify for this exception.
11/2014 C-III [M-1002] 509

APPENDIX W M-1002
18.3.4 Inspection of Intersections

18.3.4.1 An inspection of an intersection shall include at least 6 in. (152 mm) of the longitudinal
joint and at least 2 in. (50.8 mm) of the circumferential joint on each side of the intersection.
18.3.4.2 When a weld joint contains an unacceptable defect, inspection of a 6 in. (152 mm) length
of the weld joint in question, on each side of the defective weld area, is required.
18.3.4.3 If the welds adjacent to the defective welds are acceptable, then the tank welding in
question shall be deemed acceptable, and the defective welds shall be repaired and inspected until
they are acceptable.
18.3.4.4 If the welding of the adjacent areas does not comply with the acceptance standards, then
all double-welded butt joints in that weld category in the tank, as well as in the two successive
tanks, shall be inspected throughout their entire length. These three tanks shall be considered the
first of an initial series with respect to that category only, and the inspection examination
procedure shall revert to that specified in paragraph 18.3.1 above.
18.3.5 Succeeding tanks
18.3.5.1 In each successive series of 20 tanks, only the intersections of the longitudinal and
circumferential double-welded butt joints need be inspected, except that one tank, selected at
random by the inspector, shall be inspected in accordance with paragraph 18.2.1 above.
18.3.5.2 If there are no more than two unacceptable defects in any inspected circumferential
joint, nor more than one unacceptable defect in any 15 ft (4570 mm) length of inspected
longitudinal joint, then for the remaining tanks in the series, only the intersections of the
longitudinal and circumferential double-welded butt joints need be inspected. The two
unacceptable defects in a circumferential joint must be separated by no less than 10 times the
shell thickness to qualify for this exception.
18.3.5.3 If defects exceed those in paragraph 18.3.5.2 above, then the tank shall be treated as the
first in an initial series of 20 tanks, and the inspection procedure shall revert to that specified in
paragraph 18.3.1 above.
C-III [M-1002] 510 11/2014

M-1002 APPENDIX W
REINFORCING BARS CLAMPED OR WELDED TO

BACK OF TEST PLATES. TEST PLATES SHALL BE TACK WELDED
TO THE SHELL OR OTHERWISE SUPPORTED IN POSITION
TEST PLATES
TANK SHELL
TEST PLATE TEST PLATE
REINFORCING BARS
TANK
SHELL
SKETCH A: ONE METHOD OF PREPARING TEST PLATE
CORROSION TEST SPECIMENS

SPECIMENS
IMPACTS OF HEAT-AFFECTED ZONE
1 7/8'' L x 7/8'' W x 3/8'' T

REDUCED-SECTION TENSION
THIS PIECE
THIS PIECE
TEST
GUIDED-BEND SPECIMEN
IMPACTS OF WELD METAL
One specimen to be taken with center

(But not less than 10")
of length at center of weld.

6'' + 6t
of width at center of weld.
One specimen to be taken in base

metal.
DISCARD
DISCARD
CORROSION
All three specimens to be taken as

near one plate surface as is practicable.
For plate thickness less than 3/8'',

make specimen thickness T equal to t.
Sufficient length to
provide required specimens
T
Guided-Bend Specimens
Allow additional material as shown in
Fig. W.3, Sketch A, when dissimilar
materials used permit longitudinal face-
and root-bend specimens.
SKETCH B: SUGGESTED ORDER OF REMOVAL OF SPECIMENS
Fig. W.1 Test plate
11/2014 C-III [M-1002] 511

APPENDIX W M-1002
REINFORCING BARS CLAMPED OR WELDED TO

BACK OF TEST PLATES. TEST PLATES SHALL BE TACK WELDED
TO THE SHELL OR OTHERWISE SUPPORTED IN POSITION
TEST PLATES
TANK SHELL
TEST PLATE TEST PLATE
REINFORCING BARS
TANK
SHELL
SKETCH A: ONE METHOD OF PREPARING TEST PLATE
CORROSION TEST SPECIMENS

SPECIMENS
IMPACTS OF HEAT-AFFECTED ZONE
47.6 L x 22.2 W x 9.52 T

REDUCED-SECTION TENSION
THIS PIECE
THIS PIECE
TEST
IMPACTS OF WELD METAL

(But not less than 254)
of length at center of weld.

152 + 6t
of width at center of weld.
One specimen to be taken in base

metal.
DISCARD
DISCARD
CORROSION
All three specimens to be taken as

near one plate surface as is practicable.
For plate thickness less than 9.52,

make specimen thickness T equal to t.
Sufficient length to
provide required specimens
T
Guided-Bend Specimens
Allow additional material as shown in
Fig. W.3, Sketch A, when dissimilar
materials used permit longitudinal face-
and root-bend specimens.
SKETCH B: SUGGESTED ORDER OF REMOVAL OF SPECIMENS
Fig. W.1.1 Test plateSI units
C-III [M-1002] 512 11/2014

M-1002 APPENDIX W
10'' approximately t
"
Edge of widest On ferrous material

W face of weld these edges may be
flame cut
"
Weld reinforcement shall
2'' R be machined flush with
W = 1 1/2'' 0.01'', if t base material
does not exceed 1''
" Minimum This section machined,
W = 1'' 0.01'', if t preferably by milling
exceeds 1''
SKETCH A: FLAT, REDUCED-SECTION TENSION SPECIMEN
D R
C
WELD
B A B
L
SKETCH B: TURNED, REDUCED-SECTION TENSION SPECIMEN
Standard Dimensions (in.)

(a) (b) (c) (d)
0.505 Specimen 0.353 Specimen 0.252 Specimen 0.188 Specimen
Areduced section length See Note 4 See Note 4 See Note 4 See Note 4
Bend section length 1 3/8 approx. 1 1/8 approx. 7/8 approx. 1/2 approx.
Cend section diameter 3/4 1/2 3/8 1/4
Ddiameter 0.500 0.010 0.350 0.007 0.250 0.005 0.188 0.003
Rradius of fillet 3/8 minimum 1/4 minimum 3/16 minimum 1/8 minimum
NOTES:
1. Use maximum diameter specimen (a), (b), (c), or (d) that can be cut from test plate.
2. Weld should be in center of reduced section.
3. Where only a single specimen is required, the center of the specimen should be cut midway between the surfaces.
4. Reduced section A should be not less than width of weld plus two D in length.
5. The ends may be of any shape to fit the holders of the testing machine in such a way that the load is applied axially.
Fig. W.2 Joint-tension specimens
11/2014 C-III [M-1002] 513

APPENDIX W M-1002
6.35 254 approximately t
Edge of widest On ferrous material

W face of weld these edges may be
flame cut
6.35 Weld reinforcement shall

50.8 R be machined flush with
W = 37.9 to 38.3 if t base material
does not exceed 25.4
6.35 minimum This section machined,
W = 25.2 to 25.6 if t preferably by milling
exceeds 25.4
SKETCH A: FLAT, REDUCED-SECTION TENSION SPECIMEN
D R
C
WELD
B A B
L
SKETCH B: TURNED, REDUCED-SECTION TENSION SPECIMEN
Standard Dimensions (mm)

(a) (b) (c) (d)
12.83 Specimen 8.97 Specimen 6.40 Specimen 4.78 Specimen
Areduced section length See Note 4 See Note 4 See Note 4 See Note 4
Bend section length 35 approx. 29 approx. 22 approx. 13 approx.
Cend section diameter 19.0 12.7 9.52 6.35
Ddiameter 12.45 to 12.95 8.72 to 9.06 6.23 to 6.47 4.70 to 4.85
Rradius of fillet 9.82 minimum 6.38 minimum 4.76 minimum 3.18 minimum
NOTES:
1. Use maximum diameter specimen (a), (b), (c), or (d) that can be cut from test plate.
2. Weld should be in center of reduced section.
3. Where only a single specimen is required, the center of the specimen should be cut midway between the surfaces.
4. Reduced section A should be not less than width of weld plus two D in length.
5. The ends may be of any shape to fit the holders of the testing machine in such a way that the load is applied axially.
Fig. W.2.1 Joint-tension specimensSI units
C-III [M-1002] 514 11/2014

M-1002 APPENDIX W
When all-weld-metal tension, impact, or
WELD
TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
corrosion test specimens are required,
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN provide additional material as shown in
DISCARD
DISCARD
SKETCH A: SUGGESTED ORDER OF REMOVAL OF TEST SPECIMENS
FACE-BEND ROOT-BEND
R = 1/8 in. max
T (in.)
WELD 1 " Materials in All Other
R R t (in.) Table M.10.2 Materials
1/161/8 t t
T T
6" MINIMUM 1/83/8 1/8 t
t t
Over 3/8 1/8 3/8
Weld reinforcement and backing strip, if any, shall LF LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W.3 Test plate and guided-bend test specimens for dissimilar metals
11/2014 C-III [M-1002] 515

APPENDIX W M-1002
When all-weld-metal tension, impact, or
WELD
TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
LONGITUDINAL
LONGITUDINAL
corrosion test specimens are required,
LONGITUDINAL
LONGITUDINAL
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN
provide additional material as shown in

DISCARD
DISCARD
SKETCH A: SUGGESTED ORDER OF REMOVAL OF TEST SPECIMENS
FACE-BEND ROOT-BEND
R = 3.18 max
T (mm)
WELD 38.1 Materials in All Other
R R t (mm) Table M.10.2 Materials
1.59 to 3.18 t t
T T
152 MINIMUM 3.18 to 9.52 3.18 t
t t
Over 9.52 3.18 9.52
Weld reinforcement and backing strip, if any, shall LF LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W.3.1 Test plate and guided-bend test specimens for dissimilar metalsSI units
C-III [M-1002] 516 11/2014

M-1002 APPENDIX W
RELATION OF T AND t FOR

FACE-BEND AND ROOT-BEND SPECIMENS
THICKNESS T (inches)
t FERROUS AND ASTM B 209
(inches) NONFERROUS (a/) ALLOY 6061
MATERIALS
1/16 1/8 t t
1/8 3/8 t 1/8
Over 3/8 3/8 1/8
Note a/ Except Alloy 6061
SKETCH A FACE-BEND SPECIMEN
NOTES FOR FACE-BEND AND ROOT-BEND
SPECIMENS:
1. Weld reinforcement, and backing

strip if used, shall be removed
flush with the surface of the
specimen. If a recessed ring is
used, this surface of the specimen
may be machined to a depth
not exceeding the depth of the
recess to remove the ring, except
that in such cases the thickness
of the finished specimen shall be
that specified in the table above.
CROSS-HATCHED AREAS INDICATE

METAL REMOVAL BY MACHINING TO
SKETCH B ROOT-BEND SPECIMEN OBTAIN DIMENSION T AND THE
THICKNESS OF SIDE-BEND SPECIMENS

SIDE-BEND SPECIMENS
THICKNESS T (inches)
t FERROUS AND
(inches) NONFERROUS (a/) ASTM B 209
MATERIALS ALLOY 6061
3/8 1 1/2 t t
Over 1 1/2 b/ 1 1/2
Note b/ For plates over 1 1/2'' thick, cut specimen into
approximately equal strips between 3/4'' and
1 1/2'' wide and test each strip.
SKETCH C SIDE-BEND SPECIMEN Note c/ Machine specimen on this side when t exceeds
1 "
SKETCH D SIDE-BEND SPECIMEN FOR ASTM B 209 ALLOY 6061: This specimen to be the same as Sketch C
except for specimen thickness and corner radius. The finished thickness shall
be 1/8'' rather than 3/8'' and the radius shall be 1/16'' max. rather than 1/8'' max.
For longitudinal-face bend and
longitudinal-root bend types of
guided-bend specimens, see
Fig. W.3, Sketch B.
Fig. W.4 Guided-bend test specimens
11/2014 C-III [M-1002] 517

APPENDIX W M-1002

FACE-BEND AND ROOT-BEND SPECIMENS
THICKNESS T (mm)
t FERROUS AND ASTM B 209
(mm) NONFERROUS (a/) ALLOY 6061
MATERIALS
1.59 to 3.18 t t
3.18 to 9.52 t 3.18
Over 9.52 9.52 3.18
SKETCH A FACE-BEND SPECIMEN
NOTES FOR FACE-BEND AND ROOT-BEND
SPECIMENS:
1. Weld reinforcement, and backing

strip if used, shall be removed
flush with the surface of the
specimen. If a recessed ring is
used, this surface of the specimen
may be machined to a depth
not exceeding the depth of the
recess to remove the ring, except
that in such cases the thickness
of the finished specimen shall be
that specified in the table above.
CROSS-HATCHED AREAS INDICATE

METAL REMOVAL BY MACHINING TO
SKETCH B ROOT-BEND SPECIMEN OBTAIN DIMENSION T AND THE
THICKNESS OF SIDE-BEND SPECIMENS

SIDE-BEND SPECIMENS
THICKNESS T (mm)
t FERROUS AND
(mm) NONFERROUS (a/) ASTM B 209
MATERIALS ALLOY 6061
9.52 to 38.1 t t
over 38.1 b/ 38.1
Note b/ For plates over 38.1 thick, cut specimen into
approximately equal strips between 19 and
38.1 wide and test each strip.
SKETCH C SIDE-BEND SPECIMEN Note c/ Machine specimen on this side when t exceeds
38.1
SKETCH D SIDE-BEND SPECIMEN FOR ASTM B 209 ALLOY 6061: This specimen to be the same as Sketch C
except for specimen thickness and corner radius. The finished thickness shall
be 3.18 rather than 9.52 and the radius shall be 1.59 max. rather than 3.18 max.
For longitudinal-face bend and
longitudinal-root bend types of
guided-bend specimens, see Fig. W.3,
Sketch B.
Fig. W.4.1 Guided-bend test specimensSI units
C-III [M-1002] 518 11/2014

M-1002 APPENDIX W
Thickness of A B C D
Specimen, (in.) (in.) (in.) (in.) (in.)
3/8a/ 1 1/2 3/4 2 3/8 1 3/16a/
ta/ 4t 2t 6t + 1/8 3t + 1/16a/
1/8b/ 2 1/16 1 1/32 2 3/8 1 3/16b/
3/8c/ 2 1/2 1 1/4 3 3/8 1 11/16c/
td/ 6 2/3t 3 1/3t 8 2/3t + 1/8 4 1/3t + 1/16d/
a/ Use for all materials not otherwise indicated.
b/ Use only for P-23 aluminum alloys.
c/ Use only for P-25 aluminum alloys.
d/ Use only for P-25 aluminum alloys where thickness, t, is less than 3/8 in.
Fig. W.5 Guided-bend test jig
11/2014 C-III [M-1002] 519

APPENDIX W M-1002
To determine
SI dimensions,
see
Thickness of A B C D
Specimen, (mm) (mm) (mm) (mm) (mm)
9.52a/ 38.1 19.0 60.3 30.2a/
ta/ 4t 2t 6t + 3.18 3t + 1.59a/
3.18b/ 52.4 26.2 60.3 30.2b/
9.52c/ 63.5 31.8 85.7 42.9c/
td/ 6 2/3t 3 1/3t 8 2/3t + 3.18 4 1/3t + 1.59d/
a/ Use for all materials not otherwise indicated.
b/ Use only for P-23 aluminum alloys.
c/ Use only for P-25 aluminum alloys.
d/ Use only for P-25 aluminum alloys where thickness, t, is less than 9.52 mm.
Fig. W.5.1 Guided-bend test jigSI units
C-III [M-1002] 520 11/2014

M-1002 APPENDIX W
MACRO TEST
DIRECTION OF LOADING
NOTES: T
1. FOR FERROUS MATERIALS:
L = 10" STOP AND RESTART
W = 3" WELDING NEAR THE 1"
T = 16" to 2 " CENTER
3 1
MAXIMUM FILLET SIZE = 2 "

1
2. FOR NONFERROUS MATERIALS: 3"

L
L = 4"
W = 4"
T = 16" to 8 "
3 3
MAXIMUM FILLET SIZE = THE 1"

SAME AS DIMENSION T
T W
SKETCH A: FOR PERFORMANCE QUALIFICATION TEST
MACRO TEST
12" MIN.
NOTE:
T = MAXIMUM THICKNESS OF 1"
BASE MATERIAL IN TANK AT POINT 6" MIN.
OF WELDING OR 1", WHICHEVER IS
SMALLER
FIVE EQUAL SECTION
DISCARD END SECTIONS

1"
T 6" MIN.
SKETCH B: FOR PROCEDURE QUALIFICATION TEST
Fig. W.6 Fillet-welded tee-joint test specimens
11/2014 C-III [M-1002] 521

APPENDIX W M-1002
MACRO TEST
NOTES: DIRECTION OF LOADING

1. FOR FERROUS MATERIALS:
L = 254 MM
W = 76.2 MM
T = .1875 TO 12.7 MM
MAXIMUM FILLET SIZE = 6.35 MM STOP AND RESTART
WELDING NEAR THE
2. FOR NONFERROUS MATERIALS: CENTER
L = 102 MM
W = 102 MM
T = 4.76 TO 9.52 MM L
MAXIMUM FILLET SIZE = THE
SAME AS DIMENSION T.
SKETCH A: FOR PERFORMANCE QUALIFICATION TEST
MACRO TEST
NOTE:
T = MAXIMUM THICKNESS OF
BASE MATERIAL IN TANK AT POINT
OF WELDING OR 25.4 MM, WHICHEVER IS
SMALLER
FIVE EQUAL SECTION
DISCARD END SECTIONS
SKETCH B: FOR PROCEDURE QUALIFICATION TEST
Fig. W.6.1 Fillet-welded tee-joint test specimensSI units
C-III [M-1002] 522 11/2014

M-1002 APPENDIX W
80 90
Axis
limits
for E
Axis limits for C E
125 0
Axis limits for D D 360
235
150 C
A 0 360
B 210 Vertical
125 B plane
15 235
P
Axis limits
for A and B
0 C 360 Horizontal plane
Notes:
1. The horizontal reference plane is always taken to lie below the weld under consideration.
2. The inclination of axis is measured from the horizontal reference plane toward the vertical reference plane.
3. The angle of rotation of the face is determined by a line perpendicular to the theoretical face of the weld which passes through the axis of
the weld. The reference position (0) of rotation of the face invariably points in the direction opposite to that in which the axis angle increases.
When looking at point P, the angle of rotation of the face of the weld is measured in a clockwise direction from the reference position (0).
Tabulations of Positions of Fillet Welds

Diagram Inclination Rotation
Position Reference of Axis of Face
Flat A 0 to 15 150 to 210
Horizontal B 0 to 15 125 to 150
210 to 235
Overhead C 0 to 80 0 to 125
235 to 360
Vertical D 15 to 80 125 to 235
E 80 to 90 0 to 360
Fig. W.7 Weld orientation and test positionsfillet welds
11/2014 C-III [M-1002] 523

APPENDIX W M-1002
80 90
Axis
limits
for E
Axis limits for C E
D 0
Axis limits for D 360
80
280
0 C 360 Vertical
150 A plane
210
B
15 B
80 P
Axis limits 280

for A and B C 360
0
Horizontal plane
0
Notes:
1. The horizontal reference plane is always taken to lie below the weld under consideration.
2. The inclination of axis is measured from the horizontal reference plane toward the vertical reference plane.
3. The angle of rotation of the face is determined by a line perpendicular to the theoretical face of the weld which passes through the axis of the
weld. The reference position (0) of rotation of the face invariably points in the direction opposite to that in which the axis angle increases.
When looking at point P, the angle of rotation of the face of the weld is measured in a clockwise direction from the reference position (0).
Tabulations of Positions of Groove Welds

Diagram Inclination Rotation
Position Reference of Axis of Face
Flat A 0 to 15 150 to 210
Horizontal B 0 to 15 80 to 150
210 to 280
Overhead C 0 to 80 0 to 80
280 to 360
Vertical D 15 to 80 80 to 280
E 80 to 90 0 to 360
Fig. W.8 Weld orientation and test positionsgroove welds
C-III [M-1002] 524 11/2014

M-1002 APPENDIX W
BASE MATERIAL WELD

BASE METAL
MATERIAL
DIRECTION OF
ROLLING
LONGITUDINAL SPECIMEN
TRANSVERSE
SPECIMEN
WELD
PLATE SURFACE
LOCATE SPECIMEN WITHIN 16" (1.59) OF PLATE
1
SURFACE FOR MATERIAL 1'' (25.4) AND THINNER.

LONGITUDINAL SPECIMEN IF OVER 1'' (25.4) THICK, TAKE SPECIMEN MIDWAY
BETWEEN SURFACE AND CENTER OF PLATE
THICKNESS.
TRANSVERSE SKETCH BWELD METAL
SPECIMEN
LOCATE SPECIMENS AS NEAR SURFACE AS

PRACTICABLE FOR MATERIAL " (12.7) AND
THINNER. IF OVER " (12.7) TAKE SPECIMEN
MIDWAY BETWEEN SURFACE AND CENTER OF
PLATE THICKNESS.
SKETCH ABASE MATERIAL WELD BASE
METAL MATERIAL
NOTES:
1. ALL NOTCHES CUT PERPENDICULAR TO
PLATE SURFACE.
CUT TO FINISHED LENGTH AFTER NOTCHING
2. ALL COMMENTS APPLY TO FULL SIZE OR
SUBSIZE SPECIMENS.
3. ALL COMMENTS APPLY TO TYPE A
(CHARPY V-NOTCH), TYPE B (CHARPY
KEYHOLE NOTCH), OR TYPE C (CHARPY
U-NOTCH) SPECIMENS
WELD
LOCATE SPECIMEN AS NEAR PLATE SURFACE

AS PRACTICABLE. ETCH SPECIMEN AND
LOCATE NOTCH IN HEAT-AFFECTED ZONE.
SKETCH CHEAT-AFFECTED ZONE
Fig. W.9 Impact test specimen location and orientation
11/2014 C-III [M-1002] 525

APPENDIX W M-1002
8 mm.
(0.315'')
0.25 mm.
(0.010'') rad.
10 mm.
(0.394'') VEE-NOTCH
L/2
55 mm
(2.165'') 10 mm. 45
L (0.394'')
SKETCH AFULL SIZE CHARPY VEE-NOTCH SPECIMEN
D = 8 mm
(0.315'') D 10 mm. D 10 mm. D
(0.394'') (0.394'')
2 1/2 mm. 5 mm. 7 1/2 mm.

(0.098'') (0.197'') (0.295'')
SKETCH BSUBSIZE CHARPY VEE-NOTCH SPECIMEN
Permissible Dimensional Variations

Angle between adjacent sides 90 degrees +10 minutes
Cross-section dimensions 0.025 mm (0.001")
Length of section (L) +0, 2.5 mm (0.100")
Centering of notch (L/2) 1 mm (0.039")
Angle of notch 1 degree
Radius of notch 0.025 mm (0.001")
Dimension to bottom of notch 0.025 mm (0.001")
Surface finish requirements 2 (63 microinches AA) on notched surface and opposite face;
(AA = arithmetical average) 4 (125 microinches AA) on other two surfaces.
Fig. W.10 Type A Charpy (simple beam) impact test specimen dimensions
C-III [M-1002] 526 11/2014

M-1002 APPENDIX W

Company Name _________________________________________ By: _____________________________________
Welding Procedure Spec. No. _____________ Date:__________ Supporting PQR No.(s) ___________________
Rev. No. ________________________________ Date:__________
Welding Process(es)_________________________________ Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
JOINTS DETAILS
Joint Design __________________________________________
Backing (Yes) __________________ (No)__________________
Backing Material (Type) _______________________________
(Refer to both backing and retainers)
Metal Nonfusing Metal
Nonmetallic Other
Sketches, production drawings, weld symbols or written
description should show the general arrangement of the
parts to be welded. Where applicable, the root spacing and
the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be
attached to illustrate joint design, weld layers and bead
sequence, e.g., for notch toughness procedures, for multiple
process procedures, etc.)
*BASE METALS
P-No. _________________________________________ to P-No.____________________________________________
OR
Specification Type and Grade ________________________________________________________________________
to Specification Type and Grade _____________________________________________________________________
OR
Chemical Analysis and Mechanical Properties ________________________________________________________
to Chemical Analysis and Mechanical Properties ______________________________________________________
Thickness Range:
Base Metal: Groove _____________________________ Fillet__________________________________
Other
*FILLER METALS
Specification No. ___________________________________________________________________________________
AWS No. (Class) ____________________________________________________________________________________
F-No. ______________________________________________________________________________________________
A-No. ______________________________________________________________________________________________
Size of Filler Metals ________________________________________________________________________________
Deposited Weld Metal_______________________________________________________________________________
Electrode-Flux (Class) ______________________________________________________________________________
Flux Trade Name___________________________________________________________________________________
Consumable Insert _________________________________________________________________________________
Other______________________________________________________________________________________________
*Each base metal-filler metal combination should be recorded individually.
Revised 3/16/88 Page 1 of 2
Fig. W.11 Suggested format for welding procedure specification (WPS)

11/2014 C-III [M-1002] 527
APPENDIX W M-1002
WPS No. ____________ Rev. _________________
POSITIONS POSTWELD HEAT TREATMENT

Position(s) of Groove __________________________
Temperature Range ___________________________
Welding Progression: Up ________ Down ________
Position(s) of Fillet ____________________________ Time Range __________________________________
PREHEAT GAS
Percent Composition
Preheat Temperature, Min. ____________________
Gas(es) Mixture Flow Rate
Interpass Temperature, Max. __________________
Shielding _________ ________ _________
Preheat Maintenance _________________________
Trailing _________ ________ _________
(Continuous or special heating, where applicable,
should be recorded) Backing _________ ________ _________
ELECTRICAL CHARACTERISTICS
Current AC or DC __________ Polarity _________________________
Amps (Range) ___________________ Volts (Range) _______________
(Amps and volts range should be recorded for each electrode size, position and thickness, etc.
This information may be listed in a tabular form similar to that shown below)
Tungsten Electrode Size & Type_________________________________________________________________
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW ______________________________________________________________
(Spray, arc, short-circuited arc, etc.)
Electrode Wire Feed Speed Range _______________________________________________________________
TECHNIQUE
String or Weave Bead __________________________________________________________________________
Orifice or Gas Cup Size _________________________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) __________________________________________
_______________________________________________________________________________________________
Method of Back Gouging________________________________________________________________________
Oscillation ____________________________________________________________________________________
Contact Tube to Work Distance _________________________________________________________________
Multiple or Single Pass (per side)________________________________________________________________
Multiple or Single Electrodes ___________________________________________________________________
Travel Speed (Range)___________________________________________________________________________
Peening _______________________________________________________________________________________
Other _________________________________________________________________________________________
_____________________________________________________________________________________________
Filler Metal Current OTHER
Travel (e.g. Remarks, Comments,
Weld Type Amperage Voltage Speed Hot Wire Addition, Tech-
Layer(s) Process Class Diameter Polarity Range Range Range nique, Torch Angle, etc.)
Fig. W.11 Suggested format for welding procedure specification (WPS) (concluded)
C-III [M-1002] 528 11/2014

M-1002 APPENDIX W

PQR No._______________
Company Name
Welding Procedure Spec. No. Date:
Welding Process(es)
Types (Manual, Automatic, Semi-Automatic)
JOINTS
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or
process used.)
BASE METALS POSTWELD HEAT TREATMENT
Material Specification__________________________ Temperature____________________________________
Type or Grade _________________________________ Time ___________________________________________
P-No. _______________ to P-No. ________________ Other __________________________________________
Thickness of Test Coupon_______________________ ________________________________________________
Diameter of Test Coupon _______________________ ________________________________________________
Other_________________________________________ GAS
______________________________________________ Percent Composition
______________________________________________ Gas(es) Mixture Flow Rate
______________________________________________
______________________________________________ Shielding ________ ________ ________
______________________________________________ Trailing ________ ________ ________
Backing ________ ________ ________
FILLER METALS ELECTRICAL CHARACTERISTICS

AWS Specification _____________________________ Current ________________________________________
AWS Classification ____________________________ Polarity ________________________________________
Filler Metal F-No. _____________________________ Amps _____________________ Volts _______________
Weld Metal Analysis A-No. _____________________ Tungsten Electrode Size _________________________
Size of Filler Metal ____________________________ Other __________________________________________
Other_________________________________________ ________________________________________________
______________________________________________
Deposited Weld Metal __________________________
POSITION TECHNIQUE
Position of Groove _______________________________ Travel Speed____________________________________
Weld Progression (Upward, Downward) ___________ String of Weave Bead ____________________________
Other __________________________________________ Oscillation______________________________________
________________________________________________ Multipass or Single Pass (per side)________________
________________________________________________ Single or Multiple Electrodes_____________________
Other __________________________________________
PREHEAT ________________________________________________
Preheat Temperature ____________________________ ________________________________________________
Interpass Temperature __________________________ ________________________________________________
Other __________________________________________ ________________________________________________
________________________________________________ ________________________________________________

Fig. W.12 Suggested format for procedure qualification record (PQR)
11/2014 C-III [M-1002] 529

APPENDIX W M-1002
PQR No. _______________________

REDUCED SECTION TENSILE SPECIMEN TESTS
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb. psi Location
ALLWELDMETAL TENSION SPECIMEN TEST
ULTIMATE TENSILE
STRENGTH
YIELD
Type & STRENGTH REDUCTION
Figure Diameter Area Total Load Unit Stress (0.2% offset) ELONGA- OF AREA
No. in. sq. In. lb. psi psi TION (%) (%)
GUIDED BEND TESTS

Type and Figure No. Result
CHARPY IMPACT TESTS

Test Lateral
Specimen Notch Notch Temp- Impact Percent Expansion
No. Location Type erature Values Shear Mils
FILLET WELD TESTS

Result-Satisfactory: Yes _____ No _____ Penetration into Parent Metal: Yes _____ No _____
Macro-Results _________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
OTHER TESTS
Type of Test ___________________________________________________________________________________________
Deposit Analysis _______________________________________________________________________________________
Other _________________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Welders Name ____________________________________________ Clock No. _______________ Stamp No. _________
Tests Conducted By: _______________________________________________________ Laboratory Test No. _________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
We certify that the statements in this record are correct and that the test welds were prepared, welded, and
tested in accordance with the requirements of Appendix W.
Manufacturer: _________________________________________________________________________________________
Date ____________________________________________ By: __________________________________________________
Fig. W.12 Suggested format for procedure qualification record (PQR) (concluded)
C-III [M-1002] 530 11/2014

M-1002 APPENDIX W
RECORD OF WELDER PERFORMANCE QUALIFICATION TEST
Welder's name Clock number Stamp no.
Welding process(es) used Type
Identification of WPS followed by welder during welding of test coupon
Base material(s) welded Thickness
Manual or Semiautomatic Variables for Each Process (W12.04) Used Qualified
Backing (metal, weld metal, welded from both sides, flux, etc.)
P-No. to P-No.
Filler metal specification (AWS) / Classification
Filler metal F-No.
Consumable insert
Weld thickness
Welding position (1G, 5G, etc.)
Progression (uphill/downhill)
Backing gas for GTAW
GMAW transfer mode
GTAW welding current type/polarity
Machine Welding Variables for the Process Used W12.02
Guided Bend Test Results
Guided Bend Tests Type: Fig W5 Sketch C (Side)

Fig W5 Sketches A & B (Trans. R & F)
Fig W5 Sketch B (Long, R & F)
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination (see paragraphs W15.3, 15.4, 15.5, and 15.9) Acceptable Yes No
Radiographic test results
(For alternative qualification of groove welds by radiography)
Fillet weld Fracture test Length and percent of defects in.
Macro test fusion Fillet leg size in. in. Concavity/convexity in.
Welding test conducted by
Mechanical tests conducted by Laboratory test no.
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in
accordance with the requirements of Appendix W.
Organization
Date By
Fig. W.13 Record of Welder Performance Qualification Test
11/2014 C-III [M-1002] 531

APPENDIX W M-1002
Plate horizontal. Axis of weld horizontal. Plate vertical. Axis of weld horizontal.
FLAT POSITION 1G HORIZONTAL POSITION 2G
Plate vertical.
Axis of weld vertical.
Plate and axis of weld horizontal. Weld made from below.
VERTICAL POSITION 3G OVERHEAD POSITION 4G

Fig. W.14 Positions of test plates for butt welds (joint design optional)
C-III [M-1002] 532 11/2014

M-1002 APPENDIX W
Axis of Weld
Horizontal
Throat of Weld
Vertical
45
FLAT POSITION 1F HORIZONTAL POSITION 2F
Axis of Weld Axis of Weld

Vertical. Horizontal
VERTICAL POSITION 3F OVERHEAD POSITION 4F
Fig. W.15 Positions of test plates for fillet welds
11/2014 C-III [M-1002] 533

APPENDIX W M-1002
Dimension, inches No. of Indications
0.10 0.031 0.0195 1 15 35
ASSORTED
0.10 4
LARGE
0.031 40
MEDIUM
0.0195 101
FINE
TYPICAL NUMBER AND SIZE PERMITTED

IN ANY 6-IN. LENGTH OF WELD.
1/2-IN. WELD THICKNESS
TOTAL INDICATION AREA PERMITTED IS 0.030 SQ IN.
Fig. W.16 Rounded indication charts
C-III [M-1002] 534 11/2014

M-1002 APPENDIX W
Dimension, millimeters No. of Indications
2.54 0.787 0.495 1 15 35
ASSORTED
2.54 4
LARGE
0.787 40
MEDIUM
0.495 101
FINE

IN ANY 152 MM LENGTH OF WELD.
12.7 MM WELD THICKNESS
TOTAL INDICATION AREA PERMITTED IS 19.4 SQ. MM.
Fig. W.16.1 Rounded indication chartsSI units
11/2014 C-III [M-1002] 535

APPENDIX W M-1002
0.024 35
0.034 19
0.125 1
ASSORTED
0.125 4
LARGE
0.034 50
MEDIUM
0.024 99
FINE

IN ANY SIX INCH LENGTH OF WELD.
THREE QUARTER INCH WELD THICKNESS.
TOTAL INDICATION AREA PERMITTED IS .045 SQ. IN.
C-III [M-1002] 536 11/2014

M-1002 APPENDIX W
0.610 35
0.864 19
3.18 1
ASSORTED
3.18 4
LARGE
0.864 50
MEDIUM
0.610 99
FINE

19.0 MM WELD THICKNESS.
Fig. W.17.1 Rounded indication charts
11/2014 C-III [M-1002] 537

APPENDIX W M-1002
0.0275 38
0.039 21
0.125 1
ASSORTED
0.125 5
LARGE
0.039 50
MEDIUM
0.0275
101
FINE

IN ANY 6-IN. LENGTH OF WELD.
1-IN. WELD THICKNESS.
TOTAL INDICATION AREA PERMITTED IS 0.060 SQ. IN.
C-III [M-1002] 538 11/2014

M-1002 APPENDIX W
0.698 38
0.991 21
3.18 1
ASSORTED
3.18 5
LARGE
0.991 50
MEDIUM
0.698 101
FINE

11/2014 C-III [M-1002] 539

APPENDIX W M-1002
0.039 38
0.055 21
0.125 2
ASSORTED
0.125 10
LARGE
0.055 51
MEDIUM
0.039 100
FINE

IN ANY SIX INCH LENGTH OF WELD.
TWO INCH WELD THICKNESS.
TOTAL INDICATION AREA PERMITTED IS .120 SQ. IN.
C-III [M-1002] 540 11/2014

M-1002 APPENDIX W
0.991 38
1.40 21
3.18 2
ASSORTED
3.18 10
LARGE
1.40 51
MEDIUM
0.991 100
FINE

11/2014 C-III [M-1002] 541

APPENDIX W M-1002
DISCARD THIS PIECE DISCARD THIS PIECE

REDUCED-SECTION TENSION SPECIMEN SIDE-BEND SPECIMEN
ROOT-BEND SPECIMEN REDUCED-SECTION TENSION SPECIMEN
FACE-BEND SPECIMEN SIDE-BEND SPECIMEN
ALL-WELD-METAL TENSION SPECIMEN ALL-WELD-METAL TENSION SPECIMEN
IMPACTS OF HEAT-AFFECTED ZONE IMPACTS OF HEAT-AFFECTED ZONE

IMPACTS OF WELD METAL IMPACTS OF WELD METAL
THREE CORROSION TEST SPECIMENS THREE CORROSION TEST SPECIMENS
FOR DETAILS SEE FIG. W.1B FOR DETAILS SEE FIG. W.1B
ROOT-BEND SPECIMEN SIDE-BEND SPECIMEN

FACE-BEND SPECIMEN REDUCED-SECTION TENSION SPECIMEN
REDUCED-SECTION TENSION SPECIMEN SIDE-BEND SPECIMEN
WELD WELD
SKETCH AFOR PLATES 1/16" TO 3/4" (1.59 TO 19.0) THICK SKETCH BFOR PLATES 3/8" (9.52) AND OVER THICK
WELDING PROCEDURE QUALIFICATION SPECIMEN
ROOT-BEND SPECIMEN SIDE-BEND SPECIMEN

FACE-BEND SPECIMEN SIDE-BEND SPECIMEN
WELD WELD
SKETCH CFOR PLATES 1/16" TO 3/4" (1.59 TO 19.0) THICK SKETCH DFOR PLATES 3/8" (9.52) AND OVER THICK
WELDER PERFORMANCE QUALIFICATION SPECIMEN
Fig. W.20 Order of removal of test specimens
C-III [M-1002] 542 11/2014

M-1002 APPENDIX W
Fig. W.21 Welding symbols

11/2014 C-III [M-1002] 543
APPENDIX W M-1002
Fig. W.21.1 Welding symbols

C-III [M-1002] 544 11/2014
M-1002 APPENDIX X
APPENDIX X
DOT REGULATIONS
CONTENTS
Paragraph Subject Page No.

1.0 Introduction C-III546
11/2014 C-III [M-1002] 545

APPENDIX X M-1002
APPENDIX X
DOT REGULATIONS
1.0 INTRODUCTION
DOT requirements for tank cars are set forth in the Code of Federal Regulations, Title 49, Sections
173.31, 173.314, 173.319, and 173.320 and Parts 179 and 180.
Published in DOT Notice 93-12 is a list of thermal protection systems that may be used, without
further test verification, on DOT Specification 105, 111, 112, and 114 tank cars to satisfy thermal
protection requirements.
C-III [M-1002] 546 11/2014

M-1002 APPENDIX Y
APPENDIX Y
SELECTED AAR CIRCULAR LETTERS
CONTENTS

Fig. No. Letter and Subject Date Page

Fig. Y.1 C-6370 thermal coating overspray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10-79 C-III549
Fig. Y.2 C-6494 pressure car bottom fittings protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21-80 C-III550
Fig. Y.3 D.V. 2007 Exhibit 2, bottom fittings protectioncommodity groups . . . . . . . . . . . . 5-28-82 C-III552
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protectionprotection requirements (Levels A,
B, C, and D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28-82 C-III553
Fig. Y.5 D.V. 2007 addendumadditional commodity requirements . . . . . . . . . . . . . . . . . . 9-1-90 C-III570
Fig. Y.6 CPC-1097 stub sill inspection programnew Form SS-3 (page 1 of 5). . . . . . . . . 9-7-99 C-III571
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 1 of 4). . 5-10-01 C-III576
Fig. Y.8 CPC-1116 Shop practices for installation and maintenance of bottom outlet valves
(page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30-01 C-III580
11/2014 C-III [M-1002] 547

APPENDIX Y M-1002
APPENDIX Y
SELECTED AAR CIRCULAR LETTERS
1.0 INTRODUCTION
Certain letters to members and private car owners contain information not found in the
Specifications for Tank Cars, but are believed to be of long-term relevance. These are copied in this
appendix for reference.
C-III [M-1002] 548 11/2014

M-1002 APPENDIX Y
Fig. Y.1 C-6370 thermal coating overspray
11/2014 C-III [M-1002] 549

APPENDIX Y M-1002
Fig. Y.2 C-6494 pressure car bottom fittings protection
C-III [M-1002] 550 11/2014

M-1002 APPENDIX Y
1. Type A bottom outlet valves (Fisher and Rego internal valves with vertical lift seats)
must be protected in accordance with Appendix E, paragraph 8.0, of the AAR Tank Car Spec-
ifications. Such fittings will be exempted from this requirement if the shear groove can be
relocated, in an approved manner, to the bottom of the tank flange providing the maximum
projection of the tank outlet flange from the shell envelope does not exceed 2 inches. This will
apply only to Type A valves with the closure seat above the shear groove and attached so that
the seat will remain intact if the outlet leg is sheared off at the tank flange face. Relocating
the shear groove will mean eliminating the tongue and groove connection between the tank
flange and the valve and reducing the strength of the bolted joint.
2. Type B (Jamesbury internal ball valve) bottom outlets must be protected in accor-
dance with Appendix E, paragraph 8.0, of the AAR Tank Car Specifications except that the
Tank Car Committee will be receptive to proposals of alternate protection schemes when sub-
mitted by car owners.
3. Sumps on existing cars, not exceeding 5 inches in depth, are exempt from require-
ments of Appendix E, paragraph 8.0,. Sump reference here is to weld cap type of pressed steel
sumps (pressed into tank shell or a separate pressing welded into or onto the tank shell). The
exemption does not include sumps formed of straight nozzles with essentially flat cover
plates, bolted or welded in place. Sumps not referred to above or sumps of 5 inches or greater
depth are subject to additional review by the Tank Car Committee for design features.
4. Blind flanged outlets must be protected in accord with one of the following three
options:
a. Protection in accordance with Appendix E, paragraph 8.0,
b. Provide an internal closure similar to those required for washouts. Remove the tongue
from the appropriate flange to provide a shear groove at the bottom of the tank flange.
The maximum allowable projection of the tank outlet flange from the shell envelope is
2 in. Reinstall the blind flange with proper gasketing to provide a secondary closure
and hydrostatically retest the assembly. Maximum protrusion of the outlet, including
studs, is not to exceed 4 5/8 in. from the shell envelope.
c. Weld a steel plug into the shell, thus sealing the outlet, remove the blind flange and
hydrostatic test. Radiographing any butt weld involved will be waived since it is not
practical. No protrusion will be allowed below the plane of the tank flange and the
protrusion of the tank flange beyond the shell envelope is not to exceed two inches.
Fig. Y.2 C-6494 pressure car bottom fittings protection (continued)
11/2014 C-III [M-1002] 551

APPENDIX Y M-1002
Exhibit 2
Mechanical Division Circular D.V. 2007
Bottom Fittings Protection RequirementsAAR Commodity Groups 1 through 9(1)

Group 1EPA Categories X, A, B
Group 2Flammable and thermally unstable(2)
Flammable and polymerizable(3)
Flammable and poison
Flammable and corrosive
Group 3EPA Categories C, D
Group 4Vacant
Group 5Poison
Group 6Flammable
Group 7Corrosive
Group 8Combustible
Group 9ORM Hazardous Substances(4)
Notes:
(1)Bottom discontinuity protection is not required on tank cars built before 1979 used to transport molten sul-
phur.
(2)Thermally unstableA material which, when exposed to elevated temperatures, will spontaneously
decompose with evolution of heat and pressure.
(3)PolymerizableA material which will react with itself to form a larger molecule, usually with evolution
of heat.
(4)Group 9 commodities are evaluated on an individual basis and protection levels are assigned as deemed
appropriate. See Fig. Y5 for Group 9 commodities which have been assigned protection levels.
Fig. Y.3 D.V. 2007 Exhibit 2, bottom fittings protectioncommodity groups
C-III [M-1002] 552 11/2014

M-1002 APPENDIX Y
Exhibit 2
AAR Groups 1 through 9

Protection required when commodities are carried in existing nonpressure stub sill
tank cars. (New tank cars and those where a conversion or alteration involves application
or replacement of a bottom outlet saddle must have protection in accord with M-1002,
E10.00)
A. Approved protection shall be provided, as specified in paragraph E10.00 in Specifi-
cation M-1002, AAR Specifications for Tank Cars, for all bottom discontinuities
having the breakage groove or shear plane more than one inch below the tank shell
longitudinal bottom center line with the following exception: Contoured sumps
made of pipe caps or pressed steel, having a straight wall projection from the tank
shell longitudinal bottom center line not in excess of 1 3/4 inches, are exempt for
AAR Groups 3 through 9 commodities.
B.
1. Approved protection shall be provided for all bottom outlets extending more than
one inch below the tank shell longitudinal bottom center line.
2. Approved protection shall be provided for all blind flanges and washouts (not hav-
ing internal closures) that extend more than 2 5/8 inches below the tank shell longi-
tudinal bottom center line (inclusive of bolting).
3. Approved protection shall be provided for all internally closed washouts that extend
more than 5 inches to the breakage groove or shear plane measured from the tank
shell longitudinal bottom center line.
4. For AAR Group 1 and 2 commodities, approved protection shall be provided for all
sumps extending more than 5 inches below the tank shell longitudinal bottom cen-
ter line. For AAR Groups 3 through 9 commodities, sumps greater than 5 inches
that are not contoured, and contoured sumps made of pipe caps or pressed steel
which have a straight wall projection from the tank shell longitudinal bottom cen-
ter line exceeding 1 3/4 inches, must have approved protection provided.
C. Approved protection shall be provided for all bottom discontinuities extending more
than 5 inches below the tank shell longitudinal bottom center line (measurement to
the shear plane, if any, and inclusive of bolting) with the following exception: Con-
toured sumps made of pipe caps or pressed steel, having a straight wall projection
from the tank shell longitudinal bottom center line not in excess of 1 3/4 inches, are
exempt for AAR Groups 3 through 9 commodities.
D. The shipper is to furnish the Bureau of Explosives the specific physical and chemi-
cal properties of the material in order to have the required level of protection as-
signed.
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protectionprotection requirements (Levels A, B, C, and D)
11/2014 C-III [M-1002] 553

APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Acetal 6 C Alcohol, n.o.s. (alcohol, contaminated,
Acetaldehyde 3 A suitable only for blending or redistilling
purposes) 6 C
Acetic acid 3 C
Alcohol, n.o.s. (ethyl alcohol, anhydrous,
Acetic anhydride 3 B denatured in part with petroleum
Acetone 6 C products and/or chemicals, petroleum
Acetone cyanohydrin 1 A products and/or chemicals not to
Acetone oil 6 C exceed five percent) 6 C
Acetonitrile 2 B Alcohol, n.o.s. (denatured alcohol solvent) 6 C
Acetyl Bromide 3 B Alcohol, n.o.s. (denaturing alcohol, nec)
(flammable) 6 C
Acetyl chloride 3 B
Alcohol, n.o.s. (denaturing alcohol, nec)
Acetyl iodide 7 B (combustible) 8 C
Acid butyl phosphate 7 C Alcohol, n.o.s. (isopropanol and methanol
Acid, glacial methacrylic (corrosive liquid, mixture) 6 C
n.o.s.) 7 C Alcohol, n.o.s. (methanol, contaminated,
Acid, liquid, n.o.s. (acids, inorganic, nec, value only for refining) 6 C
liquid) 7 D Alcohol distillates, synthetic (alcohol, n.o.s.)
Acid, liquid, n.o.s. (acid, nec, liquid, (flammable) 6 C
organic) 7 D Alcohol distillates, synthetic (alcohol, n.o.s.)
Acrylamide solution (combustible liquid, (combustible) 8 C
n.o.s.) 8 C Alcoholic beverage (flammable) 6 C
Acrylamide solution (flammable liquid, Alcoholic beverage (combustible) 8 C
n.o.s.) 6 C
Alcohols, fatty or cyclic, ethoxylated
Acrylic acid 7 C (alcohol, n.o.s.) (combustible) 8 C
Acrylonitrile 1 A Alcohols, fatty or ethoxylated (alcohol,
Active sec-amyl alcohol (alcohol, n.o.s.) 6 C n.o.s.) (flammable) 6 C
Additives, fuel oil, gasoline, or lubricating Aldol (combustible liquid, n.o.s.) 8 C
oil, containing less than 50% by weight Aldrin 1 A
of petroleum (combustible liquid, n.o.s.) 8 C
Alkaline battery fluid 7 C
Additives, fuel oil, gasoline, or lubricating
oil, containing less than 50% by weight Alkaline (corrosive) liquid, n.o.s. 7 D
of petroleum (flammable liquid, n.o.s.) 6 C Alkaline (corrosive) liquid, n.o.s. (fatty
Adhesive, n.o.s. (flammable) 6 C alcohols, aliphatic or cyclic,
cyanoethylated and hydrogenated, and
Adhesive, n.o.s. (combustible) 8 C derivatives thereof, such as salts,
Adhesive, n.o.s. (insecticide adhesives, diamines, oxyalkylates and quarternary
liquid) (combustible) 8 C ammonium compounds) 7 C
Adhesive, n.o.s. (insecticide adhesives, Alkanesulfonic acid 7 C
liquid) (flammable) 6 C Allyl alcohol 1 A
Alcohol, n.o.s. (flammable) 6 C Allyl bromide 2 C
Alcohol, n.o.s. (combustible) 8 C Allyl chloride 2 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protectionprotection requirements (Levels A, B, C, and D) (continued)
C-III554 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Allyl trichlorosilane 7 B Antifreeze compound, liquid (combustible) 8 C
Aluminum liquid (or) paint 6 C Antifreeze preparation, liquid (flammable) 6 C
Aluminum phosphate solution 7 C Antifreeze preparation, liquid (combustible) 8 C
Aluminum sulfate 3 C Antimony pentachloride 3 C
2-(2-aminoethoxy) ethanol 7 C Antimony tribromide 3 C
Aminoethylethanolamine (corrosive liquid, 7 C Antimony trichloride 3 C
n.o.s.) Antimony trifluoride 3 B
N-aminoethylpiperazine 7 C Aromatic concentrates, suitable only for 6 C
Aminopropyldiethanolamine 7 C further processing (flammable liquid,
N-aminopropylmorpholine 7 C n.o.s.)
Ammonium bifluoride 3 C Arsenic trichloride 3 A
Ammonium bisulfite 3 C Arsenic acid solution 5 A
Ammonium hydroxide 3 C Arsenical dip, liquid (sheep dip) 5 A
Ammonium sulfide 3 C Arsenical pesticide (compounds and 6 D
preparations), liquid (flammable)
Ammonium thiocyanate 3 C
Arsenical pesticide (compounds and 5 D
Ammonium thiosulfate 3 C
preparations), liquid (poison)
Amyl acetate 3 C
Asphalt, cut back 6 C
Active primary amyl alcohol (alcohol, n.o.s.) 8 C
Asphalt, cut back (asphalt petroleum, liquid 8 C
n-sec-amyl alcohol (alcohol, n.o.s.) 6 C and tall oil pitch, mixed)
Amyl acid phosphate 7 C Asphalt pavement surface sealer, asphalt, 8 C
Primary n-amyl alcohol (alcohol, n.o.s.) 6 C coal tar or petroleum base (combustible
Tert-amyl alcohol (alcohol, n.o.s.) 6 C liquid, n.o.s.)
Amylamine 6 C Asphalt pavement surface sealer, asphalt, 6 C
coal tar or petroleum base (flammable
Amyl chloride 6 C
liquid, n.o.s.)
Amylene, (normal) 6 C
Asphalt tile plasticizer (combustible liquid, 8 C
Amyl formate 6 C n.o.s.)
Amyl mercaptan 6 C Asphalt tile plasticizer (flammable liquid, 6 C
Amyl nitrate (combustible liquid, n.o.s.) 8 C n.o.s.)
Amyl nitrite (flammable) 6 C Belt dressing (combustible liquid, n.o.s.) 8 C
Amyl phenol (corrosive liquid, n.o.s.) 7 A Belt dressing (flammable liquid, n.o.s.) 6 C
Amyl trichlorosilane 7 B Benzaldehyde 8 C
Aniline 3 B Benzene 3 A
Anisoyl chloride 7 B Benzene phosphorus dichloride 7 B
Antifreeze alcohols (alcohol, n.o.s.) 6 C Benzene phosphorus thiodichloride 7 B
(flammable) Benzidine 5 C
Antifreeze alcohols (alcohol, n.o.s.) 8 C Benzine 6 C
(combustible)
Benzoic derivative pesticide (compounds 6 D
Antifreeze compound, liquid (flammable) 6 C and preparations), liquid (flammable)
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protectionprotection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III555
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Benzoic derivate pesticide (compounds 5 D Butyl methacrylate (combustible liquid, 8 C
and preparations), liquid (poison) n.o.s.)
Benzol fore-runnings, crude, not benzol 6 C Butyl phenol (corrosive solid, n.o.s.) 7 A
(flammable liquid, n.o.s.) n-Butyl phthalate 1 A
Benzonitrile 3 A Butyl trichlorosilane 7 B
Benzoyl chloride 3 B Butyraldehyde 6 B
Benzyl chloride 1 A Butyric acid (Isobutyric acid) 3 C
Beta-propiolacetone (combustible liquid, 8 C Butyronitrile (flammable liquid, n.o.s.) 6 C
n.o.s.)
Calcium dodecylbenzenesulfonate 3 B
Biphenyl (diphenyl) (combustible liquid, 8 C
Calcium hydrogen sulfite solution 7 C
n.o.s.)
Camphor oil 8 C
Bipyridilium pesticide (compounds and 6 D
preparations), liquid (flammable) Carbamate pesticide (compounds and 6 D
Bipyridilium pesticide (compounds and 5 D
preparations), liquid (poison) Carbamate pesticide (compounds and 5 D
Bis-(aminopropyl) piperazine 7 C
Carbon black oil (combustible liquid, n.o.s.) 8 C
Boiler compound, liquid 7 D
Carbon black oil (flammable liquid, n.o.s.) 6 C
Bordeau arsenite, liquid 5 A
Carbon disulfide 3 D
Boron tribromide 7 C
Carbon remover, liquid 6 C
Boron trichloride 7 C
Carbon tetrachloride 3 C
Boron trifluoride acetic acid complex 7 C
Cement, leather 6 C
Box toe gum (flammable) 6 C
Cement, linoleum, tile, wallboard or 6 C
Box toe gum (combustible) 8 C
container, liquid
Bromoacetic acid solution 7 C
Cement, liquid, n.o.s. (flammable) 6 C
Bromobenzene 8 C
Cement, liquid, n.o.s. (combustible) 8 C
Butyl acetate (Isobutyl acetate) 3 C
Cement or concrete waterproofing 8 C
Butyl alcohol (isobutyl alcohol) 6 C compound, liquid or paste (combustible
Butyl alcohol (n-butyl alcohol) 6 C liquid, n.o.s.)
Butyl alcohol (2-butanol) 6 C Cement or concrete waterproofing 6 C
Butyl alcohol (tert-butyl alcohol) 6 C compounds, liquid or paste (flammable
liquid, n.o.s.)
Butylamine (Isobutylamine) 3 C
Cement, pyroxylin 6 C
Butyl bromide, (normal) 6 C
Cement, roofing, liquid 6 C
Butyl chloride 6 C
Cement, rubber 6 C
Butyl ether 6 C
Chemical plant waste, nec (combustible 8 D
n-Butyl isocyanate, (flammable liquid, 2 C
liquid, n.o.s.)
n.o.s.)
Chemical plant waste, nec (corrosive liquid, 7 D
Butyl lactate (combustible liquid, n.o.s.) 8 C
n.o.s.)
Butyl mercaptan 6 C
Chemical plant waste, nec (flammable 6 D
liquid, n.o.s.)
C-III556 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Chemical plant waste, nec (poisonous 5 D Coal tar light oil (combustible) 8 C
liquid, n.o.s.) Coal tar naphtha (flammable) 6 C
Chloral (corrosive liquid, n.o.s.) 7 C Coal tar naphtha (combustible) 8 C
Chlorinated lime, liquid (corrosive liquid, 7 C Coal tar nephtha and light oil of coal tar 8 C
n.o.s.) crude (combustible liquid, n.o.s.)
Chloroacetic acid, liquid (or) solution 7 C Coal tar naphtha and light oil of coal tar, 6 C
Chloroacetic acid, solid 7 C crude (flammable liquid, n.o.s.)
Chloroacetyl chloride 7 B Coal tar oil (flammable) 6 C
Chlorobenzene 1 A Coal tar oil (combustible) 8 C
Chloroform 3 C Coal tar oil, crude, nec (corrosive liquid, 7 C
Chloropentanes (combustible liquid, n.o.s.) 8 C n.o.s.)
Chloropentanes (flammable liquid, n.o.s.) 6 C Coal tar oil, crude, nec (corrosive solid, 7 C
n.o.s.)
Chlorophenyl trichlorosilane 7 B
Coal treating compounds, other than 8 D
Chloroprene 2 B
petroleum, nec, liquid (combustible
2-chloropropene 6 C liquid, n.o.s.)
Chlorosulfonic acid (Chlorosulfonic acid 3 B Coal treating compounds, other than 6 D
sulfur trioxide mixture) petroleum, nec, liquid (flammable liquid,
Chrome chloride solution (corrosive liquid, 7 C n.o.s.)
n.o.s.) Coating solution 6 C
Chromic acid 3 B Collidine (combustible liquid, n.o.s.) 8 C
Chromic fluoride solution 7 C Collodion 6 C
Chromic sulfate 3 C Combustible liquid, n.o.s. 8 D
Chromium oxychloride (or) chromyl 7 B Combustible liquid, n.o.s. (absorption oil, 8 C
chloride belt oil, compression oil, cordage oil,
Chromous chloride 3 C floor oil, harness oil, leather oil,
Coal briquette binder (combustible liquid, 8 C neatsfoot oil, putty oil, tanners oil,
n.o.s.) tobacco oil, transformer oil or wood oil,
petroleum)
Coal briquette binder (flammable liquid, 6 C
n.o.s.) Combustible liquid, n.o.s. (alcohol, 8 C
contaminated, suitable only for blending
Coal spraying oil, petroleum (combustible 8 C
or redistilling purposes)
liquid, n.o.s.)
Combustible liquid, n.o.s. (aromatic 8 C
Coal tar distillate (flammable) 6 C
concentrates, suitable only for further
Coal tar distillate (combustible) 8 C processing)
Coal tar dye, liquid (not otherwise 7 D Combustible liquid, n.o.s. (bond breaking 8 C
specifically named in section 172.101) compound, consisting of naphtha,
Coal tar fibre saturant, liquid (combustible 8 C petroleum resins and vegetable oils)
liquid, n.o.s.) Combustible liquid, n.o.s. (fungicides, 8 D
Coal tar fibre saturant liquid (flammable 6 C agricultural, nec, liquid)
liquid, n.o.s.) Combustible liquid, n.o.s. (lubricating oil, 8 C
Coal tar light oil (flammable) 6 C nec)
11/2014 C-III557
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Combustible liquid, n.o.s. (lubricating 8 C Compounds, hectograph (combustible 8 D
system sight feed fluid) liquid, n.o.s.)
Combustible liquid, n.o.s. (petroleum 8 C Compounds, hectograph (flammable liquid, 6 D
lubricating oil) n.o.s.)
Combustible liquid, n.o.s. (petroleum 8 C Compounds, leather finishing, nec 8 D
partially refined, for further processing) (combustible liquid, n.o.s.)
Combustible liquid, n.o.s. (petroleum oil 8 C Compounds, leather finishing, nec 6 D
residuum) (flammable liquid, n.o.s.)
Combustible liquid, n.o.s. (rubber tire 8 C Copper based pesticide (compounds and 6 D
lacquer, paint or shellac) preparations), liquid (flammable)
Combustible liquid, n.o.s. (smoke flue 8 D Copper based pesticide (compounds and 5 D
cleaning compounds) preparations), liquid (poison)
Combustible liquid, n.o.s. (wallpaper 8 D Copper naphthenate petroleum solution, 8 C
remover, liquid) not more than 8% copper naphthenate
Compound, cleaning, liquid (corrosive)) 7 C (combustible liquid, n.o.s.)
Compound, cleaning, liquid (flammable) 6 C Copper naphthenate petroleum solution, 6 C
not more than 8% copper naphthenate
Compound, cleaning, liquid (combustible) 8 C
(flammable liquid, n.o.s.)
Compound, cleaning, liquid (smoke flue 6 D
Corrosive liquid, n.o.s. 7 D
cleaning compounds)
Corrosive liquid, poisonous, n.o.s. 7 D
Compound, enamel 6 C
Corrosive solid, n.o.s. 7 D
Compound, lacquer, paint (or) varnish 7 C
removing, liquid Cosmetics, n.o.s., liquid 7 D
Compound, lacquer, paint, (or) varnish 6 C Cosmetics, n.o.s. (flammable) 6 D
removing, reducing (or) thinning, liquid Cosmetics, n.o.s. (combustible) 8 D
(flammable) Cresol 3 A
Compound, lacquer, paint (or) varnish, 8 C Creosote, coal tar 8 B
removing, reducing, (or) thinning, liquid
Crotonaldehyde 1 A
(combustible)
Crotonic acid 7 C
Compound, polishing, liquid 6 C
Crotonylene 6 C
Compound, rust preventing (or) compound, 7 C
rust removing Crude oil, petroleum (flammable) 6 C
Compound, tree (or) weed killing, liquid 8 D Crude oil, petroleum (combustible) 8 C
(combustible) Cumene (combustible liquid, n.o.s.) 8 C
Compound, tree (or) weed killing 7 D Cupriethylene-diamine solution 7 C
(corrosive) Cutch, catechu or japonica extract, liquid 8 C
Compound, vulcanizing, liquid (corrosive) 7 D (combustible liquid, n.o.s.)
Compound, vulcanizing, liquid (flammable) 6 C Cutch, catechu, or japonica extracts, liquid 6 C
Compounds, calking or glazing 8 C (flammable liquid, n.o.s.)
(combustible liquid, n.o.s.) Cyanide solution, n.o.s. 5 B
Compounds, calking or glazing (flammable 6 C Cyclohexane 3 C
liquid, n.o.s.) Cyclohexanone (combustible liquid, n.o.s.) 8 C
C-III558 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Cyclohexenyl trichlorosilane 7 B Dichloropropene 3 B
Cyclohexyl trichlorosilane 7 B Dichloropropene (Dichloropropane 3 B
Cyclohexylamine 6 C Mixture)
Cyclopentane 6 C 2, 2-Dichloropropionic acid 3 C
Cyclopentane, methyl 6 C Diethylamine 3 B
Decahydronaphthalene 8 C Diethylaminoethanol (combustible liquid, 8 C
n.o.s.)
Decyl alcohol, other than perfumery grade 8 C
(alcohol, n.o.s.) Diethylbenzene (combustible liquid, 8 C
n.o.s.)
Defoaming compound, nec, liquid 8 C
(combustible liquid, n.o.s.) Diethyl dichlorosilane 6 B
Defoaming compound, nec, liquid 6 C Diethylenetrimine (corrosive liquid, n.o.s.) 7 C
(flammable liquid, n.o.s.) Diethylhydroxylamine (combustible liquid, 8 C
Degumming compounds, fabric or fibre 8 C n.o.s.)
(combustible liquid, n.o.s.) Diethyl ketone 6 C
Degumming compounds, fabric or fibre 6 C Dihydropyran 6 C
(flammable liquid, n.o.s.) Diisobutylamine (flammable liquid, n.o.s.) 6 C
De-inking compounds, liquid, used in 7 C Diisobutyl carbinol (alcohol, n.o.s.) 8 C
recycling paper (corrosive liquid, n.o.s.)
Diisobutylene (flammable liquid, n.o.s.) 6 C
Denatured alcohol 6 C
Diisobutyl ketone 8 C
Detergent intermediates, other than cyclic 8 C
Diisooctyl acid phosphate 7 C
or petroleum (combustible liquid, n.o.s.)
Diisopropylamine 6 C
Detergent intermediates, other than cyclic 6 C
or petroleum (flammable liquid, n.o.s.) Diisopropylether 6 C
Diacetone alcohol 6 C Dimethylamine, aqueous solution 3 B
Diacetyl 6 C Dimethylaminoethanol (combustible liquid, 8 C
n.o.s.)
Dicamba 3 C
Dimethylaminoethyl methacrylate 8 C
Dichlobenil 3 C
(combustible liquid, n.o.s.)
Dichlorobenzene 1 A
2, 3-dimethylbutane 6 C
Dichloroacetic acid 7 C
Dimethyl carbonate 6 C
Dichloroacetyl chloride 7 B
Dimethyl chlorothiophosphate (or) dimethyl 7 B
Dichlorobutene (corrosive) 7 C phosphorochloridothioate
Dichlorobutene (flammable) 2 C 1, 4-dimethylcyclohexane 6 C
Dichloroethyl ether (poisonous liquid, 5 C Dimethylethylamine (flammable liquid, 6 C
n.o.s.) n.o.s.)
Dichlorethylene 6 C Dimethylhydrazine, unsymmetrical 2 A
Dichloroisopropyl ether 7 C Dimethyl sulfate 7 B
Dichloropentane 6 C Dimethyl sulfide 6 C
Dichlorophenyl trichlorosilane 7 B Dinitrobenzene 3 C
Dichloropropane 3 B Dinitrochlorobenzene 5 C
11/2014 C-III559
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Dinitrophenol 3 B Enamel (enamel, other than watch dial) 6 C
Dinitrotoluene 3 C (flammable)
Dioxane 6 C Enamel (enamel other than watch dial) 8 C
(combustible)
Dioxolane 6 C
Enamel whitening compounds, nec 8 C
Diphenyl dichlorosilane 7 B
Diphenylmethylbromide, solution 7 C
Enamel whitening compounds, nec 6 C
Di-n-propylamine (flammable liquid, n.o.s.) 6 C (flammable liquid, n.o.s.)
Diquat 3 C Epichlorohydrin 2 A
Disinfectant, liquid (corrosive) 7 D Eradicator, paint (or) grease, liquid 6 C
Disinfectant, liquid (poison) 5 D Ethyl acetate 6 C
Disinfectant, liquid, n.o.s. 8 D Ethyl acrylate 2 B
Distillate 6 C Ethyl alcohol 6 C
Dithiocarbamate pesticide (compounds and 6 D Ethyl benzene 3 C
Ethyl butyl acetate 8 C
Dithiocarbamate pesticide (compounds and 5 D
Ethyl-n-butylamine (flammable liquid, 6 C
n.o.s.)
Divinyl ether 6 C
Ethyl butyl ether 6 C
Dodecylbenzenesulfonic acid 3 B
Ethyl butyraldehyde 6 C
Dodecyltrichlorosilane 7 B
Ethyl butyrate 6 C
Drugs, n.o.s. (flammable) 6 D
Ethyl chloride 6 C
Drugs, n.o.s. (combustible) 8 D
Ethyl chloroacetate 8 C
Drugs, n.o.s., liquid (poison) 5 D
Ethyl crotonate 6 C
Drugs, n.o.s., liquid (corrosive) 7 D
Ethyl-N-cyclohexylamine (flammable liquid, 6 C
Drugs, n.o.s., solid 7 D n.o.s.)
Dye intermediate, liquid 7 D Ethyl dichlorosilane 6 B
Electric wire saturating or finishing 8 C Ethylene diamine 3 C
compound, asphalt or pitch base
Ethylene dibromide 3 B
Ethylene dichloride 3 B
Electric wire saturating or finishing 6 C
compound, asphalt or pitch base Ethylene glycol diethyl ether 8 C
(flammable liquid, n.o.s.) Ethylene glycol monoethyl ether 8 C
Electric wire saturating or finishing 8 C Ethylene glycol monoethyl ether acetate 8 C
compound, paraffine base (combustible Ethylene glycol monomethyl ether 8 C
liquid, n.o.s.)
Ethylene glycol monomethyl ether acetate 8 C
Electric wire saturating or finishing 6 C
Ethylene imine 2 A
compound, paraffine base (flammable
liquid, n.o.s.) Ethylene oxide 6 B
Electrolyte (acid), battery fluid (not over 7 C Ethyl ether 6 C
47% acid) Ethyl formate 6 C
Ethylhexaldehyde 8 C
C-III560 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Ethylhexyl acrylate (combustible liquid, 8 C Fireproofing compounds, liquid, nec 7 C
n.o.s.) (corrosive liquid, n.o.s.)
Ethyl lactate 8 C Flame retardant compound, liquid 7 C
Ethyl mercaptan 6 C Flammable liquid, n.o.s. 6 D
n-ethyl-metatoluidine (combustible liquid, 8 C Flammable liquid, n.o.s. (bond breaking 6 C
n.o.s.) compound consisting of naphtha,
Ethyl methyl ether 6 C petroleum resins and vegetable oils)
Ethyl nitrate 2 C Flammable liquid, n.o.s. (petroleum oil 6 C
additive, containing more than 50
Ethyl nitrite 2 C
percent by weight of petroleum)
Ethyl phenyl dichlorosilane 7 B
Flammable liquid, corrosive, n.o.s. 6 D
Ethyl phosphonothioic dichloride, 7 B
Flammable liquid, poisonous, n.o.s. 6 D
anhydrous
Floor covering underlayment compounds, 8 C
Ethyl phosphonous dichloride, anhydrous 7 B
nec (combustible liquid, n.o.s.)
Ethyl phosphorodichloridate 7 B
Floor covering underlayment compounds, 6 C
Ethyl propionate 6 C nec (flammable liquid, n.o.s.)
Ethyl silicate 8 C Fluorosulfonic acid (or) fluosulfonic acid 7 B
Extract, liquid, flavoring 6 C Formaldehyde 3 A
Extracts, chestnut or quebracho, liquid 8 C Formic acid 3 C
Fuel oil 8 C
Extracts, chestnut or quebracho, liquid 6 C
Fuel, aviation, turbine engine (flammable) 6 C
Fuel, aviation, turbine engine (combustible) 8 C
Extracts, fustic or logwood, liquid or paste 8 C
(combustible liquid, n.o.s.) Fuel oil treating compounds (corrosive 7 D
liquid, n.o.s.)
Extracts, fustic or logwood, liquid or paste 6 C
(flammable liquid, n.o.s.) Fumaryl chloride 7 B
Extracts, hypernic, liquid or paste 8 C Fungicides, agricultural, nec, liquid 6 D
(combustible liquid, n.o.s.) (flammable liquid, n.o.s.)
Extracts, hypernic, liquid or paste 6 C Furan 6 C
(flammable liquid, n.o.s.) Furfural 3 C
Extracts, tanning, nec, liquid or paste 8 C Furfuryl alcohol (alcohol, n.o.s.) 8 C
(combustible liquid, n.o.s.) Fusel oil 8 C
Extracts, tanning, nec, liquid or paste 6 C Gambier extracts, liquid (combustible 8 C
(flammable liquid, n.o.s.) liquid, n.o.s.)
Ferric chloride 3 B Gambier extracts, liquid (flammable liquid, 6 C
Ferrous chloride 1 A n.o.s.)
Ferrous sulfate 3 C Gas drips, hydrocarbon (flammable) 6 C
Fertilizer solution, consisting of water, free 7 C Gas drips, hydrocarbon (combustible) 8 C
ammonia and sulphur, total ammonia Gas odorants, not compressed gas 8 C
content not to exceed 30 percent by (combustible liquid, n.o.s.)
weight (corrosive liquid, n.o.s.)
11/2014 C-III561
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Gas odorants, not compressed gas 6 C Hydrobromic acid (more than 49% 7 C
(flammable liquid, n.o.s.) strength)
Gasohol (gasoline mixed with ethyl alcohol) 6 C Hydrobromic acid not more than 49% 7 C
(gasolines, blended, consisting of motor strength
fuels containing 50% or more of Hydrochloric acid 3 A
gasolines) Hydrochloric acid
Gasoline 6 C Hydrochloric acid mixture
Gasoline preservative, nec, liquid 8 D Hydrochloric acid solution inhibited
(combustible liquid, n.o.s.) Hydrochloric acid (muriatic acid, spent)
Gasoline preservative, nec, liquid 6 D Hydrofluoric acid 3 C
(flammable liquid, n.o.s.) Hydrofluosilicic acid 7 A
Geraniol-nerol mixture (combustible liquid, 8 C Hydroxyethyl acrylate (corrosive liquid, 7 C
n.o.s.) n.o.s.)
Glue catalyst, nec (combustible liquid, 8 D Hydroxypropyl acrylate (corrosive liquid, 7 B
n.o.s.) n.o.s.)
Glue catalyst, nec (flammable liquid, n.o.s.) 6 D Iminobispropylamine 7 C
Glycerine, crude, (spent lye) concentrated 7 C Ink (flammable) 6 C
(corrosive liquid, n.o.s.) Ink (combustible) 8 C
Glycol ethers (combustible liquid, n.o.s.) 8 C Ink materials, nec (flammable liquid, n.o.s.) 6 C
Heptane 6 C Ink materials, nec (combustible liquid, 8 C
Hexachlorocyclopentadiene 1 A n.o.s.)
Hexadecyltrichlorosilane 7 B Insecticide adhesives, spreaders or 7 C
Hexadiene 6 C stickers, liquid (corrosive liquid, n.o.s.)
Hexaldehyde 6 C Insecticide, liquid, n.o.s. (insecticides, 8 D
agricultural, nec, liquid) (combustible)
Hexamethylene diamine, solid 7 C
Insecticide, liquid, n.o.s. (insecticides, 6 D
Hexamethylene diamine, solution 7 A
agricultural, nec, liquid) (flammable)
Hexamethylene imine 7 B
Insecticide, liquid, n.o.s. (vermin 6 D
Hexane 6 C exterminator) (flammable)
Hexanoic acid 7 C Insecticide, liquid, n.o.s. (vermin 8 D
Hexyl alcohol, other than perfumery grade 8 C exterminator) (combustible)
(alcohol, n.o.s.) Isoamyl alcohol (alcohol, n.o.s.) 8 C
Hexyl trichlorosilane 7 B Isobutyl acrylate (flammable liquid, n.o.s.) 2 C
Hydroxy aldehydes, waste (combustible 8 C Isobutyraldehyde (flammable liquid, n.o.s.) 6 C
liquid, n.o.s.)
Isobutyric anhydride 7 C
Hydroxy aldehydes, waste (flammable 6 C
Isobutyronitrile (flammable liquid, n.o.s.) 6 C
liquid, n.o.s.)
Isoheptyl alcohol (alcohol, n.o.s.) 8 C
Hydrazine, anhydrous 2 A
Isooctane 6 C
Hydrazine, aqueous solution 7 A
Isooctene 6 C
Hydriodic acid 7 C
C-III562 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Isooctyl alcohol, other than perfumery 8 C Methallyl chloride (flammable liquid, n.o.s.) 6 C
grade (alcohol, n.o.s.) Methyl aceto-acetate (combustible liquid, 8 C
Isooctyl alcohol, perfumery grade (alcohol, 8 C n.o.s.)
n.o.s.) Methyl acrylate 2 B
Isopentane 6 C Methyl amyl ketone 8 C
Isopentanoic acid 7 C Methanol (methyl alcohol) 6 C
Isoprene 2 C Methyl acetone 6 C
Isopropanol 6 C Methyl acetate 6 C
Isopropyl acetate 6 C Methylal 6 C
Isopropylamine 6 C Methyl amyl acetate 6 C
Isopropyl nitrate 2 C Methyl butene 6 C
Isopropyltoluene (combustible liquid, n.o.s.) 8 C Methyl butyl ketone (flammable liquid, 6 C
Kelthane 3 B n.o.s.)
Kerosene 8 C Methyl butyrate 6 C
Lacquer thinning compound (lacquer 6 C Methyl chloroformate 6 C
thinning compounds, used) (flammable) Methylcyclohexane 6 C
Lacquer thinning compound (lacquer 8 C Methyl dichloroacetate 7 C
thinning compounds, used)
Methyl dichlorosilane 6 B
(combustible)
Methylethanolamine (combustible liquid, 8 C
Leather bleach (flammable) 6 D
n.o.s.)
Leather bleach (combustible) 8 D
Methyl ethyl ketone 6 C
Leather dressing (flammable) 6 D
Methyl ethyl pyridine 7 B
Leather dressing (combustible) 8 D
Methyl formate 6 C
Lighter fluid 6 C
Methylfuran 6 C
Lutidene (flammable liquid, n.o.s.) 6 C
Methylhydrazine 6 A
Maleic anhydride 3 C
Methyl isobutyl carbinol (alcohol, n.o.s.) 8 C
Medicines, n.o.s. 6 D
Methyl isobutyl ketone (flammable liquid, 6 C
Medecine, n.o.s. 8 D n.o.s.)
Medicines, n.o.s., liquid (corrosive) 7 D Methyl isopropenyl ketone 2 C
Medicines, n.o.s., liquid (poison) 5 D Methyl methacrylate monomer 2 A
Medicines, n.o.s., solid 7 D Methyl methoxy pentanone (combustible 8 C
Mercaptan mixture, aliphatic (flammable) 6 C liquid, n.o.s.)
Mercaptan mixture, aliphatic (combustible) 8 C Methylpentadiene 6 C
Mercuric iodide solution 5 B Methyl pentane 6 C
Mercury based pesticide (compounds and 6 D Methyl phosphonothioic dichloride, 7 B
preparations), liquids (flammable) anhydrous
Mercury based pesticide (compounds and 5 D Methyl propionate 6 C
preparations), liquids (poison) Methyl propyl ketone 6 C
Mesityloxide 6 C Methyltrichlorosilane 6 B
11/2014 C-III563
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Methyl vinyl ketone inhibited 2 B Nicotine, liquid 5 B
Mexacarbate 3 B Nicotine salicylate 5 B
Mining reagent, liquid (containing 20% or 7 B Nicotine sulfate, liquid 5 B
more cresylic acid) Nicotine tartrate 5 B
Mixed chlorosilanes (flammable liquid, 6 B Nitric acid 3 B
corrosive, n.o.s.) Nitric acid (over 40%)
Mono-tert-butyl-meta-cresol (combustible 8 B Nitric acid, fuming
liquid, n.o.s.) Nitric acid, 40% or less
Monoethanolamine 7 C Nitroaniline 5 C
Monoethylamine 3 B Nitrobenzene 3 B
Monomethylamine, aqueous solution 3 B Nitrochlorobenzene, ortho, liquid 5 C
Monoisopropanolamine (corrosive liquid, 7 C Nitrophenol 3 B
n.o.s.) Nitrotoluene 3 C
Morpholine 6 C Nitroxylol 5 C
Morpholine, aqueous, mixture (corrosive) 7 C Nonyl trichlorosilane 7 B
Morpholine, aqueous, mixture (flammable) 6 C Octane 6 C
Mortar stain, liquid (flammable) 6 C Octadecyltrichlorosilane 7 B
Mortar stain, liquid (combustible) 8 C Octyl alcohol, other than perfumery grade 8 C
Motor fuel, n.o.s. (flammable) 6 C (alcohol, n.o.s.)
Motor fuel, n.o.s. (combustible) 8 C Octyl alcohol, perfumery grade (alcohol, 8 C
Mud treating compounds, nec, gas or oil 8 C n.o.s.)
well drilling (combustible liquid, n.o.s.) Octyl trichlorosilane 7 B
Mud treating compounds, nec, gas or oil 6 C Oil, n.o.s., petroleum oil, (or) petroleum oil, 6 C
well drilling (flammable liquid, n.o.s.) n.o.s. (flammable)
Naphtha (flammable) 6 C Oil, n.o.s., petroleum oil, (or) petroleum oil, 8 C
Naphtha (combustible) 8 C n.o.s. (combustible)
Naphtha distillate (flammable) 6 C Organic phosphate, organic phosphate 5 D
compound, (or) organic phosphorus
Naphtha distillate (combustible) 8 C
compound, liquid
Naphtha, solvent (flammable) 6 C
Organochlorine pesticide (compounds and 6 D
Naphtha, solvent (combustible) 8 C preparations), liquid (flammable)
Naphthalene 3 C Organochlorine pesticide (compounds and 5 D
Neohexane 6 C preparations), liquid (poison)
Neo pentanoic acid (combustible liquid, 8 C Organophosphorus pesticide (compounds 6 D
n.o.s.) and preparations), liquid (flammable)
Nickel plating solution (corrosive liquid, 7 C Organophosphorus pesticide (compounds 5 D
n.o.s.) and preparations), liquid (poison)
Nickel plating solution (poisonous liquid, 5 B Organotin pesticide (compounds and 6 D
n.o.s.) preparations), liquid (flammable)
Nicotine hydrochloride 5 B
C-III564 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Organotin pesticide (compounds and 5 D Petroleum oil, n.o.s. (petroleum oil 6 C
preparations), liquid (poison) residuum)
Paint (asphaltum or coal tar paint) 6 C Petroleum oil, n.o.s. (petroleum, partially 6 C
(flammable) refined, for further processing)
Paint (asphaltum or coal tar paint) 8 C Petroleum propylene tetramer (combustible 8 C
(combustible) liquid, n.o.s.)
Paint drier, liquid (flammable) 6 C Petroleum propylene trimer (flammable 6 C
Paint drier, liquid (combustible) 8 C liquid, n.o.s.)
Paint, lacquer or shellac (rubber tire 6 C Petroleum refinery sulfide waste (corrosive 7 B
lacquer, paint or shellac) liquid, n.o.s.)
Paint, lacquer, stain, (or) varnish, bronze, or 6 C Phenol (Carbolic acid) 3 A
gold, liquid (or) lacquer base, liquid Phenoxy pesticide (compounds and 6 D
(flammable) preparations), liquid (flammable)
Paint, lacquer, stain, (or) varnish, bronze, or 8 C Phenoxy pesticide (compounds and 5 D
gold, liquid (or) lacquer base, liquid preparations), liquid (poison)
(combustible) Phenyl trichlorosilane 7 B
Paint oil compounds (combustible liquid, 8 C Phenylurea pesticide (compounds and 6 D
n.o.s.) preparations), liquid (flammable)
Paint oil compounds (flammable liquid, 6 C Phenylurea pesticide (compounds and 5 D
n.o.s.) preparations), liquid (poison)
Paint oils, nec (combustible liquid, n.o.s.) 8 C Phosphoric acid 3 C
Paint oils, nec (flammable liquid, n.o.s.) 6 C Phosphorus 1 A
Paraldehyde 6 B Phosphorus oxybromide 7 B
Pentane 6 C Phosphorus oxychloride 3 B
Perchloro-methyl-mercaptan 5 B Phosphorus tribromide 7 B
Petroleum distillate (flammable) 6 C Phosphorus trichloride 3 A
Petroleum distillate (combustible) 8 C Phthalimide derivative pesticide 6 D
Petroleum ether 6 C (compounds and preparations), liquid
Petroleum ether (polyethylligroin) 6 C (flammable)
Petroleum naphtha (flammable) 6 C Phthalimide derivative pesticide 5 D
(compounds and preparations), liquid
Petroleum naphtha (combustible) 8 C
(poison)
Petroleum oil additive, containing more 8 C
Picoline (combustible liquid, n.o.s.) 8 C
than 50 percent by weight of petroleum
(combustible liquid, n.o.s.) Picoline (flammable liquid, n.o.s.) 6 C
Petroleum oil, n.o.s. (absorption oil, belt oil, 6 C Pinene 6 C
compression oil, cordage oil, floor oil, Pine Oil 8 C
harness oil, leather oil, neatsfoot oil, Plastic solvent, n.o.s. (flammable) 6 C
putty oil, tanners oil, tobacco oil,
Plastic solvent, n.o.s. (combustible) 8 C
transformer oil or wood oil, petroleum)
Plasticizer alcohol (alcohol, n.o.s.) 6 C
Petroleum oil, n.o.s. (coal spraying oil, 6 C
(flammable)
petroleum)
11/2014 C-III565
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Plasticizer alcohol (alcohol, n.o.s.) 8 C Pulp mill liquid (combustible liquid, n.o.s.) 8 C
(combustible) Pulp mill liquid (flammable liquid, n.o.s.) 6 B
Plasticizers, paint, lacquer or varnish 8 C Pyridine 6 B
Pyroligneous acid (combustible liquid, 8 C
Plasticizers, paint, lacquer or varnish 6 C n.o.s.)
Pyroligneous acid (flammable liquid, n.o.s.) 6 C
Poisonous liquid, n.o.s. (animal or poultry 5 D
Pyro sulfuryl chloride 7 B
dip, nec, liquid)
Pyroxylin solution (flammable) 6 C
Poisonous solid, corrosive, n.o.s. 5 D
Pyroxylin solution (combustible) 8 C
Polish, metal, stove, furniture (or) wood, 8 C
liquid (combustible) Pyroxylin solvent, n.o.s. (flammable) 6 C
Polish, metal, stove, furniture (or) wood, 6 C Pyroxylin solvent, n.o.s. (combustible) 8 C
liquid (flammable) Pyrrolidine 6 C
Polishing wheel cement thinner 8 C Quinaldine (combustible liquid, n.o.s.) 8 C
(combustible liquid, n.o.s.) Quinoline 3 C
Polishing wheel cement thinner (flammable 6 C Refinery cracking stock (combustible liquid, 8 C
liquid, n.o.s.) n.o.s.)
Polychlorinated biphenyls 1 A Refinery cracking stock (flammable liquid, 6 C
Polyethylbenzene (combustible liquid, 8 C n.o.s.)
n.o.s.) Resin solution (resin compound, liquid) 6 C
Polyethylligroin (combustible liquid, n.o.s.) 8 C (flammable)
Potassium cyanide 1 A Resin solution (resin compound, liquid) 8 C
Potassium fluoride solution 7 C (combustible)
Potassium hydrogen fluoride solution 7 C Road asphalt or tar, liquid 6 C
Potassium hydroxide (Caustic Potash) 3 C Road asphalt (or) tar, liquid (petroleum road 8 C
oil)
1-propanol (alcohol, n.o.s.) 6 C
Road oil (petroleum road oil) 8 C
Propargyl alcohol 6 B
Rosin gloss or ester gum (combustible 8 C
Propionaldehyde (propyl aldehyde) 6 C
liquid, n.o.s.)
Propionic acid 3 C
Rosin gloss or ester gum (flammable liquid, 6 C
Propionic anhydride 3 C n.o.s.)
Propyl acetate 6 C Rosin liquor, consisting of rosin and not 8 C
Propyl chloride 6 C more than 40% alcohol or mineral
Propylamine (mono-n-propylamine) 6 C spirits (combustible liquid, n.o.s.)
Propylenediamine 6 C Rosin liquor (flammable liquid, n.o.s.) 6 C
Propylene dichloride 3 B Rosin residue (combustible liquid, n.o.s.) 8 C
Propylene imine 2 A Rosin residue (flammable liquid, n.o.s.) 6 C
Propylene oxide 2 A Rosin solution (combustible liquid, n.o.s.) 8 C
Propyl mercaptan 6 C Rosin solution (flammable liquid, n.o.s.) 6 C
Propyl trichlorosilane 7 B
C-III566 11/2014
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Rubber accelerators or softeners, other 8 D Sodium nitrite 1 A
than petroleum, nec (combustible Sodium phenolate, solid 7 C
liquid, n.o.s.)
Sodium solution waste (corrosive liquid, 7 C
Rubber accelerators or softeners, other 6 D n.o.s.)
than petroleum, nec (flammable liquid,
Solution, copper plating (corrosive liquid, 7 C
n.o.s.)
n.o.s.)
Rubber preservative, nec (combustible 8 D
Solution, copper plating (poisonous liquid, 5 B
liquid, n.o.s.)
n.o.s.)
Rubber preservative, nec (flammable liquid, 6 D
Solvent, n.o.s. (flammable) 6 D
n.o.s.)
Solvent, n.o.s. (combustible) 8 D
Rubbing alcohol compounds (alcohol, 8 C
n.o.s.) (combustible) Solvent, n.o.s. (solvents, paint, lacquer, 6 C
varnish or resin) (flammable)
Rubbing alcohol compounds (alcohol, 6 C
n.o.s.) (flammable) Solvent, n.o.s. (solvents, paint, lacquer, 8 C
varnish or resin) (combustible)
Rum, denatured 6 C
Solvent refined coal, liquid (combustible 8 C
Rust preventive coating (pipe line rust 8 C
liquid, n.o.s.)
preventive coating)
Spirits of turpentine (combustible liquid, 8 C
Selenic acid, liquid 7 B
n.o.s.)
Selenium oxychloride (poisonous liquid, 5 B
Spirits of turpentine (flammable liquid, 6 C
n.o.s.)
n.o.s.)
Shellac, liquid (flammable) 6 C
Styrene monomer 2 A
Shellac, liquid (combustible) 8 C
Substituted nitrophenol pesticide 6 D
Silicon chloride (or) silicon tetrachloride 7 B (compounds and preparations), liquid
Sludge acid 7 B (flammable)
Sludge acid (sludge, acid, containing not 7 C Substituted nitrophenol pesticide 5 D
less than 75% water) (compounds and preparations), liquid
Sludge, alkali, containing not less than 75% 7 C (poison)
water (corrosive liquid, n.o.s.) Sulfur trioxide 7 B
Sodium aluminate solution 7 C Sulfuric acid 3 A
Sodium arsenite 3 B Nitrating acid
Hydrofluoric and sulfuric acid mixture
Sodium chlorite solution (not exceeding 42 7 C
Oleum
percent sodium chlorite)
Sulfuric acid
Sodium chromate 3 B Sulfuric acid, spent
Sodium bifluoride 3 C Nitrating acid, spent
Sodium bisulfite 3 C Sulfur monochloride 3 A
Sodium cyanide 1 A Sulfurous acid 7 C
Sodium fluoride 3 C Sulfuryl chloride 7 B
Sodium hydrogen sulfate solution 7 C Sulphates, mixed ethyl, consisting of 7 C
Sodium hydroxide (Caustic Soda) 3 C monoethyl sulphate and diethyl
sulphate (corrosive liquids, n.o.s.)
Sodium methylate 3 C
11/2014 C-III567
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Sulphide waste (corrosive liquid, n.o.s.) 7 B Trichloroethylene 3 C
Tallow alcohol (alcohol, n.o.s.) (flammable) 6 C Trichlorophenol 1 A
Tallow alcohol (alcohol, n.o.s.) 8 C Trichlorosilane 6 B
(combustible) Triethylamine 3 B
Tanners depilatory, nec (corrosive liquid, 7 D Triethylenetetramine (corrosive liquid, 7 C
n.o.s.) n.o.s.)
Tar, liquid (flammable) 6 C Triethyl phosphite (combustible liquid, 8 C
Tar, liquid (combustible) 8 C n.o.s.)
1,2,3,6-tetrahydrobenzaldehyde 7 C Trimethyl acetylchloride 7 B
Tetrahydrofuran 6 C Trimethylamine, aqueous solution 3 B
Tetrahydrofurfuryl alcohol (combustible 8 C Trimethylchlorosilane 6 B
liquid, n.o.s.) Trimethyl phosphite (flammable liquid, 6 C
Tetramethylammonium hydroxide, liquid 7 C n.o.s.)
Textile treating compound (or) mixture, 7 D Turpentine (flammable) 6 C
liquid Turpentine (combustible) 8 C
Thinner for rust preventive coating 6 C Turpentine residue, liquid (flammable 6 C
(flammable) liquid, n.o.s.)
Thinner for rust preventive coating 8 C Turpentine residue, liquid (combustible 8 C
(combustible) liquid, n.o.s.)
Thioglycolic acid 7 C Turpentine substitute (flammable) 6 C
Thionyl chloride 7 B Turpentine substitute (combustible) 8 C
Thiophosphoryl chloride 7 B Uranyl acetate 3 A
Tin tetrachloride, anhydrous 7 B Uranyl nitrate (Uranyl nitrate hexahydrate 3 A
Titanium tetrachloride 7 B solution)
Titanium sulfate solution (containing not 7 C Valeric acid 7 C
more than 45% sulfuric acid) Valeryl chloride 7 D
Toluene 3 C Vanadium oxytrichloride 7 B
Toluene diisocyanate 5 A Vanadium tetrachloride 7 B
Toluene sulfonic acid, liquid 7 C Varnish (asphaltum or coal tar varnish) 6 C
Toluidene (combustible liquid, n.o.s.) 8 C (flammable)
Toxaphene 1 A Varnish (asphaltum or coal tar varnish) 8 C
Triazine pesticide (compounds and 6 D (combustible)
preparations), liquid (flammable) Vinyl acetate 3 A
Triazine pesticide (compounds and 5 D Vinylidene chloride, inhibited 3 C
preparations), liquid (poison) Vinyl isobutyl ether 2 C
Tri-n-butylamine (combustible liquid, n.o.s.) 8 C Vinyl ethyl ether 2 C
Trichlorfon 3 B Vinyl toluene, inhibited, liquid (combustible 8 C
Trichloroacetic acid, solid 7 C liquid, n.o.s.)
Trichloroacetic acid solution 7 C Vinyl trichorosilane 6 B
C-III568 11/2014
M-1002 APPENDIX Y
Protection
Required
Group
Commodity
Wallpaper remover liquid (flammable liquid, 6 D
n.o.s.)
Waste, chemical plant, zinc chloride 7 C
(corrosive liquid, n.o.s.)
Waste etchant solution, suitable only for 7 C
reclamation of metallic content
Waste liquor, consisting of not less than 50 8 C
percent by weight of water, resulting
from sulphate or soda pulping process
Water treatment compounds, liquid 7 C
Wax, liquid 8 C
Wood bleach (corrosive liquid, n.o.s.) 7 D
Wood turpentine (corrosive liquid, n.o.s.) 8 C
Wood turpentine (flammable liquid, n.o.s.) 6 C
Xylene 3 C
Xylenol 3 B
Zinc arsenate 5 A
Zinc chloride 3 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protectionprotection requirements (Levels A, B, C, and D) (concluded)
11/2014 C-III [M-1002] 569

APPENDIX Y M-1002
Exhibit 2
AddendumSeptember 1, 1990
The following commodities have been reviewed since the publication of D.V. 2007
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Adipic acid solution 3 C Hazardous waste, liquid, n.o.s. 9 C
Alpha methyl styrene 8 C Hexamethylene diamine solution 7 C*
Aluminum sulfate solution 9 C Lasso 8 A
Ammonium chloride 3 C Maleic acid 3 C
Ammonium fluoride 3 C Methyl butynol 6 C
Ammonium hydroxide (less than 12% NH3) 9 C 2-Methyl cyclohexylamine 2 B
Ammonium oxalate 9 C Methyl pentynol 6 C
Ammonium sulfite 3 C Methyl styrene 8 C
Benzoic acid 3 C Paraquat 1 A
Bis-para-aminocyclohexyl methane 7 C N-Pentanol 6 C
Butyl acrylate 8 C Petroleum distillate engine fuel 8 C
Diazo-bicyclo-undecane 7 A Other regulated substances, liquid, n.o.s. 9 C
N-Dibutylamine 8 C (hazardous substances)
Dichloromethane (Methylene chloride) 9 A Piperidine 2 A
Dicyclohexylamine 7 C Propyl acetate 6 C
N-N diethylaniline 5 B Sodium chlorate solution C
Dimethyl aminopropylamine 2 A Sodium dichromate (bichromate) 9 B
Dimethyl cyclohexylamine 7 C Sodium hydrosulfide solution 3 C
Dimethyl formamide 8 C Sodium nitrite 40% solution 1 A
Dioctyl phthalate 1 B Tetrachloroethylene (Perchloroethylene) 9 A
Dowanol (propylene glycol methyl ether) 6 C Toluenediamine 3 B
Environmentally hazardous substances, 9 C Tri-n-propylamine 8 B
liquid, n.o.s. 1,1,1,-Trichloroethane (Methyl chloroform) 9 A
Ethyl cyclohexylamine 7 C Vapam (sodium methyldithiocarbamate) 7 B
Ethyl octynol 8 C Zinc bromide 3 C
Ferric sulfate 3 C Zinc sulfate 3 C
Formaldehyde solution (50-54%) 3 A
*Revision to D.V. 2007
Fig. Y.5 D.V. 2007 addendumadditional commodity requirements

C-III [M-1002] 570 11/2014
M-1002 APPENDIX Y
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
Executive Director - Tank Car Safety
September 7, 1999
CASUALTY PREVENTION CIRCULAR
(CPC-1097)
SUBJECT: New Requirements for Inspections of Stub Sills on Tank Cars T79.20.20-98
TO MEMBERS AND PRIVATE CAR OWNERS:
Please refer to circular letter no. CPC-1094, dated April 15, 1999, wherein the new stub sill
inspection program was introduced, to become effective July 1, 1999 for all stub sill tank cars.
At their July 1999 Executive Session, the Tank Car Committee approved two actions to modify
that program. First, the committee approved a new Form SS-3 (attached), to be used by
proponents to record inspection information for their cars. It is expected that Windows-based
software will be available for distribution by October. In the meantime, cars can be inspected
and the inspection results recorded using Form SS-3. When the SS-3 software is available,
proponents can enter their inspection data for transmission to AARs designated agent.
Please be advised that initial inspections of cars subject to O&M Circular No. 1 (stub sill
cars built prior to January 1, 1984) must be reported to the old SS-2 database using the SS-2
form and the SILSPEC program. Use of the SS-3 form is required for all other stub sill
inspections.
The Committee also addressed the situation where stub sill tank cars built since January 1,
1984 may be overdue for inspection in accord with CPC-1094, based on time or mileage. The
Committee agreed that a 3-year catch-up period until July 1, 2002 should be allowed for such
overdue cars. This date coincides with the deadline for initial Rule 88B inspections for tank cars.
Sincerely,
P. G. Kinnecom

50 F Street, N.W., Washington, D.C. 20001-1564
Phone (202) 639-2147; FAX (202) 639-2930; e-mail pkinneco@aar.org
Fig. Y.6 CPC-1097 stub sill inspection programnew Form SS-3 (page 1 of 5)
11/2014 C-III [M-1002] 571

APPENDIX Y M-1002
Form SS-3
REPORT OF TANK CAR STUB SILL INSPECTION Form SS-3
1. Car Reporting 2. Inspection Performed

Mark and Number by (Company)
3. Stencil Class 4. Shop Loc. (Town) State or Province

Mo Yr Mo Day Yr
5. Built Date 6. Date of Inspection
7. Car Jacketed? (Y,N) 8. Reserved (design specific)
9. Reserved (design specific) 10. Original AAR Certificate

of Construction Number
11. Builder 12. Stub Sill Design Style (as inspected)
13. Total Mileage to Nearest 1,000 Miles Note: Lines 10 - 13 Provided By Car Owner
(actual cumulative mileage required)
Transverse Weld Cracks (if more than one, record longest)

Enter max crack length to nearest 1/4 inch. (0, .25, .5, .75) A-END B-END
Enter 0 if no crack. Inspection Number Maximum Inspection Number Maximum
Enter N/A if item not applicable Technique of Cracks Length Technique of Cracks Length
14. A-1 Pad to Tank ________ ___________ ___________ ________ ___________ ___________
15. B-1 Pad to Sill (if no head brace) ________ ___________ ___________ ________ ___________ ___________
16. C-1 Head Brace to Sill ________ ___________ ___________ ________ ___________ ___________
17. D-1 Head Brace to Pad ________ ___________ ___________ ________ ___________ ___________
18. E-1 Other - Car Builder Specified ________ ___________ ___________ ________ ___________ ___________
Longitudinal Weld Cracks (if more than one, record longest)

19. A-2 Pad to Tank ________ ___________ ___________ ________ ___________ ___________
20. B-2 Pad to Sill ________ ___________ ___________ ________ ___________ ___________
Parent Metal Cracks (if more than one, record longest)

24. Tank ________ ___________ ___________ ________ ___________ ___________
25. Pad ________ ___________ ___________ ________ ___________ ___________
26. Sill Webs ________ ___________ ___________ ________ ___________ ___________
27. Sill Top Flange ________ ___________ ___________ ________ ___________ ___________
28. Sill Bottom Flange ________ ___________ ___________ ________ ___________ ___________
29. Head Brace ________ ___________ ___________ ________ ___________ ___________
30. Other - Design Specific ________ ___________ ___________ ________ ___________ ___________
31. Inspector's Name: 32. Car Owner's Representative:
SS-3 9/1/99
C-III [M-1002] 572 11/2014

M-1002 APPENDIX Y
33. Design Specific Information:

(optional - car builder specified)
Inspection Technique Codes:

AE Acoustical Emission OH Optical Holography RV Remote Visual
AH Acoustical Holography OT Other UT Ultrasonic
ET Electro-Magnetic PT Liquid Penetrant VT Visual
MT Magnetic Particle RT Radiographic
SS-3 9/1/99
11/2014 C-III [M-1002] 573

APPENDIX Y M-1002
Form SS-3 is intended to facilitate collection of data during the stub sill inspection process. Written reports
must be completed and then transferred to the computer file format specified by AAR. A record of each
stub sill inspection is then submitted in electronic format to the designated AAR contractor as well as the
car owner. The following instructions must be followed in filling out the report (item numbers represent
line numbers on the form):
1.) Enter the car reporting mark and number.

2.) Enter the name of the company performing the inspection.
3.) Enter the tank specification as stenciled on the car. (e.g.: DOT-105A300W)
4.) Enter the shop location town as well as state or province.
5.) Enter the built date month and four-digit year.
6.) Enter the inspection date month, day, and four-digit year.
7.) Enter Y (yes) or N (no) to indicate if the car is jacketed.
8.) Reserved (design-specific)
9.) Reserved (design-specific)
10.) Provided by the car owner - Enter the original AAR Certificate of Construction number.
11.) Provided by the car owner - Enter the tank car builder.
12.) Provided by the car owner - Enter the stub sill design style (as inspected)
13.) Provided by the car owner - Enter the total mileage, rounded to the nearest 1,000 miles. The actual
cumulative mileage is required. If actual mileage is not known at the first SS-3 inspection, the car
owner may estimate mileage. Subsequent inspections should reflect the estimated mileage plus the
actual mileage since last inspection.
Items 14-30 are for recording crack measurements in specified areas of the stub sill and adjacent tank shell.
Each location has six fields available, which are to be completed for the specified area.
The fields are: A-end inspection technique, A-end number of cracks, A-end maximum crack length, B-end
inspection technique, B-end number of cracks, and B-end maximum crack length.
A key for the Inspection Technique codes can be found at the bottom of page 2 of the SS-3 Form. An entry
for inspection method is required on Line 14. The database program will assume that the same inspection
technique is used for Lines 15 30 unless an entry is made on those lines indicating a different inspection
method.
If there is more than one crack present in the indicated area, the longest crack is to be recorded. All
recorded cracks are to be measured to the nearest inch and recorded in decimal format (e.g.: 3 =3.75).
The field locations are as follows:
14.) A-1 pad to tank, transverse weld cracks

15.) B-1 pad to sill (if no head brace), transverse weld cracks
16.) C-1 head brace to sill, transverse weld cracks
17.) D-1 head brace to pad, transverse weld cracks
18.) E-1 other car builder specified, transverse weld cracks
19.) A-2 pad to tank, longitudinal weld cracks
20.) B-2 pad to sill, longitudinal weld cracks
21.) C-2 head brace to sill, longitudinal weld cracks
22.) D-2 head brace to pad, longitudinal weld cracks
23.) E-2 other car builder specified, longitudinal weld cracks
24.) Tank, parent metal cracks
25.) Pad, parent metal cracks
26.) Sill webs, parent metal cracks
27.) Sill top flange, parent metal cracks
28.) Sill bottom flange, parent metal cracks
29.) Head brace, parent metal cracks
30.) Other design-specific, parent metal cracks
C-III [M-1002] 574 11/2014

M-1002 APPENDIX Y
31.) Inspectors name

32.) Car owner representatives name
33.) Design-specific information, optionally specified by the car builder, may be documented in this space.
(on page 2)
Form SS-3 contains six reserved fields for special data collection purposes. Lines 8, 9, 18, 23, 30, and 33
should not be used unless specified by the car builder. The car builder may customize Form SS-3 to collect
data specific to a particular stub sill design using these fields.
9/1/99
11/2014 C-III [M-1002] 575

APPENDIX Y M-1002
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
May 10, 2001
(CPC-1114)
SUBJECT: Requirements for SS-3 Inspections of Tank Car Stub Sills T79.20.20
Please refer to circular letter no. CPC-1094, dated April 15, 1999, wherein the new stub sill
inspection program was introduced, effective July 1, 1999 for all stub sill tank cars. Refer also to
circular letter no. CPC-1097, dated September 7, 1999, wherein Form SS-3 was introduced to
capture the inspection data from the new program.
The stub sill inspection interval defined in CPC-1094 is conditionally tied to the interval for the
Federal qualification time, reference 49 CFR Part 180. In accord with the provisions of CPC-
1094, the stub sill inspection can be due before the Part 180 tank qualification time if the car
exceeds 200,000 miles (in the case of cars that are not designed to a one-million mile fatigue life
requirement; 500,000 for cars that are so designed) since any of the following:
1) built date
2) last Rule 88.B.2 inspection, or
3) last stub sill inspection.
It is believed that some cars that received a hydrostatic tank retest shortly before the new Part
180 rules took effect may not have received stub sill inspections, based on the erroneous
assumption that stub sills did not have to be inspected until the cars qualification time under the
terms of 49CFR Part 180. This circular is intended to clarify this and serve as a reminder of the
requirements of CPC-1094.
To address this situation, the Tank Car Committee has agreed to modify the SS-3 inspection
program to include a maximum 10-year interval for stub sill inspections for cars that are not
designed to the one-million mile fatigue life criteria.
CPC-1097 also addressed a potential conflict in which stub sill tank cars built since January 1,
1984 could, on the basis of accumulated mileage, be immediately overdue for inspection under
the provisions of CPC-1094. The Tank Car Committee rectified that by allowing a three-year
catch-up period until July 1, 2002 for such cars. Since cars can now become immediately
overdue on either a time or mileage basis, the Committee agreed to extend the catch-up period
until July 1, 2003.

Phone (202) 639-2147; FAX (202) 639-2930; e-mail pkinnecom@aar.org
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 1 of 4)
C-III [M-1002] 576 11/2014

M-1002 APPENDIX Y
CPC-1114
May 10, 2001
Page 2
As information, the amended stub sill inspection program description is attached.
Sincerely,
P. G. Kinnecom

11/2014 C-III [M-1002] 577

APPENDIX Y M-1002
Page 1 of 2
(Attachment to Circular Letter No. CPC-1114 dated May 10, 2001)
Interim Stub Sill Inspection Program

Introduction:
AAR Circular letter CPC-1082 stipulated that, effective July 1, 1999, each tank car stub sill would be
inspected in accord with a plan based on a damage tolerance analysis (DTA) or at a default inspection
interval of five years or 75,000 miles. That proposal was based on the anticipation that DTA would then
be fully developed as a tool to establish tank car inspection intervals. At present, the DTA method is not
providing reliable or consistent results when applied to railcar structures. More development work is
required to establish DTA as a tool that is effective in driving inspection and maintenance processes for
railcars.
The following is an alternate inspection plan that provides an equivalent level of safety, includes
provisions for reporting inspection results and monitoring ongoing stub sill performance, provides
information required for enforcement, prioritizes inspections, and is in harmony with the qualification
requirements of 49 CFR180. Note that established accelerated inspection programs in effect at the time
of its adoption will continue under their existing schedules.
The Stub Sill Working Group (SSWG) is committed to continuing the development of DTA and considers
the following plan to be an interim measure until such time that DTA has been sufficiently developed for
use in establishing tank car inspection intervals. The SSWG is committed to achieving success in
utilization of the DTA method. The success of this program will be dependent, in part, on the continued
commitment of railcar owners, shippers and regulatory agencies to funding and supporting the
continuation of DTA research.
Interim Inspection Requirements:
Effective July 1, 1999, the following interim inspection program will be required for all stub sill tank cars:
A. Inspection Requirements
1. All cars of stub sill design must receive inspections of the stub sills to ensure structural
integrity of the sills, using inspection procedures specified in Section B.
2. Inspection is due at the time of the next 49 CFR 180.509 tank qualification or AAR
Appendix D tank qualification, except:
a. not to exceed 10 years or 200,000 miles (whichever occurs first) from built date,
Rule 88.B.2 inspection or last stub sill inspection unless stub sills are designed to one
million mile fatigue life requirement.
b. not to exceed 500,000 miles from built date, Rule 88.B.2 inspection or last stub sill
inspection for cars with sills that do meet the one million mile fatigue life requirement.
3. Any extensions to the inspection interval allowed by 49 CFR 180.509 (or DOT-E 12095)
will not be cause for extension of the stub sill inspection interval unless approved under
the alternate inspection provisions set forth in Section C.
4. For the purpose of Paragraph 2, actual mileage shall be used whenever possible. When
actual mileage of the car is not known, mileage may be estimated using an assumed
20,000 miles per year as established in AAR O&M Circular No. 1.

C-III [M-1002] 578 11/2014

M-1002 APPENDIX Y
Page 2 of 2
(Attachment to Circular Letter No. CPC-1094 dated April 15, 1999)
Interim Stub Sill Inspection Program (cont.)
B. Inspection Procedures
1. Inspections required in Section A of this interim inspection procedure will be conducted in

the same areas as previously defined in FRA Emergency Order 17 and AAR O&M
Circular No. 1.
2. Until August 31, 1999, inspections will be documented on Form SS-2. Inspection data
will be submitted to AARs designated database administrator according to the
procedures defined for the program prescribed under FRA Emergency Order 17 and AAR
O&M Circular No. 1.
3. Starting September 1, 1999, inspections will be documented on Form SS-3. Inspection

data will be submitted to AARs designated database administrator according to the
procedures that will be defined and publicized for that reporting form.
C. Alternate Inspection Provisions
1. The AAR Tank Car Committee may establish inspection intervals that are shorter than
the requirements set forth in Section A and may require more extensive inspections when
the performance history of a design merits such action. Established accelerated
inspection programs in effect at the time of adoption of this program will continue under
their existing schedules.
2. Car owners may use alternate inspection intervals when an alternate inspection protocol
has been approved by the AAR Tank Car Committee (e.g. DTA or other analytic tool).

11/2014 C-III [M-1002] 579

APPENDIX Y M-1002
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
May 30, 2001
(CPC-1116)
SUBJECT: Shop Practices for Installation and Maintenance of Bottom Outlet Ball Valves
on Tank Cars T10.29
This Circular Letter is intended to provide guidance on shop practices for installation and maintenance of
bottom outlet ball valves on tank cars equipped with linings or coatings.
Tank car owners and shops that apply bottom outlet ball valves or provide maintenance services for tank
cars are reminded that replacement of components in valves must be a replacement in-kind. Seals used in
valves should be selected to match the valve manufacturers design and performance criteria.
Assembled valves are to be used only in the configuration for which they were granted AAR approval.
Likewise, the application of a valve to a tank car must reflect the configuration shown in the applicable
arrangement drawing specified on the certificate of construction. Failure to return a valve to its approved
configuration after a maintenance activity may cause the valve to be in non-compliance with its approval.
Tank car owners and shops are advised to discontinue the following practices effective upon the issue
date of this Circular Letter.
1. Bottom Outlet Valve Lining or Coating Application
Some car owners have adopted the practice of lining or coating the interior surface of bottom outlet valves
on tank cars equipped with linings or coatings. Unless the valve was specifically designed to accept a
lining or coating, the application of such material to a valve changes the configuration of the valve with
respect to its AAR approval. The presence of a lining or coating may alter the operating characteristics of
the valve and may adversely impact the ability of the seals to perform as intended.
Tank car owners and shippers who operate lined or coated cars should consider the use of bottom outlet
valves with stainless steel bodies or use valves already approved for lining or coating application.
Individuals who wish to obtain AAR approval for a valve with a lining or coating applied may apply for
approval through established procedures. During service trial, the proponent will demonstrate that the
presence of the material in the valve body does not reduce the effectiveness of the seals and does not
adversely impact the ability of the valve to operate as intended.

Fig. Y.8 CPC-1116 Shop practices for installation and maintenance of bottom outlet valves (page 1 of 2)
C-III [M-1002] 580 11/2014

M-1002 APPENDIX Y
CPC-1116
May 30, 2001
Page 2
2. Shims Used During Assembly of Bottom Outlet Valves
Some shops have adopted the practice of using shims in conjunction with ball seals to compensate for
variations in the dimensions of the seals. This practice is intended to assist in obtaining a leak-tight seal
and often occurs after the interior of the valve body has been lined or coated.
The practice of using shims is an undesirable practice that alters the configuration of the valve relative to
its approval. Valves applied to tank cars must be configured in accord with their approved designs.
Sincerely,
P. G. Kinnecom

Fig. Y.8 CPC-1116 Shop Practices for Installation and Maintenance of Bottom Outlet Valves (page 2 of 2)
11/2014 C-III [M-1002] 581

APPENDIX Y M-1002
C-III [M-1002] 582 11/2014

Application for Approval and Certificate of Construction
APPLICATION FOR APPROVAL AND CERTIFICATE OF CONSTRUCTION

1. APPROVAL REQUESTED OF: PRECEDENT 2. TYPE: CONSTRUCTION WELDED REPAIRS 3. AAR NO.
NONPRECEDENT ALTERATION OTHER 4. DATE
CONVERSION 4.1 ORDER DATE
5. APPLICANT NO.
6. APPLICANT 7. TANK SPECIFICATION
8. STENCILLED SPEC
9. REPORTING MARKS AND NUMBERS 10. NUMBER OF CARS
11 Initial Commodity 12 Density (Lb Per Gallon)

13 Full Water capacity, (Gallons) 14 Dome Capacity or Outage (Gallons)
15 Material Type / Grade Heads 15.1 Head Material Normalized
15.2 Tank Head Spliced 15.3 Charpy Requirements
16 Material Type and Grade Shell 16.1 Tank Shell Material Normalized
16.2 Charpy Requirements 17 Material Thickness Heads (Inches)
18 Material Thickness Shell (Inches) 19 Lining Type
20 Inside Diameter Center (Inches) 21 Inside Diameter End Rings (Inches)
22 Head Radius, Main (Inches if not 2:1) 23 Test Pressure (PSI)
24 Insulation Type 25 Insulation Thickness (Inches)
26 Thermal Conductivity (BTU in/hr. ft sq. degree F) 27 Type of Safety Relief Devices
27.1 Number of Safety Relief Devices 28 Pressure Relief Device Start-to-Discharge (PSI)
29 Pressure Relief Device Flow Capacity (CFM Required) 30 Pressure Relief Device Flow Capacity (CFM Actual)
31 Tank Surface Area (Sq Ft) 32 Underframe or Stub Sill Type
33 Center of Gravity Loaded (Inches)loaded 34 Estimated Light Weight (lb)
35 AAR Clearance Diagram 35 Rail Load Limit. (lb)
37 Truck Capacity (Tons) 38 Head Shield Type
38.1 Head Shield Thickness (inches)
Notes:
Original certificate
Builder
Date
Former lading
The Following Prior Approval Apply

The Following Drawings Apply Drawing Number Drawing Number Application / Certificate no.
39 General Arrangement
40 Tank Arrangement
41 Reinforce Openings Including Calculations
42 Anchorage, Including Calculations
43 Fittings Arrangement
44 Manway Assembly
45 Protective Housing
46 Venting, Loading, and Discharge Valves
47 Pressure Relief Devices
48 Heater Systems (Int. Ext. )
49 Gauging Devices
50 Bottom Outlet Valve
51 Repairs
52 Manway Cover
53 Calculations
54 Tank Qualification Drawing
REVISIONS: APPLICATION BY:
I certify the foregoing conforms to all applicable DOT and

AAR requirements. Including specifications, regulation, rules
of interchange and the DOT Railroad Safety Appliance
Standards.
SIGNATURE
TITLE
APPROVAL - AAR Tank Car Committee

Date Approved:
CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications,
regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as
required by 49 CFR Part 179.5 before these cars are placed in service.
Initials and Car Numbers
Name Date
Title
Form AAR 4-2 Revised10.2014

Approval AAR Tank Committee
AAR No. __________________________
Applicants No. _____________________
Date _____________________________
APPLICATION BY: __________________________________________

I certify that the foregoing conforms to all applicable DOT and AAR
requirements, including specifications, regulations, rules of interchange,
and the DOT Railroad Safety Appliance Standards.
SIGNATURE _______________________________________________
TITLE_____________________________________________________
APPROVALAAR Tank Car Committee
Date Approved _____________________________________________

(signature) on behalf of the Tank Car Committee
Form AAR 4-2.1 Revised 7/30/2014 Page of

Application for Approval of Pressure Relief Device
APPLICATION FOR APPROVAL OF PRESSURE RELIEF DEVICE
AAR NO. PRD-

Applicants No.
APPROVAL REQUESTED OF AAR TANK CAR COMMITTEE Date
Device identification No.
Applicant
1. Manufacturer
Address
2. Test facility name 3. Test facility location
6. Device 7. Start-to-discharge 8. Flow rating 9. Vapor-tight 10. Flow capacity
Number psi kPa psi kPa psi kPa SCFM std.m3/s
11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa)
Test medium
12. Commodity: Regulated Commodity Nonregulated Commodity Specific Commodity
Precedent
The following drawings apply Drawing number Application/
Latest revision Drawing number Certificate
13. Valve Assembly..
14. Valve Mounting Nozzle..
15. .
16. .
REVISIONS:
CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and
the devices tested conform with the drawings listed above.
By: Title
APPROVAL of Service Trial by AAR Tank Car Committee

APPROVAL of Design by AAR Tank Car Committee
Date Service Trial Completed Date AAR Received )RUPAAR 4-6
Date Approved
Expiration Date
Form AAR 4-3 Revised 8/1/2014
AAR Tank Service Trial Report
AAR TANK CAR SERVICE TRIAL REPORT*

AAR No.
AAR Docket No.
Reporting company AAR Service Trial No.
Address Date
Covering Period

1. Applicants No. 2. Device Identification. No.
4. Number cars authorized to applicant 5.Number of cars this report
9. This Report 10. To Date
8. Date Initial
6. Reporting Marks 7. Commodity
Installation Loaded Distance Loaded Distance
Trips (Miles) Trips (Miles)
AVERAGES
11. Loading temperature F ( C) 12. Unloading temperature F ( C)

13. Loading Pressure psi ( kPa) 14. Unloading pressure psi ( kPa)
15. Maintenance required (specify by reporting mark and car no.)
16. General performance remarks
17. Continue test

18. Discontinue test

Final acceptance subject to Tank Car Committee Approval on Form AAR 4-6.

*This report is to be completed and submitted to the Executive Director every six months as required in Chapter 1 of M-1002. Failure to
submit report may result in cancellation of service trial authorization, and revocation of all approvals.

Submitted by Title

Application for Approval of Valves, Closures, and Fittings
APPLICATION FOR APPROVAL OF VALVES, CLOSURES, AND FITTINGS

Applicant AAR No.
Description of Device
Applicant No. Device Ident. No. Date
1. Manufacturer
2. Address City State Zip
3. Test facility if other than the manufacturer Address
Title: .
TEST PROCEDURE
5. Description of prototype testing:

6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
F psi F _psi
C _kPa C kPa
F psi F _psi
C _kPa C kPa
F psi F _psi
C _kPa C kPa

7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity
8. Flow rate (if applicable) gpm ( L/min)

Drawing Number Precedent
Applicable drawings Material latest revision Drawing Number Application/Certificate
9. Device application . . . . . .
10. Device assembly . . . . . . . .
11. Device details . . . . . . . . . .
12. Quality Control Statement
REVISIONS:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices
tested conform with drawings listed above.

By Title
APPROVAL AAR Tank Car Committee Service Trial Required
Service Trial Number

APPROVAL AAR Tank Car Committee Service Completed / Not Required
Date Service Trial Completed Date AAR Received Form AAR 4-6 .
Date Approved _____________________________________
Expiration Date ____________________________________ ________________________________________________
Final Service Trial Inspection Report
FINAL SERVICE TRIAL INSPECTION REPORT

1. Applicant AAR No.
Address AAR Docket No.
2. Manufacturer AAR Service Trial No.
Address Date
4. Device designation or model no.
5. Total number of devices in service 6. Number of devices for teardown
7. Service data for service equipment under this inspection
Total load/unload cycles and average Total loaded mileage and average
Total service time and average
8. Teardown data Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

From car number
Last lading
Model no.
Serial no.
Test pressure psi (kPa)
Test temp F (C)
Test medium
STD psi (kPa)
Vapor tight, psi (kPa)
Test remarks...
Physical condition..
Compare critical final
dimensions to original...
9. Drawing numbers.....
(Ref. Form AAR 4-3 or AAR 4-5)
Revisions made......
Revision date..........
10. Conclusions
11. Recommendations to Tank Car Committee
12. CERTIFICATION
The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested
conform to the drawings listed above.
MANUFACTURER or APPLICANT INDEPENDENT OBSERVER/QA MANAGER
(Signature) (Signature)
Title Title
Company Company
13. APPROVAL AAR Tank Car Committee
Date approved
Form AAR 4-6 Revised 2-8-2014

Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings
APPLICATION FOR RENEWAL OF APPROVAL FOR PRESSURE RELIEF

DEVICES, VALVES, CLOSURES, AND FITTINGS
1. AAR APPROVAL No.

2. Date of Application
3. Previous AAR Approval
4. Applicant:
5. Address:
6. Drawing No. 7. Latest rev. 8. Date of latest rev.
9. Description of device: 10. Device ID No.
CERTIFICATION: The subject device is unchanged from the previous approval, and conforms with the
latest revision of AAR Specifications for Tank Cars, Appendix A. The device conforms
with drawing listed above.
11. By: Title:
If device is changed since latest approval, fill in the following blanks
12. Reference Previous Drawing New Drawing If on Service Trial

13. New drawing supersedes previous one or does not obsolete it
CHANGES REASONS FOR CHANGES
14. a. a.
b. b.
c. c.
d. d.
(if needed use supplemental sheet)
15. Normal operational effect of changes of device:
16. Drawing submitted with this application:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars,
Appendix A. The device conforms with drawing listed above.
17. By: Title:
APPROVAL AAR Tank Car Committee:
Date Approved:
(Signature) on behalf of Committee
Form AAR 4-7 8/1/2014
Exhibit B-1 Subcontractor Evaluation Sheet
EXHIBIT B1
SUBCONTRACTOR EVALUATION SHEET

Each facility shall complete and retain a copy of this form for each subcontractor required by Appendix B. A company
representative responsible for the activity shall attest that the subcontractor uses appropriate equipment, procedures, and
personnel to meet the requirements of this specification. This form expires one year after the date verified below.
Part 1: Subcontractor
1 Company Name
2 Address 3 City

Part 2: Primary Subcontractor Contact
7 Name 8 Title
12 Email Address
Part 3: Subcontractor Activity
13 Select the applicable activities provided to the Certified Facility :
Personnel Process Equipment Service Product
For each activity identified above, explain how the company representative responsible for that activity verifies that the
subcontractor understands and conforms to the requirements of the Association of American Railroads Manual of
Standards and Recommended Practices, Section C Part III, Specification for Tank Cars (M-1002).
14 Personnel
15 Processes
16 Equipment
17 Service
18 Product
Part 4: Company Representative

19 Company Name
20 Name 21 Title
25 Address 26 City
30 Signature (Attesting)
31 Date Verified [MM/DD/YYYY] 32 Date of Expiration [MM/DD/YYYY]
Save Print Reset
AAR Manual of Standards and Recommended Practices M-1002

Page 1 of 1
Exhibit B1 (Rev. January 2014)
Exhibit B-2 AAR Tank Car Committee Shop Evaluation
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Save Print Reset
([KLELW%5HY0DUFK
Exhibit B-3 Registration for Class F, G, and L Facilities
EXHIBIT B3
This form is both the application for AAR Technical Certification for a single tank car facility and used as change
notification as required by paragraph 3.10. This application must be accompanied by an initial payment as required by
paragraph 3.13. This form is part of the application package (see paragraph 3.1.2), which must be submitted to

425 Third Street, SW Suite 1000
Part 1: General Application Information
1 Application for Initial Certification Inspection Recertification Inspection Change Notification
2 Application Date [MM/DD/YYYY]
3 Do you have a valid M-1003 Quality Assurance Program Certification? Yes No

If No, the facility must apply for M-1003 QAP certification. (NOTE: In addition to technical certification, QA
certification is required in order to perform any tank car activity listed in Part 4 of this application and in Appendix B
Table B.2.)
4 Applicable to facilities requesting certification for manufacturing (A19) and/or assembling (B78) tank cars: Do you
have a valid S-2034 Car Builder Certification? Yes No
If No, the facility must apply for S-2034 Car Builder Certification.
5 If you are an existing AAR Registered Tank Car Facility, provide the following:
What is your Station Stencil?
Do you prefer to keep the same Station Stencil? Yes No
Part 2: Tank Car Facility Information
6 Station Stencil (Assigned by AAR; however Station Stencil request can be made in field 36 Comments)
7 Company Name
8 Address 9 City
Part 3: Primary Contact at Facility
13 Name 14 Title
18 Email Address
Part 4: Applicant
19 Is the applicant the contact identified in Part 3 and located as identified in Part 2?
Yes (if so, skip this part) No
20 Company Name
21 Name 22 Title
23 Address 24 City
31 Email Address
Part 5: Recipient of Certification from AAR
32 Select the Recipient (NOTE: This facility must have the ability to produce the certification letter upon request.)
Applicant (Part 4) Primary Contact (Part 3)

EXHIBIT B3
Part 6: Facility Certification Information
NOTE: Certified facility must be capable of performing, or arrange to have performed, all associated tank car activities for
which the facility is certified.
33 Select activity codes that apply:
A19 Manufacturer of tank cars
B82 Manufacture of tank car tanks, including support structure, that are moved to and from the facility without trucks
(running gear)
B85 Manufacturer of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
B86 Repair of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
C4 Manufacturer of tank car service equipment
C5 Reconditioner/repair and qualification of tank car service equipment
34 Select each applicable material group (1, 2, 3, 4, 7) or N/A:

MG 1 TC-128 Included MG 2 MG 3 MG 4 MG 7(s) N/A
35 Select a repair level capability if applying for B24 and/or B83:
RL1Demonstrate proficiency in performing welding to tank car tank material, NDT method MT or PT, and postweld heat
treatment. This level excludes repairing a through-the-tank-car tank defect ( insert or through-the-shell/head crack). This
demonstration must be performed on a tank car tank or test plate and must be performed on a material from a material group for
which the facility seeks certification.
RL2Demonstrate proficiency in performing welding to tank car tank material, NDT, and postweld heat treatment. This level
includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This demonstration must be
performed on a tank car tank or test plate and must be performed on a material from a material group for which the facility
seeks certification.
Part 7: Fee Information

36 Is the initial payment, as required by paragraph 3.13 of Appendix B, attached? Yes
(NOTE: AAR will not process application without initial payment)

11/2014
EXHIBIT B3
37 Comments
This is to attest that the information provided in this application meets all requirements of M-1002, Appendix B, and that
all information required by M-1002, Appendix B, Form B-3A, has been included.
38 Applicants Name 39 Applicants Signature
40 Company 41 Signature Date [MM/DD/YYYY]

42 Title
Save Print Reset

Certification Additional Information Form
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Gaskets
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1. Reporting marks and car number
2. Tank specification
3. Stenciled specification
4. Tank capacity in gallons (liters)
5. Tank test pressure, psi (kPa)a/
6. Interior heater system test pressure, psi (kPa)a/
7. Pressure relief valve (PRV) No. 1 No. 2
a. Name and location of company performing test of PRV
b. Name and location of company applying PRV
c. Manufacturer and model/type number
d. Serial number
e. Start-to-discharge pressure, psi (kPa)b/
f. Vapor-tight pressure, psi (kPa)b/
g. Valve seals replaced (Y/N) (only those exposed to product)
h. New seal material
8. Combination device
a. Rupture disc pressure, psi (kPa)
b. Breaking pin lower diaphragm tight at psi (kPa)
9. Rupture disc device
a. Number of rupture disc devices
b. Rupture disc pressure, psi (kPa)
10. Excess flow valve seat tightness checked (Y/N)
11. Test date (date stenciled on car)
12. Tank built/conversion date
13. Test due stencil
14. Name and location of company performing tank and/or heater
system test
a/ Tested with hydrostatic pressure shown, for the required time period, without leaks or evidence of distress.
b/ Valve has been set to start-to-discharge and is vapor-tight at pressure shown. For combination devices, the
start-to-discharge and vapor-tight pressures of the valve portion is shown.
I HEREBY CERTIFY THAT TESTS PERFORMED TO TANK CAR TANKS, PRESSURE RELIEF VALVES
AND/OR HEATER SYSTEMS WERE DONE IN ACCORD WITH THE DEPARTMENT OF TRANSPORTATION
REGULATIONS AND THE AAR SPECIFICATIONS FOR TANK CARS AND REPORTED CORRECTLY.
Date (Signed) Owner/Tester

Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
EXHIBIT R1 REPORT OF TANK REPAIRS, ALTERATION, OR CONVERSION
1. To AAR Executive DirectorTank Car Safety 2. Reporting mark and number:_____________________

3. Reported by: _________________________________ 4. Date work performed: __________________________
5. Work performed at: ______________________________________________________________________________
6. Report of: Tank repairs Alterations Conversions Relief device sizing Other
7. Built date: ___________________________________ 8. Built by: _____________________________________
9. Original AAR Certificate No.:_____________________ 10. Commodity: __________________________________
11. Constructed car spec: __________________________ 12. Car spec (after this work): _______________________
13. Stenciled spec (after this work): __________________
14. Tank repairs (Reference M-1002 Appendix R, Fig. R2)
A) Nature and location of defect:
B) Procedure and materials:
15. For alterations, conversions, pressure relief devices, or other, list procedure and materials:
16. Pertinent approved drawings:
DRAWING TITLE DRAWING NUMBER AAR CERTIFICATE NUMBER

A.
B.
C.
D.
E.
F.
17. Revisions and notes:
The cars listed above conform to all approvals mentioned and to all applicable DOT and AAR requirements, including
specifications, regulations, rules of interchange, and the DOT safety appliance standards.
FACILITY
Company name: __________________________________ Location (City/State): _______________________________
Management Representative (Name): __________________________________________ Title: __________________
Management Representative Signature: ________________________________________ Date: __________________
Rev. 04/2010
Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
1. Car Owner __________________________________ 2. Reporting Mark and Number ________________________
3. Reported by ___________________________________ 4. Performed at _____________________________________
5. Date ______________ 6. Tank Built Date ______________ 7. Built by ____________________________________
8. Original AAR Cert. of Const. No. _____________________ 9. Commodity (after this work)___________________
Tank spec.: 10. (as const.) ______________ 11. (after this work) _______________ 12. Stenciled ______________
13. Stub Sill Design Style _______________________ 14. Car Jacketed? (Y/N) ______ 15. Head Brace? (Y/N) ______
16. Component Where Failure Occurred:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Tank Shell-Interior (B)-Tank ShellExterior (C)-Tank HeadInterior (D)-Tank HeadExterior (E)-Cen-
ter SillWeb (F)-Center SillFlange (G)-Center SillBoth (H)-Bolster Pad (Tank Cradle) (J)-Tank Reinforc-
ing Pad (Inboard of Bolster) (M)-Brake Support (N)-Tank Bolster (O)-Other (Explain in Item 24. Comments)
(P)-WeldBolster Pad to Tank (Q)-Stub Sill Web (R)-Stub Sill Top Flange (S)-Stub Sill Bottom Flange
(T)-Head Brace (U)-Head Pad (V)-Top Longitudinal Centerline (W)-Bottom Longitudinal Centerline.
Cracks in Stub Sill Related Welds (See Figs. R3.1 through R3.6):
Transverse Welds: (A1)-Pad to Tank, (B1)-Pad to Sill, (C1)-Brace to Sill, (D1)-Brace to Pad, (E1)-Other. Longi-
tudinal Welds: (A2)-Pad to Tank, (B2)-Pad to Sill, (C2)-Brace to Sill, (D2)-Brace to Pad, (E2)-Other (BF)-Bot-
tom Outlet Flange (MW)-Manway Nozzle (SN)-Safety Device Nozzle.
17. Type of Failure: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Buckle (B)-Crack in Parent Metal (C)-Crack in Weld (D)-CorrosionRandom Pits (E)-CorrosionGrouped
Pits (F)-CorrosionAdjacent to Weld (G)-CorrosionGeneral (H)-Other (Explain in Item 24. Comments)
(I)-CorrosionBathtub Ring (BL)-Blister.
18. Cause of Failure: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-Fatigue (B)-Workmanship (C)-Missing Weld (D)-Unknown (E)-Overstressed (F)-Abused (G)-Corrosion
(BL)-Blister.
19. How Repaired: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-10.2 (B)-10.5 (C)-25.0 (D)-11.1 (E)-13.2 (F)-Replaced in Kind (G)-Precedent Certificate of Construction,
Number: a. ________; b. ________; c. ________; d. ________; e. ________; f. ________
(H)-12.2 Buckles (I)-Rule 82 Weld Sill (J)-Rule 57 (K)-Other (Explain in Item 24. Comments).
20. Length of Crack: If Item 17 is (B) or (C) [crack], enter length in inches:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
21. Location of Corrosion: If Item 17 is (D), (E), or (F) [corrosion], indicate approximate location on sketches on
reverse side of form. Dimensions are not required.
22. Location of Repair on Car:
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(A)-A End (B)-B End (C)-BR Side (D)-BL Side (E)-AR Side (F)-AL Side (P)-Top or Bottom of Transverse Cen-
terline (Q)-Transverse Centerline Left (R)-Transverse Centerline Right (S)-Top Long. Centerline (T)-Bottom
Long. Centerline a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(G)-Circumferential Distance on Tank Shell from Bottom Longitudinal Centerline, (xxx) inches
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(H)-Longitudinal Distance on Tank Shell from Head/Shell Seam Along Longitudinal Axis, (xxx) inches
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(J)-Horizontal Curved Distance on Head Shell from Vertical Centerline of Head, (xxx inches)
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(M)-Vertical Curved Distance on Head from Top of Sill, (xxx inches)
a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(N)-Horizontal Distance from Striker, (xxx inches)
23. Inspection Method Used to Detect Defect: a. ______; b. ______; c. ______; d. ______; e. ______; f. ______.
(AE)-Acoustic (RVT)-Fiber Optic (LP)-Liquid Penetrant (MT)-Magnetic Particle (UT)-Ultrasonics (VT)-Visual
(RT)-X-RAY (OT)-Other (Explain in Item 24. Comments)
24. Comments: ________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
25. Completed by:_____________ Date:____________ Title:________________ Signature: ________________________
Distribution: OriginalCar owner; Electronic copyAAR
11/2014
11/2014
A1
A2
D2 A1 A2
A1 A2
C2 D1 B1
A1 C1
A2
D1 C2
C1 B1
B2 B2 B2
CL LONG CL LONG
Fig. R3.1 Fig. R3.2
NON-STRUCTURAL
A2 A2 SEAL WELD.
NOT REPORTABLE
A1
A2
A2
A2
B2 B2 B2
CL LONG C
A1 L LONG
Fig. R3.3 Fig. R3.4
SEAL WELD
A2
A1 A1
B1
A1
B1
B2
A2 CL LONG
CL LONG
Fig. R3.5 Fig. R3.6
11/2014
Form SS-1 Report of Tank Car Stub Sill Inspection
FORM SS-1
REPORT OF TANK CAR STUB SILL INSPECTION
1. To: Car Owner 2. Reporting mark and

_____________________________________________________ Number _________________
_________________________
3. Reported by __________________________________________
4. Performed at _________________________________________ 5. Date______________________
6. Tank Car Builder _____________________________________ 7. Built Date________________
8. Current AAR Certificate ______________________________ 9. Commodity_______________
10. Constructed Tank Spec. _______________________________ __________________________
11. Stenciled Tank Spec. __________________________________ 12. Car Jacketed (Y/N)________
13. Top & Bottom Shelf Couplers (Y/N) ____________________ 14. Head Shields (Y/N)________
15. Priority Level for This Inspection: ______________________ 16. Head Braces (Y/N) ________
INSPECTION RESULTS A-END B-END
17. Any evidence of striker damage? (Y/N) _______ _______
AR AL BR BL
18. Is draft sill bent or warped? (Y/N) _____ _____ _____ _____
19. Any evidence of passed couplers?(Y/N) _____ _____ _____ _____
20. Any damage to front draft lugs? (Y/N) _____ _____ _____ _____
21. Any damage to rear draft lugs? (Y/N) _____ _____ _____ _____
22. Describe prior sill repairs ____________________________________________________________
23. Inspect for defects at welds. Note inspection method used . . . [AE = Acoustic, F = Fiber Optic,
LP = Liquid Penetrant, V=Visual, O=Other (Explain)]
METHOD A-END B-END
A1 - Pad to Tank (Transverse) ________ ________ ________
B1 - Pad to Sill (Transverse) ________ ________ ________
C1 - Brace to Sill (Transverse) ________ ________ ________
D1 - Brace to Pad (Transverse) ________ ________ ________
Other Transverse - (Describe)
_______________________________ ________ ________ ________
AR AL BR BL
A2 - Pad to Tank (Long.) _______ _______ _______ _______ _______
B2 - Pad to Sill (Long.) _______ _______ _______ _______ _______
C2 - Brace to Sill (Long.) _______ _______ _______ _______ _______
D2 - Brace to Pad (Long.) _______ _______ _______ _______ _______
Other Long. - (Describe)
_______________________________ _______ _______ _______ _______ _______
24. Describe location and nature of defects found (e.g., C23-in. crack in weld)
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
25. Disposition of Car: ____________________________________________________________________
Inspected by: ____________________________________ Title: __________________________________
rev 12/00
Form SS-3 Report of Tank Car Stub Sill Inspection
1. Car Reporting 2. Inspection Performed

Mark and Number by (Company)
3. Stencil Class 4. Shop Loc. (Town) State or Province

Mo Yr Mo Day Yr
5. Built Date 6. Date of Inspection
7. Car Jacketed? (Y,N) 8. Reserved (design specific)
9. Reserved (design specific) 10. Original AAR Certificate

of Construction Number
11. Builder 12. Stub Sill Design Style (as inspected)
13. Total Mileage to Nearest 1,000 Miles Note: Lines 10 - 13 Provided By Car Owner
(actual cumulative mileage required)
Transverse Weld Cracks (if more than one, record longest)

14. A-1 Pad to Tank ________ ___________ ___________ ________ ___________ ___________
15. B-1 Pad to Sill (if no head brace) ________ ___________ ___________ ________ ___________ ___________
Longitudinal Weld Cracks (if more than one, record longest)

19. A-2 Pad to Tank ________ ___________ ___________ ________ ___________ ___________
20. B-2 Pad to Sill ________ ___________ ___________ ________ ___________ ___________
Parent Metal Cracks (if more than one, record longest)

24. Tank ________ ___________ ___________ ________ ___________ ___________
25. Pad ________ ___________ ___________ ________ ___________ ___________
26. Sill Webs ________ ___________ ___________ ________ ___________ ___________
27. Sill Top Flange ________ ___________ ___________ ________ ___________ ___________
28. Sill Bottom Flange ________ ___________ ___________ ________ ___________ ___________
29. Head Brace ________ ___________ ___________ ________ ___________ ___________
30. Other - Design Specific ________ ___________ ___________ ________ ___________ ___________
31. Inspector's Name: 32. Car Owner's Representative:
SS-3 9/1/99
33. Design Specific Information:

(optional - car builder specified)
Inspection Technique Codes:

AE Acoustical Emission OH Optical Holography RV Remote Visual
AH Acoustical Holography OT Other UT Ultrasonic
ET Electro-Magnetic PT Liquid Penetrant VT Visual
MT Magnetic Particle RT Radiographic
SS-3 9/1/99

Company Name _________________________________________ By: _____________________________________
Welding Procedure Spec. No. _____________ Date:__________ Supporting PQR No.(s) ___________________
Rev. No. ________________________________ Date:__________
Welding Process(es)_________________________________ Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
JOINTS DETAILS
Joint Design __________________________________________
Backing (Yes) __________________ (No)__________________
Backing Material (Type) _______________________________
(Refer to both backing and retainers)
Metal Nonfusing Metal
Nonmetallic Other
Sketches, production drawings, weld symbols or written
description should show the general arrangement of the
parts to be welded. Where applicable, the root spacing and
the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be
attached to illustrate joint design, weld layers and bead
sequence, e.g., for notch toughness procedures, for multiple
process procedures, etc.)
*BASE METALS
P-No. _________________________________________ to P-No.____________________________________________
OR
Specification Type and Grade ________________________________________________________________________
to Specification Type and Grade _____________________________________________________________________
OR
Chemical Analysis and Mechanical Properties ________________________________________________________
to Chemical Analysis and Mechanical Properties ______________________________________________________
Thickness Range:
Base Metal: Groove _____________________________ Fillet__________________________________
Other
*FILLER METALS
Specification No. ___________________________________________________________________________________
AWS No. (Class) ____________________________________________________________________________________
F-No. ______________________________________________________________________________________________
A-No. ______________________________________________________________________________________________
Size of Filler Metals ________________________________________________________________________________
Deposited Weld Metal_______________________________________________________________________________
Electrode-Flux (Class) ______________________________________________________________________________
Flux Trade Name___________________________________________________________________________________
Consumable Insert _________________________________________________________________________________
Other______________________________________________________________________________________________
*Each base metal-filler metal combination should be recorded individually.

WPS No. ____________ Rev. _________________
POSITIONS POSTWELD HEAT TREATMENT

Position(s) of Groove __________________________
Temperature Range ___________________________
Welding Progression: Up ________ Down ________
Position(s) of Fillet ____________________________ Time Range __________________________________
PREHEAT GAS
Percent Composition
Preheat Temperature, Min. ____________________
Gas(es) Mixture Flow Rate
Interpass Temperature, Max. __________________
Shielding _________ ________ _________
Preheat Maintenance _________________________
Trailing _________ ________ _________
(Continuous or special heating, where applicable,
should be recorded) Backing _________ ________ _________
ELECTRICAL CHARACTERISTICS
Current AC or DC __________ Polarity _________________________
Amps (Range) ___________________ Volts (Range) _______________
(Amps and volts range should be recorded for each electrode size, position and thickness, etc.
This information may be listed in a tabular form similar to that shown below)
Tungsten Electrode Size & Type_________________________________________________________________
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW ______________________________________________________________
(Spray, arc, short-circuited arc, etc.)
Electrode Wire Feed Speed Range _______________________________________________________________
TECHNIQUE
String or Weave Bead __________________________________________________________________________
Orifice or Gas Cup Size _________________________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) __________________________________________
_______________________________________________________________________________________________
Method of Back Gouging________________________________________________________________________
Oscillation ____________________________________________________________________________________
Contact Tube to Work Distance _________________________________________________________________
Multiple or Single Pass (per side)________________________________________________________________
Multiple or Single Electrodes ___________________________________________________________________
Travel Speed (Range)___________________________________________________________________________
Peening _______________________________________________________________________________________
Other _________________________________________________________________________________________
_____________________________________________________________________________________________
Filler Metal Current OTHER
Travel (e.g. Remarks, Comments,
Weld Type Amperage Voltage Speed Hot Wire Addition, Tech-
Layer(s) Process Class Diameter Polarity Range Range Range nique, Torch Angle, etc.)


PQR No._______________
Company Name
Welding Procedure Spec. No. Date:
Welding Process(es)
Types (Manual, Automatic, Semi-Automatic)
JOINTS
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or
process used.)
BASE METALS POSTWELD HEAT TREATMENT
Material Specification__________________________ Temperature____________________________________
Type or Grade _________________________________ Time ___________________________________________
P-No. _______________ to P-No. ________________ Other __________________________________________
Thickness of Test Coupon_______________________ ________________________________________________
Diameter of Test Coupon _______________________ ________________________________________________
Other_________________________________________ GAS
______________________________________________ Percent Composition
______________________________________________ Gas(es) Mixture Flow Rate
______________________________________________
______________________________________________ Shielding ________ ________ ________
______________________________________________ Trailing ________ ________ ________
Backing ________ ________ ________
FILLER METALS ELECTRICAL CHARACTERISTICS

AWS Specification _____________________________ Current ________________________________________
AWS Classification ____________________________ Polarity ________________________________________
Filler Metal F-No. _____________________________ Amps _____________________ Volts _______________
Weld Metal Analysis A-No. _____________________ Tungsten Electrode Size _________________________
Size of Filler Metal ____________________________ Other __________________________________________
Other_________________________________________ ________________________________________________
______________________________________________
Deposited Weld Metal __________________________
POSITION TECHNIQUE
Position of Groove _______________________________ Travel Speed____________________________________
Weld Progression (Upward, Downward) ___________ String of Weave Bead ____________________________
Other __________________________________________ Oscillation______________________________________
________________________________________________ Multipass or Single Pass (per side)________________
________________________________________________ Single or Multiple Electrodes_____________________
Other __________________________________________
PREHEAT ________________________________________________
Preheat Temperature ____________________________ ________________________________________________
Interpass Temperature __________________________ ________________________________________________
Other __________________________________________ ________________________________________________
________________________________________________ ________________________________________________

PQR No. _______________________
REDUCED SECTION TENSILE SPECIMEN TESTS
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb. psi Location
ALLWELDMETAL TENSION SPECIMEN TEST
ULTIMATE TENSILE
STRENGTH
YIELD
Type & STRENGTH REDUCTION
Figure Diameter Area Total Load Unit Stress (0.2% offset) ELONGA- OF AREA
No. in. sq. In. lb. psi psi TION (%) (%)
GUIDED BEND TESTS

Type and Figure No. Result
CHARPY IMPACT TESTS

Test Lateral
Specimen Notch Notch Temp- Impact Percent Expansion
No. Location Type erature Values Shear Mils
FILLET WELD TESTS

Result-Satisfactory: Yes _____ No _____ Penetration into Parent Metal: Yes _____ No _____
Macro-Results _________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
OTHER TESTS
Type of Test ___________________________________________________________________________________________
Deposit Analysis _______________________________________________________________________________________
Other _________________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Welders Name ____________________________________________ Clock No. _______________ Stamp No. _________
Tests Conducted By: _______________________________________________________ Laboratory Test No. _________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
We certify that the statements in this record are correct and that the test welds were prepared, welded, and
tested in accordance with the requirements of Appendix W.
Manufacturer: _________________________________________________________________________________________
Date ____________________________________________ By: __________________________________________________
Record of Welder Performance Qualification Test
RECORD OF WELDER PERFORMANCE QUALIFICATION TEST
Welder's name Clock number Stamp no.
Welding process(es) used Type
Identification of WPS followed by welder during welding of test coupon
Base material(s) welded Thickness
Manual or Semiautomatic Variables for Each Process (W12.04) Used Qualified
Backing (metal, weld metal, welded from both sides, flux, etc.)
P-No. to P-No.
Filler metal specification (AWS) / Classification
Filler metal F-No.
Consumable insert
Weld thickness
Welding position (1G, 5G, etc.)
Progression (uphill/downhill)
Backing gas for GTAW
GMAW transfer mode
GTAW welding current type/polarity
Machine Welding Variables for the Process Used W12.02
Guided Bend Test Results
Guided Bend Tests Type: Fig W5 Sketch C (Side)

Fig W5 Sketches A & B (Trans. R & F)
Fig W5 Sketch B (Long, R & F)
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination (see paragraphs W15.3, 15.4, 15.5, and 15.9) Acceptable Yes No
Radiographic test results
(For alternative qualification of groove welds by radiography)
Fillet weld Fracture test Length and percent of defects in.
Macro test fusion Fillet leg size in. in. Concavity/convexity in.
Welding test conducted by
Mechanical tests conducted by Laboratory test no.
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in
accordance with the requirements of Appendix W.
Organization
Date By
11/2014

M-1002 MSRP-C3 - 2014

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11/2014

Association of American Railroads

SPECIFICATIONS FOR TANK CARS

ISSUE OF NOVEMBER 2014

The Association of American Railroads

ORDERS FOR Publications Department

THIS PAGE LEFT BLANK INTENTIONALLY

Appendix Subject Page

11/2014 C-III [M-1002] v

Exhibit B-1 Exhibit B-1 Subcontractor Evaluation Sheet

Certificate of Test Form

Exhibit R-1 Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion

Suggested Format for Welding Procedure Specification (WPS)

C-III [M-1002] vi 11/2014

Paragraph Subject Page

11/2014 C-III [M-1002] 1

C-III [M-1002] 2 11/2014

CHAPTER 1. INTRODUCTIONS, APPROVALS, AND REPORTS

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1.1.3 General Design Requirement

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1.1.5 List of Specifications

Table 1.1 List of tank car specifications (page 1 of 6)

ARA-I Before 1903 1-1-03

AAR-203 Special 8-31-56

AAR-204X 4-27-67 4-27-67 d/

AAR-205A300W 6-14-51 6-14-51 e/

AAR-206W 6-28-62 11-10-71

Table 1.1 List of tank car specifications (page 2 of 6)

AAR-211A100W5 Pending Implemented CPC

ICC-104A-ALW 10-25-52 9-21-54 g/

ICC-104AW 1-7-41 8-31-56 h/

DOT-104W 1-7-41 12-31-71 10-1-03

ICC-105A300 8-15-28 8-31-56

DOT-105A200F 12-19-64 12-31-71 11-30-84 d/

DOT-105A200W 9-23-57 12-31-71 i/

DOT-105A300W 1-7-41 12-31-71 i/

DOT-105A400W 1-7-41 12-31-71 i/

DOT-105A500W 1-7-41 12-31-71 i/

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Table 1.1 List of tank car specifications (page 3 of 6)

DOT-105A600W 1-7-41 12-31-71 i/

DOT-105A100ALW 10-25-52 12-31-71 i/

DOT-105A200ALW 9-23-57 12-31-71 i/

DOT-105A300ALW 8-31-56 12-31-71 i/

ICC-106A500 10-10-29 12-19-64

ICC-106A800 10-10-29 12-19-64

DOT-110A800W 8-21-61 12-19-64 j/

DOT-110A3000W 11-8-61 5-19-94 12-31-78 j/

DOT-110A2000W 10-4-93 5-19-94 j/

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Table 1.1 List of tank car specifications (page 4 of 6)

ICC-111A60ALW 7-19-59 12-19-64 5-27-67

DOT-111A60W1 2-17-63 12-31-71

DOT-111A100F2 9-25-63 12-31-71 11-30-84 d/

DOT-111A100W1 9-23-57 12-31-71

DOT-112A340W 2-17-63 7-13-78 k/

DOT-112A400F 12-20-61 7-13-78 11-30-84 d/

DOT-112A400W 9-23-57 7-13-78 k/

DOT-112A500W 6-20-60 7-13-78 k/

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Table 1.1 List of tank car specifications (page 5 of 6)

DOT-112J340W 10-19-77 7-13-78 k/